Komatsu PC88MR-10 Shop Manual
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Komatsu PC88MR-10 Shop Manual

Hydraulic excavator
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Table of Contents

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SEN06467-05
HYDRAULIC
PC88MR
-10
EXCAVATOR
7001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu PC88MR-10

  • Page 1 SEN06467-05 HYDRAULIC PC88MR EXCAVATOR 7001 SERIAL NUMBERS and up...
  • Page 3 SHOP MANUAL HYDRAULIC EXCAVATOR PC88MR-10 Model Serial Number PC88MR-10 7001 and up 00 Index and foreword 1 00 Index and foreword PC88MR-10 00-1...

  • Page 4: Table Of Contents

    Hydraulic tank........................10-40 CLSS ..........................10-44 Main pump ........................10-48 Control valve ........................10-60 Swing motor ........................10-108 Travel motor ........................10-119 Work equipment and swing PPC valve................10-130 Travel PPC valve ......................10-137 Blade PPC valve ......................10-143 00-2 PC88MR-10...

  • Page 5: Index

    Testing oil pressure of control circuit ..................30-48 Testing and adjusting oil pressure in pump PC control circuit..........30-49 Testing and adjusting oil pressure in pump LS control circuit ..........30-52 Testing outlet pressure of solenoid valve ................30-55 PC88MR-10 00-3...
  • Page 6 Failure code [B@BCNS] Eng Water Overheat ..............40-127 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ..........40-128 Failure code [CA122] Charge Air Pressure Sensor High Error ..........40-129 Failure code [CA123] Charge Air Pressure Sensor Low Error..........40-131 00-4 PC88MR-10...
  • Page 7 Failure code [CA2249] Common Rail Pressure Low Error 2 ..........40-223 Failure code [CA2272] EGR Valve Position Sensor Low Error ..........40-224 Failure code [CA2311] IMV Solenoid Error ................. 40-226 Failure code [CA2349] EGR Valve Solenoid Open Circuit Error ..........40-227 PC88MR-10 00-5...
  • Page 8 Failure code [DKULKA] PPC Lock Relay Open Circuit............40-325 Failure code [DKULKB] PPC Lock Relay Short Circuit............40-327 Failure code [DKULKY] PPC Lock Relay Hot Short Circuit........... 40-329 Failure code [DV20KB] Travel Alarm Short Circuit............... 40-331 Failure code [DW43KA] Travel Speed Solenoid Open Circuit ..........40-333 00-6 PC88MR-10...
  • Page 9 E-25 Travel speed monitor does not change when travel speed switch is operated ....40-414 E-26 Travel speed does not change while travel speed selection is changed......40-415 E-27 Alarm buzzer does not stop sounding................. 40-416 E-28 Service meter is not displayed, while starting switch is in OFF position......40-417 PC88MR-10 00-7...
  • Page 10 H-20 Machine does not travel straight ................40-493 H-21 Travel speed is slow ....................40-495 H-22 Machine is hard to steer or travel power is low ............40-497 H-23 Travel speed does not change, or travel speed is too slow or fast ......... 40-500 00-8 PC88MR-10...
  • Page 11 Removal and installation of fuel cooler assembly ..............50-60 Removal and installation of fuel tank assembly ..............50-61 Removal and installation of engine hood assembly ............... 50-63 Removal and installation of KDOC muffler................50-64 Removal and installation of KCCV ventilator................. 50-67 PC88MR-10 00-9...
  • Page 12 Removal and installation of machine monitor assembly ............50-220 Removal and installation of mass air flow and temperature sensor ........50-222 Removal and installation of KOMTRAX terminal assembly ..........50-223 60 Maintenance standard........................60-1 Table of contents ........................60-2 Engine and cooling system ......................60-3 00-10 PC88MR-10...
  • Page 13 Circuit diagram and arrangement of connector pins............... 80-24 System diagram......................... 80-26 Input and output signals of the air conditioner controller ............80-27 Air conditioner unit ......................80-29 Parts and connectors layout....................80-31 Testing air leakage (duct) ....................80-37 PC88MR-10 00-11...
  • Page 14 Symbols in hydraulic circuit diagram ..................90-3 Hydraulic circuit diagram....................... 90-7 Electric circuit diagram ........................ 90-9 Symbols in electric circuit diagram ..................90-9 Electrical circuit diagram ..................... 90-13 Electrical circuit diagram of air conditioner unit..............90-23 Index..................................1 00-12 PC88MR-10...

  • Page 15: 00 Index And Foreword

    Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manual describes the effective and safe servicing and repair methods recommended by Komatsu. Some of these methods require the use of the special tools designed by Komatsu for the specific purpose. The symbol mark is used for such matters that require special cautions during the work.
  • Page 16 Keep putting on the gloves during sling work. When removing piping, prevent the fuel or oil (Put on the leather gloves, if available.) from spilling out. If any fuel or oil drips onto the 00-14 PC88MR-10...
  • Page 17 Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc. Before starting work, check the wire ropes, Apply wire ropes to the middle part of the hook. brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter PC88MR-10 00-15...
  • Page 18 However, do not apply oil to the threaded 22.6 part of a bolt, nut or union. 28.6 35.3 Manufacturer Part name 55.3 DENSO ND-OIL8 79.6 ZXL100PG (equivalent to VALEO THERMAL 141.6 14.4 PAG46) SYSTEMS 221.6 22.6 SANDEN SP-10 318.3 32.4 00-16 PC88MR-10...
  • Page 19 (Use a torque wrench for tightening). a Example of fitting of O-ring An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see "Others", "Precautions for disconnection and connection of air conditioner piping". PC88MR-10 00-17...
  • Page 20 Fire around the machine due to highly heated materials to a safe place before starting. exhaust gas Some machines are equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. Its exhaust discharged...
  • Page 21 As for rubber, plastics, or parts (hoses, cables, and wiring harnesses, etc.) which contain those materials, ask the industrial waste treatment firms for their disposals in accordance with the local regulations. PC88MR-10 00-19...

  • Page 22: How To Read The Shop Manual

    (Rev. 2012/10) Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. Materials and specifications are subject to change without notice.
  • Page 23 Drain drained are indicated. Unit In this shop manual, the units are indicated with International System of units (SI). For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }. PC88MR-10 00-21...

  • Page 24: Explanation Of Terms For Maintenance Standard

    The dimensions of parts change because of the of new products or equivalent are called the wear or deformation while they are used. When "standard value", which is indicated by a range the dimension changes exceeding certain value, or a target value. 00-22 PC88MR-10...
  • Page 25 "allowable interference". The allowable interference shows the repair limit of the part of smaller tolerance. The parts whose interferences are out of the allowable interference must be replaced or repaired. PC88MR-10 00-23...

  • Page 26: Handling Equipment Of Fuel System Devices

    If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. The common rail fuel injection system (CRI)

  • Page 27: Handling Of Intake System Parts

    Foreword, safety and general information Handling of intake system parts (PC220-A900-2A4-K-00-A) (Rev.2013/10) The Komatsu Variable Geometry Turbocharger consists of more precise parts (variable mechanism) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the air intake system.

  • Page 28: Handling Of Hydraulic Equipment

    If the old oil is left in the system, the contaminant and sludge in the oil mix with the new oil and shorten the life of the new hydraulic oil. 00-26 PC88MR-10...
  • Page 29 The oil cleaning equipment can remove the ultra fine (approximately 3 m) particles that the filter built in the hydraulic equipment can not remove. So, it is an extremely effective device. PC88MR-10 00-27...

  • Page 30: Method Of Disconnecting And Connecting Of Push-Pull Type Coupler

    3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the (Fig. 3) rubber cap will move approximately 3.5mm toward the hose, however, it is not a problem. a Since some hydraulic oil flows out, prepare an oil container. 00-28 PC88MR-10...
  • Page 31 (Fig. 9) 2. While keeping the condition of Step 1, turn lever (8) to the right (clockwise). (Fig. 7) 3. While keeping the conditions of Steps 1 and 2, pull out whole body (7) to disconnect it. (Fig. 8) PC88MR-10 00-29...
  • Page 32 (10) straight until it hits contact surface (b) of the hexagonal portion on the male side. (Fig. 3. While keeping the conditions of Steps 1 and 2, pull out whole body (9) to disconnect it. (Fig. 12) 00-30 PC88MR-10...

  • Page 33: Handling Of Electrical Equipment

    The corroded or oxidized harness may be broken. contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times. PC88MR-10 00-31...
  • Page 34 If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or 00-32 PC88MR-10...
  • Page 35 If the connector cannot be corrected easily, remove the clamp and adjust the position. Connecting connectors 1. Check the connector visually. PC88MR-10 00-33...
  • Page 36 3. Perform a continuity test on the connector. After drying, leave wiring harness disconnected and perform a continuity test to check for any short circuits between pins caused by water. a After the connector is completely dried, blow the contact restorer and reassemble them. 00-34 PC88MR-10...
  • Page 37 1. Insert the connector securely until a click is (FRAMATOME-24) heard. Disconnection Pull lock type 1. Slide down lock (red) (L1). (PACKARD-2) Disconnection 1. Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward. PC88MR-10 00-35...
  • Page 38 [1] since you cannot insert your fingers. While pushing up lock (C) of the connector Connection with flat-head screwdriver [1], pull out 1. Insert the connector securely until a click is connector (3) in the direction of the arrow. heard. 00-36 PC88MR-10...
  • Page 39 Housing (H1) is left on the wiring harness in a place where it is exposed to rain. side. Do not place the controller on oil, water, or soil, or in a place that can be heated to a high PC88MR-10 00-37...
  • Page 40 If there is any value change on the multimeter, there may be a defective contact in the circuit. 00-38 PC88MR-10...

  • Page 41: How To Read Electric Wire Code

    CAVS automobile (nominal No. 1.25 and lower) (Type 2) Heat- General wiring for extremely resistant low- cold weather specification Heat-resistant cross voltage wire -50 to +110 linked polyethylene Wiring at high ambient temperature place automobile PC88MR-10 00-39...
  • Page 42 Nominal No. 0.5f 0.75f 0.85 1.25f 1.25 Number of 7/round 11/round 16/round strands/ compression compression compression Diameter of strand Conductor Cross- sectional 0.56 0.88 1.29 area (mm d (approx.) CAVS Standard a "f" of nominal No. denotes "flexible". 00-40 PC88MR-10...
  • Page 43 Examples) GW means that the background is "Green" and marking is "White". Types of circuits and color codes Type of wire AVS, AV, CAVS Charge Ground Start Light Instrument Signal Type of circuit Others PC88MR-10 00-41...

  • Page 44: Precautions When Performing Operation

    Disconnection of face seal type hoses and tubes Pipe joint side Hose side O-ring (3) Nominal No. Plug (1) Nut (2) 07376-70210 02789-00210 02896-11008 07376-70315 02789-00315 02896-11009 07376-70422 02789-00422 02896-11012 07376-70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 00-42 PC88MR-10...
  • Page 45 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032 01044 51035 07379- 07372- 58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032 01250 51035 07379- 01010- 66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232 01260 81245 07379- 07372- 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232 01460 51240 PC88MR-10 00-43...
  • Page 46 O-ring (2) Nominal No. 07040-10807 07002-10823 07040-11007 07002-11023 07040-11209 07002-11223 07040-11409 07002-11423 07040-11612 07002-11623 07040-11812 07002-11823 07040-12012 07002-12034 07040-12412 07002-12434 07041-13012 07002-13034 07040-13316 07002-13334 07041-13612 07002-13634 07040-14220 07002-14234 07040-15223 07002-15234 Removal of pipe joints of taper pipe thread type 00-44 PC88MR-10...
  • Page 47 If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is pushed out, and that can cause oil leakage. PC88MR-10 00-45...
  • Page 48 When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.

  • Page 49: Practical Use Of Komtrax

    3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual (For Key Person)". PC88MR-10 00-47...

  • Page 50: Standard Tightening Torque Table

    824 to 1,030 {84 to 105} 1,180 to 1,470 {120 to 150} 1,520 to 1,910 {155 to 195} 1,960 to 2,450 {200 to 250} 2,450 to 3,040 {250 to 310} 2,890 to 3,630 {295 to 370} *1: Split flange bolt. *2: Flanged bolt. 00-48 PC88MR-10...
  • Page 51 333 to 451 {34 to 46} 392 {40} -7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54} -7UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79} -6UNC PC88MR-10 00-49...
  • Page 52 35 to 63 {3.5 to 6.5} 44 {4.5} Varies 59 to 98 {6.0 to 10.0} 78 {8.0} depending on type of 84 to 132 {8.5 to 13.5} 103 {10.5} 03, 04 connector. 128 to 186 {13.0 to 19.0} 157 {16.0} 05, 06 00-50 PC88MR-10...
  • Page 53 Table of tightening torque for hose (taper seal type and face seal type) a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque shown in the table below. a The table is applied to the threads coated with engine oil (wet threads) PC88MR-10 00-51...
  • Page 54 Thread diameter (mm) Tightening torque (Nm {kgm}) 10 ± 2 {1.02 ± 0.20} 24 ± 4 {2.45 ± 0.41} 43 ± 6 {4.38 ± 0.61} 77 ± 12 {7.85 ± 1.22} 00-52 PC88MR-10...
  • Page 55 20 ± 2 {2.04 ± 0.20} 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31} 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41} 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51} PC88MR-10 00-53...

  • Page 56: List Of Abbreviation

    Electronic control device uses the signals from the sensors on the machine. This signal Electronic Control Electronic control system indicates the optimum actuation to the Module actuators. (Same as E.C.U.) 00-54 PC88MR-10...
  • Page 57 Inlet Metering Valve Engine control fuel discharge of supply pump. Same as I.M.V. (I.M.A.) This mechanism separates oil in blowby gas Komatsu Closed Engine and returns it to the intake side to afterburn it KCCV Crankcase Ventilation there. It primarily consists of filters.
  • Page 58 Abbrevia- Actual word spelled applicable machine (*), or Explanation tion equipment/device) This filter captures soot in exhaust gas. Komatsu Catalyzed Engine KCSF Soot Filter It is built in to KDPF. The catalyst used for purifying exhaust gas. Komatsu Diesel Engine...
  • Page 59 Actual word spelled out Abbreviation Air Conditioner Analogue-to-Digital Air Mix Damper Accessory Additional Auxiliary Battery Relay Clockwise Counter Clockwise Electronic Control Unit Electronic Control Module Engine EXGND External Ground F.G. Frame Ground Ground Inlet Metering Actuator No Connection Steering STRG PC88MR-10 00-57...
  • Page 60 00 Index and foreword Foreword, safety and general information Actual word spelled out Abbreviation Signal Solenoid Standard Option PRESS Pressure Specification SPEC Switch Temperature TEMP Torque Converter Transmission 00-58 PC88MR-10...

  • Page 61: Conversion Table

    2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 PC88MR-10 00-59...
  • Page 62 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153 00-60 PC88MR-10...
  • Page 63 1,172 1,179 1,186 1,193 1,201 1,208 1,215 1,222 1,130 1,237 1,244 1,251 1,259 1,266 1,273 1,280 1,288 1,295 1,302 1,309 1,316 1,324 1,331 1,338 1,345 1,353 1,360 1,367 1,374 1,382 1,389 1,396 1,403 1,410 1,418 1,425 1,432 1,439 PC88MR-10 00-61...
  • Page 64 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542 00-62 PC88MR-10...
  • Page 65 167.0 65.6 302.0 -14.4 42.8 105.8 24.4 168.8 68.3 311.0 -13.9 44.6 107.6 25.0 170.6 71.1 320.0 -13.3 46.4 109.4 25.6 172.4 73.9 329.0 -12.8 48.2 111.2 26.1 174.2 76.7 338.0 -12.2 50.0 113.0 26.7 176.0 79.4 347.0 PC88MR-10 00-63...
  • Page 66 00 Index and foreword Foreword, safety and general information 00-64 PC88MR-10...

  • Page 67: 01 Specification

    SHOP MANUAL HYDRAULIC EXCAVATOR PC88MR-10 Model Serial Number PC88MR-10 7001 and up 01 Specification 2 01 Specification PC88MR-10 01-1...

  • Page 68: Table Of Contents

    Table of contents (ALL-0310-002-A-00-A) 01 Specification..........................01-1 Table of contents ........................01-2 Specifications..........................01-3 Specification drawing ......................01-3 Working range drawings ....................... 01-4 Specifications ........................01-5 Weight table ........................01-9 Table of fuel, coolant, and lubricants ..................01-11 01-2 PC88MR-10...

  • Page 69: Specifications

    8,600 8,640 With blade (8,460) (8,500) Bucket capacity 0.28 0.20 Engine model Komatsu SAA4D95LE-6 diesel engine Engine rated horsepower SAE J1995 (gross) 50.7 {68.0} / 1,950 {1,950} kW {HP}/min 50.7 {68.0} / 1,950 {1,950} ISO 14396 {rpm} ISO 9249 / SAE 48.8 {65.5} / 1,950 {1,950}...

  • Page 70: Working Range Drawings

    01 Specification Working range drawings Working range drawings (ALL-2110-001-A-02-A) PC88MR-10 (PC88MR-2111-931-A-03-A) PC88MR 10 Item Unit 1,650 mm arm 2,100 mm arm A Max. digging reach 6,935 7,345 B Max. digging depth 4,110 4,565 C Max. digging height 6,620 6,800 Max. vertical wall...

  • Page 71: Specifications

    01 Specification Specifications Specifications (ALL-2111-001-A-01-A) PC88MR-10 (PC88MR-2111-931-A-02-A) PC88MR 10 Machine model 1,650 mm arm 2,100 mm arm Unit 7001 and up Serial No. Bucket capacity 0.28 0.20 Machine weight 8,600 (8,460) 8,640 (8,500) Performance Working ranges Max. digging depth 4,110 4,565 Max.
  • Page 72 1 (each side) Carrier roller 5 (each side) Track roller Track shoe Assembly type road liner, 39 pieces on each Road liner side Assembly type triple grouser shoe, 39 pieces Steel shoe on each side One-piece rubber shoe Rubber shoe 01-6 PC88MR-10...
  • Page 73 Cylinder bore Piston rod diameter Stroke Max. distance between pins 2,123 Min. distance between pins 1,262 Bucket cylinder Type Double-acting piston type Cylinder bore Piston rod diameter Stroke Max. distance between pins 1,765 Min. distance between pins 1,055 PC88MR-10 01-7...
  • Page 74 Double-acting piston type Cylinder bore Piston rod diameter Stroke 638.5 Max. distance between pins 1,712.5 Min. distance between pins 1,074 Blade cylinder Type Double-acting piston type Cylinder bore Piston rod diameter Stroke Max. distance between pins Min. distance between pins 01-8 PC88MR-10...

  • Page 75: Weight Table

    01 Specification Weight table Weight table (ALL-2120-001-A-01-A) PC88MR-10 (PC88MR-2120-931-A-01-A) This weight table is prepared for your reference when handling or transporting the components. Unit: kg Machine model PC88MR 10 7001 and up Serial No. Engine assembly (excluding coolant and oil)
  • Page 76 Blade (welded edge type) Wide blade (welded edge type) Reinforced blade (BOC type, including BOC) Boom cylinder assembly Arm cylinder assembly Bucket cylinder assembly Boom swing cylinder assembly Blade cylinder assembly a BOC: Abbreviation for Bolt On Cutting edge 01-10 PC88MR-10...

  • Page 77: Table Of Fuel, Coolant, And Lubricants

    For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual. Unit: l PC88MR 10 Applicable part Specified capacity Refill capacity Engine oil pan 12.5 11.5 Swing machinery case Final drive case (each of right and left) PTO gear case Hydraulic oil system Cooling system Fuel tank PC88MR-10 01-11...
  • Page 78 01 Specification Table of fuel, coolant, and lubricants 01-12 PC88MR-10...

  • Page 79: 10 Structure And Function

    SHOP MANUAL HYDRAULIC EXCAVATOR PC88MR-10 Model Serial Number PC88MR-10 7001 and up 10 Structure and function 3 10 Structure and function PC88MR-10 10-1...

  • Page 80: Table Of Contents

    Cab and its attachments ......................10-166 Cab mount and cab tipping stopper ................... 10-166 ROPS cab ........................10-168 Electrical system ........................10-170 Electrical control system ....................10-170 Machine monitor system ....................10-214 KOMTRAX system ......................10-236 Sensor ..........................10-238 10-2 PC88MR-10...

  • Page 81: Engine And Cooling System

    10 Structure and function Engine related parts Engine and cooling system (ALL-R401-001-K-00-A) Engine related parts (PC88MR-A001-041-K-00-A) 1. KDOC muffler 2. KCCV ventilator 3. Dust indicator 4. Auto-tensioner 5. Variable flow turbocharger 6. EGR cooler 7. Engine oil filter 8. Fuel filter PC88MR-10 10-3...
  • Page 82 12.Air cleaner (*1) 13.Mass air flow and temperature sensor 14.Air conditioner compressor *1: For details, see Engine Shop Manual. *2: The crankshaft pulley side of the engine mount is the front and the flywheel side is the rear. 10-4 PC88MR-10...

  • Page 83: Pto

    1. Breather and oil filler plug 2. Flywheel 3. Coupling 4. Drain plug 5. Oil level plug 6. Main pump shaft Specifications (PC88MR-D400-030-K-00-A) Type of PTO Wet type Oil used for PTO TO30 Quantity of PTO oil (l) PC88MR-10 10-5...

  • Page 84: Variable Flow Turbocharger

    10 Structure and function Variable flow turbocharger Variable flow turbocharger (ENG95-AA10-041-K-00-A) a The shape is subject to machine models. A: Air intake inlet B: Air intake outlet C: Exhaust inlet D: Exhaust outlet 10-6 PC88MR-10...
  • Page 85 10 Structure and function Variable flow turbocharger 1. Variable flow turbocharger motor 2. Flange bolt 3. Bracket 4. Thrust sleeve PC88MR-10 10-7...
  • Page 86 28. Connector assembly 29. Snap ring 30. Snap ring 31. Lock plate 32. Flange bolt E: Oil inlet F: Oil outlet Specifications (ENG95-AA10-030-K-00-A) Model: TD04M4t-VFT Applicable exhaust temperature: Max. 700°C (turbine inlet) Rotation direction: Clockwise (seen from intake air inlet) 10-8 PC88MR-10...
  • Page 87 The flow rate into large scroll (1) side is controlled by opening or closing the flow control valve (4). The position of the flow control valve (4) is controlled by the actuator which is driven by the command from the engine controller. PC88MR-10 10-9...

  • Page 88: Egr System Piping Drawing

    Function (ENG95-A9J0-042-K-00-A) EGR valve (driven with electric motor) Controls the gas flow from exhaust side to intake side. Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows into the intake side. EGR cooler 10-10 PC88MR-10...
  • Page 89 Control each part of the EGR circuit and control the EGR rate according to the operating condition to clean the exhaust gas constantly. Monitor the condition of the EGR circuit and perform troubleshooting to prevent a serious failure. PC88MR-10 10-11...

  • Page 90: Egr System Circuit Diagram

    If EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10) into EGR cooler (5) through the EGR piping. The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6), merges with the intake air in the air intake connector, and flows into intake manifold (11). 10-12 PC88MR-10...

  • Page 91: Egr Valve

    Small-sized EGR valve driven with a DC motor. The DC motor has a position sensor in it to sense the valve position. Since 2 valves are combined to cancel the EGR gas pressure, the operating effort is small. PC88MR-10 10-13...
  • Page 92 When valve (7) opens, the EGR gas flows into the air intake manifold. Close valve: The DC motor is turned in reverse and DC motor shaft (2) is pulled in, then rod (3) is pushed back by spring (9) and valve (7) closes. 10-14 PC88MR-10...

  • Page 93: Egr Cooler

    A: EGR gas inlet B: Air vent C: Coolant outlet D: EGR gas outlet E: Coolant inlet 1. Flat tube 2. Inner fin Operation (ENG95-A9L0-044-K-00-A) The EGR gas enters from (A) and flows through 9 flat tubes (1). PC88MR-10 10-15...
  • Page 94 Coolant enters from (E) and flows around flat tube (1) in the shell and then goes out from (C). The EGR gas is effectively cooled by flat tubes (1) with inner fins (2) and flows out from EGR gas outlet (D). 10-16 PC88MR-10...

  • Page 95: Kccv Layout Drawing

    10 Structure and function KCCV layout drawing KCCV layout drawing (PC88MR-A180-04D-K-00-A) a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation a The shape is subject to machine models. 1. Variable flow turbocharger 2. Breather 3. Crankcase pressure sensor 4. CDR valve 5.
  • Page 96 The left side of the following figure shows the traditional flow of blowby gas that has been discharged to the atmosphere. The right side shows the flow of blowby gas recirculated to the intake system by the KCCV ventilator. 10-18 PC88MR-10...
  • Page 97 Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and then the cleaned gas (B) is recirculated to the intake side of the variable flow turbocharger. Removed engine oil (C) flows through a check valve and falls to the oil pan. PC88MR-10 10-19...

  • Page 98: Kccv Ventilator

    10 Structure and function KCCV ventilator KCCV ventilator (ENG95-A18H-041-K-00-A) a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation a The shape is subject to machine models. 1. Case 2. Filter 3. CDR valve 4. Relief valve A: Blowby gas inlet (from breather)
  • Page 99 (P1) decreases, force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily blocks the flow. Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is pushed up again and blowby gas starts to flow again. PC88MR-10 10-21...

  • Page 100: Kdoc Muffler

    10 Structure and function KDOC muffler KDOC muffler (ENG95-A9H2-041-K-00-A) a KDOC: Abbreviation for Komatsu Diesel Oxidation Catalyst a The shape is subject to machine models. 1. DOC unit 2. Silencer unit 3. Exhaust gas outlet piping 4. Exhaust gas inlet piping 5.
  • Page 101 (carbon monoxide) contained in the engine exhaust gas to clean the exhaust gas. It also has a silencer to reduce the exhaust noise. Function of DOC unit (1) Oxidization of SOF (soluble organic fraction) (2) Oxidization of HC (hydrocarbon) (3) Oxidization of CO (carbon monoxide) Function of silencer unit Reduction of exhaust noise PC88MR-10 10-23...

  • Page 102: Cooling System

    10 Structure and function Cooling system Cooling system (PC88MR-B000-041-K-00-A) 10-24 PC88MR-10...
  • Page 103 3. Aftercooler inlet tube 4. Radiator inlet hose 5. Radiator outlet hose 6. Fan guard 7. Net (if equipped) 8. Fuel cooler 9. Radiator drain plug 10. Radiator 11. Radiator cap 12. Aftercooler 13. Hydraulic oil cooler 14. Shroud PC88MR-10 10-25...
  • Page 104 3.5/2 4.0/2 4.0/2 Total heat dissipation area (m 23.55 5.11 6.17 0.97 Cracking pressure of pressure valve 49.1 ± 14.7 (kPa {kg/cm {0.5 ± 0.15} Cracking pressure of vacuum valve -4.9 to 0 (kPa {kg/cm {-0.05 to 0} 10-26 PC88MR-10...

  • Page 105: Power Train

    4. Merge-divider valve 5. Self-pressure reducing valve 6. Swing motor 7. Travel motor 8. Main pump (for swing and blade) 9. Main pump (for work equipment and travel) 10. Engine 11. Center swivel joint 12. PPC lock solenoid valve PC88MR-10 10-27...
  • Page 106 10 Structure and function Power train system 13. 2nd travel speed selector solenoid valve 14. Swing parking brake solenoid valve 15. Merge-divider solenoid valve 16. Swing machinery 17. Swing circle 10-28 PC88MR-10...

  • Page 107: Swing Circle

    10 Structure and function Swing circle Swing circle (PC88MR-J110-041-K-00-A) a: Position of inner race soft zone b: Position of outer race soft zone c: Greasing port of swing circle pinion PC88MR-10 10-29...
  • Page 108 10 Structure and function Swing circle 1. Swing circle bearing grease fitting 2. Outer race 3. Ball 4. Seal 5. Inner race (number of teeth: 80) Specifications (PC88MR-J110-030-K-00-A) Reduction ratio 80 / 11 = 7.273 Grease G2-LI Quantity of grease (l) 10-30 PC88MR-10...

  • Page 109: Swing Machinery

    6. No. 1 sun gear (number of teeth: 14) 7. Swing motor 8. Oil filler pipe 9. Dipstick 10. No. 1 planetary gear (number of teeth: 26) 11. No. 2 planetary gear (number of teeth: 26) 12. No. 2 planetary carrier 13. Drain plug PC88MR-10 10-31...
  • Page 110 10 Structure and function Swing machinery Specifications (PC88MR-J130-030-K-00-A) (14 + 67) / 14 x (14 + 67) / 14 = 33.47 Reduction ratio Swing reduction ratio 33.47 x 7.273 = 243.45 Swing speed (rpm) 10.0 10-32 PC88MR-10...

  • Page 111: Undercarriage And Frame

    1. Track shoe 2. Track frame 3. Sprocket 4. Travel motor 5. Track roller 6. Carrier roller 7. Track roller guard (if equipped) 8. Idler guard (steel shoe, road liner) 9. Idler 10. Bracket for fixing machine for transport PC88MR-10 10-33...
  • Page 112 10 Structure and function Track frame Specifications (PC88MR-DT20-030-K-00-A) Model PC88MR 10 Number of carrier rollers (each side) Number of track rollers (each side) Standard shoe Shoe width (mm) Link pitch (mm) 154.3 Number of shoes (each side) 10-34 PC88MR-10...

  • Page 113: Idler Cushion

    (PC88MR-DTBP-041-K-00-A) 1. Idler 2. Support 3. Rod 4. Cylinder 5. Recoil spring 6. U-packing 7. Collar 8. Nut 9. Valve 10. Grease fitting Specifications (PC88MR-DTBP-030-K-00-A) Grease G2-LI Quantity of grease (cc) road liner , Metal shoe Rubber shoe PC88MR-10 10-35...

  • Page 114: Hydraulic System

    Hydraulic component layout Hydraulic system (ALL-C000-001-K-00-A) Hydraulic component layout (PC88MR-C000-04D-K-00-A) 1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Center swivel joint 5. Hydraulic tank 6. Attachment selector valve (for machines ready for installation of attachment) 7. Control valve 10-36 PC88MR-10...
  • Page 115 17. Attachment flow control EPC valve (for machines ready for installation of attachment) 18. Boom swing cylinder 19. Blade cylinder 20. Blade PPC valve 21. R.H. work equipment PPC valve 22. L.H. work equipment PPC valve 23. Travel PPC valve 24. Boom swing PPC valve *1: North America specification PC88MR-10 10-37...

