PC 88 MR 10

SEN06467-05
HYDRAULIC PC88MR -10

EXCAVATOR SERIAL NUMBERS 7001 and up
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
Index
Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-13
Important safety notice ....................................................................................................... 00-13
How to read the shop manual.............................................................................................. 00-20
Explanation of terms for maintenance standard .................................................................... 00-22
Handling equipment of fuel system devices .......................................................................... 00-24
Handling of intake system parts........................................................................................... 00-25
Handling of hydraulic equipment.......................................................................................... 00-26
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-28
Handling of electrical equipment.......................................................................................... 00-31
How to read electric wire code............................................................................................. 00-39
Precautions when performing operation ............................................................................... 00-42
Practical use of KOMTRAX ................................................................................................. 00-47
Standard tightening torque table.......................................................................................... 00-48
List of abbreviation ............................................................................................................. 00-54
Conversion table ................................................................................................................ 00-59
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
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
PTO.................................................................................................................................... 10-5
Variable flow turbocharger .................................................................................................... 10-6
EGR system piping drawing ................................................................................................ 10-10
EGR system circuit diagram ................................................................................................ 10-12
EGR valve......................................................................................................................... 10-13
EGR cooler........................................................................................................................ 10-15
KCCV layout drawing ......................................................................................................... 10-17
KCCV ventilator ................................................................................................................. 10-20
KDOC muffler .................................................................................................................... 10-22
Cooling system .................................................................................................................. 10-24
Power train............................................................................................................................... 10-27
Power train system............................................................................................................. 10-27
Swing circle ....................................................................................................................... 10-29
Swing machinery ............................................................................................................... 10-31
Undercarriage and frame........................................................................................................... 10-33
Track frame ....................................................................................................................... 10-33
Idler cushion ...................................................................................................................... 10-35
Hydraulic system ...................................................................................................................... 10-36
Hydraulic component layout ................................................................................................ 10-36
Valve control...................................................................................................................... 10-38
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
Index
Boom swing PPC valve .................................................................................................... 10-145

Solenoid valve ................................................................................................................. 10-147
Multi-control valve ............................................................................................................ 10-151
Anti-drop valve for boom ................................................................................................... 10-152
Anti-drop valve for arm ..................................................................................................... 10-156
Center swivel joint ............................................................................................................ 10-160
Accumulator .................................................................................................................... 10-161
Work equipment ..................................................................................................................... 10-163
Work equipment............................................................................................................... 10-163
Work equipment shim....................................................................................................... 10-164
Bucket play adjustment shim............................................................................................. 10-165
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
20 Standard value tables.................................................................................................................... 20-1
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
30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Testing engine speed ........................................................................................................... 30-8
Testing exhaust gas color ..................................................................................................... 30-9
Testing and adjusting valve clearance .................................................................................. 30-10
Testing compression pressure............................................................................................. 30-12
Testing blowby pressure ..................................................................................................... 30-14
Testing engine oil pressure ................................................................................................. 30-15
Testing fuel pressure .......................................................................................................... 30-16
Testing fuel return rate and leakage ..................................................................................... 30-17
Bleeding air from fuel system .............................................................................................. 30-20
Testing fuel circuit for leakage ............................................................................................. 30-22
Handling cylinder cutout mode operation.............................................................................. 30-23
Handling no-injection cranking operation.............................................................................. 30-24
Testing and adjusting air conditioner compressor belt tension ................................................ 30-25
Check fan belt, replace ....................................................................................................... 30-26
Check auto-tensioner, replace............................................................................................. 30-28
Writing compensation values at replacement of injector and engine controller ......................... 30-31
Power train............................................................................................................................... 30-35
Testing swing circle bearing clearance ................................................................................. 30-35
Testing and adjusting track tension ...................................................................................... 30-36
Releasing remaining pressure from hydraulic circuit .............................................................. 30-37
Testing and adjusting oil pressure in work equipment and travel circuits .................................. 30-42
Testing and adjusting swing and blade circuit oil pressure...................................................... 30-45
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
Index
Testing PPC valve outlet pressure ....................................................................................... 30-56

Adjusting play of work equipment and swing PPC valves....................................................... 30-57
Isolating the parts causing hydraulic drift in work equipment................................................... 30-58
Testing and adjusting travel deviation................................................................................... 30-59
Testing oil leakage ............................................................................................................. 30-61
Bleeding air from hydraulic circuit ........................................................................................ 30-65
Cab and its attachments ............................................................................................................ 30-68
Testing, cleaning and lubricating slide door rail and roller ....................................................... 30-68
Adjusting mirrors ................................................................................................................ 30-69
Testing and adjusting hood catcher...................................................................................... 30-71
Electrical system ...................................................................................................................... 30-73
Special functions of machine monitor ................................................................................... 30-73
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
40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting......................................................................................... 40-8
Troubleshooting points ......................................................................................................... 40-8
Sequence of events in troubleshooting................................................................................. 40-10
Checks before troubleshooting ............................................................................................ 40-12
Inspection procedure before troubleshooting ........................................................................ 40-14
Preparation for troubleshooting of electrical system............................................................... 40-31
Classification and procedures for troubleshooting ................................................................. 40-36
Symptom and troubleshooting numbers ............................................................................... 40-39
Information in troubleshooting table ..................................................................................... 40-42
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 40-44
Connector list and layout .................................................................................................... 40-46
Connector contact identification........................................................................................... 40-55
T-branch box and T-branch adapter table ............................................................................. 40-94
Fuse location table ............................................................................................................. 40-99
Failure codes table........................................................................................................... 40-101
Troubleshooting by failure code (Display of code) ...................................................................... 40-108
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit............................................ 40-108
Failure code [879AKB] A/C Recirc Air Temp Sens Short ...................................................... 40-109
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit............................................. 40-110
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit ..............................................40-111
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-112
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-113
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-114
Failure code [879EMC] Ventilation Damper Malfunction ...................................................... 40-115
Failure code [879FMC] Air Mix Damper Malfunction ............................................................ 40-116
Failure code [879GKX] Refrigerant Press Input Sig Out of Range......................................... 40-117
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-118
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-119
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-120
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3............................................ 40-121
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 ............................................ 40-122
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2............................................ 40-123
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-124
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-126
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
Index
Failure code [CA131] Throttle Sensor High Error................................................................. 40-133

Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-135
Failure code [CA144] Coolant Temperature Sensor High Error ............................................. 40-137
Failure code [CA145] Coolant Temperature Sensor Low Error.............................................. 40-139
Failure code [CA153] Charge Air Temperature Sensor High Error......................................... 40-141
Failure code [CA154] Charge Air Temperature Sensor Low Error ......................................... 40-143
Failure code [CA187] Sensor 2 Supply Voltage Low Error.................................................... 40-145
Failure code [CA221] Ambient Pressure Sensor High Error ................................................. 40-147
Failure code [CA222] Ambient Pressure Sensor Low Error .................................................. 40-149
Failure code [CA227] Sensor 2 Supply Voltage High Error ................................................... 40-151
Failure code [CA234] Engine Overspeed ........................................................................... 40-152
Failure code [CA238] NE Speed Sensor Supply Voltage Error ............................................. 40-153
Failure code [CA239] NE Speed Sensor Supply Voltage High Error...................................... 40-154
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 [CA343] Engine Controller Internal Failure....................................................... 40-165
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-166
Failure code [CA352] Sensor1 Supply Voltage Low Error..................................................... 40-167
Failure code [CA356] MAF Sensor High Error..................................................................... 40-169
Failure code [CA357] MAF Sensor Low Error ..................................................................... 40-171
Failure code [CA386] Sensor1 Supply Voltage High Error .................................................... 40-173
Failure code [CA435] Engine Oil Pressure SW Error ........................................................... 40-174
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-175
Failure code [CA442] Battery Voltage High Error................................................................. 40-177
Failure code [CA449] Common Rail Pressure High Error 2 .................................................. 40-178
Failure code [CA451] Common Rail Pressure Sensor High Error.......................................... 40-179
Failure code [CA452] Common Rail Pressure Sensor Low Error .......................................... 40-181
Failure code [CA466] KVGT Motor Driver Position Error ...................................................... 40-183
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error........................................... 40-185
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error............................................ 40-187
Failure code [CA555] Crankcase Pressure High Error 1 ...................................................... 40-190
Failure code [CA559] Common Rail Pressure Low Error 1 ................................................... 40-192
Failure code [CA689] Engine NE Speed Sensor Error ......................................................... 40-195
Failure code [CA691] Intake Air Temperature Sensor High Error .......................................... 40-197
Failure code [CA692] Intake Air Temperature Sensor Low Error ........................................... 40-199
Failure code [CA697] Engine Con Internal Temp Sens High Error......................................... 40-201
Failure code [CA698] Engine Con Internal Temp Sens Low Error ......................................... 40-202
Failure code [CA731] Engine Backup Speed Sensor Phase Error ........................................ 40-203
Failure code [CA778] Engine Backup Speed Sensor Error................................................... 40-205
Failure code [CA1117] Engine Controller Partial Data Lost Error........................................... 40-209
Failure code [CA1695] Sensor 5 Supply Voltage High Error ................................................. 40-210
Failure code [CA1696] Sensor 5 Supply Voltage Low Error .................................................. 40-211
Failure code [CA1843] Crankcase Pressure Sensor High Error ............................................ 40-212
Failure code [CA1844] Crankcase Pressure Sensor Low Error............................................. 40-214
Failure code [CA1896] EGR Valve Stuck Error.................................................................... 40-216
Failure code [CA1942] Crankcase Pressure Sensor In Range Error ..................................... 40-217
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error............................................. 40-218
Failure code [CA2185] Throttle Sensor Supply Voltage High Error........................................ 40-219
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error......................................... 40-221
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
Index
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error ............................................ 40-229
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-231
Failure code [CA2765] Injector Trim Data Mismatch ............................................................ 40-232
Failure code [CA3419] MAF Sensor Supply Voltage High Error ............................................ 40-233
Failure code [CA3421] MAF Sensor Supply Voltage Low Error............................................. 40-235
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error........................................ 40-237
Failure code [CA3918] KVGT Stuck Error........................................................................... 40-239
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................ 40-240
Failure code [CA3921] KVGT Servo Error 2........................................................................ 40-241
Failure code [CA3922] KVGT Motor Driver Open Error ........................................................ 40-242
Failure code [CA3923] KVGT Motor Driver Short Error ........................................................ 40-244
Failure code [D110KB] Battery Relay Output Short Circuit ................................................... 40-246
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
Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX)................................ 40-256
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-258
Failure code [DA22KK] Pump Con Solenoid Power Volt Low Error ....................................... 40-259
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error ............................................. 40-261
Failure code [DA29KQ] Model Selection Sig Mismatch (Pump Con) ..................................... 40-263
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-265
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-267
Failure code [DA2QKR] CAN 2 Defective Communication (Pump Con)................................. 40-268
Failure code [DA2RKR] CAN 1 Defective Communication (Pump Con)................................. 40-270
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-271
Failure code [DAF0MC] Monitor Malfunction....................................................................... 40-272
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-273
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor) ..................................... 40-274
Failure code [DAFGMC] GPS Module Malfunction .............................................................. 40-275
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-276
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-278
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) ..................................... 40-279
Failure code [DAZ9KQ] Model Selection Sig Mismatch (A/C) ............................................... 40-280
Failure code [DAZQKR] CAN2 Defective Communication (A/C ECU) ................................... 40-281
Failure code [DB2QKR] CAN2 Defective Communication (Engine Con)................................ 40-285
Failure code [DB2RKR] CAN1 Defective Communication (Engine Con) ................................ 40-289
Failure code [DDNRKA] WE Lever Lock SW Open Circuit ................................................... 40-293
Failure code [DDNRKY] WE Lever Lock SW Short Circuit ................................................... 40-295
Failure code [DDNS00] Lock Lever Auto Lock Release SW On............................................ 40-297
Failure code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault ........................................ 40-299
Failure code [DHPAMA] Front Pump Press Sens Defective Function .................................... 40-301
Failure code [DHS3MA] Arm IN PPC Press Sensor Def Function ......................................... 40-303
Failure code [DHS4MA] Bucket CURL PPC Press Sens Def Function .................................. 40-305
Failure code [DHS5MA] Travel PPC Sensor Abnormality..................................................... 40-307
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function .................................... 40-309
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function.................................... 40-311
Failure code [DHSAMA] Swing Right PPC Press Sens Def Function .................................... 40-313
Failure code [DHSBMA] Swing Left PPC Press Sensor Def Function.................................... 40-315
Failure code [DHSCMA] Arm OUT PPC Press Sens Def Function........................................ 40-317
Failure code [DHSDMA] Bucket DUMP PPC Press Sens Def Function ................................. 40-319
Failure code [DHSPMA] Boom Swing LH PPC Press Sensor Abnormality............................. 40-321
Failure code [DHSQMA] Boom Swing RH PPC Press Sensor Abnormality............................ 40-323
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
Index
Failure code [DW43KB] Travel Speed Solenoid Short Circuit ............................................... 40-335
Failure code [DW43KY] Travel Speed Sol Hot Short Circuit ................................................. 40-337
Failure code [DW45KA] Swing Parking Brake Solenoid Open Circuit .................................... 40-338
Failure code [DW45KB] Swing Parking Brake Solenoid Short Circuit .................................... 40-341
Failure code [DW45KY] Swing Brake Sol Hot Short Circuit .................................................. 40-343
Failure code [DW4CKY] PPC lock Sol Hot Short Circuit....................................................... 40-345
Failure code [DWJ0KA] Merge-divider Sol Open Circuit....................................................... 40-347
Failure code [DWJ0KB] Merge-divider Sol Short Circuit....................................................... 40-349
Failure code [DWJ0KY] Merge-divider Sol Short Circuit....................................................... 40-351
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit .................................... 40-352
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit..................................... 40-354
Failure code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit ............... 40-356
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
Failure code [DXEAKY] Service Current EPC5 Hot Short Circuit .......................................... 40-366
Failure code [DY20KA] Wiper Motor Open Circuit ............................................................... 40-368
Failure code [DY20MA] Wiper Motor Defective Function...................................................... 40-370
Failure code [DY2CKB] Washer Motor Short Circuit ............................................................ 40-372
Failure code [DY2DKB] Wiper Motor (Normal) Short Circuit ................................................. 40-374
Failure code [DY2EKB] Wiper Motor (Reverse) Short Circuit................................................ 40-376
Troubleshooting of electrical system (E-mode) .......................................................................... 40-378
E-1 Engine does not start (Engine does not crank) .............................................................. 40-378
E-2 Manual preheating system does not work..................................................................... 40-384
E-3 While preheating is working, preheating monitor does not light up .................................. 40-387
E-4 When starting switch is turned to ON position, machine monitor displays nothing............. 40-389
E-5 Engine coolant temperature monitor lights up in white while engine is running ................. 40-392
E-6 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-393
E-7 Charge level monitor lights up while engine is running ................................................... 40-394
E-8 Fuel level monitor lights up in red while engine is running .............................................. 40-395
E-9 Engine coolant temperature monitor lights up in red while engine is running .................... 40-396
E-10 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-397
E-11 Engine oil pressure monitor lights up in red while engine is running............................... 40-398
E-12 Fuel gauge display does not move from minimum or maximum .................................... 40-399
E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-400
E-14 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-401
E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full
nor empty).......................................................................................................... 40-402
E-16 Hydraulic oil temperature gauge does not move from minimum or maximum ................. 40-403
E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-405
E-18 Some areas of machine monitor screen are not displayed............................................ 40-406
E-19 Function switch does not work................................................................................... 40-407
E-20 Automatic warm-up system does not operate (in cold season)...................................... 40-408
E-21 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration
switch is operated ............................................................................................... 40-409
E-22 Auto-deceleration function does not operate or is not canceled while lever is
operated ............................................................................................................ 40-410
E-23 Working mode selection screen is not displayed while working mode selector switch is
operated ............................................................................................................ 40-412
E-24 Setting of engine and hydraulic pump is not changed while working mode is
changed............................................................................................................. 40-413
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
Index
E-29 Service mode cannot be selected .............................................................................. 40-418