  • Page 116: Valve Control

    2. R.H. work equipment PPC valve 3. L.H. work equipment control lever (for operation of arm and swing) 4. L.H. work equipment PPC valve 5. Lock lever 6. Accumulator (for PPC circuit) 7. Quadruple type solenoid valve 8. Attachment flow adjustment EPC valve 10-38 PC88MR-10...
  • Page 117 10 Structure and function Valve control 9. Travel PPC valve 10. Travel pedal 11. Boom swing control pedal 12. Travel lever 13. Control valve 14. Blade control lever 15. Boom swing PPC valve 16. Blade PPC valve PC88MR-10 10-39...

  • Page 118: Hydraulic Tank

    10 Structure and function Hydraulic tank Hydraulic tank (PC88MR-PM30-041-K-00-A) 1. Hydraulic tank 2. Intake breather 3. Oil filler cap and pressure valve 10-40 PC88MR-10...
  • Page 119 4. Sight gauge 5. Drain valve 6. Suction strainer 7. Bypass valve 8. Filter element Specifications (PC88MR-PM30-030-K-00-A) Hydraulic tank capacity (l) Hydraulic oil in tank (l) Bypass valve set pressure (MPa {kg/cm 0.25 ± 0.05 {2.5 ± 0.5} PC88MR-10 10-41...
  • Page 120 When the pressure in the tank exceeds the set pressure, bottom plate (2) is pushed up to release the pressure in the tank and prevent pressure rise. (Cracking pressure of pressure valve: 38.2 ± 14.7 kPa {0.39 ± 0.15 kg/cm 10-42 PC88MR-10...
  • Page 121 At this time, valve assembly (5) is opened by the differential pressure from the ambient pressure, and ambient pressure is transmitted into the tank to prevent generation of negative pressure in the tank (Set pressure of air intake valve: 2 ± 0.3 kPa {0.02 ± 0.003 kg/cm PC88MR-10 10-43...

  • Page 122: Clss

    Energy saving by variable discharge pump control Configuration CLSS consists of variable capacity piston pump, control valves, and respective actuators. The hydraulic pump consists of a pump body, PC valve, and LS valve. 10-44 PC88MR-10...
  • Page 123 LS valve (when the actuator load pressure is high). The pump swash plate shifts toward the minimum angle position when LS differential pressure is higher than the set pressure (when the actuator load pressure is low). PC88MR-10 10-45...
  • Page 124 10 Structure and function CLSS LS differential pressure (dPLS) and pump swash plate angle a For details of the operation, see "Hydraulic pump". Pressure compensation control 10-46 PC88MR-10...
  • Page 125 (outlet port) of the spool of each valve is kept the same among them regardless of the level of the load (pressure). The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and (S2) of each valve. PC88MR-10 10-47...

  • Page 126: Main Pump

    10 Structure and function Main pump Main pump (PC88MR-C200-041-K-00-A) P1: Pump discharge port P1T: Travel deviation adjustment orifice P2: Pump discharge port 10-48 PC88MR-10...
  • Page 127 PPLS: Pump pressure input port (from control valve port PP) PPT: PTO oil filler port PS1: Main pump suction port PEPC1: EPC source pressure input port 1. Main pump 2. Servo valve 3. Swing and blade pump 4. EPC valve 5. Bleeder PC88MR-10 10-49...
  • Page 128 Main pump P3: Gear pump pressure input port PAV: Pump average pressure port PDE: EPC drain port PEN: Control pressure input port PEPC: EPC source pressure input port PH: Pump shuttle port T: Drain port 1. Shaft 2. Flange 10-50 PC88MR-10...
  • Page 129 The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (7) through valve plate (8). Function (PC88MR-C200-042-K-00-A) This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic pressure and discharges pressurized oil corresponding to the load. PC88MR-10 10-51...
  • Page 130 Cylinder block (7) has even numbered holes (10 holes). Each hole fits in every second slot (2 places) of valve plate (8). Pressurized oil which is worth of 5 pistons is discharged to each pump discharge ports (P1) and (P2). 10-52 PC88MR-10...
  • Page 131 Servo piston (11) moves in a linear reciprocating motion corresponding to the signal pressure from the PC valve and LS valve. This linear motion is transmitted to rocker cam (4). Rocker cam (4) which is supported by ball (12) in flange (2) rotates. PC88MR-10 10-53...
  • Page 132 PAV: Pump average pressure input port PDE: EPC drain port PE: Control piston pressure port PEPC: EPC source pressure input port PH: Pump shuttle pressure port PLS: LS pressure input port PM: PC mode selector pressure input port 10-54 PC88MR-10...
  • Page 133 2. Spool 3. Plug 4. Seat 5. Piston 6. Sleeve 7. PC valve 8. LS valve 9. Plug 10. Lock nut 11. Spring 12. PC-EPC valve 13. Spool 14. Ball 15. Plug 16. PC mode selector current connector PC88MR-10 10-55...
  • Page 134 Consequently, spool (3) moves to the left and port (C) is disconnected from port (D), and ports (B) and (C) are connected. Since the pressure in port (C) rises and the piston pressure is increased, servo piston (6) stops moving to the left. 10-56 PC88MR-10...
  • Page 135 Consequently, spool (3) moves to the right and port (C) is disconnected from port (B), and drain pressure ports (D) and (C) are connected. Since pressure in port (C) reduces and the piston pressure decreases, servo piston (6) stops moving to the right. PC88MR-10 10-57...
  • Page 136 PC-EPC valve changes output pressure corresponding to the input current from the controller to change the pressing force of spool (5). As a result, the pump discharged volume changes similarly to the changes when (PAVE) increases or decreases. 10-58 PC88MR-10...
  • Page 137 This pump has 2 discharge ports and the average of respective discharged pressures (P1) and (P2) is sensed. The average of (P1) and (P2) is called (PAVE), and the relationship between it and the pump discharged volume [total discharge of (P1) and (P2)] is as shown in the figure below. PC88MR-10 10-59...

  • Page 138: Control Valve

    10 Structure and function Control valve Control valve (PC88MR-C030-041-K-00-A) 10-spool valve (EU specification) 10-60 PC88MR-10...
  • Page 139 PB5: From boom SWING R.H. PPC valve PB6: From boom LOWER PPC valve PB7: From arm IN PPC valve PB8: From bucket CURL PPC valve PA9: From attachment solenoid valve PP: To pump LS valve (LS pressure input) PC88MR-10 10-61...
  • Page 140 10. Bucket valve 11. Service 1 valve 12. Cover 13. LS check valve 14. Travel junction valve + LS check valve 15. Boom hydraulic drift prevention valve 16. Cooler bypass valve 17. Equalizer valve 18. Self-pressure reducing valve 10-62 PC88MR-10...
  • Page 141 10 Structure and function Control valve (1/6) 1. Suction safety valve (blade) 2. Suction valve (left travel) 3. Suction valve (right travel) PC88MR-10 10-63...
  • Page 142 20. Spool (assistant valve) 21. Spool (blade) 22. Spool (swing) 23. Spool (left travel) 24. Spool (right travel) 25. Spool (boom swing) 26. Spool (boom) 27. Spool (arm) 28. Spool (bucket) 29. Spool (service 1) 30. Unload valve 10-64 PC88MR-10...
  • Page 143 10 Structure and function Control valve (2/6) 1. Pressure compensation valve F (left travel) 2. Pressure compensation valve F (right travel) 3. Pressure compensation valve F (boom swing) PC88MR-10 10-65...
  • Page 144 11. Pressure compensation valve R (arm) 12. Pressure compensation valve R (boom) 13. Pressure compensation valve R (boom swing) 14. Pressure compensation valve R (right travel) 15. Pressure compensation valve R (left travel) F: Flow control valve R: Pressure reducing valve 10-66 PC88MR-10...
  • Page 145 10 Structure and function Control valve (3/6) Block 1. Boom raise assist valve 2. Main relief valve Blade valve 3. Suction safety valve 4. Suction valve 5. Spool PC88MR-10 10-67...
  • Page 146 7. Spool 8. Check valve L.H. travel valve 9. Pressure compensation valve F 10. Suction valve 11. Suction valve 12. Spool 13. Pressure compensation valve R 14. LS check valve F: Flow control valve R: Pressure reducing valve 10-68 PC88MR-10...
  • Page 147 10 Structure and function Control valve (4/6) R.H. travel valve 1. Pressure compensation valve F 2. Suction valve 3. Suction valve 4. Spool 5. Pressure compensation valve R 6. Travel junction valve + LS check valve PC88MR-10 10-69...
  • Page 148 Merge-divider valve block 12. Merge-divider valve spool 13. Unload valve 14. Check valve 15. Cooler bypass valve 16. Unload valve 17. Main relief valve 18. Check valve 19. Sequence valve F: Flow control valve R: Pressure reducing valve 10-70 PC88MR-10...
  • Page 149 10 Structure and function Control valve (5/6) Boom valve 1. Hydraulic drift prevention valve 2. Suction valve 3. Spool 4. Pressure compensation valve R 5. Pressure compensation valve F 6. Suction valve PC88MR-10 10-71...
  • Page 150 15. Pressure compensation valve R 16. Pressure compensation valve F Service valve 17. Port relief valve 18. Port relief valve 19. Spool 20. Pressure compensation valve R 21. Pressure compensation valve F F: Flow control valve R: Pressure reducing valve 10-72 PC88MR-10...
  • Page 151 10 Structure and function Control valve (6/6) 1. Safety valve 2. Filter 3. Check valve PC88MR-10 10-73...
  • Page 152 9-spool valve (North America specification) A9: To attachment, actuator B9: To attachment, actuator PA9: From attachment solenoid valve PA9: From attachment solenoid valve 1. Pressure compensation valve F (attachment) 2. Pressure compensation valve R (attachment) 3. Suction valve 10-74 PC88MR-10...
  • Page 153 10 Structure and function Control valve 4. Suction valve 5. Spool (attachment) F: Flow control valve R: Pressure reducing valve PC88MR-10 10-75...
  • Page 154 10 Structure and function Control valve Hydraulic circuit diagram and names of valves (PC88MR-C030-054-K-00-A) 1. Block 2: Blade valve 10-76 PC88MR-10...
  • Page 155 Relief pressure: 21.1 MPa {215 kg/cm 34. Relief valve Relief pressure: 26.5 MPa {270 kg/cm 35. Unload valve Relief pressure: 2.9 MPa {30 kg/cm 36. Equalizer valve 37. Self-pressure reducing valve 38. Sequence valve 39. LS bypass valve PC88MR-10 10-77...
  • Page 156 10 Structure and function Control valve 9-spool valve (North American specification) 40. Suction valve 10-78 PC88MR-10...
  • Page 157 (2.45 MPa {25.0 kg/cm Spool (1) moves to the left. Pump circuits (PP1) and (PP2) are connected to tank circuit (T) through the notch of spool (1). Pump discharged pressures (PP1) and (PP2) are set to 2.45 MPa {25.0 kg/cm PC88MR-10 10-79...
  • Page 158 The differential pressure between pump discharged pressure (PP1)/(PP2) and LS pressure (PLS1)/ (PLS2) reaches the load at installed height of spring (2) (2.45 MPa {25.0 kg/cm Spool (1) moves to the left. Pump circuits (PP1) and (PP2) are interconnected to tank circuit (T). 10-80 PC88MR-10...
  • Page 159 When the fine control operation of the right and left travels are performed, LS pressures (PLS1) and (PLS2) are generated and they act on the left side of spool (1) [(PP1)/(PP2) and (PLS1)/(PLS2) are divided from each other]. PC88MR-10 10-81...
  • Page 160 Operation When the full operation of the right and left travels are performed, LS pressures (PLS1) and (PLS2) are generated and they act on the left side of spool (1). [(PP1)/(PP2) and (PLS1)/(PLS2) are divided from each other]. 10-82 PC88MR-10...
  • Page 161 The swash plate angle becomes maximum and the discharged volume becomes maximum. (For details, see "merge-divider valve") Operation When left travel operation is performed to maximum and right travel is in HOLD When L.H. travel valve is operated to the stroke end, LS pressure (PLS1) is generated. PC88MR-10 10-83...
  • Page 162 Pump discharged pressure (PP2) reaches the load at installed height of the spring (2.45 MPa {25.0 kg/ }). The spool moves to the left. All of pump discharged volume (Q) on the (PP2) side is drained into tank circuit (T). 10-84 PC88MR-10...
  • Page 163 Pressure reducing valve (3) is balanced at a position where actuator circuit pressure (PA) and the pressure of spring chamber (PLSS) are the same. Pump discharged pressure (PP) reduced at notch (c) becomes actuator circuit pressure (A) and is transmitted into LS circuit (PLS). PC88MR-10 10-85...
  • Page 164 (e) and LS circuit (PLS). Actuator circuit pressure (PA) = (A) is sent through notch (c) and internal check valve to notch (d), and then further sent to LS circuit (PLS). 10-86 PC88MR-10...
  • Page 165 Since merge-divider spool (1) is located at the merge position, the pressurized oil in LS circuits (PLS1), (PLS2), and (PLS3) is drained from filter (a) at the end of LS bypass valve (2) on the (P2) side through orifice (b) into tank circuit (T). PC88MR-10 10-87...
  • Page 166 Pressurized oil (PLS1) is drained through filter (a) at the end of LS bypass valve (3) on (P1) side and orifice (b) to tank circuit (T). Pressurized oil (PLS2) is drained through filter (a) at the end of LS bypass valve (2) on (P2) side and orifice (b) to tank circuit (T). 10-88 PC88MR-10...
  • Page 167 The pressure differences between upstream pressure (PPA) and downstream pressure (PA) of both spools operated for combined operation becomes the same and the pump flow is divided in proportion to the opening area of notch (a) of each spool. PC88MR-10 10-89...
  • Page 168 [(PP) - (PPB)] > [(PLS) - (PA (= A))], thus less oil flow is supplied to the compensated side for the open area ratio of the spool. When ratio is below 1.00: [(PP) - (PPB)] < [(PLS) - (PA (= A))], thus more oil flow is supplied to the compensated side for the open area ratio of the spool. 10-90 PC88MR-10...
  • Page 169 (1) is higher than head pressure (B). A part of return flow from the bottom side flows through regeneration passage (a) of boom spool (2) to the head side by pushing check valve (3) to open. The boom lowering speed is increased. PC88MR-10 10-91...
  • Page 170 If the boom is loaded during the boom LOWER operation, head pressure (B) of boom cylinder (1) is higher than bottom pressure (A). Check valve (2) is closed by pressure (B) on the head side and spring (3). The head side and bottom side circuits are disconnected. 10-92 PC88MR-10...
  • Page 171 A part of the return oil on the bottom side flows through the notch of arm spool (2) to regeneration circuit (a) and opens check valve (3). Then, the above oil flows from check valve (3) to the bottom side of arm cylinder (1) to increase the arm IN speed. PC88MR-10 10-93...
  • Page 172 If the arm is loaded during the arm "IN" operation, bottom pressure (B) of arm cylinder (1) is higher than head pressure (A). Check valve (3) is closed by bottom pressure (B) and spring (4), and circuits on head side and bottom side are disconnected. 10-94 PC88MR-10...
  • Page 173 The controller does not generate output signal and the merge-divider valve does not generate output pressure. Pump discharged pressures (PP1) and (PP2) are merged and LS pressures (PLS1), (PLS2), and (PLS3) are also merged (PP1 = PP2, PLS1 = PLS2 = PLS3). PC88MR-10 10-95...
  • Page 174 (PP1) and (PLS1) are supplied to the left travel circuit, and (PP2) and (PLS2) are supplied to the right travel circuit. Whichever is the higher of pump discharged pressures (PP1) and (PP2) is output as the LS pressure. The pump swash plate angle becomes its maximum, and the maximum flow is discharged. 10-96 PC88MR-10...
  • Page 175 If pressure (PR) of the self-pressure reducing valve becomes abnormal, ball (6) compresses spring (5) and separates from the seat. The pressurized oil flows through port (PR) to (TS) to reduce pressure (PR). Thus, the hydraulic components such as the PPC valves and solenoid valves are protected from abnormal pressure. PC88MR-10 10-97...
  • Page 176 10 Structure and function Control valve Travel junction valve (PC88MR-C6C0-042-K-00-A) (R.H. and L.H. travel junction circuits) When traveling straight 10-98 PC88MR-10...
  • Page 177 Control valve When steering while traveling Function When R.H and L.H. travel spools are operated to correct the flow difference between the right and left travel circuits while the machine is traveling straight, the travel junction circuit is opened. PC88MR-10 10-99...
  • Page 178 When the R.H. travel spool (Right 1) is returned to neutral from the straight-travel condition and the steering operation is performed, load pressure difference (PB) is made between R.H. and L.H. actuator circuits (B) [(Left B) > (Right B)]. 10-100 PC88MR-10...
  • Page 179 10 Structure and function Control valve Travel LS air bleeding circuit, travel junction valve (PC88MR-C600-042-K-01-A) When normally operated PC88MR-10 10-101...
  • Page 180 10 Structure and function Control valve When travel and another actuator are operated 10-102 PC88MR-10...
  • Page 181 (3) and (4) of the bleed circuit and notch (a) of pressure reducing valve (2) to travel circuit (PB). LS pressure (PLS) which is the same as boom circuit pressure (A) decreases since it released into travel circuit (B). PC88MR-10 10-103...
  • Page 182 When the boom RAISE operation is performed, poppet (2) is pushed up by the pressurized oil from the control valve. The pressurized oil from the control valve flows through the valve to the bottom side of the boom cylinder. 10-104 PC88MR-10...
  • Page 183 If the control lever is returned to NEUTRAL when the boom is raised, the holding pressure on the bottom side of the boom cylinder is closed by poppet (2). The pressurized oil flowing in through orifices (a1) and (a2) is closed by pilot spool (3). The boom is held. PC88MR-10 10-105...
  • Page 184 (b) is decreased by orifices (a1) and (a2). When the pressure in chamber (b) decreases below that in port (Ab), poppet (2) opens and the pressurized oil from port (Ab) flows into port (Aa) and then flows into the control valve. 10-106 PC88MR-10...
  • Page 185 Oil cooler inlet pressure (PA) acts on the left surface of piston (1). Piston (1) moves to the right. Piston (1) balances so that the oil cooler inlet pressure (PA) is as follows. (PA) - (PT) = Reaction force of spring (2) / Pressure receiving area (S2-S1) of piston (1) PC88MR-10 10-107...

  • Page 186: Swing Motor

    10 Structure and function Swing motor Swing motor (PC88MR-J610-041-K-00-A) Model: LMF30AEL B: From swing parking brake solenoid valve MA: From control valve MB: From control valve S: From control valve T: To tank 1. Reverse prevention valve 2. Relief valve 10-108 PC88MR-10...
  • Page 187 10 Structure and function Swing motor 1. Output shaft 2. Shoe 3. Piston 4. Cylinder block 5. Housing 6. Valve plate 7. Center spring 8. Swash plate 9. Brake spring PC88MR-10 10-109...
  • Page 188 12. Plate 13. Relief valve 14. Check valve 15. Shuttle valve Specifications (PC88MR-J610-030-K-00-A) Model LMF30AEL Motor capacity (cm /rev) Relief valve set pressure (MPa {kg/cm 20.6 {210} Rated speed (rpm) 2,287 Brake releasing pressure (MPa {kg/cm 1.32 {13.5} 10-110 PC88MR-10...
  • Page 189 When the swing parking brake solenoid valve is de-energized, the pressurized oil from the charge pump is blocked. Port (B) is connected to tank circuit (T). Brake piston (2) is pushed up by brake spring (1). Discs (3) and plates (4) are pressed and the brake operates. PC88MR-10 10-111...
  • Page 190 The pressurized oil from the charge pump flows into brake chamber (a) through port (B). The pressurized oil in chamber (a) compresses brake spring (1) and moves down brake piston (2). Discs (3) and plates (4) separate and the brake is released. 10-112 PC88MR-10...
  • Page 191 (6) to port (MA). The pressure in port (MA) increases and generates starting torque in the motor, and the motor starts to rotate. The pressurized oil from the motor output returns from port (MB) through control valve (6) to the tank. PC88MR-10 10-113...
  • Page 192 Cavitation in port (MA) is prevented. Swing modulating relief valve function (PC88MR-J6B3-042-K-00-A) The swing motor relief valve has characteristics of preventing sudden increase of the relief pressure to reduce shocks generated when the machine stops and starts swinging. 10-114 PC88MR-10...
  • Page 193 The relief passage to port (S) for the oil in chamber (a) compressed by movement of seat (1) is narrowed by ball (2), thus seat (1) moves slower than valve (3). Accordingly, the relief pressure increases gradually from (P1) to (P2) until seat (1) reaches sleeve (5). PC88MR-10 10-115...
  • Page 194 10 Structure and function Swing motor Swing motor reverse prevention valve (PC88MR-J6B2-041-K-00-A) MA: From control valve MB: From control valve 10-116 PC88MR-10...
  • Page 195 This valve can reduce such movement. The valve contributes in preventing spill of load when the swing is stopped and also contributes in reducing cycle time (enhances the positioning performance, and enables to proceed to the next work quicker). PC88MR-10 10-117...
  • Page 196 Port (MA) and chamber (b) are interconnected. The oil flows through drilled hole (h) of spool (5) and ports (b) and (f) are interconnected. The reverse pressure of port (MA) is bypassed to port (T) to prevent the second reverse rotation. 10-118 PC88MR-10...

  • Page 197: Travel Motor

    A: From center swivel joint (port B2) B: From center swivel joint (port A2) D1: Plug D2: To center swivel joint (port DR2) P: From center swivel joint (port G2) 1. Oil filler plug 2. Oil level plug 3. Drain plug PC88MR-10 10-119...
  • Page 198 7. Regulator piston 8. Planetary pinion B 9. Hub 10. Carrier 11. Cover 12. Planetary pinion A 13. Sun gear A 14. Sun gear B 15. Ring nut 16. Pivot 17. Piston 18. Disc 19. Plate 20. Cylinder 10-120 PC88MR-10...
  • Page 199 2-stage travel speed selector mechanism (4) consists of the regulator valve and regulator piston and changes the rotation speed to 2 levels by changing the displacement of hydraulic motor (2). Parking brake Parking brake (5) is a multiple disc type brake and integrated with hydraulic motor (2). PC88MR-10 10-121...
  • Page 200 8. Main pump 9. Travel control valve 10. Merge-divider valve 11. Self-pressure reducing valve 12. Brake valve Since 2nd travel speed selector solenoid valve (1) is de-energized, the pressurized oil from main pump (8) does not flow into port (P). 10-122 PC88MR-10...
  • Page 201 (f) of regulator valve (2) into control chamber (C) and pushes regulator piston (5) to the left. Swash plate (6) is set to the minimum angle, and consequently the motor capacity becomes minimum and the machine travels at high speed. PC88MR-10 10-123...
  • Page 202 If the machine travels downhill with the engine at low speed, the motor runs idle and the machine runs away. This is very dangerous. This valve prevents the machine from running away and makes it travel in accordance with the engine speed (pump discharged volume). 10-124 PC88MR-10...
  • Page 203 When the oil pressure in chamber (D) increases above the reaction force of spring (3), it pushes counterbalance valve (2) to the left. Ports (MB) and (PB) are interconnected and the motor starts rotating. Ports (PA) and (E) are interconnected and the pressurized oil flows to brake piston (4) to release the parking brake. PC88MR-10 10-125...
  • Page 204 Even if the pressurized oil flowing into port (PA) is blocked, the motor continues to rotate with the inertial force and cavitation can occur. Since check valve (1a) is operated by a very small pressure, ports (PA) and (MA) are interconnected to prevent cavitation. 10-126 PC88MR-10...
  • Page 205 When motor outlet port (MB) is throttled, the oil pressure on the outlet side increases and rotating resistance is generated in the motor. The speed is controlled in accordance with the pump discharged volume to prevent the machine from running away. PC88MR-10 10-127...
  • Page 206 When the oil pressure in chamber (A) exceeds the reaction force of spring (3), it pushes brake piston (2) to the left. The friction force between plate (4) and disc (5) is lost and the parking brake is released. 10-128 PC88MR-10...
  • Page 207 When the pressure in chamber (A) decreases below the reaction force of spring (3), brake piston (2) is pushed back to the right. Brake piston (2) presses plate (4) and disc (5) together, and the parking brake operates. PC88MR-10 10-129...

  • Page 208: Work Equipment And Swing Ppc Valve

    10 Structure and function Work equipment and swing PPC valve Work equipment and swing PPC valve (PC-PL28-041-K-00-A) a PPC: Abbreviation for Proportional Pressure Control 10-130 PC88MR-10...
  • Page 209 P: From self-pressure reducing valve P1: To control valve (boom LOWER port) P2: To control valve (boom RAISE port) P3: To control valve (bucket CURL port) P4: To control valve (bucket DUMP port) T: To hydraulic oil tank PC88MR-10 10-131...
  • Page 210 10 Structure and function Work equipment and swing PPC valve 10-132 PC88MR-10...
  • Page 211 Operation (PC-PL28-044-K-00-A) When valve is in neutral Ports (A) and (B) of the valve and ports (P1) and (P2) of the PPC valve are connected respectively through fine control hole (f) of spool (1) to drain chamber (D). PC88MR-10 10-133...
  • Page 212 Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool. 10-134 PC88MR-10...
  • Page 213 When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into chamber (B) to replenish the port with pressurized oil. PC88MR-10 10-135...
  • Page 214 The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows from port (P1) to port (A) and pushes the control valve spool. The oil returning from port (B) flows from port (P2) through fine control hole (f') into drain chamber (D). 10-136 PC88MR-10...

  • Page 215: Travel Ppc Valve

    PPC: Abbreviation for Proportional Pressure Control P: From self-pressure reducing valve P1: To control valve (L.H. reverse port) P2: To control valve (L.H. forward port) P3: To control valve (R.H. reverse port) P4: To control valve (R.H. forward port) T: To hydraulic tank PC88MR-10 10-137...
  • Page 216 10 Structure and function Travel PPC valve 1. Plate 2. Case 3. Piston 4. Seal 5. Spool 6. Damper 10-138 PC88MR-10...
  • Page 217 Operation (PC-C6V0-044-K-00-A) When valve is in neutral Ports (A) and (B) of the valve and ports (P1) and (P2) of the PPC valve are connected respectively through fine control hole (f) of spool (1) to drain chamber (D). PC88MR-10 10-139...
  • Page 218 Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool. 10-140 PC88MR-10...
  • Page 219 When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into chamber (B) to replenish the port with pressurized oil. PC88MR-10 10-141...
  • Page 220 The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows from port (P1) to port (A) and pushes the control valve spool. The oil returning from port (B) flows from port (P2) through fine control hole (f') into drain chamber (D). 10-142 PC88MR-10...

  • Page 221: Blade Ppc Valve

    For explanation of operation, see "Work equipment and swing PPC valve". P: From solenoid valve P1: To blade and boom swing valve P2: To blade and boom swing valve T: To tank 1. Spool 2. Piston 3. Lever PC88MR-10 10-143...
  • Page 222 10 Structure and function Blade PPC valve 4. Plate 5. Retainer 6. Body 7. Filter 10-144 PC88MR-10...

  • Page 223: Boom Swing Ppc Valve

    For explanation of operation, see "Work equipment and swing PPC valve". P: From solenoid valve P1: To blade and boom swing valve P2: To blade and boom swing valve T: To tank 1. Spool 2. Piston 3. Lever PC88MR-10 10-145...
  • Page 224 10 Structure and function Boom swing PPC valve 4. Plate 5. Retainer 6. Body 7. Filter 10-146 PC88MR-10...

  • Page 225: Solenoid Valve

    10 Structure and function Solenoid valve Solenoid valve (PC88MR-PQPT-041-K-00-A) a Quadruple type solenoid valve P1: From main pump port P4 A1: To PPC valve PC88MR-10 10-147...
  • Page 226 (2) pushes plunger (1) to the left and port (ACC) and port (P) is disconnected, thus the accumulated pressure in the accumulator is held. When the engine is running, the pilot pressure in port (P) pushes plunger (1) to the right, and between port (P) and port (ACC) are interconnected. 10-148 PC88MR-10...
  • Page 227 The circuit between port (P) and port (A) opens and pilot pressure oil flows from port (A) to the actuator. At the same time, port (T) closes and oil from actuator does not flow to the hydraulic tank. PC88MR-10 10-149...
  • Page 228 C1: To control valve port PA9 C2: To control valve port PB9 P: From 4-spool solenoid valve port A1 T: To hydraulic tank 1. 1st-line attachment L.H. flow adjustment EPC valve 2. 1st-line attachment R.H. flow adjustment EPC valve 3. Block 10-150 PC88MR-10...

  • Page 229: Multi-Control Valve

    10 Structure and function Multi-control valve Multi-control valve (PC88MR-PKP0-041-K-00-A) a This valve is installed as standard to North America specification machines. (if equipped) 1) ISO pattern 2) BACKHOE pattern Control pattern changeover diagram (Port names refer to symbols in drawing) PC88MR-10 10-151...

  • Page 230: Anti-Drop Valve For Boom

    3. Spool (1) is pressed to the left by the force of spring (2) and (3). 4. Chamber (a) and chamber (b) are disconnected. 5. The pressurized oil does not flow from control valve to work equipment cylinder. The work equipment cylinder is held. 10-152 PC88MR-10...
  • Page 231 When there is a damage in the piping 1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder, the pressurized oil of chamber (a) leaks through the damaged part to the outside. PC88MR-10 10-153...
  • Page 232 6. Spool (1) moves rightward further, and chamber (a) and chamber (b) are interconnected. (The second stroke) 7. The pressurized oil returns from the work equipment cylinder to the control valve. When there is a damage in the piping 10-154 PC88MR-10...
  • Page 233 (a) leaks through the damaged part to the outside, but it is supplied from chamber (b). 2. The pressurized oil flows through the opening (C) of spool (1), and it prevents the work equipment from sudden lowering. PC88MR-10 10-155...

  • Page 234: Anti-Drop Valve For Arm

    3. Spool (1) is pressed to the left by the force of spring (2) and (3). 4. Chamber (a) and chamber (b) are disconnected. 5. The pressurized oil does not flow from control valve to work equipment cylinder. The work equipment cylinder is held. 10-156 PC88MR-10...
  • Page 235 When there is a damage in the piping 1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder, the pressurized oil of chamber (a) leaks through the damaged part to the outside. PC88MR-10 10-157...
  • Page 236 6. Spool (1) moves rightward further, and chamber (a) and chamber (b) are interconnected. (The second stroke) 7. The pressurized oil returns from the work equipment cylinder to the control valve. When there is a damage in the piping 10-158 PC88MR-10...
  • Page 237 (a) leaks through the damaged part to the outside, but it is supplied from chamber (b). 2. The pressurized oil flows through the opening (C) of spool (1), and it prevents the work equipment from sudden lowering. PC88MR-10 10-159...

  • Page 238: Center Swivel Joint

    E2: To R.H. and L.H. blade cylinder heads F2: To R.H. and L.H. blade cylinder bottoms G2: To R.H. and L.H. travel motor port P DR2: From R.H. and L.H travel motor ports D1 and D2 1. Cover 2. Rotor 3. Slipper seal 4. Shaft 10-160 PC88MR-10...

  • Page 239: Accumulator

    Specifications (PC88MR-PL40-030-K-00-A) Nitrogen gas Gas to be used Volume of gas (cc) Charged pressure 1.18 {12} (MPa {kg/cm (at 80°C) Max. pressure used 6.86 {70} (MPa {kg/cm PC88MR-10 10-161...
  • Page 240 6.86 {70} (MPa {kg/cm Function (PC138-PL40-042-K-02-A) This accumulator is installed to the attachment piping to absorb the oil pulsation generated by the breaker work into the compressed nitrogen gas in it for protection of the hydraulic component and piping. 10-162 PC88MR-10...

  • Page 241: Work Equipment

    10 Structure and function Work equipment Work equipment (ALL-L000-001-K-00-A) Work equipment (PC88MR-L410-041-K-00-A) 1. Bucket 2. Bucket link 3. Bucket cylinder 4. Arm 5. Arm cylinder 6. Boom 7. Boom cylinder 8. Boom swing bracket 9. Boom swing cylinder 10.Braid cylinder 11.Braid PC88MR-10 10-163...

  • Page 242: Work Equipment Shim

    The purpose of the plastic shim is to reduce the play in the right and left direction of the work equipment and prevent a creak and scuffing caused by rubbing of the end faces of steel parts of a joint. 10-164 PC88MR-10...

  • Page 243: Bucket Play Adjustment Shim

    Split-type iron shims are used for the joint of the arm and bucket. The play in the joint can be adjusted by adjusting the number of the shims. a When the play is large, you can reduce it by removing one or more shims. PC88MR-10 10-165...

  • Page 244: Cab And Its Attachments

    10 Structure and function Cab mount and cab tipping stopper Cab and its attachments (ALL-K000-001-K-00-A) Cab mount and cab tipping stopper (PC88MR-K138-041-K-00-A) 1. Mount rubber (front left, front right) 10-166 PC88MR-10...
  • Page 245 As shown below, mount rubbers (1), (2), and (3) are different in diameter and thickness, depending on their locations. Mount rubber diameter (mm) Mount rubber thickness (mm) Mount rubber location Front left, front right 18.5 Rear left 18.5 Rear right 25.5 PC88MR-10 10-167...

  • Page 246: Rops Cab

    4. Ceiling window 5. KOMTRAX GPS antenna 6. Radio antenna 7. Air conditioner fresh air filter 8. Door 9. Mirror Function (PC220-K000-042-K-00-A) ROPS cab protects the operator fastening a seat belt from being crushed when the machine rolls over. 10-168 PC88MR-10...
  • Page 247 10 Structure and function ROPS cab Take wiring harness out of cab (PC88MR-K16F-520-K-00-A) 1. Grommet Structure 2 grommets (1) are installed to take the wiring out of the cab. PC88MR-10 10-169...

  • Page 248: Electrical System

    10 Structure and function Electrical control system Electrical system (ALL-RA1D-001-K-01-A) Electrical control system (PC220-C050-001-K-00-A) General system drawing (PC88MR-C050-051-K-00-A) a Devices marked with "*1" in the figure are optional. 10-170 PC88MR-10...
  • Page 249 10 Structure and function Electrical control system PC88MR-10 10-171...
  • Page 250 10 Structure and function Electrical control system 10-172 PC88MR-10...
  • Page 251 When you cannot stop the engine due to stuck starting switch (6), engine shutdown secondary switch (7) is usable for stopping the engine. Starting engine When starting switch (6) is turned to "ON" position, engine controller (8) sends a command current to fuel supply pump (16). PC88MR-10 10-173...
  • Page 252 Above induces the same state as when starting switch (6) is turned to "OFF" position, and the engine stops. Engine and pump combined control function (PC88MR-C3W0-042-K-00-A) 1. Battery disconnect switch 2. Battery 3. Battery relay 4. Fusible link 10-174 PC88MR-10...
  • Page 253 When the engine speed decreases, the pump controller reduces the pump absorption torque to prevent the engine from stalling. PC88MR-10 10-175...
  • Page 254 (Q) to increase the engine speed near the matching point. When the load decreases and the pressure decreases accordingly, the controller increases the pump discharged volume until the engine speed reaches near the matching point. 10-176 PC88MR-10...
  • Page 255 Control function when traveling When the machine travels in P mode or ATT-P mode, engine speed (N) increases. Engine speed (N) and pump absorption torque do not change when the machine travels in mode E, ATT-E, B, or L. PC88MR-10 10-177...
  • Page 256 Normal (when normal) a Pump secondary drive switch (1) is alternative type. If the operator operates the machine with this switch at the "Emergency (a)" position while the machine is normal, action level "L03" appears on the display. 10-178 PC88MR-10...
  • Page 257 Function When all the control levers are set to "NEUTRAL" positions while waiting for a dump truck or next work, the engine speed decreases to the control speed automatically to improve the fuel economy and reduce the noise. PC88MR-10 10-179...
  • Page 258 (C). A: All control levers in "NEUTRAL" B: Control lever "operated" C: Fuel control dial set speed D: Engine control speed (approx. 1,175 rpm) E: 4 sec F: Max. 2 sec G: Max. 1 sec 10-180 PC88MR-10...
  • Page 259 12. Fuel supply pump 13. Various sensors 14. Hydraulic oil temperature sensor 15. Main pump 15a. Servo 15b. LS valve 15c. PC valve 16. Control valve 16a. Merge-divider valve 16b. Self-pressure reducing valve 17. PC-EPC valve Input/output signal a. CAN signal PC88MR-10 10-181...
  • Page 260 10 Structure and function Electrical control system b. PC-EPC valve drive signal c. Solenoid valve ground d. Hydraulic oil temperature signal e. Throttle signal f. Fuel supply pump control signal g. Various sensor signals 10-182 PC88MR-10...
  • Page 261 Coolant temperature: Min. 30 Automat- Warm-up operation time: Min. 10 Coolant temperature: Min. 65°C minutes Ambient temperature: Min. 10°C Fuel control dial: Held at 70% of high idle Manual (Max.) for 3 seconds. Canceled Engine speed: Any PC88MR-10 10-183...
  • Page 262 Hydraulic oil temperature: reduced according to the Below 100°C Hydraulic oil temperature: Min. torque control signal. When above condition is 100ºC satisfied, state before Travel judgment: Any position operation is restored (automatic restoration). 10-184 PC88MR-10...
  • Page 263 Hydraulic oil temperature: Alarm buzzer: Sounds Below 105°C Hydraulic oil temperature: Min. Fuel control dial: Return to Low 105ºC idle (MIN) position. Travel judgment: Any position When above condition is satisfied, state before operation is restored (manual restoration). PC88MR-10 10-185...
  • Page 264 B: Turbocharger protection time (approximately 0 to 20 seconds) C: Modulation time (approximately 1.5 second) D: 500 rpm E: 1,175 rpm F: 2,050 rpm (*1) Working mode: P mode Fuel control dial: High idle (MAX) position Swing lever at full stroke 10-186 PC88MR-10...
  • Page 265 The swing parking brake (automatic) is interlocked with the swing operation and prevents hydraulic drift after swing is stopped. To reduce the load on the swing device during digging work, the swing parking brake is released simultaneously with arm IN operation or boom SWING operation. PC88MR-10 10-187...
  • Page 266 Take care. a Swing parking brake cancel switch (2) is alternate type. When it is set to the "RELEASE (a)" position, the swing lock pilot lamp on the machine monitor flashes. 10-188 PC88MR-10...
  • Page 267 Oil pressure sensor signal b. CAN signal c. Travel junction/ pump merge-divider solenoid valve drive signal d. 2-stage travel speed selector solenoid valve drive signal e. Oil pressure sensor signal f. Travel alarm operation signal g. Throttle signal PC88MR-10 10-189...
  • Page 268 When the travel is operated singly, a signal is sent to the merge-divider solenoid valve to set the flow rates to the right and left travel motors independently to improve the travel performance during steering. 10-190 PC88MR-10...
  • Page 269 When no work equipment is operated (work equipment PPC oil pressure Divide switch is "OFF") Travel PPC pressure: Min. 0.49 MPa {5 kg/ When work equipment is operated (work equipment PPC oil pressure Merge switch is "ON") PC88MR-10 10-191...
  • Page 270 When PPC lock switch (8) is turned to "OFF" position, the current flowing into PPC lock solenoid valve (11) is cut out and the work equipment and machine body do not move even if any control lever or pedal is operated. 10-192 PC88MR-10...
  • Page 271 The length of time when the auto idle stop function operates is set on the user menu or service menu on the machine monitor. Conditions for starting operation The auto idle stop function starts when all of the following conditions are satisfied at the same time. PC88MR-10 10-193...
  • Page 272 Fixing auto idle stop time (user menu) Setting Contents of setting Auto idle stop function does not operate. (Default) Stop engine Y minutes (set time at left) after lock lever is set to LOCK position. Y min. 10-194 PC88MR-10...
  • Page 273 If the number of occurrence is not reset by using "Reset number of abrupt stops by auto idle stop", failure code "A900FR" is sent again next time and after. Accordingly, be sure to reset after replacing the turbocharger assembly. PC88MR-10 10-195...
  • Page 274 Lock lever automatic lock cancel switch signal d: Lock lever automatic lock relay drive signal e: PPC lock solenoid valve drive signal f: Switch potentiometer signal g: Breaker operating switch signal h: Oil pressure sensor signal i: Oil pressure switch signal 10-196 PC88MR-10...
  • Page 275 Lock lever automatic lock cancel switch (1) is an alternate type switch. If it is set to "EMERGENCY" (a) position while PPC lock lever is in the free state, the lock lever automatic lock cancel pilot lamp lights up on the display. PC88MR-10 10-197...
  • Page 276 ON position, and then turn it to OFF position, and the lamp goes off in 2 minutes. After system operating lamp (3) goes off, turn battery disconnect switch (1) immediately to "OFF" position. 10-198 PC88MR-10...
  • Page 277 Battery disconnect switch function (PC88MR-AW1P-042-K-00-A) a Battery disconnect switch (1) and system operating lamp (2) are installed inside the left side cover of the machine. 1. Battery disconnect switch 2. System operating lamp (O): OFF position (I): ON position PC88MR-10 10-199...
  • Page 278 If battery disconnect switch (1) is turned OFF for a long period, the machine monitor and the clock of the radio may be initialized. In this case, re-setting is required. 10-200 PC88MR-10...
  • Page 279 16. PC-EPC valve 17. Attachment circuit selector valve 18. Attachment Input/output signal a. 2nd-line attachment flow adjustment EPC valve drive signal b. 1st-line attachment flow adjustment EPC valve drive signal c. Switch potentiometer signal d. Breaker operating switch signal PC88MR-10 10-201...
  • Page 280 The symbols in the signal classification column in the Input/output signal table are as follows. A: Power supply B: Input C: Ground/Shield/Return D: Output E: Communication DRC26 60P(1) [ECM J1(CN-CE01)] Signal name Signal classification Pin No. (*1) (*1) Crankcase pressure sensor (*1) Charge temperature sensor 10-202 PC88MR-10...
  • Page 281 (*1) SCV ( ) (*1) (*1) (*1) Injector #3 (-) Injector #2 (-) Injector #4 (-) (*1) Injector #1 (-) (*1) (*1) (*1) (*1) (*1) Injector #3 ( ) Injector #2 ( ) Injector #4 ( ) (*1) PC88MR-10 10-203...
  • Page 282 (*1) Sensor power supply (5 V) Sensor power supply (5 V) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) EGR valve hall sensor (V) EGR valve hall sensor (W) Variable flow turbocharger hall sensor (V) (*1) (*1) 10-204 PC88MR-10...
  • Page 283 (*1) (*1) (*1) System operating lamp (*1) Continuous power supply (24 V) Continuous power supply (24 V) (*1) (*1) (*1) (*1) CAN_A(+) (KOMNET/c) CAN_A ( ) (KOMNET/c) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) PC88MR-10 10-205...
  • Page 284 (*1) (*1) (*1) (*1) Sensor power supply (5 V) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) Throttle signal (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) (*1) *1: Never connect these pins. Malfunctions or failures may occur. 10-206 PC88MR-10...
  • Page 285 Service oil pressure sensor Input (*1) 1st-line attachment potentiometer 2 Input Oil pressure sensor of pump Input Swing RIGHT PPC oil pressure sensor Input Boom "LOWER" PPC oil pressure sensor Input Arm "IN" PPC oil pressure sensor Input (*1) (*1) (*1) PC88MR-10 10-207...
  • Page 286 Machine model selection 5 (*1) (*1) Starting switch C signal Input External starting signal Input Potentiometer power supply (5 V) Output CAN (C)_L Input/output (*1) (*1) 2nd-line attachment potentiometer 1 Input (*1) Bucket "CURL" PPC oil pressure sensor Input 10-208 PC88MR-10...
  • Page 287 Output (*1) (*1) (*1) (*1) Output Travel alarm Battery relay drive Output (*1) 1st-line attachment R.H. flow adjustment EPC Output (*1) (*1) (*1) Wiper motor ( ) Output GND (solenoid) Input Solenoid power supply Input GND (solenoid) Input PC88MR-10 10-209...
  • Page 288 As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes and a throttle signal is sent to the engine controller. The hatched areas in the graph are abnormality detection areas. If the throttle voltage is within the area, the engine speed drops down to low idle. 10-210 PC88MR-10...
  • Page 289 This resistor allows a proper current to flow to EPC valve, according to the condition, when the pump secondary drive switch s turned to "ON" position. a No current flows normally. CAN terminating resistor (PC220-Q2V1-041-K-00-A) a CAN: Abbreviation for Controller Area Network PC88MR-10 10-211...
  • Page 290 3. O-ring Specifications (PC220-ABK6-030-K-00-A) Contact type: Normally closed Function (ENG95-ABK6-042-K-00-A) This oil pressure sensor is installed to the cylinder block, senses the engine oil pressure, and turns "ON" when the engine oil pressure decreases below the specified pressure. 10-212 PC88MR-10...
  • Page 291 Resetting (OFF) pressure: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm Function (PC88MR-E610-042-P-00-A) This switch is installed to 2 places of the control valve, senses the PPC oil pressure while each actuator is operated, and turns the switch "ON" when the PPC oil pressure exceeds the specified pressure. PC88MR-10 10-213...

  • Page 292: Machine Monitor System

    6. KOMTRAX terminal 7. Sensors and switches 8. Wiper motor and window washer motor 9. Camera (if equipped) Input/output signal a: Power supply b. CAN signal c. Sensor signals and switch signals d. Drive signal e. Camera signal 10-214 PC88MR-10...
  • Page 293 In this case, the machine monitor display may go off for a moment. However, this phenomenon is not a failure. Continuous operation of the machine monitor may display blue bright spots on the screen having a black background; it is quite normal. PC88MR-10 10-215...
  • Page 294 Signal name Input/output signal Pin No. Power supply for camera (8 V) Output Camera NTSC signal 1 Input (*1) (*1) GND (power supply for camera) (*1) (*1) GND (shield) *1: Never connect these pins. Malfunctions or failures may occur. 10-216 PC88MR-10...
  • Page 295 2. Coolant temperature caution lamp 3. ECO gauge 4. Engine coolant temperature gauge 5. Hydraulic oil temperature gauge 6. Hydraulic oil temperature caution lamp 7. Working mode pilot lamp 8. Travel speed pilot lamp 9. Fuel level gauge PC88MR-10 10-217...
  • Page 296 18.Charge level caution lamp 19.Air conditioner pilot lamp, air conditioner system caution lamp 20.Windshield wiper pilot lamp 21.Swing lock pilot lamp 22.Preheater pilot lamp 23.Auto-deceleration pilot lamp 24.Maintenance time caution lamp 25.System caution lamp 26.Action level display 27.ECO guidance 10-218 PC88MR-10...
  • Page 297 3. Hydraulic oil temperature gauge 4. Hydraulic oil temperature caution lamp 5. Engine oil temperature gauge 6. Engine oil temperature caution lamp 7. Working mode pilot lamp 8. Travel speed pilot lamp 9. Fuel level gauge 10.Fuel level caution lamp PC88MR-10 10-219...
  • Page 298 18.Air conditioner pilot lamp, air conditioner system caution lamp 19.Windshield wiper pilot lamp 20.Swing lock pilot lamp 21.Preheater pilot lamp 22.Auto-deceleration pilot lamp 23.Engine oil pressure caution lamp 24.Maintenance time caution lamp 25.System caution lamp 26.Action level pilot lamp 27.ECO guidance 10-220 PC88MR-10...
  • Page 299 (Displays when "ECO Orange Heavy 9, 10 Guidance"o"Confi- gurations"o"ECO Gauge" on user menu is set to "ON".) Indicates accumulated engine operating hours (alternator is Service meter 00000.0 h to 99999.9 h generating). (Press F4 switch to change clock display.) PC88MR-10 10-221...
  • Page 300 *1: If the gauge signal is not available due to an open circuit in the CAN communication line, the gauge pointer disappears. *2: Display can be switched by selecting another item in "ECO Guidance"o"Configurations" on user menu. 10-222 PC88MR-10...
  • Page 301 Maintenance After starting switch time warning is turned to "ON" When Lights up position, monitor maintenance (Yellow) lights up if condition notice time is for lighting it up is over satisfied, and then goes out in 30 seconds. PC88MR-10 10-223...
  • Page 302 *1: This is included in the Check before starting items. After the staring switch is turned to "ON" position, the monitor is lit for 2 seconds, and changes to the standard screen if no failure is found. *2: The notice time is changeable from the items in "Maintenance Mode Setting". 10-224 PC88MR-10...
  • Page 303 10 Structure and function Machine monitor system *3: Be lit for 2 seconds, and then goes out. PC88MR-10 10-225...
  • Page 304 (Unread) Monitor goes out: No message Message Displays the state of the message. (No return Lights up: There is a read message which has not been message, replied. already- Goes out: No message read message) 10-226 PC88MR-10...
  • Page 305 Lo: Low-speed travel Travel speed. speed Hi: High-speed travel Idling stop guidance Indicates Deterrence guidance of hydraulic relief guidance to E-mode recommendation guidance support operation guidance Reduce travel speed recommendation guidance of machine. Low fuel level guidance PC88MR-10 10-227...
  • Page 306 Each time the switch is pressed, (*2) operation of the wiper changes. INT: Intermittent operation Wiper switch INT (intermittent) o ON (continuous) ON: Continuous operation o OFF (stopped) o INT (intermittent) [Numeral key pad: 5] Goes out: Stopped 10-228 PC88MR-10...
  • Page 307 *3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to "HIGH" and does not change even if the set temperature is reached. *4: When the fan is stopped, the air conditioner does not start even if the switch is pressed. PC88MR-10 10-229...
  • Page 308 Green arrow: Moves to the left tab. Move selected item White arrow: Moves to left. (Moves to rightmost item when at leftmost item.) Moves to upper page. (Moves to bottom page when Move selected item at top page.) 10-230 PC88MR-10...
  • Page 309 Cancels holding value of monitoring item. (Use for Cancel holding monitoring) Omits inputting ID on operator ID input screen and moves to Start Work screen. Omit operator ID input (Only when ID No. input SKIP is enabled in operator ID setting) PC88MR-10 10-231...
  • Page 310 Information transmitted can be checked with background colors. Select "Current Abnormality" screen Red: When action level of L2, L3, or L4 is displayed. Yellow: When action level of L0 is displayed. *1: Only for the machine equipped with camera 10-232 PC88MR-10...
  • Page 311 Items available in the operator mode are as follows: Cate- Display order (*2) gory Item (*1) Display of KOMATSU logo Display of password input Display of service person identification state Display of operator ID input screen Display of Check before starting Display of warning after check before starting...
  • Page 312 For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator mode (Outline)" section in Testing and adjusting. a For the operating method of the engine start lock function, see "Password setting, changing and canceling manual". 10-234 PC88MR-10...
  • Page 313 Attachment EPC3 Adjustent Attachment EPC4 Adjustent Attachment EPC5 Adjustent No-Injection Terminal Status KOMTRAX Settings GPS & Communication State Modem Information Service Message a For operating method of the service mode functions, see "Service mode" in Testing and adjusting. PC88MR-10 10-235...

  • Page 314: Komtrax System

    4. Abnormality record a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately. KOMTRAX terminal (PC88MR-Q220-042-K-00-A) Model: TC635/636 1. GPS antenna connection 2. Machine harness connection (070-18P) 3. Machine harness connection (070-12P) 10-236 PC88MR-10...
  • Page 315 When commencing the operation of the KOMTRAX system or changing the country in which the system is used, you must give notice to Komatsu Ltd. a When operating the system in Japan, it is required to install a terminal dedicated for use in Japan.

  • Page 316: Sensor

    "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and temperature". 10-238 PC88MR-10...
  • Page 317 Coolant temperature sensor (ENG-BA87-041-K-00-A) 1. Connector 2. Sensor 3. O-ring Function (ENG-BA87-042-K-00-A) This sensor, installed on the cylinder head of the engine, converts the temperature variation into the resistance variation, and outputs the corresponding signals. Ne (crankshaft) speed sensor (ENG-AG42-041-K-00-A) PC88MR-10 10-239...
  • Page 318 Common rail pressure sensor (ENG95-AE28-041-K-00-A) 1. Common rail pressure 2. Sensor 3. Connector Function (ENG-AE28-042-K-00-A) This sensor, installed to the common rail in the engine, detects the fuel pressure to output the corresponding variable voltage. 10-240 PC88MR-10...
  • Page 319 The variable flow turbocharger motor has a position sensor in it to sense the valve position. EGR valve (with built-in position sensor) (ENG95-AA57-041-K-00-A) a EGR: Abbreviation for Exhaust Gas Recirculation a The shape is subject to machine models. PC88MR-10 10-241...
  • Page 320 This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and temperature into the resistance variation, and outputs the corresponding signals. a The "MAF (Mass Air Flow)" means the "intake air flow". 10-242 PC88MR-10...
  • Page 321 This sensor is installed to the breather top, senses the crankcase pressure (blowby pressure), and outputs it as a variable voltage. Fuel level sensor (PC88MR-AD41-041-K-00-A) 1. Connector 2. Float 3. Arm 4. Body 5. Spring 6. Contact 7. Spacer PC88MR-10 10-243...
  • Page 322 Front pump oil pressure sensor (PC228-C3W4-041-K-00-A) 1. O-ring 2. Sensor 3. Connector Function (PC138-C3WJ-042-K-00-A) This sensor is installed to the control valve, senses the main pump pressure, and outputs it as a variable voltage. 10-244 PC88MR-10...
  • Page 323 3. Connector Function (PC88MR-E720-042-P-00-A) The PPC oil pressure sensor is installed to the control valve connecting part of the work equipment, travel, or swing pilot circuit. It detects the pilot pressure, and outputs a variable voltage. Output characteristics PC88MR-10 10-245...
  • Page 324 10-246 PC88MR-10...

  • Page 325: 20 Standard Value Tables

    SHOP MANUAL HYDRAULIC EXCAVATOR PC88MR-10 Model Serial Number PC88MR-10 7001 and up 20 Standard value tables 4 20 Standard value tables PC88MR-10 20-1...

  • Page 326: Table Of Contents

    Table of contents (ALL-0310-002-A-00-A) 20 Standard value tables........................20-1 Table of contents ........................20-2 Standard service value table......................20-3 Standard value table for engine ..................... 20-3 Standard value table for machine ..................20-5 Standard value table for electrical system................20-21 20-2 PC88MR-10...

  • Page 327: Standard Service Value Table

    20 Standard value tables Standard value table for engine Standard service value table (ALL-A000-001-K-00-A) Standard value table for engine (PC88MR-A000-033-K-00-A) PC88MR-10 Machine model PC88MR-10 Engine SAA4D95LE-6 Standard value Repair limit Item Measurement condition Unit for new machine Maximum 1,950 ± 50 speed(*1) Coolant temperature: 75 to 94°C...
  • Page 328 20 Standard value tables Standard value table for engine Machine model PC88MR-10 Engine SAA4D95LE-6 Standard value Repair limit Item Measurement condition Unit for new machine Fuel Coolant temperature: 75 to 94°C 883 to 1,471 {9 883 to 1,471 {9 {kg/...

  • Page 329: Standard Value Table For Machine

    20 Standard value tables Standard value table for machine Standard value table for machine (PC88MR-0000-033-K-00-A) Engine speed Machine model PC88MR-10 Standard value Repair limit Item Measurement condition Unit for new machine Hydraulic oil temperature: 45 to 55°C Coolant temperature: 75 to When pump is relieved 1,850 ±...
  • Page 330 20 Standard value tables Standard value table for machine Control effort of control lever Machine model PC88MR-10 Standard value Repair limit Item Measurement condition Unit for new machine 15.7 ± 3.9 Max. 24.5 Boom control lever {1.6 ± 0.4} {Max. 2.5} 15.7 ±...
  • Page 331 20 Standard value tables Standard value table for machine Hydraulic pressure Machine model PC88MR-10 Standard value Repair limit Item Measurement condition Unit for new machine Hydraulic oil temperature: 45 to 55°C Engine: High idle 3.43 ± 0.98 3.43 ± 0.98...
  • Page 332 20 Standard value tables Standard value table for machine Machine model PC88MR-10 Standard value Repair limit Item Measurement condition Unit for new machine Hydraulic oil Pump 26.5 ± 0.98 26.5 ± 1.47 temperature: 45 to discharge {270 ± 10} {270 ± 15} 55 °C...
  • Page 333 20 Standard value tables Standard value table for machine Swing Machine model PC88MR-10 Standard value Repair limit Item Measurement condition Unit for new machine Arm length: 1650 mm Bucket: Rated load (451 kg) Arm length: 2100 mm For measuring posture, see "Swing 1"...
  • Page 334 20 Standard value tables Standard value table for machine Travel Machine model PC88MR-10 Standard value Repair limit Item Measurement condition Unit for new machine For measuring posture, see "Travel 1" 37± 4 Max. 44 Engine: High idle Hydraulic oil temperature: 45 Travel speed (idle running) to 55 °C...
  • Page 335 20 Standard value tables Standard value table for machine Work equipment Machine model PC88MR-10 Standard value for new Repair limit Item Measurement condition Unit machine Whole work Arm length: 2100 mm equipment For measuring posture, Max. 350 Max. 600 (Hydraulic drift of see "Work equipment 1"...
  • Page 336 20 Standard value tables Standard value table for machine Machine model PC88MR-10 Standard value for new Repair limit Item Measurement condition Unit machine 2.8 ± 0.3 Arm length: (To just 1650 mm before Max. 3.5 For measuring cushion) posture, see...
  • Page 337 20 Standard value tables Standard value table for machine Machine model PC88MR-10 Standard value for new Repair limit Item Measurement condition Unit machine For measuring posture, see "Work equipment 7" Engine: Low idle Hydraulic oil temperature: 45 to 55 °C...
  • Page 338 20 Standard value tables Standard value table for machine Pump performance Machine model PC88MR-10 Discharged Discharged volume volume Item Measurement condition Unit Standard Repair limit value Pump speed (rpm): 1,850 rpm PC-EPC current value (mA): 350 mA Test pump discharged pressure (MPa {kg/...
  • Page 339 20 Standard value tables Standard value table for machine PC88MR-10 20-15...
  • Page 340 Standard value table for machine Machine posture and procedure for measuring performance (PC88MR-0000-321-K-00-A) Control valve: Spool stroke Swing 1: Flow during swing stop, time required for swing start, time required for swing Swing 2: Swing drift on a slope 20-16 PC88MR-10...
  • Page 341 20 Standard value tables Standard value table for machine Travel 1: Travel speed (idle turns) Travel 2: Travel speed (actual travel) and travel deviation Travel 3: Travel deviation Travel 4: Machine drift on a slope PC88MR-10 20-17...
  • Page 342 20 Standard value tables Standard value table for machine Work equipment 1: Hydraulic drift of work equipment Work equipment 2: Boom speed Work equipment 3: Arm speed Work equipment 4: Bucket speed 20-18 PC88MR-10...
  • Page 343 20 Standard value tables Standard value table for machine Work equipment 5: Offset speed Work equipment 6: Blade speed Work equipment 7: Boom time lag Work equipment 8: Arm time lag PC88MR-10 20-19...
  • Page 344 20 Standard value tables Standard value table for machine Work equipment 9: Bucket time lag Work equipment 10: Blade time lag 20-20 PC88MR-10...

  • Page 345: Standard Value Table For Electrical System

    1. Turn starting switch to OFF position. 2. Disconnect connector TWTR, and connect socket to male side. Coolant temperature sensor a Regard coolant temperature sensor as normal if its resistance is 700 z to 37 kz when coolant temperature is min. 0°C. PC88MR-10 20-21...
  • Page 346 25 to 28 kz Intake air temperature 0°C 5.5 to 6.1 kz Between P55 (male) (3) and (4) sensor 25°C 1.9 to 2.1 kz Resistance a Intake air temperature- 40°C 1.1 to 1.2 kz Resistance characteristics 180 to 185 z 100°C 20-22 PC88MR-10...
  • Page 347 Between V921 (male) (1) and ground Min. 1 Mz 1. Turn starting switch to OFF position. Attachment oil flow 2. Disconnect connector V92, and connect T-adapter to male side. adjustment EPC solenoid Between V92 (male) (1) and (2) Resistance 3 to 14 z PC88MR-10 20-23...
  • Page 348 0.5 to 4.5 V 1. Turn starting switch to OFF position. 2. Insert T-adapter into connector P10. Swing right pressure 3. Turn starting switch to ON position. sensor Voltage Between P10 (2) and (1) Sensor output 0.5 to 4.5 V 20-24 PC88MR-10...
  • Page 349 1. Turn starting switch to OFF position. 2. Disconnect connector P21 and connect T-adapter to male side. Between P21 (male) (1) and Approx. 10 z FULL Fuel level sensor ground Resistance Approx. 85 to EMPTY a Fuel level sensor 95 z characteristics PC88MR-10 20-25...
  • Page 350 20 Standard value tables Standard value table for electrical system 20-26 PC88MR-10...