E-30 Any of work equipment, swing and travel does not work............................................... 40-419
E-31 Any of work equipment, swing and travel cannot be locked .......................................... 40-421
E-32 Upper structure does not swing while swing parking brake cancel switch is set to
CANCEL position................................................................................................ 40-423
E-33 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position .............................................................................................................. 40-425
E-34 Work equipment does not operate while lock lever automatic release switch is in release
position .............................................................................................................. 40-427
E-35 Alarm does not sound during travel ............................................................................ 40-429
E-36 Alarm does not stop sounding while machine is stopped.............................................. 40-430
E-37 Horn does not sound ................................................................................................ 40-431
E-38 Horn does not stop sounding..................................................................................... 40-433
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
E-42 Boom LOWER is not displayed correctly with monitoring function ................................. 40-438
E-43 Arm OUT is not displayed correctly with monitoring function......................................... 40-439
E-44 Arm IN is not displayed correctly with monitoring function ............................................ 40-440
E-45 Boom RAISE is not displayed correctly with monitoring function ................................... 40-441
E-46 Bucket CURL is not displayed correctly with monitoring function................................... 40-442
E-47 Bucket DUMP is not displayed correctly with monitoring function.................................. 40-443
E-48 Boom swing left is not displayed correctly with monitoring function ............................... 40-444
E-49 Boom swing right is not displayed correctly with monitoring function ............................. 40-445
E-50 Swing is not displayed correctly with monitoring function.............................................. 40-446
E-51 Travel is not displayed correctly with monitoring function ............................................. 40-447
E-52 Blade RAISE ON is not displayed correctly with monitoring function ............................. 40-448
E-53 Blade LOWER ON is not displayed correctly with monitoring function ........................... 40-450
E-54 KOMTRAX system does not operate normally ............................................................ 40-452
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-454
Information described in troubleshooting table (H-mode) ..................................................... 40-454
System chart of hydraulic and mechanical systems............................................................. 40-455
Failure mode and cause table ........................................................................................... 40-457
H-1 All of work equipments, swing and travel operations lack speed or power ....................... 40-465
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-467
H-3 Any of work equipment, swing and travel does not work ................................................ 40-468
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-469
H-5 Fine control performance or response is poor ............................................................... 40-470
H-6 Boom speed or power is low ....................................................................................... 40-471
H-7 Arm speed or power is low .......................................................................................... 40-474
H-8 Bucket speed or power is low...................................................................................... 40-476
H-9 Boom swing speed or power is low .............................................................................. 40-478
H-10 Blade speed or power is low...................................................................................... 40-480
H-11 Work equipment does not move in single operation ..................................................... 40-482
H-12 Hydraulic drift of boom is large .................................................................................. 40-483
H-13 Hydraulic drift of arm is large ..................................................................................... 40-484
H-14 Hydraulic drift of bucket is large ................................................................................. 40-485
H-15 Hydraulic drift of blade is large................................................................................... 40-486
H-16 Time lag of work equipment is large ........................................................................... 40-487
H-17 In combined operation of work equipment , equipment having heavier load moves
slower................................................................................................................ 40-489
H-18 In combined operation of swing and boom RAISE, boom rising speed is low ................. 40-490
H-19 In combined operation of work equipment or swing and travel, travel speed drops
largely................................................................................................................ 40-491
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
Index
H-24 One of tracks does not run ........................................................................................ 40-501