  • Page 351: 30 Testing And Adjusting

    SHOP MANUAL HYDRAULIC EXCAVATOR PC88MR-10 Model Serial Number PC88MR-10 7001 and up 30 Testing and adjusting 5 30 Testing and adjusting PC88MR-10 30-1...

  • Page 352: Table Of Contents

    KOMTRAX terminal start-up procedure ................30-121 Adjusting rearview camera angle ..................30-125 Handling voltage circuit of engine controller................ 30-127 Handling battery disconnect switch ..................30-128 Testing diodes ......................... 30-129 Pm clinic ..........................30-130 Pm Clinic service ......................30-130 30-2 PC88MR-10...

  • Page 353: Related Information On Testing And Adjusting

    Check auto-tensioner, 3 796 401 1310 Bracket replace 4 01583 13018 Nut 1 Size: M30 × 1.5 mm Commercially Wrench available Writing compensation Lap top type personal Commercially Windows XP SP2/VISTA/ values at replacement X 1 computer Windows7 available PC88MR-10 30-3...
  • Page 354 1 Pressure range: 50 MPa 4 796T-440-1101 Sensor adapter Pressure gauge: 2.5, 6, 40, 60 799-101-5002 Hydraulic tester Testing output 790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa pressure of solenoid valve Size: 02 2 799-401-3100 Adapter 30-4 PC88MR-10...
  • Page 355 Commercially Ruler hydraulic drift available Testing work Commercially Stopwatch equipment speed available Testing voltage and Commercially Multimeter resistance available Removal and 19 mm deep socket installation of engine 795T-981- Socket (MITOLOY 4ML-19 or equivalent) coolant temperature 1010 sensor PC88MR-10 30-5...

  • Page 356: Sketch Of Tools For Testing And Adjusting

    Sketch of tools for testing and adjusting (PC88MR-3531-061-A-00-A) Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. P4: Sensor adapter P4: Nipple (the internal parts of the sensor adapter shown in the above figure)
  • Page 357 30 Testing and adjusting Related information on testing and adjusting Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches. -: Socket PC88MR-10 30-7...

  • Page 358: Engine And Cooling System

    Power mode (P). 3) Operate the L.H. work equipment control lever to relieve the arm circuit at the OUT stroke end, and measure the engine speed. 5. Measuring the engine speed when auto- deceleration is activated 30-8 PC88MR-10...

  • Page 359: Testing Exhaust Gas Color

    1) Insert probe [1] of smoke meter B2 into the value. outlet of exhaust pipe (1), and fix it to the 8) After finishing the test, remove the testing exhaust pipe with clip. tools, and restore the machine. PC88MR-10 30-9...

  • Page 360: Testing And Adjusting Valve Clearance

    1. While fixing adjustment screw (16), loosen lock nut (17). 2. Insert feeler gauge C in the clearance between rocker arm (14) and crosshead (15) and adjust the valve clearance with adjustment screw (16). 30-10 PC88MR-10...
  • Page 361 39.2 to 49 Nm {4 to 5 kgm} a After tightening lock nut (17), check the valve clearance again. 4. After finishing the adjustment, remove the testing tools, and restore the machine. Cylinder head cover mounting nut: 7.8 to 9.8 Nm {0.8 to 1.0 kgm} PC88MR-10 30-11...

  • Page 362: Testing Compression Pressure

    3. Drain the fuel and its level lowers to 1/4 (about 31l: F5 of the fuel level gauge). a It is because it may flow back from the return circuit when the engine is cranked. 7. Connect compression gauge D1 to adapter D2. 30-12 PC88MR-10...
  • Page 363 1) Install O-ring (D4) and gasket (D3) to injector (15). a Do not fit O-ring (D4) to groove (a). a Install gasket D3 so that it does not fall from injector (15) due to its own weight. Apply grease, if necessary. PC88MR-10 30-13...

  • Page 364: Testing Blowby Pressure

    6. Start the engine, and set the working mode to power mode (P). 7. Measure the blowby pressure when the hydraulic relief is made by arm IN operation at engine high idle. a Read the blowby gas pressure when the gauge pointer stands still. 30-14 PC88MR-10...

  • Page 365: Testing Engine Oil Pressure

    2. Remove oil pressure pickup plug (3) from the engine block. 6. After finishing the test, remove the testing tools, and restore the machine. Oil pressure pickup plug: 20 to 22 Nm {2.0 to 2.2 kgm} PC88MR-10 30-15...

  • Page 366: Testing Fuel Pressure

    7.8 to 9.8 Nm {0.8 to 1.0 kgm} 2) Install adapter G2 and nipple [1] of hydraulic tester G1, and connect them to oil pressure gauge [2]. a Use the oil pressure gauge of 2.5 MPa {25 kg/cm 30-16 PC88MR-10...

  • Page 367: Testing Fuel Return Rate And Leakage

    11. Fuel cooler Be careful not to touch any hot parts when installing or removing the testing tools. a Since fuel flows out during the test, prepare an oil pan (container to catch the fuel) of approximately 20 l. PC88MR-10 30-17...
  • Page 368 If the error of no-pressure feed occurs on the supply pump, the engine speed may not rise. In this case, record the engine speed during the test as well. a For standard values, see "Standard value table for engine". 30-18 PC88MR-10...
  • Page 369 30 Testing and adjusting Engine and cooling system 3) Stop the engine after the measurement is over. 4. After finishing the measurement, remove the testing tools, and restore the machine. Joint bolt: 3.6 to 6.9 Nm {0.4 to 0.7 kgm} PC88MR-10 30-19...

  • Page 370: Bleeding Air From Fuel System

    Move the knob until its movement becomes heavy. a You may not remove the plug on the top surface of the main fuel filter. 4. After bleeding air, push knob (1) in and tighten it. 30-20 PC88MR-10...
  • Page 371 Fuel tank o prefilter o feed pump o main filter o SCV (suction control valve) o fuel tank 1. Fuel tank 2. Fuel prefilter 3. Priming pump 4. Main filter 5. Feed pump 6. SCV (Suction control valve) 7. Common rail 8. Injector 9. Supply pump 10. Fuel cooler PC88MR-10 30-21...

  • Page 372: Testing Fuel Circuit For Leakage

    Y is sprayed. a If any fuel leakage is detected, repair it and perform the checks from step 1 again. 8. Start the engine and keep it running at high idle, then apply a load to the engine. 30-22 PC88MR-10...

  • Page 373: Handling Cylinder Cutout Mode Operation

    This allows to find out a defective cylinder easily. PC88MR-10 30-23...

  • Page 374: Handling No-Injection Cranking Operation

    It is performed before the engine is started, or after the machine has been stored for a long period. a When performing no-injection cranking operation, see "Special functions of machine monitor". 30-24 PC88MR-10...

  • Page 375: Testing And Adjusting Air Conditioner Compressor Belt Tension

    Check each pulley for breakage, wear of the V-groove, and contact of the V-belt with V- groove. a If the V-belt is elongated exceeding the adjustment allowance or it has a cut or a crack, replace it with a new one. PC88MR-10 30-25...

  • Page 376: Check Fan Belt, Replace

    Part whose size or length is wrong has been used. Pulley is out of the position. Pulley is damaged. auto-tensioner is damaged. Installation state is improper. Severe operating environment Oil and grease are attached to the side of the belt. 30-26 PC88MR-10...
  • Page 377 U2 and that of nut U4 become flush at this time. If holding bracket U3 is insufficiently clipped between protrusions (b) and (d), it may be removed. Therefore, securely tighten nut U4. 5. Replace fan belt (4). Check each pulley for breakage and crack. PC88MR-10 30-27...

  • Page 378: Check Auto-Tensioner, Replace

    (e). 6. Apply the wrench U5 to portion (C) (width across flats: 12.7 mm) of tensioner assembly (2), and turn it in the direction opposite to the tightening direction to decrease the tension of fan belt (4). 30-28 PC88MR-10...
  • Page 379 (2) to be aligned with the groove (7) of the 11.Remove collar U2. cylinder block. 12.Check that the arm stop part (c) of the auto- tensioner (4) does contact with the spring case stop part (e). a Replace the auto-tensioner (2) if it does not. PC88MR-10 30-29...
  • Page 380 30 Testing and adjusting Engine and cooling system 3. Install the bolt (5). bolt (5) : 43 ± 6 Nm {4.4 ± 0.6 kgm} 30-30 PC88MR-10...

  • Page 381: Writing Compensation Values At Replacement Of Injector And Engine Controller

    Section A: Make sure that "INLINE 5 USB 2. Connect INLINE 5 kit X3 and cable X4 to (J1939) Connection" is indicated. personal computer X1, and then connect the cable to service connector (CN-N08). 2) Select "Connect". PC88MR-10 30-31...
  • Page 382 Replacing engine controller Setup". When the engine controller is replaced, Section G: Make sure that "High write the injector compensation value Pressure Common Rail Injector Setup" is written on the old engine controller to the indicated. new engine controller. 30-32 PC88MR-10...
  • Page 383 "Cylinder1". Section J: Select "Apply." 7) Screen that indicates data writing is over. Select "OK". Section M: Select "OK." 5) After writing data, turn the starting switch to OFF position and select "OK". Section K: Select "OK." PC88MR-10 30-33...
  • Page 384 (After rechecking data, perform the cylinders, in the same way as you did in the operation again.) above when you replaced the injector. 6. Disconnect and end the communication with the engine controller. Section Q: Select "Disconnect from ECM." 30-34 PC88MR-10...

  • Page 385: Power Train

    4. Set the arm at about a right angle to the ground, and lower the boom until the track shoe at the front of the machine rises 150 to 200 mm above the ground. a At this time, the front of the upper structure rises and the rear lowers. PC88MR-10 30-35...

  • Page 386: Undercarriage And Frame

    3) After finishing adjustment, check that the tension is correct according to the preceding procedure. T 2 P 0 2 8 0 0 30-36 PC88MR-10...

  • Page 387: Hydraulic System

    Pressure cannot be released with this however, after the work equipment procedure if the function of accumulator control levers are operated two to three is deteriorated. times. PC88MR-10 30-37...
  • Page 388 3. Turn the starting switch to ON position. 1) Turn the starting switch to ON position and 4. Set the work equipment lock lever in FREE set the work equipment lock lever to FREE position. position, and then operate the right and left 30-38 PC88MR-10...
  • Page 389 2. Keep the work equipment at the maximum reach, turn the starting switch to OFF position, and stop the engine. 3. Turn the starting switch to ON position. 2. Release remaining pressure in hydraulic cylinder circuit PC88MR-10 30-39...
  • Page 390 The remaining pressure in the swing motor circuit can be released by performing the same operation as that described in preceding "Releasing remaining pressure in hydraulic cylinder circuit" (Operate the lever to SWING only, however). Releasing remaining pressure from travel motor circuit 30-40 PC88MR-10...
  • Page 391 The engine does not start unless the lock lever is set to LOCK position. 4. Repeat above steps 2) and 3) 2 to 3 times, and all remaining pressure is released from the piping completely. PC88MR-10 30-41...

  • Page 392: Testing And Adjusting Oil Pressure In Work Equipment And Travel Circuits

    The oil pressure at which the unload valve unloads is displayed. 3. Testing the work equipment relief pressure 1) Start the engine, and operate the cylinder to be measured to the stroke end. 30-42 PC88MR-10...
  • Page 393 (pump discharged pressure) can be checked from the "Pre-defined Monitoring" or the "Self-define Monitoring" screen of the machine monitor. 1. Start the engine and set the machine monitor to the "Pre-defined Monitoring" or the "Self-define Monitoring" screen. PC88MR-10 30-43...
  • Page 394 Approximately 19.6 MPa {Approximately 200 kg/cm 4. While fixing holder (4), tighten lock nut (5). Lock nut: 39 to 49 Nm {4 to 5 kgm} 5. After finishing the adjustment, check the oil pressure again according to the above procedure. 30-44 PC88MR-10...

  • Page 395: Testing And Adjusting Swing And Blade Circuit Oil Pressure

    The pressure when the safety valve of the swing motor relieved is displayed. a The swing relief pressure is lower than the main relief pressure. 3. Testing blade (LOWER) relief pressure PC88MR-10 30-45...
  • Page 396 19.6 MPa {200 kg/cm 2) After finishing the adjustment, tighten lock 2) After finishing the adjustment, tighten lock nut (4). nut (7). Lock nut: Lock nut: 93.2 to 117.7Nm {9.5 to 12kgm} 39 to 49 Nm {4 to 5 kgm} 30-46 PC88MR-10...
  • Page 397 Quantity of adjustment per turn of adjusting screw: 19.6 MPa {200 kg/cm 2) After finishing the adjustment, tighten lock nut (10). Lock nut: 39 to 49 Nm {4 to 5 kgm} PC88MR-10 30-47...

  • Page 398: Testing Oil Pressure Of Control Circuit

    3. Start the engine, set the working mode to power mode (P), and turn the auto deceleration OFF. 4. Run the engine at high idle, set all of control levers and pedals of work equipment, swing, and travel in neutral, and measure the oil pressure. 30-48 PC88MR-10...

  • Page 399: Testing And Adjusting Oil Pressure In Pump Pc Control Circuit

    IN stroke end. 4) Set the working mode to Power Mode (P). 5) Run the engine at high idle, operate the left work equipment control lever to relieve the arm cylinder circuit at IN end, and measure the oil pressure. PC88MR-10 30-49...
  • Page 400 (If it is rotated in the reverse direction, you can easily return it to the original position.) 1. Loosen lock nut (5). 2. Adjust by rotating adjustment screw (6) clockwise or counterclockwise. 30-50 PC88MR-10...
  • Page 401 3. Tighten lock nut (5). Lock nut: 29.4 to 39.2 Nm {3.0 to 4.0 kgm} 4. After finishing adjustment, check again that the pump control pressure (the inlet pressure of servo piston) is normal according to the preceding check procedure. PC88MR-10 30-51...

  • Page 402: Testing And Adjusting Oil Pressure In Pump Ls Control Circuit

    (1): Pump discharged pressure pickup port (2): LS valve output pressure pickup plug 4. Start the engine, run the engine at high idle, set the control levers in NEUTRAL, and measure the oil pressure at the full stroke of bucket CURL. 30-52 PC88MR-10...
  • Page 403 5. After finishing the test, remove the testing tools and restore the machine. Adjusting (PC88MR-C2A4-270-K-00-A) Adjustment of LS valve a If the LS differential pressure is abnormal, adjust the LS valve according to the following "Self-define Monitoring" screen procedure. (3): LS valve PC88MR-10 30-53...
  • Page 404 1.27 MPa {13 kg/cm 3. While fixing adjustment screw (4), tighten lock nut (5). Lock nut: 29.4 to 39.2 Nm {3 to 4 kgm} 4. After finishing the adjustment, check the LS differential pressure again according to the above procedure. 30-54 PC88MR-10...

  • Page 405: Testing Outlet Pressure Of Solenoid Valve

    2. Install adapter Q2 and connect the disconnected hose again. 3. Install nipple [1] of hydraulic tester Q1, and connect them to oil pressure gauge [2]. a Use the oil pressure gauge of 5.9 MPa {60 kg/cm PC88MR-10 30-55...

  • Page 406: Testing Ppc Valve Outlet Pressure

    6. After finishing the test, remove the testing tools, hydraulic circuit. For details, see "Releasing and restore the machine. remaining pressure in hydraulic circuit". a Before testing PPC valve output pressure, check that the control circuit source pressure is normal. 30-56 PC88MR-10...

  • Page 407: Adjusting Play Of Work Equipment And Swing Ppc Valves

    (Portion J): Apply grease (G2 L1) of 7 to 10 ml all around. (Portion P): Apply gear oil of 0.2 to 0.4 ml to the sliding parts (4 places) of the joints and pins. 5. Install boot (1). PC88MR-10 30-57...

  • Page 408: Isolating The Parts Causing Hydraulic Drift In Work Equipment

    If the accumulator pressure is reduced, run the engine for approximately 10 seconds to accumulate the pressure. a In case of a difference of lowering volume between the LOCK and FREE positions, the PPC valve is defective (internal defect). 30-58 PC88MR-10...

  • Page 409: Testing And Adjusting Travel Deviation

    3. Run the engine at high idle and measure travel deviation (a) in travel of 20 m after running up 10 a Install oil pressure gauge and check that discharged pressures P and P of the hydraulic pump are even. PC88MR-10 30-59...
  • Page 410 Adjustment limit (2 turns/ 720 deg. or less) by adjustment plug must not be exceeded. 2. Loosen lock nut (3) while fixing plug (1) or (2) with a hexagonal wrench (width across flats: 4 mm). a Securely insert the hexagonal wrench. 30-60 PC88MR-10...

  • Page 411: Testing Oil Leakage

    2. Testing oil leakage of arm cylinder on the cylinder bottom side. 1) Set the arm cylinder to arm IN operation side a Use the following parts to block the hose. to the end of its stroke, and stop the engine. 07376-70422 (Plug #04) PC88MR-10 30-61...
  • Page 412 1 minute. relieve the circuit by right swing. 6) Restore the machine after finishing the test. 6. Testing oil leakage of swing motor Be careful not to operate the lever to 1) Remove cover (6). "Left SWING" side. 30-62 PC88MR-10...
  • Page 413 Use the following parts to block the hose. 07376-70315 (Plug #03) 4) Start the engine, run it at high idle, relieve the travel circuit, and measure the leakage at this time. PC88MR-10 30-63...
  • Page 414 1 minute. a Measure several times, moving the motor a little each time (changing the relative position between the valve plate and cylinder and that between the cylinder and piston). 5) Restore the machine after finishing the test. 30-64 PC88MR-10...

  • Page 415: Bleeding Air From Hydraulic Circuit

    Keep the oil filler cap of the hydraulic tank loosened during air bleeding work of the Air bleeder: hydraulic pump. 7.8 to 9.8 Nm {0.8 to 1.0 kgm} 1) Loosen air bleeder (1), and check that oil oozes out from the air bleeder. PC88MR-10 30-65...
  • Page 416 Do not perform the swing operation guide. during this work. Oil temperature 10 to 30°C: Halfway 2) Run the engine at low idle and slowly swing between H and L at least 2 times to the right and left. 30-66 PC88MR-10...
  • Page 417 30 Testing and adjusting Hydraulic system Oil temperature 50 to 80°C: Around H level PC88MR-10 30-67...

  • Page 418: Cab And Its Attachments

    Lubricating oil recommended by manufacturer: THREEBOND PANDO 18C 1. Spray lubricating oil sufficiently to bearing (4) and rotary shaft (5) of the slide door roller. 2. After spraying the lubricating oil, check that the door opens and closes smoothly. 30-68 PC88MR-10...

  • Page 419: Adjusting Mirrors

    Adjust the mirror so that the side of the machine is reflected in it as shown in the following figure. a Adjust the mirror so that the side of the machine is reflected in it as shown in the following figure. PC88MR-10 30-69...
  • Page 420 30 Testing and adjusting Cab and its attachments 30-70 PC88MR-10...

  • Page 421: Testing And Adjusting Hood Catcher

    1) Adjusting stopper (3) height a (center part) Remove the rubber cover of handle (2), adjust the protrusion of stopper (3) until stopper (3) touches bracket (6) from hole (9) of the hood handle, and install it. PC88MR-10 30-71...
  • Page 422 30 Testing and adjusting Cab and its attachments 3) Open/close the hood a few times to check if the play is not detected, and then return the rubber cover of handle (2) to the original position. 30-72 PC88MR-10...

  • Page 423: Electrical System

    30 Testing and adjusting Electrical system Electrical system (ALL-RA1D-001-K-01-A) Special functions of machine monitor (PC220-Q170-042-K-01-A) PC88MR-10 30-73...
  • Page 424 Each switch has the function indicated by the icon on it and the function of inputting a numeral. a The machine monitor automatically judges which function of each switch is currently enabled according to the screen display of the multi- information display panel (a). 30-74 PC88MR-10...
  • Page 425 This function is used for special setting, testing, adjusting, or troubleshooting. Operator mode (outline) Service mode A Display of KOMATSU logo(PAGE 30-77) Monitoring/ Pre-defined(PAGE 30-91) A Password input(PAGE 30-77) Monitoring(PAGE 30-94) Display of technician identification status(PAGE...
  • Page 426 OFF position B: Display/Function when machine monitor switch is operated C: Display/Function when certain condition is satisfied D: Display/Function that require special operations of switches 30-76 PC88MR-10...
  • Page 427 KOMATSU logo is displayed for 2 seconds. Display of standard screen 7 5 6 4 5 5 a After the KOMATSU logo screen is displayed for (PAGE 30-80) 2 seconds, the screen changes to "Password Display of end screen(PAGE 30-80) input"...
  • Page 428 Before performing checking and adjusting, responsible for the operation of KOMTRAX in check in advance that the input setting of ID of your Komatsu distributor and ask for remedy. the operator identification function has already been set by the customer.
  • Page 429 After the display of the working mode and travel mode settings is finished, the screen changes to a The following figure shows that engine oil level the display of standard screen. monitor (a) is warning of low engine oil level. PC88MR-10 30-79...
  • Page 430 ECO gauge (b) is displayed at the left end of the screen. (Switch the display in the operator mode.) If you turn the engine shutdown secondary switch to OFF position, the KOMATSU logo appears once, and then the display changes to the standard screen. Selection of auto-deceleration...
  • Page 431 If not operating both of the function switch display of travel speed monitor (b) is also and working mode selector switch for 5 changed. seconds or longer, the selection is entered and the standard screen appears again. PC88MR-10 30-81...
  • Page 432 If the switch is not operated for 5 seconds or longer while the air conditioner setting screen is displayed, the screen changes to the standard screen. 30-82 PC88MR-10...
  • Page 433 [F6] and then [F1] or [F2] to change the monitor to returns to the standard screen (camera used in the maintenance screen. Then you can check the combination). information. a To reset the remaining time after finishing the maintenance, further operations are required. PC88MR-10 30-83...
  • Page 434 For technician: It denotes the messages transmitted from the KOMTRAX base station to technicians. Upon receiving a message, nothing is displayed on the standard screen. Operate "Service message display" of the service mode when viewing contents of a message. 30-84 PC88MR-10...
  • Page 435 Low fuel level guidance If the operable time estimated from the current fuel level latest average fuel consumption is shorter than 8 hours, the low fuel level guidance is displayed. PC88MR-10 30-85...
  • Page 436 Stop the work once, and run the engine at medium speed with no load or stop the engine. If no improvement is seen, ask your Komatsu distributor for checking and (Intermittent) repair services. Some functions may be limited. However, you can perform the work.
  • Page 437 (points that remain lit) may appear on this screen. It a Default password: [000000] does not indicate that the LCD panel is faulty or a When the input password is correct, the defective. screen changes to the next screen. PC88MR-10 30-87...
  • Page 438 [F6]: Enters selection. numeral input switches and confirm it by using the function switch. [F5]: Deletes input numbers/Returns to standard screen. [F6]: Enters input password. 30-88 PC88MR-10...
  • Page 439 If the input password is different from the one input before, the message to request inputting again is displayed. If the standard screen is displayed after the screen to notify completion of setting is displayed, the password is changed successfully. PC88MR-10 30-89...
  • Page 440 [F5]: Returns the display to the standard screen (operator mode) [F6]: Enters selection a When you input a 2-digit code by using the numeral input switches, the corresponding menu is directly selected. Accordingly, you may enter the selection by using [F6]. 30-90 PC88MR-10...
  • Page 441 (If the Hold is selected, HOLD part is hatched.) [F5]: Returns the display to service menu screen a For the items not displayed in the "Pre- defined Monitoring", you can freely select and check from the "Monitoring / Custom" items. PC88MR-10 30-91...
  • Page 442 EGR Opening 18105 VFT Opening 19000 Pre-defined Monitoring screen (5/11) Intake and exhaust pressure system Unit (SI) Applicable Item name component Imperial Metric Engine Speed r/min 01002 kg/cm 37400 Ambient Pressure Charge Pressure kg/cm 36500 kg/min kg/min kg/min 48200 30-92 PC88MR-10...
  • Page 443 Hydraulic Oil Temperature 04401 °C °C °F PUMP Pre-defined Monitoring screen (11/11) PPC pressure Unit (SI) Applicable Item name component Imperial Metric Engine Speed 01002 r/min kg/cm PUMP 07101 Travel PPC Pressure Hydraulic Oil Temperature 04401 °C °C °F PUMP PC88MR-10 30-93...
  • Page 444 If the color of the selected box changes from the necessary operation of the machine and yellow to red, the selection of the item of that check the monitoring information. box is entered. a Monitoring information is indicated by value, ON/OFF, or special display. 30-94 PC88MR-10...
  • Page 445 [F6] in the the new setting is held even after the screen following screen. returns to the ordinary screen after KOMTRAX terminal screen monitoring is finished. "With/Without Attachment" screen Functional specification screen Air conditioner setting screen PC88MR-10 30-95...
  • Page 446 30 Testing and adjusting Electrical system 30-96 PC88MR-10...
  • Page 447 07400 Boom Raise PPC Pressure PUMP kg/cm 07500 Boom Lower PPC Pressure PUMP kg/cm 07200 Arm IN PPC Pressure PUMP kg/cm 07600 Arm OUT PPC Pressure PUMP kg/cm 07300 Bucket CURL PPC Pressure PUMP kg/cm 07301 Bucket DUMP PPC Pressure PUMP PC88MR-10 30-97...
  • Page 448 Key SW (ACC) ON, OFF PUMP ON, OFF Lock Lever SW PUMP ON, OFF Lock Lever SW 2 PUMP PPC Lock Solenoid 02203 SW Input 4 ON, OFF PUMP State Lever Auto Lock ON, OFF PUMP Release SW 30-98 PC88MR-10...
  • Page 449 20402 Monitor S/N 20228 Monitor Program P/N 20200 Monitor Program Version 55300 A/C Compressor State ON, OFF 55000 A/C Fresh Air Temp Code 55100 A/C Recirc Air Temp Code 55200 A/C Mode Data (Monitor) 55201 A/C Mode Data (A/C ECU) PC88MR-10 30-99...
  • Page 450 PUMP: The pump controller is in charge of detecting the monitoring information. MON: The machine monitor detects monitoring information. Note 1: Instantaneous fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it is a theoretical value, it is slightly different from the actual fuel consumption ratio.) 30-100 PC88MR-10...
  • Page 451 [F6]. 4. Clearing abnormality record The contents of an abnormality record of the 3. Information displayed on "Abnormality Record" mechanical system cannot be deleted. screen On "Mechanical Sys Abnormality Record" screen, the following information is displayed. PC88MR-10 30-101...
  • Page 452 3. Information displayed on "Abnormality Record" 1) While the "Electrical Sys Abnormality screen Record" screen is displayed, perform the On "Electrical Sys Abnormality Record" screen, following operation by using the numeral the following information is displayed. input switches. 30-102 PC88MR-10...
  • Page 453 1. Selecting menu Select "Maintenance Record" on "Service Menu" screen. 3) After "Electrical Systems Abnormality Record Reset" screen is displayed, operate the function switches. PC88MR-10 30-103...
  • Page 454 "47 KCCV Filter Change" item is directly selected. Accordingly, you "10 Hydraulic Oil Change" may enter the selection by using [F6]. 3. Items displayed on Maintenance Record screen The following information is displayed. 30-104 PC88MR-10...
  • Page 455 [F6]: Enters setting and returns to [F6]: Enters selection and returns to Maintenance mode setting screen "Maintenance Mode Change" screen a Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual setting. PC88MR-10 30-105...
  • Page 456 A while after [F6] is pressed, the initialization mode (the time increases or decreases in completion screen is displayed. Then, when multiples of 25 hours). the "Maintenance Mode Setting" screen is [F3]: Decreases set value displayed, initialization is complete. [F4]: Increases set value 30-106 PC88MR-10...
  • Page 457 [F4]: Moves the input position to the next 1. Selecting a menu right place (if not blank) Select "Default" on the "Service Menu" screen. [F5]: Resets input digit/ Returns the display to the service menu screen [F6]: Validates the entry PC88MR-10 30-107...
  • Page 458 ON position. [F3]: Moves selection downward a Selecting method is the same as on the [F4]: Moves selection upward "Service Menu" screen. [F5]: Cancels selection and returns the display to Default screen 30-108 PC88MR-10...
  • Page 459 When an attachment is installed, if this setting is not configured correctly, the attachment setting in the operator mode cannot be performed. As a result, the attachment may not work normally or the hydraulic components may be damaged. PC88MR-10 30-109...
  • Page 460 Use the menu of "Default" to check or change 3. Selecting camera setting various settings of the machine monitor and After the "Camera" screen is displayed, select a machine. setting by using the function switch. Not Use: Camera is not used 30-110 PC88MR-10...
  • Page 461 [F6]: Enters selection and returns the display to Default screen a When this setting is "OFF", the auto idle stop does not operate. Accordingly, the auto idle stop time setting in the operator mode is disabled. PC88MR-10 30-111...
  • Page 462 Accordingly, the auto idle stop time setting in the operator mode and a Selecting method is the same as on the the auto idle stop time fixing in the service "Service Menu" screen. menu are disabled. 30-112 PC88MR-10...
  • Page 463 In this case, lower the engine speed with the fuel control dial and judge by increase of the injection rate command. 4. Releasing cut out cylinder When changing a cylinder to be cut out or when cylinder cutout operation is finished, select a cut PC88MR-10 30-113...
  • Page 464 "Service Menu" screen. 3. Setting selectable time After the "Reset Number of Abrupt Engine Stop by AIS" screen is displayed, select a setting by using the function switch. [F5]: Returns to the "Diagnostic Tests" screen [F6]: Executes reset 30-114 PC88MR-10...
  • Page 465 The 3-digit number in the left column does -29.4 Nm {-3 kgm} not change since it is the code of this -39.2 Nm {-4 kgm} function. Adjustment (Attachment Flow Adjustment) (PC88MR-Q1F9-100-K-00-A) You can perform various adjustments related to the machine with the machine monitor. PC88MR-10 30-115...
  • Page 466 Attachment EPC 5 Adjustment 2. Displaying check screen When the "No Injection" screen is displayed, the message "Begin Injectionless Cranking?" appears. Select the answer by using the function switch. [F5]: Do not perform (return to Service Menu screen) [F6]: Executes 30-116 PC88MR-10...
  • Page 467 "The engine is operating" is Terminal setting status is used for checking the displayed and the No Injection cranking does not setting condition of the KOMTRAX terminal. become effective. 1. Selecting a menu Select "KOMTRAX Settings" on "Service Menu" screen. PC88MR-10 30-117...
  • Page 468 "Communication": Communication environment and connecting condition of the communication modem "Number of message not yet sent": Number of message(s) not yet sent: Number of unsent mails existing in the machine monitor [F5]: Returns the screen to "KOMTRAX Settings" screen 30-118 PC88MR-10...
  • Page 469 Since this message is special for the technician, the message monitor is not displayed when it is received with the 3. Details displayed on Modem Status screen machine monitor in the operator mode. PC88MR-10 30-119...
  • Page 470 This message is different from that sent to the operator in the operator mode. a Since this message is special for the technician, the message monitor is not displayed when it is received with the machine monitor in the operator mode. 30-120 PC88MR-10...

  • Page 471: Komtrax Terminal Start-Up Procedure

    Communication opening. Accordingly, it is preferable to park the machine outdoors. The a For details, see "KOMTRAX-Keyperson opening may not be completed when the operation manual". machine is placed indoor where radio wave from Outside Japan: the satellite is blocked. PC88MR-10 30-121...
  • Page 472 If "Modem" does not become "OK", check the communication antenna and cable for 2) The screen confirms if you want to external failure. If any, repair it and repeat implement KOMTRAX Communication KOMTRAX Communication opening again. 30-122 PC88MR-10...
  • Page 473 If any, repair it and repeat KOMTRAX Communication opening again. 4) When all items are "OK", "KOMTRAX Communication Opened." screen is automatically displayed. Press Enter switch. "GPS & Communication Status" appears, machine side opening is completed. PC88MR-10 30-123...
  • Page 474 30 Testing and adjusting Electrical system 30-124 PC88MR-10...

  • Page 475: Adjusting Rearview Camera Angle

    The claw of cover (3) is made of plastic, so be careful not to break it when removing. 5. After adjusting, tighten bolts (5). Camera mounting bolt: 11.8 to 14.7 Nm {1.2 to 1.5 kgm} 2. Remove bolts (4) (2 places). 3. Remove cover (2). PC88MR-10 30-125...
  • Page 476 30 Testing and adjusting Electrical system 6. Install covers (2) and (3). 30-126 PC88MR-10...

  • Page 477: Handling Voltage Circuit Of Engine Controller

    2. If the T-adapter is inserted in or connected to the connector between the engine controller and engine harness for troubleshooting, do not start the engine. a You may turn the starting switch to OFF or ON position but must not turn it to START position. PC88MR-10 30-127...

  • Page 478: Handling Battery Disconnect Switch

    (2) is kept lit, turn the starting switch to "ON" position once and then turn it to "OFF (O)" position. Lamp (2) goes out in max. 2 minutes. After system operating lamp (2) goes out, turn the battery disconnect switch immediately to "OFF (O)" position. 30-128 PC88MR-10...

  • Page 479: Testing Diodes

    (normal) (note) Note: In the case of a silicon diode, a value in the range from 460 to 600 mV is indicated. The indicated value is 0 or approximate The diode has internal short circuit (defective). PC88MR-10 30-129...

  • Page 480: Pm Clinic

    30 Testing and adjusting Pm clinic Pm clinic (ALL-2160-001-A-00-A) Pm Clinic service (PC88MR-2160-209-A-00-A) Model Serial No. Service meter T PC88MR-10 Date of inspection Inspector User name Specification Main parts Attachment Shoe width T Standard T Breaker Boom T 450 mm...
  • Page 481 Color of monitor light (a) 105°C 102°C 100°C 80°C Blue 60°C 30°C White Max. range of hydraulic oil temperature gauge Oil temperature level Hydraulic oil temperature Color of monitor light (a) 105°C 102°C 100°C 80°C Blue 40°C 20°C White PC88MR-10 30-131...
  • Page 482 Pm clinic Check sheet (PC88MR-2160-033-A-00-A) a Perform the checks after sufficient warm-up operation of the engine. Date of Inspector Model Serial No. Service meter User name inspection PC88MR-10 Engine Machine model PC88MR-10 Engine SAA4D95LE-6 goo- Standard Mea- Testing conditions Repair limit...
  • Page 483 30 Testing and adjusting Pm clinic Work equipment speed Machine model PC88MR-10 Engine SAA4D95LE-6 Standard Mea- Testing conditions Repair limit Item Unit value for new sured machine item Hydraulic oil temperature: 45 to 55°C Arm length: Engine: High idle 1650 mm Working mode: P mode 2.5 to 3.1...
  • Page 484 30 Testing and adjusting Pm clinic Machine model PC88MR-10 Engine SAA4D95LE-6 Standard Mea- Testing conditions Repair limit Item Unit value for new sured machine item Hydraulic oil temperature: 45 to 55°C Engine: High idle Working mode: P mode Measurement range: Between...
  • Page 485 30 Testing and adjusting Pm clinic Machine model PC88MR-10 Engine SAA4D95LE-6 Standard Mea- Testing conditions Repair limit Item Unit value for new sured machine item Hydraulic oil temperature: 45 to 55°C Engine: High idle Working mode: P mode Boom Measurement range: Between...
  • Page 486 30 Testing and adjusting Pm clinic Travel speed Machine model PC88MR-10 Engine SAA4D95LE-6 goo- Standard Mea- Testing conditions Repair limit Item Unit value for new sured machine item Hydraulic oil 33.0 to 41.0 Max. 44.0 temperature: 45 to 55°C Engine: High idle...
  • Page 487 30 Testing and adjusting Pm clinic Hydraulic circuit Machine model PC88MR-10 Engine SAA4D95LE-6 goo- Mea- Standard Testing conditions Repair limit Item Unit sured value for new item machine Hydraulic oil temperature: 45 to 55°C Control Engine: High idle 2.7 to 3.7 2.7 to 3.7...
  • Page 488 30 Testing and adjusting Pm clinic Machine model PC88MR-10 Engine SAA4D95LE-6 goo- Standard Mea- Testing conditions Repair limit Item Unit value for new sured machine item Front pump 25.5 to 27.5 25.0 to 28.0 discharge {260 to 280} {255 to 285}...

  • Page 489: 40 Troubleshooting

    SHOP MANUAL HYDRAULIC EXCAVATOR PC88MR-10 Model Serial Number PC88MR-10 7001 and up 40 Troubleshooting 6 40 Troubleshooting PC88MR-10 40-1...

  • Page 490: Table Of Contents

    Failure code [CA271] PCV1 Short Circuit Error ..............40-155 Failure code [CA272] PCV1 Open Circuit Error ..............40-156 Failure code [CA322] Injector #1 (L#1) Open or Short Circuit ..........40-157 Failure code [CA324] Injector #3 (L#3) Open or Short Circuit ..........40-159 40-2 PC88MR-10...
  • Page 491 Failure code [D19JKZ] Personal Code Relay Open or Short ..........40-248 Failure code [D811MC] KOMTRAX Malfunction ..............40-251 Failure code [D862KA] GPS Antenna Open Circuit ............. 40-252 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ........40-253 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ........40-255 PC88MR-10 40-3...
  • Page 492 Failure code [DXE7KB] Att Flow Regulating EPC 2 Short Circuit .......... 40-358 Failure code [DXE7KY] Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit ........................ 40-360 Failure code [DXEAKA] Att Flow Regulating EPC 5 Open Circuit ......... 40-362 Failure code [DXEAKB] Att Flow Regulating EPC 5 Short Circuit.......... 40-364 40-4 PC88MR-10...
  • Page 493 E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated ......................40-434 E-40 Wiper does not operate while wiper switch is operated ..........40-435 E-41 Window washer does not operate while window washer switch is operated ....40-437 PC88MR-10 40-5...
  • Page 494 H-35 Oil flow in attachment circuit cannot be controlled ............40-513 Troubleshooting of engine (S-mode)..................40-514 Information mentioned in troubleshooting table (S mode)............. 40-514 S-1 Engine does not crank when starting switch is turned to START position......40-515 40-6 PC88MR-10...
  • Page 495 S-16 Water mixes into engine oil (milky) ................40-535 S-17 Coolant temperature rises too high (overheating) ............40-536 S-18 Unusual noise is heard ..................... 40-537 S-19 Vibration is excessive ....................40-538 S-20 Air cannot be bled from fuel circuit ................40-539 PC88MR-10 40-7...

  • Page 496: Related Information On Troubleshooting

    5) Had any repairs been performed before the failure? When were these repairs performed? 6) Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Is there any sign of irregularities of the machine? 2) Make checks before starting day's work. 40-8 PC88MR-10...
  • Page 497 6. Measures to remove root cause of failure Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is eliminated. To that end, you must locate and eliminate the primary cause behind the given failure. PC88MR-10 40-9...

  • Page 498: Sequence Of Events In Troubleshooting

    40 Troubleshooting Related information on troubleshooting Sequence of events in troubleshooting (ALL-5140-42A-A-00-A) (Rev. 2011. 7) 40-10 PC88MR-10...
  • Page 499 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-11...

  • Page 500: Checks Before Troubleshooting

    Refilling of oil H and L Between 7 Check of damper case oil level Refilling of oil H and L Refilling of oil 8 Check of final drive case oil level Bleed air from 9 Air bleeding cylinder 40-12 PC88MR-10...
  • Page 501 Clean or repair 1 Check of undercarriage Correct 2 Check of handrails and steps Correct Clean or repair 3 Check of rear view mirrors 1 Check of gauges and monitors Clean or replace Replace 2 Check of seat belt PC88MR-10 40-13...

  • Page 502: Inspection Procedure Before Troubleshooting

    If any of them has a problem, repair the (machine with the air conditioner)". damage. a14. Check around KDOC muffler and dirt removal Check and remove any accumulated dirt and combustibles (dead leaves, twigs,etc.) around KDOC muffler. a15. Check around KDOC muffler for gas leakage 40-14 PC88MR-10...
  • Page 503 Never bring open flames near fuel. a A special filter with high-efficiency filtering properties is adopted for Komatsu genuine fuel filter cartridges. Be sure to use Komatsu genuine parts when replacing. PC88MR-10...
  • Page 504 The common rail fuel injection system used on this machine consists of more precise parts than those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine fuel prefilter cartridge is used, foreign materials may enter and problem may occur in the injection system.
  • Page 505 11.When installing the cartridge, tighten it until the those in the conventional injection pump and packing surface contacts the sealing surface of nozzles. If any cartridge other than a Komatsu the filter head, then tighten it 3/4 of a turn. genuine fuel filter cartridge is used, foreign...
  • Page 506 Remove cap (B) in center, and install filter cartridge (3). 3) Push in and tighten fuel feed pump knob (4). 10.After replacing filter cartridge (3), start the engine and run it at low idle for 10 minutes. 40-18 PC88MR-10...
  • Page 507 If the oil level is below L mark, add oil through oil to the radiator and then to the reservoir tank. filler port (F). a If inside the reservoir tank (1) is so dirty that it is difficult to check the coolant level, clean it. PC88MR-10 40-19...
  • Page 508 If the element is cleaned frequently before the red piston is projected, the air cleaner will not deliver the optimum performance, and the cleaning effect will decrease. 3. Clean the inside of the air cleaner body and cover (3). 40-20 PC88MR-10...
  • Page 509 If it 1. Open the battery cover on the rear left of the has a small hole or thin part, replace it. machine, remove clips (2) (3 places), and remove cover (3). PC88MR-10 40-21...
  • Page 510 When removing the oil filler cap, the oil may any. spurt out. Turn it slowly to release the 1) Set new outer element (6). internal pressure, then remove it. 2) Align the match marks of body and cover (3). 40-22 PC88MR-10...
  • Page 511 80°C), the oil level should be near H mark. until the oil level comes between H mark and L 3. Pressurize the pressure in the hydraulic tank by mark of sight gauge (G). performing the steps described below when oil is added with state B. PC88MR-10 40-23...
  • Page 512 4. Remove the bolts to remove cover (3). When removing the bolts, keep pressing down cover (3) since it may jump out by spring (4). 5. Pull out the top of rod (5) upward, and remove spring (4) and strainer (6). 40-24 PC88MR-10...
  • Page 513 4. Tighten plug (P). 5. Fill it with the refill capacity of engine oil through 4. Fully insert dipstick (G) into the dipstick pipe the hole of plug (F). again, then remove it. PC88MR-10 40-25...
  • Page 514 Check before operating the machine. Do not use the battery while its electrolyte level is below LOWER LEVEL. If it is used under that condition, its inside becomes deteriorate, its service life is shortened, and it may lead to an explosion. 40-26 PC88MR-10...
  • Page 515 3. After adding fluid, tighten cap (2). explosion. 3. If the electrolyte level is below the center between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines, remove cap (2) and add purified water (example: commercially available PC88MR-10 40-27...
  • Page 516 Be especially careful for loose ground terminals and corrosion. Open the left front cover at the lower part of the cab. Check the connection of ground terminals (between cab and revolving frame (1), (T01). Open the engine hood. 40-28 PC88MR-10...
  • Page 517 Use a hexagonal wrench with 4 mm width across flats. Wipe and remove any foreign material inside connector with a cloth or others, and blow the air to clean the connector. c10. Check the connector pins for corrosion, bending and deformation PC88MR-10 40-29...
  • Page 518 E-1 described in the E Remove the cover at the rear right of the operator mode troubleshooting. seat, and the fuse holder is seen. If the relating circuit is normal, replace the battery relay. 40-30 PC88MR-10...

  • Page 519: Preparation For Troubleshooting Of Electrical System

    J1, J2, and CE03 of engine controller (8). a Since the connectors is secured with screws, loosen them before disconnecting the connector. a When restore them, tighten the screws to the specified torque. Screw:3 ± 1 Nm {0.3 ± 0.1 kgm} PC88MR-10 40-31...
  • Page 520 T-adapter. a Connector without connector cover (1). a How to disconnect connectors CP01 and CP02 While pressing lock (L1), turn lock (L2) inward. a Bar (B) comes out and the lock is released. 40-32 PC88MR-10...
  • Page 521 CK01 and CK02 of KOMTRAX locked securely with the lever. communication module (1). Accordingly, check their positions again. 6. Ambient pressure sensor (PAMB) Engine Ne speed sensor (NE) Engine Bkup speed sensor (CAM) PC88MR-10 40-33...
  • Page 522 Disconnect it according to steps (a) to (b), and connect it according to steps (c) to (d) as shown below. Disconnection: (a) Unlock and (b) disconnect the connectors. Connection: (c) Connect the connectors and (d) engage the lock. 40-34 PC88MR-10...
  • Page 523 Engage lock portion (e) on the harness side to triangle notch portion (f). (Pay attention not to take square guide portion (g) on the opposite side of triangle notch portion (f) by mistake.) PC88MR-10 40-35...

  • Page 524: Classification And Procedures For Troubleshooting

    2. On the service menu screen, press switch [F3] (R) in the panel switch section twice, and then select "03 Abnormality Record". 3. Press switch [F6] in the panel switch section to confirm, and then enter the "Abnormality record" screen. 40-36 PC88MR-10...
  • Page 525 9. While pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order to enter the "Clearing mode". (Same as 1) 10.Press switch [F2] (CLEAR) in the panel switch section. 11.Press switch [F6] in the panel switch section to clear all failure codes temporarily. PC88MR-10 40-37...
  • Page 526 15.Press switch [F2] (CLEAR) in the panel switch section to clear all codes temporarily. Check if "Abnormal" is still displayed and take record. (Same as 10 in [*1] and [*2]) 16.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen. 40-38 PC88MR-10...

  • Page 527: Symptom And Troubleshooting Numbers

    35 Abnormal sound comes out from around hydraulic pump 36 Fine control performance or response is low Problems related to work equipment 37 Speed or power of boom is low. 38 Speed or power of arm is low. PC88MR-10 40-39...
  • Page 528 75 Engine coolant temperature monitor lights up in red while engine is running. 76 Hydraulic oil temperature monitor lights up in red while engine is running. E-10 77 Engine oil pressure monitor lights up in red while engine is running. E-11 40-40 PC88MR-10...
  • Page 529 Air conditioner does not operate normally (including failure code related to air troubleshooting conditioner) procedure" in Chapter 80 95 Monitoring function does not display lever control signal normally E-42 to E-53 Others 96 KOMTRAX system does not work properly E-54 PC88MR-10 40-41...

  • Page 530: Information In Troubleshooting Table

    A harness not to be connected to the power circuit comes into contact with the power circuit accidentally. Short circuit An independent wire in the harness erroneously comes into contact with another independent wire. (poor insulation at connector and others) 40-42 PC88MR-10...
  • Page 531 Except for GND and 24 V, a signal name indicated at a junction, etc. shows that the wire is connected to another junction or controller at where the same signal name is indicated. PC88MR-10 40-43...

  • Page 532: Troubleshooting Method For Open Circuit In Wiring Harness Of Pressure Sensor System

    If there is an "apparent difference" between resistances R1 and R2 measured in step 1 and resistances R1' and R2' measured in step 2, the "wiring harness is open". a "Apparent difference" means a difference of 10 or more times. 40-44 PC88MR-10...
  • Page 533 (Measuring location on wiring harness side sensor pin side connetor) connector of engine controller) R2': Between (60) and R2: between (2) and (4) (59) (*) Charge pressure sensor R1': Between (15) and R1: between (1) and (4) (59) PC88MR-10 40-45...

  • Page 534: Connector List And Layout

    SUMITOMO Junction connector SUMITOMO Junction connector SUMITOMO Junction connector SUMITOMO Junction connector SUMITOMO Junction connector SUMITOMO Junction connector J1(CE01) Engine controller AF-6 J2(CE02) Engine controller AF-6 Pump (PC) resistor CAN terminating resistor Working lamp (boom) Room lamp AC-9 40-46 PC88MR-10...
  • Page 535 Air conditioner outer sensor (outside air temperature sensor) Fuel control dial Fuel level sensor Hydraulic oil temperature sensor Pump pressure sensor Travel pressure sensor Sunlight sensor Service pressure sensor FRAMATOME MAF sensor Ambient pressure sensor PAMB FRAMATOME AJ-6 Common rail pressure sensor PFUEL AJ-7 PC88MR-10 40-47...
  • Page 536 Coolant temperature sensor TWTR DELPHI AE-2 PPC source pressure solenoid valve Travel Hi/Lo selecting solenoid Swing parking brake solenoid valve Travel operation/Merge-divider valve PC-EPC valve IATT (LH) EPC IATT (RH) EPC Variable flow turbocharger SUMITOMO AE-3 Rear limit switch AD-7 40-48 PC88MR-10...
  • Page 537 40 Troubleshooting Related information on troubleshooting Layout of connectors (1/6) PC88MR-10 40-49...
  • Page 538 40 Troubleshooting Related information on troubleshooting Layout of connectors (2/6) 40-50 PC88MR-10...
  • Page 539 40 Troubleshooting Related information on troubleshooting Layout of connectors (3/6) PC88MR-10 40-51...
  • Page 540 40 Troubleshooting Related information on troubleshooting Layout of connectors (4/6) 40-52 PC88MR-10...
  • Page 541 40 Troubleshooting Related information on troubleshooting Layout of connectors (5/6) PC88MR-10 40-53...
  • Page 542 40 Troubleshooting Related information on troubleshooting Layout of connectors (6/6) 40-54 PC88MR-10...

  • Page 543: Connector Contact Identification

    Related information on troubleshooting Connector contact identification (ALL-5310-030-A-00-A) (Rev. 2014. 08) a The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing. PC88MR-10 40-55...
  • Page 544 40 Troubleshooting Related information on troubleshooting 40-56 PC88MR-10...
  • Page 545 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-57...
  • Page 546 40 Troubleshooting Related information on troubleshooting 40-58 PC88MR-10...
  • Page 547 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-59...
  • Page 548 40 Troubleshooting Related information on troubleshooting 40-60 PC88MR-10...
  • Page 549 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-61...
  • Page 550 40 Troubleshooting Related information on troubleshooting 40-62 PC88MR-10...
  • Page 551 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-63...
  • Page 552 40 Troubleshooting Related information on troubleshooting 40-64 PC88MR-10...
  • Page 553 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-65...
  • Page 554 40 Troubleshooting Related information on troubleshooting 40-66 PC88MR-10...
  • Page 555 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-67...
  • Page 556 40 Troubleshooting Related information on troubleshooting 40-68 PC88MR-10...
  • Page 557 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-69...
  • Page 558 40 Troubleshooting Related information on troubleshooting 40-70 PC88MR-10...
  • Page 559 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-71...
  • Page 560 40 Troubleshooting Related information on troubleshooting 40-72 PC88MR-10...
  • Page 561 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-73...
  • Page 562 40 Troubleshooting Related information on troubleshooting 40-74 PC88MR-10...
  • Page 563 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-75...
  • Page 564 40 Troubleshooting Related information on troubleshooting 40-76 PC88MR-10...
  • Page 565 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-77...
  • Page 566 40 Troubleshooting Related information on troubleshooting 40-78 PC88MR-10...
  • Page 567 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-79...
  • Page 568 40 Troubleshooting Related information on troubleshooting 40-80 PC88MR-10...
  • Page 569 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-81...
  • Page 570 40 Troubleshooting Related information on troubleshooting 40-82 PC88MR-10...
  • Page 571 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-83...
  • Page 572 40 Troubleshooting Related information on troubleshooting 40-84 PC88MR-10...
  • Page 573 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-85...
  • Page 574 40 Troubleshooting Related information on troubleshooting 40-86 PC88MR-10...
  • Page 575 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-87...
  • Page 576 40 Troubleshooting Related information on troubleshooting 40-88 PC88MR-10...
  • Page 577 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-89...
  • Page 578 40 Troubleshooting Related information on troubleshooting 40-90 PC88MR-10...
  • Page 579 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-91...
  • Page 580 40 Troubleshooting Related information on troubleshooting 40-92 PC88MR-10...
  • Page 581 40 Troubleshooting Related information on troubleshooting PC88MR-10 40-93...

  • Page 582: T-Branch Box And T-Branch Adapter Table

    16 DLI-16P q q Extension cable (ECONO ECON- 799-601-2840 type) O12P 799-601-2850 Case T-box (for DRC60, 799-601-4350 ECONO) 799-601-4360 Case 799-601-7010 Adapter for X (T-adapter) 799-601-7020 Adapter for X q q q 799-601-7030 Adapter for X q q q 40-94 PC88MR-10...
  • Page 583 799-601-9070 Adapter for DT (black) DT8B 799-601-9080 Adapter for DT (green) DT8G 799-601-9090 Adapter for DT (brown) DT8BR 799-601-9110 Adapter for DT (gray) 12 DT12GR 799-601-9120 Adapter for DT (black) 12 DT12B 799-601-9130 Adapter for DT (green) 12 DT12G PC88MR-10 40-95...
  • Page 584 795-799-5480 Cable for engine (HPI-T2) Adapter PIM for engine 799-601-4110 ITT3N (140-T3) Adapter NE, CAM for 799-601-4130 FCIN engine (CRI-T3) Adapter for engine (CRI- 799-601-4140 FCIG Ambient pressure Adapter POIL for engine 799-601-4150 FCIB (CRI-T3) Adapter for engine (CRI- 799-601-4160 4160 40-96 PC88MR-10...
  • Page 585 799-601-9710 Adapter for controller (HST) 16 HST16B 799-601-9730 Adapter for controller (HST) 26 HST26A Multi-adapter for DT 2 to 4, 799-601-9890 DTM 2 pins T-adapter for ICT control 799-902-9600 799-902-9700 T-box *: These are not T-adapters but sockets. PC88MR-10 40-97...
  • Page 586 Adapter for control box 799-902-9310 799-902-9310 Adapter for IMU 799-902-9320 799-902-9320 Adapter for MS cylinder 799-902-9330 799-902-9330 KDPF differential pressure sensor 799T-601-4611 799T-601-4611 short socket adapter KDPF outlet pressure sensor short 799T-601-4670 799T-601-4670 socket adapter 799T-601-4680 KDPF dummy temperature sensor 799T-601-4680 40-98 PC88MR-10...

  • Page 587: Fuse Location Table

    10 A Fusible link Alternator (60 A) 120 A F05 (120 A) Fusible link Preheating 120 A Locations of fusible links * Fusible links F02, F03, F04, and F05 are accessible when the rear left cover is opened. PC88MR-10 40-99...
  • Page 588 40 Troubleshooting Related information on troubleshooting Locations of fuse boxes and fuse No. 40-100 PC88MR-10...

  • Page 589: Failure Codes Table

    Failure code [CA144] Coolant Temperature Electrical CA144 Sensor High Error(PAGE 40-137) system Failure code [CA145] Coolant Temperature Electrical CA145 Sensor Low Error(PAGE 40-139) system Failure code [CA153] Charge Air Temperature Electrical CA153 Sensor High Error(PAGE 40-141) system PC88MR-10 40-101...
  • Page 590 Failure code [CA451] Common Rail Pressure Electrical CA451 Sensor High Error(PAGE 40-179) system Electrical Failure code [CA452] Common Rail Pressure CA452 Sensor Low Error(PAGE 40-181) system Electrical Failure code [CA466] KVGT Motor Driver CA466 system Position Error(PAGE 40-183) 40-102 PC88MR-10...
  • Page 591 Failure code [CA2272] EGR Valve Position Electrical CA2272 Sensor Low Error(PAGE 40-224) system Electrical Failure code [CA2311] IMV Solenoid Error CA2311 (PAGE 40-226) system Electrical Failure code [CA2349] EGR Valve Solenoid CA2349 system Open Circuit Error(PAGE 40-227) PC88MR-10 40-103...
  • Page 592 Circuit (Pump Con)(PAGE 40-267) system Failure code [DA2QKR] CAN 2 Defective Electrical DA2QKR Communication (Pump Con)(PAGE 40-268) system Electrical Failure code [DA2RKR] CAN 1 Defective DA2RKR Communication (Pump Con)(PAGE 40-270) system Electrical Failure code [DAF0MB] Monitor ROM DAF0MB system Abnormality(PAGE 40-271) 40-104 PC88MR-10...
  • Page 593 DHSDMA PUMP system Press Sens Def Function(PAGE 40-319) Failure code [DHSPMA] Boom Swing LH PPC Electrical DHSPMA PUMP system Press Sensor Abnormality(PAGE 40-321) Failure code [DHSQMA] Boom Swing RH PPC Electrical DHSQMA PUMP Press Sensor Abnormality(PAGE 40-323) system PC88MR-10 40-105...
  • Page 594 Failure code [DY2CKB] Washer Motor Short Electrical DY2CKB PUMP Circuit(PAGE 40-372) system Failure code [DY2DKB] Wiper Motor (Normal) Electrical DY2DKB PUMP Short Circuit(PAGE 40-374) system Failure code [DY2EKB] Wiper Motor (Reverse) Electrical DY2EKB PUMP Short Circuit(PAGE 40-376) system 40-106 PC88MR-10...
  • Page 595 (electrical system or mechanical system) of the service menu. a History category means the classification of either electrical system or mechanical system which is used for storage in the Failure History of the service menu. For details, see "Troubleshooting by failure code (Display of code)". PC88MR-10 40-107...

  • Page 596: Troubleshooting By Failure Code (Display Of Code)

    See chapter 80 Appendix "Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit" a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the machine, the air conditioner controller or air conditioner unit must be replaced. 40-108 PC88MR-10...

  • Page 597: Failure Code [879Akb] A/C Recirc Air Temp Sens Short

    See chapter 80 Appendix "Failure code [879AKB] A/C Recirc Air Temp Sens Short" . a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the machine, the air conditioner controller or air conditioner unit must be replaced. PC88MR-10 40-109...

  • Page 598: Failure Code [879Bka] A/C Fresh Air Temp Sens Open Circuit

    40 Troubleshooting Troubleshooting by failure code (Display of code) Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit (PC88MR-879BKA- 441-A-Z0-A) See chapter 80 Appendix "Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit" . 40-110 PC88MR-10...

  • Page 599: Failure Code [879Bkb] A/C Fresh Air Temp Sens Short Circuit

    40 Troubleshooting Troubleshooting by failure code (Display of code) Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit (PC88MR-879BKB- 441-A-Z0-A) See chapter 80 Appendix "Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit" . PC88MR-10 40-111...

  • Page 600: Failure Code [879Cka] Ventilating Sensor Open Circuit

    See chapter 80 Appendix "Failure code [879CKA] Ventilating Sensor Open Circuit" a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor installed on the machine, the air conditioner controller or air conditioner unit must be replaced. 40-112 PC88MR-10...

  • Page 601: Failure Code [879Ckb] Ventilating Sensor Short Circuit

    See chapter 80 Appendix "Failure code [879CKB] Ventilating Sensor Short Circuit" a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor installed on the machine, the air conditioner controller or air conditioner unit must be replaced. PC88MR-10 40-113...

  • Page 602: Failure Code [879Dkz] Sunlight Sensor Open Or Short Circuit

    40 Troubleshooting Troubleshooting by failure code (Display of code) Failure code [879DKZ] Sunlight Sensor Open or Short Circuit (PC88MR-879DKZ-441- A-Z0-A) See chapter 80 Appendix "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit". 40-114 PC88MR-10...

  • Page 603: Failure Code [879Emc] Ventilation Damper Malfunction

    Failure code [879EMC] Ventilation Damper Malfunction (PC88MR-879EMC-441-A-Z0-A) See chapter 80 Appendix "Failure code [879EMC] Ventilation Damper Malfunction". a Since the vent select servo motor cannot be disconnected on the machine, the air conditioner controller or air conditioner unit must be replaced. PC88MR-10 40-115...

  • Page 604: Failure Code [879Fmc] Air Mix Damper Malfunction

    Failure code [879FMC] Air Mix Damper Malfunction (PC88MR-879FMC-441-A-Z0-A) See chapter 80 Appendix "Failure code [879FMC] Air Mix Damper Malfunction". a Since the air mix servo motor connector cannot be disconnected on the machine, the air conditioner controller or air conditioner unit must be replaced. 40-116 PC88MR-10...