H-25 Upper structure does not swing to the right or left ........................................................ 40-503
H-26 Upper structure swing only to the right or left .............................................................. 40-504
H-27 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-505
H-28 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-506
H-29 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-507
H-30 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-508
H-31 Shock is large when upper structure stops swinging.................................................... 40-509
H-32 Large unusual noise is heard when upper structure stops swinging .............................. 40-510
H-33 Swing drift on a slope is large while swing parking brake is applied............................... 40-511
H-34 Swing drift on a slope is large while swing parking brake is released............................. 40-512
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
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-516
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-517
S-4 Engine startability is poor ............................................................................................ 40-518
S-5 Engine does not pick up smoothly ............................................................................... 40-520
S-6 Engine stops during operation ..................................................................................... 40-522
S-7 Engine runs rough or is unstable ................................................................................. 40-524
S-8 Engine lacks power .................................................................................................... 40-525
S-9 Exhaust smoke is black .............................................................................................. 40-527
S-10 Engine oil consumption is excessive .......................................................................... 40-529
S-11 Oil becomes contaminated quickly ............................................................................. 40-530
S-12 Fuel consumption is excessive .................................................................................. 40-531
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-532
S-14 Oil pressure drops .................................................................................................... 40-533
S-15 Fuel mixes into engine oil.......................................................................................... 40-534
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
50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system ........................................................................................................ 50-17
Removal and installation of supply pump assembly............................................................... 50-17
Removal and installation of injector assembly....................................................................... 50-20
Removal and installation of cylinder head assembly.............................................................. 50-27
Removal and installation of radiator assembly ...................................................................... 50-39
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-43
Removal and installation of aftercooler assembly .................................................................. 50-46
Removal and installation of engine and main pump assembly ................................................ 50-49
Removal and installation of engine front oil seal .................................................................... 50-57
Removal and installation of engine rear oil seal..................................................................... 50-58
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
Index
Removal and installation of air cleaner assembly .................................................................. 50-69

Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly....................... 50-71
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly........................ 50-73
Removal and installation of fan belt...................................................................................... 50-74
Power train system ................................................................................................................... 50-76
Removal and installation of travel motor and final drive assembly ........................................... 50-76
Disassembly and assembly of travel motor and final drive assembly....................................... 50-78
Removal and installation of swing motor and swing machinery assembly ...............................50-111
Disassembly and assembly of swing machinery assembly................................................... 50-113
Removal and installation of swing circle assembly .............................................................. 50-121
Undercarriage and frame......................................................................................................... 50-122
Separation and connection of track.................................................................................... 50-122
Removal and installation of sprocket.................................................................................. 50-123
Removal and installation of idler and idler cushion assembly ............................................... 50-124
Disassembly and assembly of idler assembly ..................................................................... 50-125
Disassembly and assembly of idler cushion assembly......................................................... 50-128
Disassembly and assembly of track roller assembly ............................................................ 50-131
Removal and installation of revolving frame assembly ......................................................... 50-134
Removal and installation of counterweight assembly [For machines with additional
counterweight].................................................................................................... 50-136
Hydraulic system .................................................................................................................... 50-138
Removal and installation of center swivel joint assembly ..................................................... 50-138
Disassembly and assembly of center swivel joint assembly ................................................. 50-140
Removal and installation of hydraulic tank assembly ........................................................... 50-141
Removal and installation of main pump assembly ............................................................... 50-144
Removal and installation of control valve assembly ............................................................. 50-148
Disassembly and assembly of control valve assembly......................................................... 50-152
Disassembly and assembly of work equipment PPC valve assembly.................................... 50-155
Disassembly and assembly of travel PPC valve assembly ................................................... 50-157
Disassembly and assembly of work equipment cylinder assembly........................................ 50-158
Work equipment ..................................................................................................................... 50-162
Removal and installation of work equipment assembly ........................................................ 50-162
Removal and installation of boom swing bracket ................................................................. 50-165
Removal and installation of anti-drop valve for boom assembly ............................................ 50-166
Removal and installation of anti-drop valve for arm assembly............................................... 50-169
Disassembly and assembly of anti-drop valve assembly...................................................... 50-172
Removal and installation of blade assembly ....................................................................... 50-173
Removal and installation of operator's cab assembly........................................................... 50-175
Removal and installation of operator's cab door .................................................................. 50-179
Removal and installation of operator's cab glass (adhered glass) ......................................... 50-182
Removal and installation of front window assembly ............................................................. 50-193
Removal and installation of floor frame assembly................................................................ 50-194
Removal and installation of air conditioner unit assembly..................................................... 50-199
Removal and installation of air conditioner compressor assembly......................................... 50-204
Removal and installation of air conditioner condenser assembly .......................................... 50-206
Removal and installation of operator's seat......................................................................... 50-208
Removal and installation of seat belt .................................................................................. 50-209
Removal and installation of front wiper assembly ................................................................ 50-210
Removal and installation of starting motor assembly ........................................................... 50-217
Removal and installation of engine controller assembly ....................................................... 50-218
Removal and installation of pump controller assembly......................................................... 50-219
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
00-10 PC88MR-10
Index
Engine mount ...................................................................................................................... 60-3

PTO.................................................................................................................................... 60-4
Cooling system .................................................................................................................... 60-5
Power train system ..................................................................................................................... 60-7
Swing circle ......................................................................................................................... 60-7
Swing machinery ................................................................................................................. 60-9
Sprocket............................................................................................................................ 60-11
Track frame ....................................................................................................................... 60-12
Idler cushion ...................................................................................................................... 60-13
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-15
Carrier roller ...................................................................................................................... 60-16
Track shoe ........................................................................................................................ 60-17
Hydraulic tank.................................................................................................................... 60-23
Main pump ........................................................................................................................ 60-24
Control valve ..................................................................................................................... 60-28
Swing motor ...................................................................................................................... 60-37
Travel motor ...................................................................................................................... 60-39
PPC valve................................................................................................................................ 60-40
Work equipment and swing PPC valve................................................................................. 60-40
Travel PPC valve ............................................................................................................... 60-43
Blade PPC valve ................................................................................................................ 60-45
Boom swing PPC valve ...................................................................................................... 60-47
Solenoid valve ................................................................................................................... 60-49
Anti-drop valve for boom ..................................................................................................... 60-51
Anti-drop valve for arm ....................................................................................................... 60-53
Center swivel joint .............................................................................................................. 60-55
Cab mount and cab tipping stopper ..................................................................................... 60-56
Work equipment ....................................................................................................................... 60-57
Work equipment................................................................................................................. 60-57
Boom cylinder.................................................................................................................... 60-68
Arm cylinder ...................................................................................................................... 60-69
Bucket cylinder .................................................................................................................. 60-70
Boom swing cylinder .......................................................................................................... 60-71
Blade cylinder .................................................................................................................... 60-72
80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-15
Air conditioner controller ..................................................................................................... 80-16
Compressor....................................................................................................................... 80-17
Condenser ........................................................................................................................ 80-18
Sunlight sensor .................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-26
Input and output signals of the air conditioner controller ......................................................... 80-27
Parts and connectors layout................................................................................................ 80-31
Testing air leakage (duct) .................................................................................................... 80-37
PC88MR-10 00-11
Index
Testing with self-diagnosis function ...................................................................................... 80-39

Testing vent (mode) changeover.......................................................................................... 80-42
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-47
Troubleshooting chart 1 ...................................................................................................... 80-48
Failure code list related to air conditioner.............................................................................. 80-53
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit.............................................. 80-54
Failure code [879AKB] A/C Recirc Air Temp Sens Short ........................................................ 80-55
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit............................................... 80-56
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit ............................................... 80-58
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-60
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-61
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-62
Failure code [879EMC] Ventilation Damper Malfunction ........................................................ 80-64
Failure code [879FMC] Air Mix Damper Malfunction .............................................................. 80-65
Failure code [879GKX] Refrigerant Press Input Sig Out of Range........................................... 80-66
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-67
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-69
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-72
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-74
Troubleshooting with gauge pressure................................................................................... 80-76
Connection of service tool................................................................................................... 80-79
Precautions for disconnecting and connecting refrigerant piping............................................. 80-81
Handling of compressor oil.................................................................................................. 80-83
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
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
Foreword, safety and general information
Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (ALL-1120-012-A-01-A)
(Rev. 2014/08)
• 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 k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
Safety points before starting. While working, always keep

• Good arrangement conversations of the work between your fellow
• Correct work clothes workers and your self on any step of the work.
• Observance of work standard During the work, hang the warning tag of
• Practice of making and checking signals "UNDER WORKING" in the operator's
• Prohibition of operation and handling by compartment.
unlicensed workers • Only qualified workers must perform the work
• Safety check before starting work and operation which require license or
• Wearing protective goggles (for cleaning or qualification.
grinding work) • Keep the tools in good condition. And learn the
• Wearing shielding goggles and protectors (for correct way to use the tools, and use the proper
welding work) ones among them. Before starting the work,
• Good physical condition and preparation thoroughly check the tools, lift truck, service
• Precautions against work which you are not vehicle, etc.
used to or you are used to too much • If welding repairs is required, always have a
trained and experienced welder with good
General precautions knowledge of welding perform the work. When
k Inappropriate handling causes an extreme performing welding work, always wear welding
danger. Read and understand what is gloves, apron, shielding goggles, cap, etc.
described in the operation and maintenance • Before starting work, warm up your body
manual before operating the machine. Read thoroughly to start work under good condition.
and understand what is described in this • Avoid continuing work for long hours and take
manual before starting the work. rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
• Before performing any greasing or repairs, read place.
all the safety labels stuck to the machine. For
Preparation
the locations of the safety labels and detailed
• Before adding oil or making any repairs, place
explanation of precautions, see the operation
the machine on a firm and level ground, and
and maintenance manual.
apply the parking brake and chock the wheels or
• Locate a place in the repair workshop to keep
tracks to prevent the machine from moving.
the tools and removed parts. Always keep the
• Before starting work, lower the work equipment
tools and parts in their correct places. Always
(blade, ripper, bucket, etc.) to the ground. If it is
keep the work area clean and make sure that
not possible to lower the equipment to the
there is no dirt, water or oil on the floor. Smoke
ground, insert the lock pin or use blocks to
only in the areas provided for smoking. Never
prevent the work equipment from falling. And be
smoke while working.
sure to lock all the work equipment control levers
• When performing any work, always wear the
and hang a warning tag on them.
safety shoes and helmet. Do not wear loose
• When performing the disassembling or
work cloths, or clothes with buttons missing.
assembling work, support the machine securely
1. Always wear the protective eyeglasses when with blocks, jacks, or stands before starting the
hitting parts with a hammer. work.
2. Always wear the protective eyeglasses when • Remove all of mud and oil from the steps or
grinding parts with a grinder, etc. other places used to get on and off the machine
• When performing any work with 2 or more completely. Always use the handrails, ladders of
workers, always agree on the working procedure steps when getting on or off the machine. Never
PC88MR-10 00-13
jump on or off the machine. When the scaffold is floor, wipe it off immediately. Fuel or oil on the
not provided, use steps or stepladder to secure floor can cause you to slip and can even cause
your footing. fires.
• As a general rule, do not use gasoline to wash
Precautions during work parts. Do not use gasoline to clean the electrical
• For the machine equipped with the battery parts, in particular.
disconnect switch, check that the system • Reinstall the parts removed to their original
operating lamp is turned off before starting the places. Replace the damaged parts and the
work. Then, turn the battery disconnect switch to parts which must not be used with new ones.
OFF (Q) position and remove the switch key. For When installing the hoses and wiring harnesses,
the machine not equipped with the battery be careful that they are not damaged by
disconnect switch, remove the cable from the contacting with other parts when the machine is
battery before starting the work. Be sure to operated.
remove the negative end (-) of the battery cable • When connecting the high pressure hoses and
first. tubes, make sure that they are not twisted. The
• Release the remaining pressure in the circuits damaged high pressure hoses and tubes are
completely before the work when the parts in the very dangerous when they are installed. So, be
circuits of oil, fuel, coolant and air are extremely careful when connecting the high
disconnected or removed. When the cap of the pressure pipings. In addition, check that their
oil filter, drain plug or oil pressure pickup plug is connections are correct.
removed, loose them slowly to prevent the oil • When assembling or installing the parts, be sure
from spurting out. to tighten the bolts to the specified torque. When
• When removing or installing the checking plug or installing the protective parts such as guards, or
the piping in the fuel circuit, wait 30 seconds or the parts which vibrate violently or rotate at high
longer after the engine is shut down and start speeds, be sure to check that they are installed
the work after the remaining pressure is correctly.
released from the fuel circuit. • When aligning 2 holes, never insert your fingers
• Immediately after the engine is shut down, the or hand into the holes. Align the holes with care
coolant and oil in the circuits are hot. Be careful so that your fingers are not caught in the hole.
not to get scalded by the hot coolant and oil. • When measuring hydraulic pressure, check that
Start the work after checking that the coolant the measuring tools are correctly installed.
and oil are cooled down sufficiently. • Pay attention to safety when removing and
• Start the work after the engine is shut down. Be installing the tracks of the track type machines.
sure to shut down the engine when working on When removing the track, it separates suddenly.
or around the rotating parts in particular. When The workers should not stand at either end of
checking the machine without shutting down the the track.
engine (measuring oil pressure, rotational speed, • If the engine is operated for a long time in a
oil or coolant temperature), take extreme care closed place which is not ventilated well, you
not to get caught in the rotating parts or the may suffer from gas poisoning. Accordingly,
working equipment. open the windows and doors to ventilate the
• The hoist or crane must be used to sling the place well.
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and Precautions for slinging work and making
hook) for damage before the work. Use the signals
slings with ample capacity and install them to • Only one appointed worker must make signals
the proper places. Operate the hoist or crane and co-worker must communicate with each
slowly to prevent the component from hitting any other frequently. The appointed signaler must
other part. Do not work with any part still raised make specified signals clearly at the place
by the hoist or crane. where the signaler is well seen from the
• When removing the part which is under internal operator's seat and where the signaler can see
pressure or reaction force of the spring, always the working condition easily. The signaler must
leave 2 bolts in diagonal positions. Loosen those always stand in front of the load and guide the
2 bolts gradually and alternately and release the operator safely.
pressure, then, remove the part. 1. Do not stand under the load.
• When removing the part, be careful not to break 2. Do not step on the load.
or damage the electrical wiring. The damaged • Check the slings before starting sling work.
wiring may cause electrical fires. • 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
• Measure the weight of the load by the eye and a Slinging near the tip of the hook may cause
check its center of gravity. the rope to slip off the hook during hoisting.
• Use the proper sling according to the weight of The strength of the hook is maximum at its
the load and method of slinging. If too thick wire central part.
ropes are used to sling a light load, the load may
slip and fall.
• Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
k Slinging with one rope may cause turning