  • Page 605: Failure Code [879Gkx] Refrigerant Press Input Sig Out Of Range

    40 Troubleshooting Troubleshooting by failure code (Display of code) Failure code [879GKX] Refrigerant Press Input Sig Out of Range (PC88MR- 879GKX-441-A-Z0-A) See chapter 80 Appendix "Failure code [879GKX] Refrigerant Press Input Sig Out of Range". PC88MR-10 40-117...

  • Page 606: Failure Code [989L00] Engine Controller Lock Caution 1

    Method of reproducing failure code: Turn starting switch to ON position. Procedure, measuring location, criteria and remarks Cause Replacement of machine This problem may be caused by replacement of machine monitor. monitor 40-118 PC88MR-10...

  • Page 607: Failure Code [989M00] Engine Controller Lock Caution 2

    This problem may be caused by replacement of machine monitor. monitor If this failure code is displayed while machine monitor is not replaced, machine monitor may be defective. (Since this is an internal defect, Defective machine monitor troubleshooting cannot be performed.) PC88MR-10 40-119...

  • Page 608: Failure Code [989N00] Engine Controller Lock Caution 3

    Procedure, measuring location, criteria and remarks Cause If this failure code is generated repeatedly, engine controller may be Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-120 PC88MR-10...

  • Page 609: Failure Code [A900Fr] Abrupt Engine Stop By Auto Idle Stop 3

    Procedure, measuring location, criteria, and remarks Cause If this repeatedly occurs even when the auto idle stop function is OFF, machine monitor may be defective. (Since this is an internal defect, Defective machine monitor troubleshooting cannot be performed.) PC88MR-10 40-121...

  • Page 610: Failure Code [A900N6] Abrupt Engine Stop By Auto Idle Stop 1

    Procedure, measuring location, criteria, and remarks Cause If this repeatedly occurs even when the auto idle stop function is OFF, machine monitor may be defective. (Since this is an internal defect, Defective machine monitor troubleshooting cannot be performed.) 40-122 PC88MR-10...

  • Page 611: Failure Code [A900Ny] Abrupt Engine Stop By Auto Idle Stop 2

    Procedure, measuring location, criteria, and remarks Cause If this repeatedly occurs even when the auto idle stop function is OFF, machine monitor may be defective. (Since this is an internal defect, Defective machine monitor troubleshooting cannot be performed.) PC88MR-10 40-123...

  • Page 612: Failure Code [Ab00Ke] Charge Voltage Low

    Between CM01 (female) (16) or E12 (female) (1) Resistance Min. 1 Mz and ground If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) 40-124 PC88MR-10...
  • Page 613 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to charge PC88MR-10 40-125...

  • Page 614: Failure Code [B@Bazg] Eng Oil Press Low

    Engine oil pressure may be low. Check it and remove cause if it is low. (when system works properly) If no failure is found by checks on cause 1, engine oil pressure sensor circuit Defective engine oil may be defective. Perform troubleshooting for failure codes [CA135] and pressure sensor circuit [CA141]. 40-126 PC88MR-10...

  • Page 615: Failure Code [B@Bcns] Eng Water Overheat

    Engine coolant may overheat. Check it and remove cause if it overheats. (when system is normal) If no failure is found by checks on cause 1, engine coolant temperature Defective engine coolant sensor system may be defective. Carry out troubleshooting for failure temperature sensor system codes [CA144] and [CA145]. PC88MR-10 40-127...

  • Page 616: Failure Code [Ca115] Eng Ne And Bkup Speed Sens Error

    Perform troubleshooting for failure code [CA689]. system Defective Bkup speed sensor Perform troubleshooting for failure code [CA778]. system If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-128 PC88MR-10...

  • Page 617: Failure Code [Ca122] Charge Air Pressure Sensor High Error

    1. Turn starting switch to OFF position. Hot short circuit in 2. Disconnect connector TMAP, and insert T-adapter into connector J1. wiring harness 3. Turn starting switch ON (with connector TMAP disconnected). Voltage Between J1 (15) and (59) Max. 1 V PC88MR-10 40-129...
  • Page 618 (Since this is an internal defect, troubleshooting cannot be performed.) *: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General information on troubleshooting". Circuit diagram related to charge pressure sensor 40-130 PC88MR-10...

  • Page 619: Failure Code [Ca123] Charge Air Pressure Sensor Low Error

    If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) *: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General information on troubleshooting". PC88MR-10 40-131...
  • Page 620 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to charge pressure sensor 40-132 PC88MR-10...

  • Page 621: Failure Code [Ca131] Throttle Sensor High Error

    3. Turn starting switch to ON position. Defective engine controller 4. Operate fuel dial and perform troubleshooting. Power Between CE03 (42) and (41) 4.75 to 5.25 V supply Voltage Sensor Between CE03 (51) and (41) 0.5 to 4.5 V output PC88MR-10 40-133...
  • Page 622 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to throttle sensor 40-134 PC88MR-10...

  • Page 623: Failure Code [Ca132] Throttle Sensor Low Error

    1. Turn starting switch to OFF position. 2. Disconnect connectors CE03 and P20, and connect T-adapter to Ground fault in wiring harness either female side. (contact with ground circuit) Between ground and CE03 (female) (51) or Min. 1 Mz Resistance P20 (female) (2) PC88MR-10 40-135...
  • Page 624 3. Turn starting switch to ON position. 4. Operate fuel dial and perform troubleshooting. Between CE03 (42) and (41) Power supply 4.75 to 5.25 V Voltage Between CE03 (51) and (41) Sensor output 0.4 to 4.5 V Circuit diagram related to throttle sensor 40-136 PC88MR-10...

  • Page 625: Failure Code [Ca144] Coolant Temperature Sensor High Error

    Use Coolant temperature-Resistance tance characteristics table for check on cause 2 as resistance criteria. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-137...
  • Page 626 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to coolant temperature sensor 40-138 PC88MR-10...

  • Page 627: Failure Code [Ca145] Coolant Temperature Sensor Low Error

    (contact with ground Resis- circuit) Between J1 (female) (14) and ground Min. 1 Mz tance If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-139...
  • Page 628 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to coolant temperature sensor 40-140 PC88MR-10...

  • Page 629: Failure Code [Ca153] Charge Air Temperature Sensor High Error

    Use Charge temperature-Resistance Resistance characteristics table for check on cause 2 as resistance criteria. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-141...
  • Page 630 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to charge (boost) temperature sensor 40-142 PC88MR-10...

  • Page 631: Failure Code [Ca154] Charge Air Temperature Sensor Low Error

    J1. circuit) Resistance Between J1 (female) (5) and ground Min. 1 Mz If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-143...
  • Page 632 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to charge (boost) temperature sensor 40-144 PC88MR-10...

  • Page 633: Failure Code [Ca187] Sensor 2 Supply Voltage Low Error

    1. Turn starting switch to OFF position. 2. Disconnect connector J1 and connect T-adapter to male side. Defective engine 3. Turn starting switch to ON position with connector J1 disconnected. controller 4.75 to 5.25 Voltage Between ECM J1 (male) (60) and (59) PC88MR-10 40-145...
  • Page 634 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to sensor power supply 2 circuit 40-146 PC88MR-10...

  • Page 635: Failure Code [Ca221] Ambient Pressure Sensor High Error

    3. Turn starting switch to ON position. Voltage Between PAMB (female) (3) and (2) Max. 1 V If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-147...
  • Page 636 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to ambient pressure sensor 40-148 PC88MR-10...

  • Page 637: Failure Code [Ca222] Ambient Pressure Sensor Low Error

    Open circuit in wiring Between J1 (female) (16) and PAMB (female) (3) Max. 1 z harness Between J1 (female) (59) and PAMB (female) (2) Resistance Max. 1 z Between J1 (female) (60) and PAMB (female) (1) Max. 1 z PC88MR-10 40-149...
  • Page 638 0.3 to 4.7 V PAMB (3) and (2) output If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to ambient pressure sensor 40-150 PC88MR-10...

  • Page 639: Failure Code [Ca227] Sensor 2 Supply Voltage High Error

    Problem on Engine output lowers. machine Related Method of reproducing failure code: Turn starting switch to ON position. information Procedure, measuring location, criteria, and remarks Cause Defective sensor power Perform troubleshooting for failure code [CA187]. supply 2 circuit PC88MR-10 40-151...

  • Page 640: Failure Code [Ca234] Engine Overspeed

    Usage of machine may be improper. Instruct operator on proper use of Improper use machine. If no problem is found by checks on causes 1 and 2, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-152 PC88MR-10...

  • Page 641: Failure Code [Ca238] Ne Speed Sensor Supply Voltage Error

    2. Disconnect connector J1 and connect T-adapter to male side. Defective engine 3. Turn starting switch to ON position with engine wiring harness controller disconnected. 4.75 to 5.25 Voltage Between J1 (male) (36) and (37) Circuit diagram related to Ne speed sensor PC88MR-10 40-153...

  • Page 642: Failure Code [Ca239] Ne Speed Sensor Supply Voltage High Error

    2. Disconnect connector J1 and connect T-adapters to male side. 3. Turn starting switch to ON position with engine wiring harness Defective engine controller disconnected. 4.75 to 5.25 Voltage Between J1 (male) (36) and (37) Circuit diagram related to Ne speed sensor 40-154 PC88MR-10...

  • Page 643: Failure Code [Ca271] Pcv1 Short Circuit Error

    Resistance Between J1 (female) (30) and ground Min. 1 Mz If no abnormality is found by above diagnosis, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to SCV PC88MR-10 40-155...

  • Page 644: Failure Code [Ca272] Pcv1 Open Circuit Error

    Resistance Between J1 (female) (30) and ground Min. 1 Mz If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to SCV 40-156 PC88MR-10...

  • Page 645: Failure Code [Ca322] Injector #1 (L#1) Open Or Short Circuit

    Short circuit in wiring harness Between J1 (female) (48) and each No continuity (no pin other than pin (48) sound is heard) Continuity Between J1 (female) (58) and each No continuity (no pin other than pin (58) sound is heard) PC88MR-10 40-157...
  • Page 646 If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to injector #1 40-158 PC88MR-10...

  • Page 647: Failure Code [Ca324] Injector #3 (L#3) Open Or Short Circuit

    If failure codes of other injectors are displayed, perform troubleshooting for injectors or wiring them first. harness If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-159...
  • Page 648 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to injector #3 40-160 PC88MR-10...

  • Page 649: Failure Code [Ca331] Injector #2 (L#2) Open Or Short Circuit

    If failure codes of other injectors are displayed, perform troubleshooting for injectors or wiring them first. harness If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-161...
  • Page 650 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to injector #2 40-162 PC88MR-10...

  • Page 651: Failure Code [Ca332] Injector #4 (L#4) Open Or Short Circuit

    If failure codes of other injectors are displayed, perform troubleshooting for injectors or wiring them first. harness If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-163...
  • Page 652 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to injector #4 40-164 PC88MR-10...

  • Page 653: Failure Code [Ca343] Engine Controller Internal Failure

    Power supply voltage of engine controller can be checked with monitoring function. Related (Code: 03203) information Method of reproducing failure code: Turn starting switch to ON position Procedure, measuring location, criteria and remarks Cause Defective engine Perform troubleshooting for failure code [CA441]. controller system PC88MR-10 40-165...

  • Page 654: Failure Code [Ca351] Injectors Drive Circuit Error

    Cause Check failure code (injector system failure code) that is displayed at the Defect in related system same time. If another code is displayed, perform troubleshooting for it. Defective engine controller Perform troubleshooting for failure code [CA441]. system 40-166 PC88MR-10...

  • Page 655: Failure Code [Ca352] Sensor1 Supply Voltage Low Error

    1. Turn starting switch to OFF position. 2. Disconnect connector J2 and connect T-adapter to male side. Defective engine 3. Turn starting switch to ON position with connector J2 disconnected. controller 4.75 to 5.25 Voltage Between J2 (male) (30) and (47) PC88MR-10 40-167...
  • Page 656 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to sensor power supply 1 (5 V) 40-168 PC88MR-10...

  • Page 657: Failure Code [Ca356] Maf Sensor High Error

    Between J1 (female) (23) and each pin other than Resistance Min. 1 Mz pin (23) If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-169...
  • Page 658 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to mass air flow sensor 40-170 PC88MR-10...

  • Page 659: Failure Code [Ca357] Maf Sensor Low Error

    2. Disconnect connectors J1 and P55 and connect T-adapter to female side of connector J1. Short circuit in wiring harness a Check by using multimeter in continuity mode. Between J1 (female) (23) and each pin other than Resistance Min. 1 Mz pin (23) PC88MR-10 40-171...
  • Page 660 Between P55 (female) (1) and (3) Max. 1 V If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to mass air flow sensor 40-172 PC88MR-10...

  • Page 661: Failure Code [Ca386] Sensor1 Supply Voltage High Error

    Limits engine output and runs engine. Problem on Engine output lowers. machine Related Method of reproducing failure code: Turn starting switch to ON position. information Procedure, measuring location, criteria, and remarks Cause Abnormally high sensor Perform troubleshooting for failure code [CA352]. supply voltage PC88MR-10 40-173...

  • Page 662: Failure Code [Ca435] Engine Oil Pressure Sw Error

    Resistance Between J1 (female) (31) and ground Max. 1 z If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to engine oil pressure switch 40-174 PC88MR-10...

  • Page 663: Failure Code [Ca441] Battery Voltage Low Error

    Between CE03 (1) and (21) 20 to 30 V Between CE03 (2) and (22) 20 to 30 V Voltage Between CE03 (11) and (31) 20 to 30 V Between CE03 (12) and (32) 20 to 30 V PC88MR-10 40-175...
  • Page 664 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to battery voltage system 40-176 PC88MR-10...

  • Page 665: Failure Code [Ca442] Battery Voltage High Error

    Method of reproducing failure code: Turn starting switch to ON position. Related Power supply voltage of engine controller can be checked with monitoring function. information (Code: 03203) Procedure, measuring location, criteria and remarks Cause Defective power supply Perform troubleshooting for failure code [CA441]. system of engine controller PC88MR-10 40-177...

  • Page 666: Failure Code [Ca449] Common Rail Pressure High Error 2

    Common rail pressure sensed by common rail pressure sensor can be checked with information monitoring function. (Code: 36400 (MPa)) Method of reproducing failure code: Turn starting switch to ON position. Procedure, measuring location, criteria and remarks Cause Defective common rail Perform troubleshooting for failure code [CA553]. pressure sensor system 40-178 PC88MR-10...

  • Page 667: Failure Code [Ca451] Common Rail Pressure Sensor High Error

    1. Turn starting switch to OFF position. 2. Disconnect connectors PFUEL and J2. Short circuit in wiring harness 3. Connect T-adapter to either female side. Between J2 (female) (55) and (31), or Min. 1 Mz Resistance between PFUEL (2) and (1) PC88MR-10 40-179...
  • Page 668 0.2 to 4.6 V (55) and (21) output If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to common rail pressure sensor 40-180 PC88MR-10...

  • Page 669: Failure Code [Ca452] Common Rail Pressure Sensor Low Error

    1. Turn starting switch to OFF position. 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to Ground fault in wiring harness either female side. (contact with ground circuit) Between ground and PFUEL (female) (2) or Min. 1 Mz Resistance J2 (female) (55) PC88MR-10 40-181...
  • Page 670 J2 (female) (55) and (21) If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to common rail pressure sensor 40-182 PC88MR-10...

  • Page 671: Failure Code [Ca466] Kvgt Motor Driver Position Error

    Sensor Error (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, engine controller may be defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-183...
  • Page 672 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to turbocharger 40-184 PC88MR-10...

  • Page 673: Failure Code [Ca515] Rail Pressure Sensor Sup Volt High Error

    1. Turn starting switch to OFF position. 2. Disconnect connector J2 and connect T-adapter to male side. Defective engine controller 3. Turn starting switch to ON position. Voltage Between J2 (male) (31) and (21) 4.7 to 5.25 V PC88MR-10 40-185...
  • Page 674 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to common rail pressure sensor 40-186 PC88MR-10...

  • Page 675: Failure Code [Ca516] Rail Pressure Sensor Sup Volt Low Error

    1. Turn starting switch to OFF position. 2. Disconnect connector J2, and connect T-adapter to male side. Defective engine controller 3. Turn starting switch to ON position. 4.7 to 5.25 Voltage Between J2 (male) (31) and (21) PC88MR-10 40-187...
  • Page 676 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to common rail pressure sensor 40-188 PC88MR-10...

  • Page 677: Failure Code [Ca553] Common Rail Pressure High Error 1

    The overflow valve may has a damaged spring, worn seat, or ball Defective overflow valve clogging trouble. Check it. Clogging of overflow piping Check overflow piping for clogging. Defective pressure limiter The pressure limiter may have a mechanical failure. Check it. PC88MR-10 40-189...

  • Page 678: Failure Code [Ca555] Crankcase Pressure High Error 1

    KCCV, KCCV blowby gas piping may be Blocked KCCV gas piping blocked with emulsified matter. Perform troubleshooting for coolant leaks. Crankcase pressure sensor system may be defective. Perform Crankcase pressure sensor troubleshooting for failure codes [CA1843] and [CA1844]. defective 40-190 PC88MR-10...

  • Page 679: Failure Code [Ca556] Crankcase Pressure High Error 2

    If error condition is not cleared after KCCV filter is replaced and failure code of crankcase pressure high error 2 is generated in short times, Increase of blowby gas engine may be seized or turbocharger may be defective. Perform troubleshooting for mechanical system. PC88MR-10 40-191...

  • Page 680: Failure Code [Ca559] Common Rail Pressure Low Error 1

    Note 1: Check low-pressure fuel circuit parts for following items. 1. Remaining quantity of fuel 2. Clogging of fuel tank breather 3. Looking and wear of fuel feed pump and clogging of filter 4. Leakage from or clogging of low-pressure fuel piping 40-192 PC88MR-10...
  • Page 681 Common rail (arm in relief) 36400 pressure Low idle Last injection High idle 36300 timing command (arm in relief) 36500 Charge pressure (arm in relief) Engine coolant 04107 Low idle °C temperature 14200 Fuel temperature Low idle °C PC88MR-10 40-193...
  • Page 682 Arm in hydraulic relief Return cc/min Max. 220 1,900 rpm rate: Arm in hydraulic relief cc/min Max. 230 2,000 rpm * Although upper limit is 20 cc/min, note that standard value is 0 cc/min (no leakage) in normal condition. 40-194 PC88MR-10...

  • Page 683: Failure Code [Ca689] Engine Ne Speed Sensor Error

    Short circuit in wiring Between J1 (female) (36) and (26), or between NE harness Min. 1 Mz (female) (1) and (3) Resistance Between J1 (female) (37) and (26), or between NE Min. 1 Mz (female) (2) and (3) PC88MR-10 40-195...
  • Page 684 (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to engine Ne speed sensor The Ne speed sensor detects the wide area of hole (W) in the wheel, and the engine controller calculates the engine speed and signal phase. 40-196 PC88MR-10...

  • Page 685: Failure Code [Ca691] Intake Air Temperature Sensor High Error

    Between J1 (female) (6) and each pin other than Resistance Min. 1 Mz pin (6) If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-197...
  • Page 686 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to intake air temperature sensor 40-198 PC88MR-10...

  • Page 687: Failure Code [Ca692] Intake Air Temperature Sensor Low Error

    1. Turn starting switch to OFF position. Ground fault in wiring 2. Disconnect connectors J1 and P55, and connect T-adapter to either harness female side. (contact with ground Between ground and J1 (female) (6) or P55 circuit) Resistance Min. 1 Mz (female) (4) PC88MR-10 40-199...
  • Page 688 Min. 1 Mz pin (6) If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to intake air temperature sensor 40-200 PC88MR-10...

  • Page 689: Failure Code [Ca697] Engine Con Internal Temp Sens High Error

    Improper usage of controller Check if the controller has been used in high temperature environments. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-201...

  • Page 690: Failure Code [Ca698] Engine Con Internal Temp Sens Low Error

    Improper usage of controller Check if the controller has been used in low temperature environments. If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-202 PC88MR-10...

  • Page 691: Failure Code [Ca731] Engine Backup Speed Sensor Phase Error

    Ground terminal may be poorly connected. Check following terminals: Ground terminal of machine ((-) terminal of battery) Defective connection of Ground terminal of engine ground terminal Ground terminal of engine controller Ground terminal of starting motor PC88MR-10 40-203...
  • Page 692 40 Troubleshooting Troubleshooting by failure code (Display of code) 40-204 PC88MR-10...

  • Page 693: Failure Code [Ca778] Engine Backup Speed Sensor Error

    1. Turn starting switch to OFF position. Ground fault in wiring 2. Disconnect connectors J1 and CAM, and connect T-adapter to either harness female side. (contact with ground Between ground and J1 (female) (9) or CAM Min. 1 Mz circuit) Resistance (female) (3) PC88MR-10 40-205...
  • Page 694 See Disassembly and assembly, "Removal and installation of engine front oil seal". a Keep the front seal, liquid gasket LG-7 and front seal tool (795-799-6400) on hand. Removal 1. Remove fan belt and fan, For details, see Disassembly and assembly, "Removal and installation of engine front seal". 40-206 PC88MR-10...
  • Page 695 (DP): Dowel pin Installation a See figures shown in removal procedure section. 1. Install front cover (2). Front cover: Liquid gasket (LG-7) 2. See Disassembly and assembly, "Removal and installation of engine front oil seal". 1) install front cover (3). PC88MR-10 40-207...
  • Page 696 40 Troubleshooting Troubleshooting by failure code (Display of code) 2) Install dowel pin (DP), and install crankshaft pulley. 3) Install fan and fan belt. 4) Install the cooling system assembly. 40-208 PC88MR-10...

  • Page 697: Failure Code [Ca1117] Engine Controller Partial Data Lost Error

    Improper operation of Battery disconnect switch may have been operated improperly. battery disconnect switch If no failure is found by above checks, engine controller is defective. (Since Defective engine this is an internal defect, troubleshooting cannot be performed.) controller PC88MR-10 40-209...

  • Page 698: Failure Code [Ca1695] Sensor 5 Supply Voltage High Error

    High voltage error occurs in sensor power supply 5 (5V) circuit. failure Action of None in particular controller Problem on machine Related Method of reproducing failure code: Turn starting switch to ON position. information Procedure, measuring location, criteria, and remarks Cause Perform troubleshooting for failure code [CA1696]. 40-210 PC88MR-10...

  • Page 699: Failure Code [Ca1696] Sensor 5 Supply Voltage Low Error

    1. Turn starting switch to OFF position. 2. Insert T-adapter into connector CE03. Defective engine 3. Turn starting switch to ON position. controller 4.75 to 5.25 Voltage Between CE03 (male) (52) and (43) Circuit diagram related to sensor power supply 5 circuit PC88MR-10 40-211...

  • Page 700: Failure Code [Ca1843] Crankcase Pressure Sensor High Error

    (Since this is an internal defect, troubleshooting cannot be performed.) Reference Defective engine 1. Turn starting switch to OFF position. controller 2. Insert T-adapter into connector J1. 3. Turn starting switch to ON position. Sensor Voltage Between J1 (3) and (59) 0.3 to 4.7 V output 40-212 PC88MR-10...
  • Page 701 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to crankcase pressure sensor PC88MR-10 40-213...

  • Page 702: Failure Code [Ca1844] Crankcase Pressure Sensor Low Error

    1. Turn starting switch to OFF position. Defective crankcase 2. Insert T-adapter into connector CCV. pressure sensor 3. Turn starting switch to ON position. (internal defect) Sensor 0.3 to 4.7 V Voltage Between CCV (3) and (2) output 40-214 PC88MR-10...
  • Page 703 1. Turn starting switch to OFF position. controller 2. Insert T-adapter into connector J1. 3. Turn starting switch to ON position. Sensor Voltage Between J1 (3) and (59) 0.3 to 4.7 V output Circuit diagram related to crankcase pressure sensor PC88MR-10 40-215...

  • Page 704: Failure Code [Ca1896] Egr Valve Stuck Error

    Procedure, measuring location, criteria and remarks Cause Defective EGR EGR may have mechanical failure. Check it. mechanical system If no problem is found by above checks, engine controller is defective. (Since Defective engine this is an internal defect, troubleshooting cannot be performed.) controller 40-216 PC88MR-10...

  • Page 705: Failure Code [Ca1942] Crankcase Pressure Sensor In Range Error

    If error condition is not cleared after KCCV filter is replaced and failure code of crankcase pressure high error 2 is generated in short times, Increase of blowby gas engine may be seized or turbocharger may be defective. Perform troubleshooting for mechanical system. PC88MR-10 40-217...

  • Page 706: Failure Code [Ca1961] Egr_Motor Driver Ic Over Temp Error

    Improper use Check whether controller is used in high temperature environment. environment of controller If no problem is found by above checks, engine controller is defective. (Since Defective engine this is an internal defect, troubleshooting cannot be performed.) controller 40-218 PC88MR-10...

  • Page 707: Failure Code [Ca2185] Throttle Sensor Supply Voltage High Error

    Reference 1. Turn starting switch to OFF position. 5 Defective engine controller 2. Insert T-adapter into connector CE03. 3. Turn starting switch to ON position. Power Voltage Between CE03 (42) and (41) 4.75 to 5.25 V supply PC88MR-10 40-219...
  • Page 708 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to throttle sensor 40-220 PC88MR-10...

  • Page 709: Failure Code [Ca2186] Throttle Sensor Supply Voltage Low Error

    Reference 1. Turn starting switch to OFF position. 5 Defective engine controller 2. Insert T-adapter into connector CE03. 3. Turn starting switch to ON position. Power Voltage Between CE03 (42) and (41) 4.75 to 5.25 V supply PC88MR-10 40-221...
  • Page 710 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to throttle sensor 40-222 PC88MR-10...

  • Page 711: Failure Code [Ca2249] Common Rail Pressure Low Error 2

    Common rail pressure sensed by common rail pressure sensor can be checked with information monitoring function. (Code: 36400 (MPa)) Method of reproducing failure code: Start engine. Procedure, measuring location, criteria and remarks Cause Supply pump pressure low Perform troubleshooting for failure code [CA559]. error PC88MR-10 40-223...

  • Page 712: Failure Code [Ca2272] Egr Valve Position Sensor Low Error

    (contact with ground Min. 1 Mz (female) (2) circuit) Resistance Between ground and J2 (female) (41) or EGR V Min. 1 Mz (female) (3) Between ground and J2 (female) (51) or EGR V Min. 1 Mz (female) (4) 40-224 PC88MR-10...
  • Page 713 (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to EGR valve PC88MR-10 40-225...

  • Page 714: Failure Code [Ca2311] Imv Solenoid Error

    Engine output lowers. machine Related Method of reproducing failure code: Start engine. information Procedure, measuring location, criteria, and remarks Cause Perform troubleshooting for failure codes [CA271] and [CA272]. Defective IMV solenoid Rail pressure error Perform troubleshooting for failure code [CA449]. 40-226 PC88MR-10...

  • Page 715: Failure Code [Ca2349] Egr Valve Solenoid Open Circuit Error

    Max. 1 z Between J2 (female) (5) and EGR V (female) (8) Max. 1 z If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-227...
  • Page 716 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to EGR valve 40-228 PC88MR-10...

  • Page 717: Failure Code [Ca2353] Egr Valve Solenoid Short Circuit Error

    Max 5.5 V Between J2 (5) and (47) or ground Max 5.5 V If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-229...
  • Page 718 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to EGR valve 40-230 PC88MR-10...

  • Page 719: Failure Code [Ca2357] Egr Valve Servo Error

    EGR valve may have mechanical trouble. Check it. Defective EGR valve If no failure is found by checks on causes 1 to 3, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-231...

  • Page 720: Failure Code [Ca2765] Injector Trim Data Mismatch

    Related Method of reproducing failure code: Turn starting switch to ON position. information Procedure, measuring location, criteria and remarks Cause a When replacing injectors, see chapter 30 Testing and adjusting, Injector trim data mismatch "Injector trim". 40-232 PC88MR-10...

  • Page 721: Failure Code [Ca3419] Maf Sensor Supply Voltage High Error

    3. Turn starting switch to ON position. Defective engine controller Approx. 12 Voltage Between J1 (male) (21) and (22) If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-233...
  • Page 722 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to mass air flow sensor 40-234 PC88MR-10...

  • Page 723: Failure Code [Ca3421] Maf Sensor Supply Voltage Low Error

    3. Turn starting switch to ON position. Defective engine controller Approx. 12 Voltage Between J1 (male) (21) and (22) If no failure is found by above checks, engine controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-235...
  • Page 724 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to mass air flow sensor 40-236 PC88MR-10...

  • Page 725: Failure Code [Ca3724] Egr/Kvgt Motor Driver Power Low Error

    1. Turn starting switch to OFF position. 2. Disconnect connector J2 and connect T-adapter to male side. Defective engine controller 3. Turn starting switch to ON position with connector J2 disconnected. Voltage Between J2 (male) (30) and (47) 4.75 to 5.25 V PC88MR-10 40-237...
  • Page 726 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to EGR V and turbocharger motor driver power (5 V) 40-238 PC88MR-10...

  • Page 727: Failure Code [Ca3918] Kvgt Stuck Error

    Cause Defective KVGT KVGT may have mechanical failure. Check it. mechanical system If no failure is found by above checks, engine controller may be defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-239...

  • Page 728: Failure Code [Ca3919] Kvgt Motor Driver Ic Over Temp Error

    Check whether controller is used in high temperature environment. environment of controller If no failure is found by above checks, engine controller may be defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-240 PC88MR-10...

  • Page 729: Failure Code [Ca3921] Kvgt Servo Error 2

    Defective Turbocharger Turbocharger may have mechanical failure. Check it. If no failure is found by above checks, engine controller may be defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-241...

  • Page 730: Failure Code [Ca3922] Kvgt Motor Driver Open Error

    Max. 1 z connector) Between J2 (female) (2) and VFT (female) (8) Max. 1 z If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-242 PC88MR-10...
  • Page 731 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to turbocharger PC88MR-10 40-243...

  • Page 732: Failure Code [Ca3923] Kvgt Motor Driver Short Error

    Max 5.5 V Between J2 (2) and (47) or ground Max 5.5 V If no failure is found by above checks, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-244 PC88MR-10...
  • Page 733 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to turbocharger PC88MR-10 40-245...

  • Page 734: Failure Code [D110Kb] Battery Relay Output Short Circuit

    2. Insert T-adapters into connector D01. Pump controller is defective. 3. Turn starting switch to ON position. 4. Measure voltage within 0.5 second after turning staring switch to OFF position from ON position. Voltage Between D01 (1) and ground 20 to 30 V 40-246 PC88MR-10...
  • Page 735 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to battery relay PC88MR-10 40-247...

  • Page 736: Failure Code [D19Jkz] Personal Code Relay Open Or Short

    Open circuit in wiring 3. Disconnect connector CM01 and relay R07, and connect T-adapters to harness each female side. Between F01-3 and R07 (female) (1) Max. 1 z Resistance Max. 1 z Between R07 (female) (2) and CM01 (female) (6) 40-248 PC88MR-10...
  • Page 737 Between CM01 (female) (6) and each pin other Continuity than (6) (No sound is heard.) If no failure is found by above checks, machine monitor is defective. (Since Defective machine this is an internal defect, troubleshooting cannot be performed.) monitor PC88MR-10 40-249...
  • Page 738 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to personal code relay 40-250 PC88MR-10...

  • Page 739: Failure Code [D811Mc] Komtrax Malfunction

    KOMTRAX system does not operate properly. machine Related Method of reproducing failure code: Turn starting switch to ON position. information Procedure, measuring location, criteria and remarks Cause KOMTRAX is defective. Malfunction of KOMTRAX (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-251...

  • Page 740: Failure Code [D862Ka] Gps Antenna Open Circuit

    Procedure, measuring location, criteria and remarks Cause Probable causes are defective GPS antenna, open circuit or short circuit Defective GPS antenna or in antenna cable, and defective connection of antenna cable connector antenna cable (GPS). Structural illustration 40-252 PC88MR-10...

  • Page 741: Failure Code [D8Alka] Operating Lamp Open Circuit (Komtrax)

    Resistance Between CK01 (15) and fuse F01-16 Max. 1 z connector) If no failure is found by above checks, KOMTRAX terminal is defective. Defective KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-253...
  • Page 742 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to system operating lamp 40-254 PC88MR-10...

  • Page 743: Failure Code [D8Alkb] Operating Lamp Short Circuit (Komtrax)

    Resistance Between L19 (female) (1) and (2) Min. 1 Mz If no failure is found by above checks, KOMTRAX terminal is defective. Defective KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to system operating lamp PC88MR-10 40-255...

  • Page 744: Failure Code [D8Aqkr] Can 2 Defective Communication (Komtrax)

    Defective KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) 40-256 PC88MR-10...
  • Page 745 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to KOMTRAX PC88MR-10 40-257...

  • Page 746: Failure Code [Da20Mc] Pump Controller Malfunction

    Related Method of reproducing failure code: Turn starting switch to ON position. information Procedure, measuring location, criteria and remarks Cause Pump controller is defective. Malfunction of pump controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-258 PC88MR-10...

  • Page 747: Failure Code [Da22Kk] Pump Con Solenoid Power Volt Low Error

    1. Disconnect connector F02 and connect T-adapter to male side furthermore. Between F02 (male) (2) and each of CP02 (female) Max. 1 z (116), (118), and (121) Resistance Between F04 (male) (1) and terminal R03 (M) Max. 1 z PC88MR-10 40-259...
  • Page 748 Min. 1 Mz R03 (M) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to solenoid power supply 40-260 PC88MR-10...

  • Page 749: Failure Code [Da25Kp] 5V Sensor 1 Power Voltage Low Error

    (contact with ground circuit) Resistance Between CP01 (female) (6) and ground Min. 1 Mz If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-261...
  • Page 750 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to 5 V sensor power supply 1 40-262 PC88MR-10...

  • Page 751: Failure Code [Da29Kq] Model Selection Sig Mismatch (Pump Con)

    CP01. Resistance Between CP01 (female) (58) and (81) Max. 1 z Pump controller with 1. Use monitoring function to display assembly part number and check wrong part number whether it is identical to that listed in Parts book. PC88MR-10 40-263...
  • Page 752 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to model selection abnormality 40-264 PC88MR-10...

  • Page 753: Failure Code [Da2Lka] Operating Lamp Open Circuit (Pump Con)

    CP02. circuit) Resistance Between CP02 (female) (100) and ground Min. 1 Mz If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-265...
  • Page 754 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to system operating lamp 40-266 PC88MR-10...

  • Page 755: Failure Code [Da2Lkb] Operating Lamp Short Circuit (Pump Con)

    Resistance Between L19 (female) (1) and (2) Min. 1 Mz If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to system operating lamp PC88MR-10 40-267...

  • Page 756: Failure Code [Da2Qkr] Can 2 Defective Communication (Pump Con)

    Max. 1 z Resistance Between F01-17 and CP01 (female) (1) Max. 1 z Between F01-17 and CP01 (female) (4) Max. 1 z Defective CAN Perform checks on causes 4 to 9 in troubleshooting for failure code communication 2 [DB2QKR]. system 40-268 PC88MR-10...
  • Page 757 (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to pump controller power supply PC88MR-10 40-269...

  • Page 758: Failure Code [Da2Rkr] Can 1 Defective Communication (Pump Con)

    Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) 40-270 PC88MR-10...

  • Page 759: Failure Code [Daf0Mb] Monitor Rom Abnormality

    Related Method of reproducing failure code: Turn starting switch to ON position. information Procedure, measuring location, criteria and remarks Cause Machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-271...

  • Page 760: Failure Code [Daf0Mc] Monitor Malfunction

    Related Method of reproducing failure code: Turn starting switch to ON position. information Procedure, measuring location, criteria and remarks Cause Machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) 40-272 PC88MR-10...

  • Page 761: Failure Code [Daf8Kb] Camera Power Supply Short Circuit

    4. Turn starting switch to ON position. (contact with 24 V (Disconnect camera and check that camera is not defective in advance.) circuit) Voltage Between CM04 (1) and (5) Max. 10 V Circuit diagram related to camera power supply PC88MR-10 40-273...

  • Page 762: Failure Code [Daf9Kq] Model Selection Signal Mismatch (Monitor)

    (Wrong machine model is programmed.) 1. Use monitoring function to display assembly part number and check whether it is identical to that listed in Parts book. Pump controller is Pump controller is defective. defective. (Wrong machine model is programmed.) 40-274 PC88MR-10...

  • Page 763: Failure Code [Dafgmc] Gps Module Malfunction

    ON position). information Procedure, measuring location, criteria and remarks Cause GPS module in machine monitor may be defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-275...

  • Page 764: Failure Code [Daflka] Operating Lamp Open Circuit (Monitor)

    Resistance Between CM01 (female) (8) and F01-16 Max. 1 z connector) If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) 40-276 PC88MR-10...
  • Page 765 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to system operating lamp PC88MR-10 40-277...

  • Page 766: Failure Code [Daflkb] Operating Lamp Short Circuit (Monitor)

    Resistance Between L19 (female) (1) and (2) Min. 1 Mz If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to system operating lamp 40-278 PC88MR-10...

  • Page 767: Failure Code [Dafqkr] Can 2 Defective Communication (Monitor)

    Procedure, measuring location, criteria, and remarks Cause Defective power supply Perform troubleshooting for "E-4" in E mode troubleshooting. to machine monitor Perform checks on causes 4 and after in troubleshooting for failure code Defective CAN [DB2QKR] communication PC88MR-10 40-279...

  • Page 768: Failure Code [Daz9Kq] Model Selection Sig Mismatch (A/C)

    Method of reproducing failure code: Turn starting switch to ON position. Procedure, measuring location, criteria, and remarks Cause Defective machine monitor Defective machine monitor (Wrong machine model is programmed.) Defective air conditioner controller Defective air conditioner controller (Wrong machine model is programmed.) 40-280 PC88MR-10...

  • Page 769: Failure Code [Dazqkr] Can2 Defective Communication (A/C Ecu)

    Between CE03 (female) (17) and (18) Approx. 60 Between CP01 (female) (45) and (64) Resistance Approx. 60 Between AC01 (female) (9) and (10) Approx. 60 Between CK01 (female) (10) and (11) Approx. 120 Between K02 (female) (A) and (B) PC88MR-10 40-281...
  • Page 770 Between ground and either of CM02 (8), CP01 1 to 4 V (45), CK01 (10), AC01 (2) and CE03 (17). Voltage Between ground and either of CM02 (9), CP01 1 to 4 V (64), CK01 (11), AC01 (1) and CE03 (18). 40-282 PC88MR-10...
  • Page 771 Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-283...
  • Page 772 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to CAN communication line 2 40-284 PC88MR-10...

  • Page 773: Failure Code [Db2Qkr] Can2 Defective Communication (Engine Con)

    2. Disconnect connectors CM02 and K02, and connect T-adapters to each terminating resistor male side. (internal open or short Between K02 (male) (A) and (B) 120 ± 12 z circuit) Resistance 120 ± 12 z Between CM02 (male) (7) and (9) PC88MR-10 40-285...
  • Page 774 Between CM02 (female) (8) and CK01 (female) (10) Max. 1 z Between CM02 (female) (9) and CK01 (female) (11) Max. 1 z Between CE03 (female) (17) and K02 (female) (A) Max. 1 z Max. 1 z Between CE03 (female) (18) and K02 (female) (B) 40-286 PC88MR-10...
  • Page 775 Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-287...
  • Page 776 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to CAN communication line 2 40-288 PC88MR-10...

  • Page 777: Failure Code [Db2Rkr] Can1 Defective Communication (Engine Con)

    CAN communication connectors of every controller and check whether short circuit occurs between wiring harnesses or inside controller. Approx. 120 Between CM02 (female) (11) and (12) Approx. 60 Between CP01 (female) (7) and (26) Resistance Approx. 120 Between J1 (female) (8) and (18) PC88MR-10 40-289...
  • Page 778 2. Disconnect pump controller (connector CP01). 3. Turn battery disconnect switch to ON position, and turn starting switch to ON position. Does either or both of failure codes [DA2RKR] and If YES, pump controller is [DB2RKR] disappear? defective. 40-290 PC88MR-10...
  • Page 779 Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by above checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-291...
  • Page 780 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to CAN communication line 1 40-292 PC88MR-10...

  • Page 781: Failure Code [Ddnrka] We Lever Lock Sw Open Circuit

    Max. 1 z Between CP01 (female) (78) and S14 (male) (2) Max. 1 z If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-293...
  • Page 782 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to work equipment lever lock switch 40-294 PC88MR-10...

  • Page 783: Failure Code [Ddnrky] We Lever Lock Sw Short Circuit

    Max. 1 V Voltage Between S14 (male) (3) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-295...
  • Page 784 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to work equipment lever lock switch 40-296 PC88MR-10...

  • Page 785: Failure Code [Ddns00] Lock Lever Auto Lock Release Sw On

    3. Turn starting switch to ON position. Voltage Between S25 (female) (7) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-297...
  • Page 786 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to work equipment lever lock switch 40-298 PC88MR-10...

  • Page 787: Failure Code [Dgh2Kb] Hydraulic Oil Temp Sensor Ground Fault

    Between ground and CP01 (female) (28) or P22 Resistance Min. 1 Mz (female) (2) If cause is not found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-299...
  • Page 788 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to hydraulic oil temperature sensor 40-300 PC88MR-10...

  • Page 789: Failure Code [Dhpama] Front Pump Press Sens Defective Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed for this failure code column, pump pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-301...
  • Page 790 Between P25 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to pump pressure sensor 40-302 PC88MR-10...

  • Page 791: Failure Code [Dhs3Ma] Arm In Ppc Press Sensor Def Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, arm IN PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-303...
  • Page 792 Between P05 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to arm IN PPC pressure sensor 40-304 PC88MR-10...

  • Page 793: Failure Code [Dhs4Ma] Bucket Curl Ppc Press Sens Def Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, Bucket CURL PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-305...
  • Page 794 Between P04 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to Bucket CURL PPC pressure sensor 40-306 PC88MR-10...

  • Page 795: Failure Code [Dhs5Ma] Travel Ppc Sensor Abnormality

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, Travel PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-307...
  • Page 796 Between P26 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to Travel PPC pressure sensor 40-308 PC88MR-10...

  • Page 797: Failure Code [Dhs8Ma] Boom Raise Ppc Press Sens Def Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, Boom Raise PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-309...
  • Page 798 Between P03 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to Boom Raise PPC pressure sensor 40-310 PC88MR-10...

  • Page 799: Failure Code [Dhs9Ma] Boom Lower Ppc Press Sens Def Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, Boom Lower PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-311...
  • Page 800 Between P06 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to Boom Lower PPC pressure sensor 40-312 PC88MR-10...

  • Page 801: Failure Code [Dhsama] Swing Right Ppc Press Sens Def Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, Swing Right PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-313...
  • Page 802 Between P10 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to Swing Right PPC pressure sensor 40-314 PC88MR-10...

  • Page 803: Failure Code [Dhsbma] Swing Left Ppc Press Sensor Def Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, Swing Left PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-315...
  • Page 804 Between P11 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to Swing Left PPC pressure sensor 40-316 PC88MR-10...

  • Page 805: Failure Code [Dhscma] Arm Out Ppc Press Sens Def Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, Arm OUT PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-317...
  • Page 806 Between P02 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to arm OUT PPC pressure sensor 40-318 PC88MR-10...

  • Page 807: Failure Code [Dhsdma] Bucket Dump Ppc Press Sens Def Function

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, bucket DUMP PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-319...
  • Page 808 Between P01 (female) (2) and ground Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to bucket DUMP PPC pressure sensor 40-320 PC88MR-10...

  • Page 809: Failure Code [Dhspma] Boom Swing Lh Ppc Press Sensor Abnormality

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, boom swing LH PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-321...
  • Page 810 Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to boom swing LH PPC pressure sensor 40-322 PC88MR-10...

  • Page 811: Failure Code [Dhsqma] Boom Swing Rh Ppc Press Sensor Abnormality

    3. Turn starting switch to ON position and display "Abnormality Record" screen of electrical system on machine monitor. 4. If E mark is not displayed again for this failure code, boom swing RH PPC pressure sensor is defective. a After finishing test, restore connectors. PC88MR-10 40-323...
  • Page 812 Max. 1 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to boom swing RH PPC pressure sensor 40-324 PC88MR-10...

  • Page 813: Failure Code [Dkulka] Ppc Lock Relay Open Circuit

    Max. 1 z Resistance Between R12 (female) (2) and ground Max. 1 z If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-325...
  • Page 814 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to PPC lock solenoid 40-326 PC88MR-10...

  • Page 815: Failure Code [Dkulkb] Ppc Lock Relay Short Circuit

    Between ground and CP02 (female) (99) or R12 Resistance Min 1 Mz (female) (1) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-327...
  • Page 816 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to PPC lock solenoid 40-328 PC88MR-10...

  • Page 817: Failure Code [Dkulky] Ppc Lock Relay Hot Short Circuit

    3. Turn starting switch to ON position. Voltage Between R12 (female) (1) and ground Max 4.5 V If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-329...
  • Page 818 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to PPC lock solenoid 40-330 PC88MR-10...

  • Page 819: Failure Code [Dv20Kb] Travel Alarm Short Circuit

    4. Perform troubleshooting by operating the travel lever. Never enter under the machine when operating travel lever. Travel Pump controller is control defective. lever: Max. 1 V Voltage Between M14 (1) and (2) NEUTRAL Travel control 20 to 30 V lever: Depressed PC88MR-10 40-331...
  • Page 820 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to travel alarm 40-332 PC88MR-10...

  • Page 821: Failure Code [Dw43Ka] Travel Speed Solenoid Open Circuit

    Between V02 (female) (2) and each of CP02 Max. 1 z (female) (115), (117), and (120) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-333...
  • Page 822 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to travel speed solenoid 40-334 PC88MR-10...

  • Page 823: Failure Code [Dw43Kb] Travel Speed Solenoid Short Circuit

    Between ground and CP02 (female) (93) or V02 Resistance Min. 1 Mz (female) (1) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-335...
  • Page 824 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to travel speed solenoid 40-336 PC88MR-10...

  • Page 825: Failure Code [Dw43Ky] Travel Speed Sol Hot Short Circuit

    Between V02 (female) (1) and ground Max. 4.5 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to travel speed solenoid PC88MR-10 40-337...

  • Page 826: Failure Code [Dw45Ka] Swing Parking Brake Solenoid Open Circuit

    Shake the wiring harness by hand while measuring the voltage. If the harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around pump controller this point. 1 to 4.5 V Voltage Between V03 (female) (1) and (2) 40-338 PC88MR-10...
  • Page 827 Between each of CP02 (female) (115), (117), (120) Max. 1 z and V03 (female) (2) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-339...
  • Page 828 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to swing holding brake solenoid 40-340 PC88MR-10...

  • Page 829: Failure Code [Dw45Kb] Swing Parking Brake Solenoid Short Circuit

    Between D01 (female) (3) and CP02 (female) Resistance 20 to 60 z (115), (117), or (120) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-341...
  • Page 830 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to swing holding brake solenoid 40-342 PC88MR-10...

  • Page 831: Failure Code [Dw45Ky] Swing Brake Sol Hot Short Circuit

    3. Turn starting switch to ON position. Voltage Between D01 (female) (7) and ground Max. 4.5 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-343...
  • Page 832 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to swing holding brake solenoid 40-344 PC88MR-10...

  • Page 833: Failure Code [Dw4Cky] Ppc Lock Sol Hot Short Circuit

    3. Turn starting switch to ON position. Voltage Between V01 (female) (1) and ground Max 4.5 V If no failure is found by preceding checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-345...
  • Page 834 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to PPC lock solenoid 40-346 PC88MR-10...

  • Page 835: Failure Code [Dwj0Ka] Merge-Divider Sol Open Circuit

    Between V04 (female) (2) and each of CP02 Max. 1 z (female) (115), (117), and (120) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-347...
  • Page 836 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to pump merge-divider solenoid 40-348 PC88MR-10...

  • Page 837: Failure Code [Dwj0Kb] Merge-Divider Sol Short Circuit

    Between ground and CP02 (female) (85) or V04 Resistance Min. 1 Mz (female) (1) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-349...
  • Page 838 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to pump merge-divider valve solenoid 40-350 PC88MR-10...

  • Page 839: Failure Code [Dwj0Ky] Merge-Divider Sol Short Circuit

    Between V04 (female) (1) and ground Max. 4.5 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to Pump merge-divider valve solenoid PC88MR-10 40-351...

  • Page 840: Failure Code [Dxa8Ka] Front Pump Pc-Epc Solenoid Open Circuit

    (female) (115), (117), (120) Between S25 (female) (5) and V11 (female) (2) Max. 1 z If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-352 PC88MR-10...
  • Page 841 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to PC-EPC solenoid PC88MR-10 40-353...

  • Page 842: Failure Code [Dxa8Kb] Front Pump Pc-Epc Solenoid Short Circuit

    Between ground and S25 (female) (5) or V11 Min. 1 Mz (female) (2) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-354 PC88MR-10...
  • Page 843 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to PC-EPC solenoid PC88MR-10 40-355...

  • Page 844: Failure Code [Dxe7Ka] Attachment Flow Regulating Epc 2 Solenoid Open Circuit

    Between each of CP02 (female) (115), (117), (120) connector) Max. 1 z and V92 (female) (2) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-356 PC88MR-10...
  • Page 845 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to ATT flow rate adjustment EPC2 PC88MR-10 40-357...

  • Page 846: Failure Code [Dxe7Kb] Att Flow Regulating Epc 2 Short Circuit

    Between ground and CP02 (female) (110) or V92 circuit) Resistance Min 1 Mz (female) (1) If no failure is found by above checks, pump controller is defective. Defective pump controller (Since this is an internal defect, troubleshooting cannot be performed.) 40-358 PC88MR-10...
  • Page 847 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to ATT flow rate adjustment EPC2 PC88MR-10 40-359...
  • Page 848 3. Turn starting switch to ON position. Voltage Between V92 (female) (1) and ground Max 4.5 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-360 PC88MR-10...
  • Page 849 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to ATT flow rate adjustment EPC2 PC88MR-10 40-361...

  • Page 850: Failure Code [Dxeaka] Att Flow Regulating Epc 5 Open Circuit

    Between each of CP02 (female) (115), (117), (120) connector) Max. 1 z and V91 (female) (2) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-362 PC88MR-10...
  • Page 851 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to ATT flow rate adjustment EPC5 PC88MR-10 40-363...

  • Page 852: Failure Code [Dxeakb] Att Flow Regulating Epc 5 Short Circuit

    Between ground and CP02 (female) (102) or V91 circuit) Resistance Min 1 Mz (female) (1) If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-364 PC88MR-10...
  • Page 853 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to ATT flow rate adjustment EPC5 PC88MR-10 40-365...

  • Page 854: Failure Code [Dxeaky] Service Current Epc5 Hot Short Circuit

    3. Turn starting switch to ON position. Voltage Between V91 (female) (1) and ground Max 4.5 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-366 PC88MR-10...
  • Page 855 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to ATT flow rate adjustment EPC2 PC88MR-10 40-367...

  • Page 856: Failure Code [Dy20Ka] Wiper Motor Open Circuit

    Max. 1 z Between CP02 (female) (119) and M05 (male) (3) Max. 1 z If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-368 PC88MR-10...
  • Page 857 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to wiper PC88MR-10 40-369...

  • Page 858: Failure Code [Dy20Ma] Wiper Motor Defective Function

    Max. 1 z Between CP02 (female) (119) and M05 (male) (3) Max. 1 z If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-370 PC88MR-10...
  • Page 859 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to wiper PC88MR-10 40-371...

  • Page 860: Failure Code [Dy2Ckb] Washer Motor Short Circuit

    Ignore failure codes displayed on machine monitor. Voltage Between D02 (female) (6) and ground Max. 4.5 V If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) 40-372 PC88MR-10...
  • Page 861 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to window washer motor PC88MR-10 40-373...

  • Page 862: Failure Code [Dy2Dkb] Wiper Motor (Normal) Short Circuit

    3. Turn starting switch to ON position. defective. 4. Turn wiper switch ON and OFF, and troubleshoot. Wiper Max. 3 V switch: OFF Voltage Between M05 (3) and (5) Wiper Pulse below 3 V io switch: ON above 20 V 40-374 PC88MR-10...
  • Page 863 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to wiper PC88MR-10 40-375...

  • Page 864: Failure Code [Dy2Ekb] Wiper Motor (Reverse) Short Circuit

    3. Turn starting switch to ON position. defective. 4. Turn wiper switch ON and OFF, and troubleshoot. Wiper Max. 3 V switch: OFF Voltage Between M05 (1) and (5) Wiper Pulse below 3 V io switch: ON above 20 V 40-376 PC88MR-10...
  • Page 865 40 Troubleshooting Troubleshooting by failure code (Display of code) Circuit diagram related to wiper PC88MR-10 40-377...

  • Page 866: Troubleshooting Of Electrical System (E-Mode)

    R06, for this check). personal code relay Voltage Between E12 (1) and ground R07, battery relay, or 20 to 30 V wiring harness a If voltage is abnormal, go to check on Cause 12 and after. 40-378 PC88MR-10...
  • Page 867 Before performing troubleshooting, check that the head lamp lights up. Defective starting motor 1. Turn starting switch to OFF position. cut-off relay 2. Interchange starting motor cut-off relay (R06) with light relay (R05). 3. Start engine. If engine starts, original starting motor cut-off relay is defective. PC88MR-10 40-379...
  • Page 868 Between D01 (male) (1) (+) and (5) (-) No continuity (Internal open or short Between D01 (male) (5) (+) and (1) (-) Continuity circuit) Between D01 (male) (2) (+) and (6) (-) No continuity Continuity Between D01 (male) (6) (+) and (2) (-) 40-380 PC88MR-10...
  • Page 869 Between alternator terminal R and D01 (female) (6) Max. 1 z Between F01-3 and S14 (male) (1) Max. 1 z Between S14 (male) (3) and R06 (female) (1) Max. 1 z Max. 1 z Between R06 (female) (2) and ground (T05) PC88MR-10 40-381...
  • Page 870 1. Turn starting switch to OFF position. wiring harness 2. Insert T-adapter into connector R17 or CM01. 3. Turn starting switch to ON position. (Contact with 24 V circuit) Voltage Between ground and R17 (2) or CM01 (16) Max. 1 V 40-382 PC88MR-10...
  • Page 871 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to engine starting circuit PC88MR-10 40-383...

  • Page 872: E-2 Manual Preheating System Does Not Work

    2. Disconnect connector D02 and connect T-adapter to diode. (Internal open or short a Measure it with diode range of multimeter. circuit) Continuity Between D02 (male) (1) (+) and (5) (-) No continuity Continuity Continuity Between D02 (male) (5) (+) and (1) (-) 40-384 PC88MR-10...
  • Page 873 Between heater relay terminal R15 (wiring harness Min. 1 Mz (Contact with ground side) and ground circuit) Between heater relay R16B (contact side input Resistance Min. 1 Mz terminal) and ground Between heater terminal E01 (wiring harness side) Min. 1 Mz and ground PC88MR-10 40-385...
  • Page 874 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to engine preheating system 40-386 PC88MR-10...

  • Page 875: While Preheating Is Working, Preheating Monitor Does Not Light Up

    3. Disconnect heater relay terminal R16A. monitor a To prevent current from flowing through heater when starting switch is turned to HEAT position 4. Turn starting switch to HEAT. Resistance Between CM01 (12) and (3) 20 to 30 V PC88MR-10 40-387...
  • Page 876 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to engine preheating system 40-388 PC88MR-10...

  • Page 877: When Starting Switch Is Turned To On Position, Machine Monitor Displays Nothing

    When starting switch is turned to ON position, machine monitor displays nothing. Failure When starting switch is turned to ON position, machine monitor displays KOMATSU logo, password input screen (if set), operator ID input screen (if set), check-before-starting screen, check working mode screen, check travel speed screen, and standard screen in Related order.
  • Page 878 Between ground and H15 (female) (5) or CM01 Min. 1 Mz (female) (10) If no failure is found by preceding checks, machine monitor is defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) 40-390 PC88MR-10...
  • Page 879 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to machine monitor power supply PC88MR-10 40-391...

  • Page 880: Engine Coolant Temperature Monitor Lights Up In White While Engine Is Running

    Perform following troubleshooting. Defective engine E-14 Engine coolant temperature gauge display does not move from coolant temperature minimum or maximum gauge system E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) 40-392 PC88MR-10...

  • Page 881: Hydraulic Oil Temperature Monitor Lights Up In White While Engine Is Running

    If no failure is found by preceding checks, hydraulic oil temperature gauge system may be defective. Perform following troubleshooting. Defective oil E-16 Hydraulic oil temperature gauge does not move from minimum or temperature gauge maximum system E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) PC88MR-10 40-393...

  • Page 882: E-7 Charge Level Monitor Lights Up While Engine Is Running

    Charge level monitor lights up in red while engine is running. Failure Power-generation signal from alternator can be checked with monitoring function. Related (Code: 04300) information Procedure, measuring location, criteria, and remarks Cause Defective alternator Perform troubleshooting for failure code [AB00KE]. system 40-394 PC88MR-10...

  • Page 883: E-8 Fuel Level Monitor Lights Up In Red While Engine Is Running

    If no failure is found by preceding checks, fuel gauge system may be defective. Perform following troubleshooting. Defective fuel gauge E-12 Fuel gauge display does not move from minimum or maximum system E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty) PC88MR-10 40-395...

  • Page 884: Engine Coolant Temperature Monitor Lights Up In Red While Engine Is Running

    Perform following troubleshooting. Defective engine E-14 Engine coolant temperature gauge display does not move from coolant temperature minimum or maximum gauge system E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) 40-396 PC88MR-10...

  • Page 885: Hydraulic Oil Temperature Monitor Lights Up In Red While Engine Is Running

    If no failure is found by preceding checks, hydraulic oil temperature gauge system may be defective. Perform following troubleshooting. Defective oil E-16 Hydraulic oil temperature gauge does not move from minimum or temperature gauge maximum system E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) PC88MR-10 40-397...

  • Page 886: Engine Oil Pressure Monitor Lights Up In Red While Engine Is Running

    Perform troubleshooting for failure code [CA435]. If no failure is found by check on Causes 1 to 2, machine monitor may be Defective machine defective. monitor (Since this is an internal defect, troubleshooting cannot be performed.) 40-398 PC88MR-10...

  • Page 887: Fuel Gauge Display Does Not Move From Minimum Or Maximum

    Between ground and CM01 (15) or P21 (female) (1) Approx. 3.3 Voltage If no failure is found by preceding checks, machine monitor is defective. Defective machine (Since this is an internal defect, troubleshooting cannot be performed.) monitor Circuit diagram related to fuel level sensor PC88MR-10 40-399...

  • Page 888: Fuel Gauge Indicates Incorrect Amount (Indicates Neither Full Nor Empty)

    Fuel level: 60 l Blue monitor Fuel gauge level: 3 Fuel level: 41 l light (a) Fuel gauge level: 2 Fuel level: 32 l Fuel gauge level: 1 Fuel level: 23 l Fuel gauge and fuel level monitor 40-400 PC88MR-10...

  • Page 889: Engine Coolant Temperature Gauge Display Does Not Move From Minimum Or Maximum

    [CA144] and [CA145]. system If no failure is found by check on Cause 1, machine monitor may be defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) Engine coolant temperature gauge and coolant temperature monitor PC88MR-10 40-401...

  • Page 890: Engine Coolant Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Full Nor Empty)

    Engine coolant light (a) Coolant temperature 80° temperature gauge level: Blue Engine coolant Coolant temperature 60° temperature gauge level: Engine coolant Coolant temperature 30° White temperature gauge level: Engine coolant temperature gauge and coolant temperature monitor 40-402 PC88MR-10...

  • Page 891: Hydraulic Oil Temperature Gauge Does Not Move From Minimum Or Maximum

    Between ground and CP01 (28) or P22 (female) (2) Approx. 5 V If no failure is found by preceding checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-403...
  • Page 892 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to hydraulic oil temperature sensor 40-404 PC88MR-10...

  • Page 893: Hydraulic Oil Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Full Nor Empty)

    (a) Blue temperature: 80°C gauge level: 3 Hydraulic oil Hydraulic oil temperature temperature: 40°C gauge level: 2 Hydraulic oil Hydraulic oil temperature White temperature: 20°C gauge level: 1 Hydraulic oil temperature gauge and hydraulic oil temperature monitor PC88MR-10 40-405...

  • Page 894: E-18 Some Areas Of Machine Monitor Screen Are Not Displayed

    Operation of switches: [4] and [F2] (Press simultaneously) Defective machine If no failure is found by check on Cause 1, machine monitor may be defective. monitor (Since this is an internal defect, troubleshooting cannot be performed.) (Monitor itself) 40-406 PC88MR-10...

  • Page 895: E-19 Function Switch Does Not Work

    Signal of function switch can be checked with monitoring function. Related (Code: 04503) information Procedure, measuring location, criteria, and remarks Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor PC88MR-10 40-407...

  • Page 896: Automatic Warm-Up System Does Not Operate (In Cold Season)

    1 (a: White) If no failure is found by checks on Cause 1, engine controller is defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) Engine coolant temperature gauge and engine coolant temperature monitor 40-408 PC88MR-10...

  • Page 897: Auto-Deceleration Monitor Does Not Light Up, Or Does Not Go Out, While Auto-Deceleration Switch Is Operated

    Condition of signal of auto-decelerator switch can be checked with monitoring function. Related (Code: 04504) information Procedure, measuring location, criteria, and remarks Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor PC88MR-10 40-409...

  • Page 898: Auto-Deceleration Function Does Not Operate Or Is Not Canceled While Lever Is Operated

    When lever is operated: Blade LOWER When lever is in neutral: When lever is operated: Boom swing left When lever is in neutral: Monitoring code When lever is operated: 01902 Boom swing right When lever is in neutral: 40-410 PC88MR-10...
  • Page 899 Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) If no failure is found by preceding checks, engine controller may be defective. Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-411...

  • Page 900: Working Mode Selection Screen Is Not Displayed While Working Mode Selector Switch Is Operated

    Signal of working mode switch can be checked with monitoring function. Related (Code: 04504) information Procedure, measuring location, criteria, and remarks Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor 40-412 PC88MR-10...

  • Page 901: Setting Of Engine And Hydraulic Pump Is Not Changed While Working Mode Is Changed

    Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor Pump controller may be defective. (Since this is an internal defect, Pump controller is troubleshooting cannot be performed.) defective. PC88MR-10 40-413...

  • Page 902: Travel Speed Monitor Does Not Change When Travel Speed Switch Is Operated

    Condition of signal of travel speed switch can be checked with monitoring function. Related (Code: 04504) information Procedure, measuring location, criteria, and remarks Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor 40-414 PC88MR-10...

  • Page 903: Travel Speed Does Not Change While Travel Speed Selection Is Changed

    If no failure is found by checks on Causes 1 and 2, pump controller may be Pump controller is defective. defective. (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to travel speed solenoid PC88MR-10 40-415...

  • Page 904: E-27 Alarm Buzzer Does Not Stop Sounding

    Condition of signal of alarm buzzer cancel switch can be checked with monitoring Related function. information (Code: 04504) Procedure, measuring location, criteria, and remarks Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor 40-416 PC88MR-10...

  • Page 905: Service Meter Is Not Displayed, While Starting Switch Is In Off Position

    E-4 When starting switch is turned to ON position, machine monitor displays nothing If no failure is found by check on Cause 1, machine monitor may be defective. Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-417...

  • Page 906: E-29 Service Mode Cannot Be Selected

    Operation of switches: [4] + [1]o[2]o[3] (While pressing [4], press [1], [2] and [3] in this information order.) Procedure, measuring location, criteria, and remarks Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor 40-418 PC88MR-10...

  • Page 907: E-30 Any Of Work Equipment, Swing And Travel Does Not Work

    Between V01 (female) (1) and R12 (female) (5) Max. 1 z Between R12 (female) (3) and S14 (male) (2) Resistance Max. 1 z Between fuse F01-3 outlet and S14 (male) (1) Max. 1 z Between R12 (female) (1) and CP02 (female) (99) Max. 1 z PC88MR-10 40-419...
  • Page 908 Between S14 (male) (1) and ground Min. 1 Mz If no failure is found by above checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) Circuit diagram related to PPC lock solenoid 40-420 PC88MR-10...

  • Page 909: E-31 Any Of Work Equipment, Swing And Travel Cannot Be Locked

    2. Disconnect connector V01 and connect T-adapter to female side. Hot short circuit in 3. Turn starting switch to ON position. wiring harness 4. Turn lock lever to LOCK position. Voltage Between V01 (female) (2) and (1) Max. 1 V PC88MR-10 40-421...
  • Page 910 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to PPC lock solenoid 40-422 PC88MR-10...

  • Page 911: Upper Structure Does Not Swing While Swing Parking Brake Cancel Switch Is Set To Cancel Position

    Ground fault in wiring harness 1. Turn starting switch to OFF position. 2. Disconnect connectors S25 and V03 and connect T-adapter to female side (Contact with ground of V03. circuit) Resistance Between V03 (female) (1) and ground Min. 1 Mz PC88MR-10 40-423...
  • Page 912 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to swing parking brake 40-424 PC88MR-10...

  • Page 913: Swing Brake Does Not Operate While Swing Parking Brake Cancel Switch Is Set To Normal Position

    3. Turn starting switch to ON position. wiring harness 4. Swing lock switch: ON (Contact with 24 V circuit) a Measure voltage again with swing lock switch in OFF position. Voltage Between V03 (female) (2) and ground Max. 1 V PC88MR-10 40-425...
  • Page 914 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to swing parking brake solenoid 40-426 PC88MR-10...

  • Page 915: Work Equipment Does Not Operate While Lock Lever Automatic Release Switch Is In Release Position

    (Contact with ground Between ground and V01 (female) (1) or S25 Min 1 Mz circuit) (female) (8) Between ground and S14 (male) (1) or S25 Resistance Min 1 Mz (female) (7) Between S14 (male) (1) and ground Min 1 Mz PC88MR-10 40-427...
  • Page 916 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to PPC lock solenoid 40-428 PC88MR-10...

  • Page 917: E-35 Alarm Does Not Sound During Travel

    2. Disconnect connectors CP02 and M14, and connect T-adapter to either harness female side. (Contact with ground Between CP02 (female) (107) and ground, or M14 circuit) Resistance Min. 1 Mz (female) (1) and ground Circuit diagram related to travel alarm PC88MR-10 40-429...

  • Page 918: E-36 Alarm Does Not Stop Sounding While Machine Is Stopped

    Hot short circuit in 2. Disconnect connector M14 and connect T-adapter to female side. wiring harness 3. Turn starting switch to ON position. Voltage Between M14 (female) (1) and ground Max. 1 V Circuit diagram related to travel alarm 40-430 PC88MR-10...

  • Page 919: E-37 Horn Does Not Sound

    Min. 1 Mz Between R08 (female) (3) and ground Resistance Min. 1 Mz Between R08 (female) (5) and ground Min. 1 Mz Defective horn If no failure is found by preceding checks, horn may be defective. (Internal defect) PC88MR-10 40-431...
  • Page 920 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to horn 40-432 PC88MR-10...

  • Page 921: E-38 Horn Does Not Stop Sounding

    Hot short circuit in 2. Disconnect connector M07, and connect T-adapter to female side. wiring harness 3. Turn starting switch to ON position. Voltage Between M07 (female) (1) and (2) Max. 1 V Circuit diagram related to horn PC88MR-10 40-433...

  • Page 922: Wiper Monitor Does Not Light Up, Or Does Not Go Out, While Wiper Switch Is Operated

    Condition of wiper switch signal can be checked with monitoring function. Related information (Code: 04504) Procedure, measuring location, criteria, and remarks Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor 40-434 PC88MR-10...

  • Page 923: E-40 Wiper Does Not Operate While Wiper Switch Is Operated

    3. Front window: When closed circuit) Resistance Between CP01 (female) (76) and ground Min. 1 Mz If no failure is found by preceding checks, pump controller is defective. Pump controller is defective. (Since this is an internal defect, troubleshooting cannot be performed.) PC88MR-10 40-435...
  • Page 924 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to wiper motor 40-436 PC88MR-10...

  • Page 925: Window Washer Does Not Operate While Window Washer Switch Is Operated

    (Code: 04504) information Failure in window washer is expressed by failure code [DY2CKB]. Procedure, measuring location, criteria, and remarks Cause Machine monitor may be defective. (Since this is an internal defect, Defective machine troubleshooting cannot be performed.) monitor PC88MR-10 40-437...

  • Page 926: Boom Lower Is Not Displayed Correctly With Monitoring Function

    "Boom LOWER" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01900 Pressure Switch 1 information Procedure, measuring location, criteria, and remarks Cause Defective boom LOWER PPC oil pressure sensor system Perform troubleshooting for failure codes [DHS9MA]. (internal open or short circuit) 40-438 PC88MR-10...

  • Page 927: E-43 Arm Out Is Not Displayed Correctly With Monitoring Function

    "Arm OUT" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01900 Pressure Switch 1 information Procedure, measuring location, criteria, and remarks Cause Defective Arm OUT PPC oil pressure Perform troubleshooting for failure codes [DHSCMA]. sensor system (internal open or short circuit) PC88MR-10 40-439...

  • Page 928: E-44 Arm In Is Not Displayed Correctly With Monitoring Function

    "Arm IN" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01900 Pressure Switch 1 information Procedure, measuring location, criteria, and remarks Cause Defective arm IN PPC oil pressure sensor Perform troubleshooting for failure codes [DHS3MA]. system (internal open or short circuit) 40-440 PC88MR-10...

  • Page 929: Boom Raise Is Not Displayed Correctly With Monitoring Function

    "Boom RAISE" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01900 Pressure Switch 1 information Procedure, measuring location, criteria, and remarks Cause Defective boom RAISE PPC oil pressure Perform troubleshooting for failure codes [DHS8MA]. sensor system (internal open or short circuit) PC88MR-10 40-441...

  • Page 930: Bucket Curl Is Not Displayed Correctly With Monitoring Function

    "Bucket CURL" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01901 Pressure Switch 2 information Procedure, measuring location, criteria, and remarks Cause Defective bucket CURL PPC oil pressure Perform troubleshooting for failure codes [DHS4MA]. sensor system (internal open or short circuit) 40-442 PC88MR-10...

  • Page 931: Bucket Dump Is Not Displayed Correctly With Monitoring Function

    "Bucket DUMP" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01901 Pressure Switch 2 information Procedure, measuring location, criteria, and remarks Cause Defective bucket DUMP PPC oil pressure Perform troubleshooting for failure codes [DHSDMA]. sensor system (internal open or short circuit) PC88MR-10 40-443...

  • Page 932: Boom Swing Left Is Not Displayed Correctly With Monitoring Function

    "Boom swing left" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01902 Pressure Switch 3 information Procedure, measuring location, criteria, and remarks Cause Defective Boom swing left PPC oil pressure Perform troubleshooting for failure codes [DHSPMA]. sensor system (internal open or short circuit) 40-444 PC88MR-10...

  • Page 933: Boom Swing Right Is Not Displayed Correctly With Monitoring Function

    "Boom swing right" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01902 Pressure Switch 3 information Procedure, measuring location, criteria, and remarks Cause Defective Boom swing right PPC oil pressure Perform troubleshooting for failure codes [DHSQMA]. sensor system (internal open or short circuit) PC88MR-10 40-445...

  • Page 934: E-50 Swing Is Not Displayed Correctly With Monitoring Function

    "Swing" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01900 Pressure Switch 1 information Procedure, measuring location, criteria, and remarks Cause Defective swing PPC oil pressure sensor system Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA]. (internal open or short circuit) 40-446 PC88MR-10...

  • Page 935: E-51 Travel Is Not Displayed Correctly With Monitoring Function

    "Travel" is not displayed correctly with monitoring function. Failure Related Monitoring code: 01900 Pressure Switch 1 information Procedure, measuring location, criteria, and remarks Cause Defective travel PPC oil pressure sensor system Perform troubleshooting for failure codes [DHS5MA]. (Internal open or short circuit) PC88MR-10 40-447...

  • Page 936: Blade Raise On Is Not Displayed Correctly With Monitoring Function

    Pump controller is 4. Turn starting switch to ON position. defective. If voltage between P12 (2) and (1) is below 1 V but "Blade RAISE" is displayed "OFF", pump controller is defective. a After finishing test, restore connector. 40-448 PC88MR-10...
  • Page 937 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to blade RAISE oil pressure switch PC88MR-10 40-449...

  • Page 938: Blade Lower On Is Not Displayed Correctly With Monitoring Function

    Pump controller is 4. Turn starting switch to ON position. defective. If voltage between P13 (2) and (1) is below 1 V but "Blade LOWER" is displayed "OFF", pump controller is defective. a After finishing test, restore connector. 40-450 PC88MR-10...
  • Page 939 40 Troubleshooting Troubleshooting of electrical system (E-mode) Circuit diagram related to blade LOWER oil pressure switch PC88MR-10 40-451...

  • Page 940: E-54 Komtrax System Does Not Operate Normally

    0 to 60 (normally 0) display not yet sent a Select "01 Terminal Status" from "11 KOMTRAX settings" in service menu of machine monitor. a Select "GPS & Communication Status" from "11 KOMTRAX settings" in service menu of machine monitor. 40-452 PC88MR-10...
  • Page 941 40 Troubleshooting Troubleshooting of electrical system (E-mode) PC88MR-10 40-453...

  • Page 942: Troubleshooting Of Hydraulic And Mechanical System (H-Mode)

    Information on occurred failure or troubleshooting information Procedure, measuring location, criteria and remarks Cause Probable cause of failure <Contents of description> (Each number is serial Criteria to determine probable causes number, not priority Remarks for determination of probable cause sequence.) 40-454 PC88MR-10...

  • Page 943: System Chart Of Hydraulic And Mechanical Systems

    40 Troubleshooting Troubleshooting of hydraulic and mechanical system (H- mode) System chart of hydraulic and mechanical systems (PC88MR-C000-054-K-00-A) PC88MR-10 40-455...
  • Page 944 Troubleshooting of hydraulic and mechanical system (H- mode) a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a reference material when troubleshooting the hydraulic and mechanical systems. *: Only machines with ATT 40-456 PC88MR-10...

  • Page 945: Failure Mode And Cause Table

    Machine does not travel straight H-20 Travel speed is slow H-21 Machine is hard to steer or travel power is low H-22 Travel speed does not change, or travel speed is too slow or fast H-23 PC88MR-10 40-457...
  • Page 946 Large unusual noise is heard when upper structure stops swinging H-32 When parking brake works H-33 Swing drift on a slope is large When parking brake is OFF H-34 Oil flow in attachment circuit cannot be controlled H-35 40-458 PC88MR-10...
  • Page 947 H-20 Travel speed is slow H-21 Machine is hard to steer or travel power is low H-22 Travel speed does not change, or travel speed is too slow or fast H-23 One of tracks does not run H-24 PC88MR-10 40-459...
  • Page 948 H-31 Large unusual noise is heard when upper structure stops swinging H-32 When parking brake H-33 works Swing drift on a slope is large When parking brake is H-34 Oil flow in attachment circuit cannot be controlled H-35 40-460 PC88MR-10...
  • Page 949 Machine does not travel straight H-20 Travel speed is slow H-21 Machine is hard to steer or travel power is low H-22 Travel speed does not change, or travel speed is too slow or fast H-23 PC88MR-10 40-461...
  • Page 950 Large unusual noise is heard when upper structure stops swinging H-32 When parking brake works H-33 Swing drift on a slope is large When parking brake is OFF H-34 Oil flow in attachment circuit cannot be controlled H-35 40-462 PC88MR-10...
  • Page 951 Travel speed does not change, or travel speed is too slow or fast H-23 One of tracks does not run H-24 Upper structure does not H-25 swing to the right or left Machine does not swing Upper structure swing only H-26 to the right or left PC88MR-10 40-463...
  • Page 952 Large unusual noise is heard when upper structure stops swinging H-32 When parking brake works H-33 Swing drift on a slope is large When parking brake is OFF H-34 Oil flow in attachment circuit cannot be controlled H-35 40-464 PC88MR-10...

  • Page 953: All Of Work Equipments, Swing And Travel Operations Lack Speed Or Power

    PC valve PC valve output Arm IN hydraulic relief Approx. 0.2 to 0.6 pressure When pressure cannot be adjusted to normal level, check PC valve for malfunction (fatigue of spring) or internal defect (stuck or seized PC spool). PC88MR-10 40-465...
  • Page 954 PC valve (*) If no failure is found by above checks, piston pump may have degraded Malfunction of piston performance, malfunction, or have internal failure. pump Check hydraulic tank strainer and return filter element for metal particles. 40-466 PC88MR-10...

  • Page 955: H-2 Engine Speed Drops Significantly Or Engine Stalls

    Check orifices and filters in pump servo devices for clogging. filter in serve device If no failure is found by above checks, piston pump may malfunction or have Malfunction of servo internal defect. piston Check hydraulic tank strainer and return filter element for metal particles. PC88MR-10 40-467...

  • Page 956: H-3 Any Of Work Equipment, Swing And Travel Does Not Work

    Defective piston pump Crank the engine with main oil pressure pickup port plug removed. o If any oil flows out, piston pump is normal. Defective damper Pump shaft may not rotate due to some internal defect of damper. 40-468 PC88MR-10...

  • Page 957: H-4 Unusual Sound Is Heard From Around Hydraulic Pump

    Check the return filter in the hydraulic tank may be clogged, especially Clogging of hydraulic tank by metallic materials. Check the return filter. return filter If any metallic materials are detected in Cause 4 and 5 above, piston Defective piston pump pump may have internal defect. PC88MR-10 40-469...

  • Page 958: H-5 Fine Control Performance Or Response Is Poor

    When pressure cannot be adjusted to normal level, check LS valve for Malfunction of LS valve malfunction (fatigue of spring) or internal defect (stuck or seized LS spool). Malfunction of servo Check orifices and filters in pump servo devices for clogging. piston 40-470 PC88MR-10...

  • Page 959: H-6 Boom Speed Or Power Is Low

    If any failure is found in either of above check items, interchange pressure compensation valves on RAISE and LOWER sides, and check whether failure symptom changes. (Pressure compensation valves have different area ratio, so be sure to return them to their original positions after test.) PC88MR-10 40-471...
  • Page 960 Malfunction of boom 26.5 ± 1.5 MPa control valve (suction- Boom relief pressure Boom LOWER hydraulic relief safety valve) (boom {270 ± 15 kg/cm LOWER side) a If boom LOWER relief pressure is low, suction-safety valve may be defective. 40-472 PC88MR-10...
  • Page 961 Be ready with engine stopped, then perform troubleshooting with engine at high idle. 12 Defective boom cylinder Leakage from boom Boom RAISE hydraulic relief Max. 7.5 cc/min cylinder PC88MR-10 40-473...

  • Page 962: H-7 Arm Speed Or Power Is Low

    If any failure is found in either of above check items, interchange pressure compensation valves on bucket CURL and DUMP sides, and check whether failure symptom changes. (Each area ratio is different, so be sure to restore it after checking the symptom.) 40-474 PC88MR-10...
  • Page 963 Be ready with engine stopped, then perform troubleshooting with engine at high idle. 10 Defective arm cylinder Leakage from arm Arm IN hydraulic relief Max. 7.5 cc/min cylinder PC88MR-10 40-475...

  • Page 964: H-8 Bucket Speed Or Power Is Low

    If any failure is found in either of above check items, interchange pressure compensation valves on bucket CURL and DUMP sides, and check whether failure symptom changes. (Each area ratio is different, so be sure to restore it after checking the symptom.) 40-476 PC88MR-10...
  • Page 965 Be ready with engine stopped, then perform troubleshooting with engine at Defective bucket high idle. cylinder Leakage from Bucket CURL relief Max. 7.5 cc/min bucket cylinder PC88MR-10 40-477...

  • Page 966: H-9 Boom Swing Speed Or Power Is Low

    If any failure is found in either of above check items, interchange pressure compensation valves on right and left swing sides, and check whether failure symptom changes. (Each area ratio is different, so be sure to restore it after checking the symptom.) 40-478 PC88MR-10...
  • Page 967 Be ready with engine stopped, then perform troubleshooting with engine at Defective boom swing high idle. cylinder Leakage from Boom swing right relief Max. 7.5 cc/min bucket cylinder PC88MR-10 40-479...

  • Page 968: H-10 Blade Speed Or Power Is Low

    Hydraulic oil temperature: Within side) the operating range, lifting the If visible hydraulic machine body by using blade, drift is observed, it is Hydraulic drift fully retracted arm cylinder, fully abnormal. extended bucket cylinder, and boom top face horizontal 40-480 PC88MR-10...
  • Page 969 Be ready with engine stopped, then perform troubleshooting with engine at high idle. Defective blade cylinder Leakage from Blade LOWER relief Max. 7.5 cc/min bucket cylinder Performance deterioration, malfunction, and internal defect of the gear pump 10 Defective gear pump may be occurred. Check it directly. PC88MR-10 40-481...

  • Page 970: H-11 Work Equipment Does Not Move In Single Operation

    (Reference) While work equipment is moved in single operation, if pump pressure remains at approximately 4 MPa {approximately 40 kg/cm }, control valve spool probably stays at NEUTRAL position. (All oil from pump is drained to tank through unload valve.) 40-482 PC88MR-10...

  • Page 971: H-12 Hydraulic Drift Of Boom Is Large

    Check for stuck or seized pilot piston and poppet in lock valve body (pilot control valve (lock piston and poppet must move smoothly). valve) Remove pilot piston and poppet from valve body and check them for defects and dirt. Check poppet spring for fatigue and deformation. PC88MR-10 40-483...

  • Page 972: H-13 Hydraulic Drift Of Arm Is Large

    Malfunction of arm Check for stuck or seized arm spool in control valve body. control valve (spool) (Spool must move smoothly and must not be caught.) Remove arm spool from valve body and check it for defects and dirt. 40-484 PC88MR-10...

  • Page 973: H-14 Hydraulic Drift Of Bucket Is Large

    Check for stuck or seized bucket spool in control valve body. control valve (spool) (Spool must move smoothly and must not be caught.) Remove bucket spool from valve body and check it for defects and dirt. Take care not to let foreign matter enter valve when re-installing spool. PC88MR-10 40-485...

  • Page 974: H-15 Hydraulic Drift Of Blade Is Large

    (It must be moved smoothly and must not be caught.) control valve (spool) Remove blade spool from valve body and check it for defects and dirt. Be careful to prevent foreign matter from entering into it when re-installing spool. 40-486 PC88MR-10...

  • Page 975: H-16 Time Lag Of Work Equipment Is Large

    (boom LOWER side) Malfunction of arm a Check whether arm cylinder moves slowly to arm IN side when performing control valve (pressure hydraulic relief of other work equipment. (If arm cylinder moves, it is compensation valve) abnormal.) (arm IN side) PC88MR-10 40-487...
  • Page 976 (bucket CURL side) Malfunction of bucket a Check whether bucket cylinder moves slowly to bucket DUMP side when control valve (pressure performing hydraulic relief of other work equipment. (If bucket cylinder compensation valve) moves, it is abnormal.) (bucket DUMP side) 40-488 PC88MR-10...

  • Page 977: In Combined Operation Of Work Equipment , Equipment Having Heavier Load Moves Slower

    Pressure compensation valve of control valve on smaller load side may (boom LOWER) malfunction. a Pressure compensation valve is equipped with outer seal, inner seal, and LS check valve (ball). Since slipper seal is installed to inner seal, damage on O-ring inside inner seal cannot be checked visually. PC88MR-10 40-489...

  • Page 978: In Combined Operation Of Swing And Boom Raise, Boom Rising Speed Is Low

    Check if the check valve in the spool is not caught in the middle. Remove it from spool and check if the check valve is not stained or damaged. Check spring of check valve for fatigue and deformation. 40-490 PC88MR-10...

  • Page 979: In Combined Operation Of Work Equipment Or Swing And Travel, Travel Speed Drops Largely

    (bucket CURL side) Malfunction of bucket a Check whether bucket cylinder moves slowly to bucket DUMP side when control valve (pressure performing hydraulic relief of other work equipment. (If bucket cylinder compensation valve) moves, it is abnormal.) (bucket DUMP side) PC88MR-10 40-491...
  • Page 980 (L. pressure relief {270 ± 15 kg/cm H. travel REVERSE If measured values in checks on causes (12) and (13) are same and low, side) main relief valve of front pump may malfunction. Check bucket relief pressure additionally. 40-492 PC88MR-10...

  • Page 981: H-20 Machine Does Not Travel Straight

    Check for stuck or seized travel junction valve spool in merge-divider Malfunction of travel junction valve (spool) valve body. (Spool must move smoothly and must not be caught.) Remove travel junction valve spool from valve body and check it for defects and dirt. PC88MR-10 40-493...
  • Page 982 Check for unusual noise, unusual heat, and metallic powders in drained oil 12 Defective final drive to make judgment. Defective adjustment of Adjust travel deviation adjustment plug. For details, see Testing and adjusting, travel deviation "Testing and adjusting travel deviation". adjustment plug 40-494 PC88MR-10...

  • Page 983: H-21 Travel Speed Is Slow

    Malfunction of travel Check for stuck or seized travel spool in control valve body. control valve (spool) (Spool must move smoothly and must not be caught.) Remove travel spool from valve body and check it for defects and dirt. PC88MR-10 40-495...
  • Page 984 (It may be checked whether or not the direction of travel deviation changes by swapping right and left travel motor and final drive assemblies.) a Check for unusual noise, unusual heat, and metallic powders in drained oil 14 Defective final drive to make judgment. 40-496 PC88MR-10...

  • Page 985: H-22 Machine Is Hard To Steer Or Travel Power Is Low

    Check for stuck or seized travel spool in control valve body. (spool) (Spool must move smoothly and must not be caught.) Remove travel spool from valve body and check it for defects and dirt. PC88MR-10 40-497...
  • Page 986 If pressure compensation valves are found to be normal in checks on causes (10) and (11), check valves may malfunction. Defective R.H. travel motor (check valve) Interchange check valves on FORWARD and REVERSE sides of same travel motor, and check whether failure symptom changes. 40-498 PC88MR-10...
  • Page 987 Malfunction of travel malfunction. Check them. motor (counterbalance (It may be checked from how the symptom changes after switching between valve and check valve) forward and reverse travel by a motor or after swapping right and left motors.) PC88MR-10 40-499...

  • Page 988: Travel Speed Does Not Change, Or Travel Speed Is Too Slow Or Fast

    If no failure is found by checks on causes (1), speed switching part of travel motor (speed switching motor may malfunction. section) *: Travel speed of Lo setting can be adjusted by using adjustment function of machine monitor. If it is changed from default value, the value changes slightly. 40-500 PC88MR-10...

  • Page 989: H-24 One Of Tracks Does Not Run

    If safety valve is found to be normal in checks on cause (8), sealing of check valve may be defective. Defective L.H. travel motor (check valve) Interchange check valves on FORWARD and REVERSE sides of same travel motor, and check whether failure symptom changes. PC88MR-10 40-501...
  • Page 990 (It may be checked whether or not the direction of travel deviation changes by swapping right and left travel motor and final drive assemblies.) a Check for unusual noise, unusual heat, and metallic powders in drained oil 14 Defective final drive to make judgment. 40-502 PC88MR-10...

  • Page 991: H-25 Upper Structure Does Not Swing To The Right Or Left

    Leakage from swing parking brake Swing hydraulic Max. 7 l/min motor solenoid valve relief connector. Swing machinery may have internal failure. Defective swing a Check for unusual noise, unusual heat, and metallic powders in drained oil machinery to make judgment. PC88MR-10 40-503...

  • Page 992: H-26 Upper Structure Swing Only To The Right Or Left

    When removing valve, check it for sticking and defects. Interchange check valves on left and right swing sides of swing motor, and Defective seating of check whether failure symptom changes to make judgment. swing motor (check valve) When removing valve, check it for sticking and defects. 40-504 PC88MR-10...

  • Page 993: Swing Acceleration Or Swing Speed Is Low In Both Directions (Right And Left)

    Leakage from swing parking brake Swing hydraulic Max. 7 l/min motor solenoid valve relief connector. Swing machinery may have internal failure. Defective swing a Check for unusual noise, unusual heat, and metallic powders in drained oil machinery to make judgment. PC88MR-10 40-505...

  • Page 994: Swing Acceleration Performance Is Poor Or Swing Speed Is Slow In Only One Direction

    When removing valve, check it for sticking and defects. Interchange check valves on left and right swing sides of swing motor, and Defective seating of check whether failure symptom changes to make judgment. swing motor (check valve) When removing valve, check it for sticking and defects. 40-506 PC88MR-10...

  • Page 995: Upper Structure Overruns Excessively When It Stops Swinging (Both Right And Left)

    Be ready with engine stopped, then perform troubleshooting with engine at high idle. After troubleshooting, restore the machine to its original state. Defective swing motor Remove swing Leakage from swing parking brake Swing hydraulic Max. 7 l/min motor solenoid valve relief connector. PC88MR-10 40-507...

  • Page 996: Upper Structure Overruns Excessively When It Stops Swinging (Either Right Or Left)

    When removing valve, check it for sticking and defects. Interchange check valves on left and right swing sides of swing motor, and Defective seating of check whether failure symptom changes to make judgment. swing motor (check valve) When removing valve, check it for sticking and defects. 40-508 PC88MR-10...

  • Page 997: H-31 Shock Is Large When Upper Structure Stops Swinging

    PPC to make judgment. Malfunction of swing Reverse prevention valve of swing motor may malfunction. motor (reverse Check for stuck spool and fatigue of spring. prevention valve) PC88MR-10 40-509...

  • Page 998: Large Unusual Noise Is Heard When Upper Structure Stops Swinging

    (suction valve) When removing valve, check it for sticking and defects. Swing machinery may have internal failure. Defective swing a Check for unusual noise, unusual heat, and metallic powders in drained oil machinery to make judgment. 40-510 PC88MR-10...

  • Page 999: Swing Drift On A Slope Is Large While Swing Parking Brake Is Applied

    Be ready with engine stopped, then perform troubleshooting with engine at high idle. After troubleshooting, restore the machine to its original state. Defective swing motor Remove swing Leakage from swing parking brake Swing hydraulic Max. 7 l/min motor solenoid valve relief connector. PC88MR-10 40-511...

  • Page 1000: Swing Drift On A Slope Is Large While Swing Parking Brake Is Released

    (check valve) When removing valve, check it for sticking and defects. Malfunction of swing Reverse prevention valve of swing motor may malfunction. motor (reverse Check for stuck spool and fatigue of spring. prevention valve) 40-512 PC88MR-10...

  • Page 1001: H-35 Oil Flow In Attachment Circuit Cannot Be Controlled

    If output pressure of EPC valve is 0 MPa, check "Service solenoid2 current""Service solenoid5 current" with monitoring function. (monitoring code: 01700,01702) If current value is 0.3 to 0.91 A, EPC valve may be defective. Check that output pressure changes according to selected oil flow setting. PC88MR-10 40-513...

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