of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 deg. or smaller as a
rule. • Do not use twisted or kinked wire ropes.
• When hanging a heavy load (25kg or heavier), • When slinging up a load, observe the following.
the hanging angle of the rope must be narrower 1. Wind up the rope slowly until the wire rope
than that of the hook. tensions. When putting your hands on the
wire ropes, do not grasp them but press them
a When slinging a load with 2 ropes or more,
down from above. If you grasp them, your
the larger the hanging angle is, the larger the
fingers may be caught.
tension of each rope. The figure bellow
2. After the wire ropes are stretched, stop the
shows the variation of allowable load in kg
crane and check the condition of the slung
when hoisting is made with 2 ropes, each of
load, wire ropes, and pads.
which is allowed to sling up to 9.8 kN
3. If the load is unstable or the wire rope or
{1,000kg} a load vertically, at various
chains are twisted, lower the load and lift it
hanging angles. When the 2 ropes sling a
up again.
load vertically, up to 2,000 kg of total weight
4. Do not lift up the load at an angle.
can be suspended. This weight is reduced to
• When lowering a load, pay attention to the
1,000 kg when the 2 ropes make a hanging
following.
angle of 120 deg.. If the 2 ropes sling a 2,000
kg load at a hanging angle of 150 deg., each 1. When lifting down a load, stop it temporarily
rope is subjected to a force as large as 4,000 at 30 cm above the floor, and then lower it
kg. slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane

a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane

k The hoist or crane must be used to sling the
• When installing wire ropes to an angular load, components weighing 25 kg or heavier. A
apply pads to protect the wire ropes. If the load part weighing 25 kg or heavier in
is slippery, apply proper material to prevent the "disassembly and assembly" section is
wire rope from slipping.
indicated with the symbol of 4 .
• 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
for electric shock prevention, crane collision a The allowable load is calculated as one sixth of
prevention device, and energizing warning lamp, the breaking load of the rope to be used (safety
and check the following safety items. coefficient: 6).
• Observe the signals for sling work.
• Operate the hoist at a safe place. Precautions for disconnecting and connecting
• Be sure to check the directions of the direction hoses and tubes in air conditioner circuit
indication plate (north, south, east and west) and Disconnection
the operating button.
• Do not sling a load at an angle. Do not move the k When replacing the air conditioner unit, air
crane while the slung load is swinging. conditioner compressor, condenser or
• Do not raise or lower a load while the crane is receiver drier, etc., collect the refrigerant (air
moving longitudinally or laterally. conditioner gas: R134a) from the air
• Do not drag a sling. conditioner circuit before disconnecting the
• When lifting up a load, stop it just after it leaves air conditioner hoses.
the ground and check safety, and then lift it up.
a Ask a qualified person for collecting, adding and
• Consider the travel route in advance and lift up a
filling operations of the refrigerant (air
load to a safe height.
conditioner gas: R134a). (Only registered
• Place the control switch in a position where it will
persons can work.)
not be an obstacle to work and passage.
• After operating the hoist, do not swing the a Never release the refrigerant (air conditioner
control switch. gas: R134a) to the atmosphere.
• Remember the position of the main switch so
that you can turn off the power immediately in an k If refrigerant gas (air conditioner gas: R134a)
emergency. gets in your eyes, you may lose your sight.
• Shut down the main switch when the hoist stops And if it touches your skin, you may suffer
because of a blackout. When turning on a switch from frostbite. Put on protective eyeglasses,
which is turned OFF by the ground fault circuit gloves and working clothes with long
interrupter for electric shock prevention, check sleeves while collecting the refrigerant or
that the devices related to that switch are not in filling the air conditioner circuit with the
operating condition. refrigerant.
• If you find an obstacle around the hoist, stop the
• When loosening the nuts fixing air conditioner
operation.
hoses and tubes, be sure to use 2 wrenches;
• After finishing the work, stop the hoist at the
use one wrench to fix and use the other one to
specified position and raise the hook to at least 2
loosen the nut.
meters above the floor. Do not leave the sling
attached to the hook. Connection
• When installing the hose for the air conditioner
Selecting wire ropes
circuit, take care not to allow invasion of dirt,
• Select adequate ropes depending on the weight
dusts and water into the hose.
of the parts to be hoisted, referring to the table
• Check that the O-rings are fitted to the joints
below
when connecting the air conditioner piping.
Wire rope (JIS G3525, 6 x 37 - Type A)
• Once an O-ring is used, it is deformed and
(Standard Z twist wire ropes without galvanizing) deteriorated. Accordingly, do not reuse it.
Nominal • When removing the O-rings, use a soft tool so
diameter of rope Allowable load that the piping is not damaged.
mm kN ton • Check that the O-ring is not damaged or
10 8.8 0.9 deteriorated.
12 12.7 1.3 • Apply compressor oil for refrigerant (R134a) to
the O-ring.
14 17.3 1.7
16 22.6 2.3 a However, do not apply oil to the threaded
18 28.6 2.9 part of a bolt, nut or union.
20 35.3 3.6 Manufacturer Part name
25 55.3 5.6 DENSO ND-OIL8
30 79.6 8.1 VALEO THERMAL ZXL100PG (equivalent to
40 141.6 14.4 SYSTEMS PAG46)
50 221.6 22.6 SANDEN SP-10
60 318.3 32.4
00-16 PC88MR-10
• When tightening nuts of the air conditioner

hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (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
Precautions to prevent fire (ALL-0000-17B-K-03-A)
• Fire caused by fuel, oil, coolant or window • Remove any dry leaves, chips, pieces of
washer fluid paper, coal dust, or any other flammable
Do not bring any flame or fire close to flammable materials accumulated or attached to or
substances such as fuel, oil, coolant or window around the engine exhaust manifold, muffler,
washer fluid.There is danger that they may catch or battery, or on the undercovers.
fire. Always observe the following. • To prevent fires from being caught, remove
• Do not smoke or use any flame near fuel or any flammable materials such as dry leaves,
other flammable substances. chips, pieces of paper, coal dust, or any
• Shut down the engine before adding fuel. other flammable materials accumulated
• Do not leave the machine when adding fuel around the cooling system (radiator, oil
or oil. cooler) or on the undercover.
• Tighten all the fuel and oil caps securely. • Fire coming from electric wiring
• Be careful not to spill fuel on overheated Short circuits in the electrical system can cause
surfaces or on parts of the electrical system. fire. Always observe the following.
• After adding fuel or oil, wipe up any spilled • Keep all the electric wiring connections clean
fuel or oil. and securely tightened.
• Put greasy rags and other flammable • Check the wiring every day for looseness or
materials into a safe container to maintain damage. Reconnect any loose connectors or
safety at the workplace. refasten wiring clamps. Repair or replace any
• When washing parts with oil, use a non- damaged wiring.
flammable oil. Do not use diesel oil or • Fire caused by piping
gasoline.There is danger that they may catch Check that all the clamps for the hoses and
fire. tubes, guards, and cushions are securely fixed
• Do not weld or use a cutting torch to cut any in position.
pipes or tubes that contain flammable liquids. If they are loose, they may vibrate during
• Determine well-ventilated areas for storing oil operation and rub against other parts. There is
and fuel. Keep the oil and fuel in the danger that this may lead to damage to the
specified place and do not allow hoses and cause high-pressure oil to spurt out,
unauthorized persons to enter. leading to fire and serious personal injury or
• When performing grinding or welding work death.
on the machine, move any flammable • 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 gas discharged during
purification process (regeneration) can be at
higher temperature than that from existing
models. Do not bring any flammable material
close to the outlet of the exhaust pipe.
• When there are thatched houses, dry leaves
or pieces of paper near the work site, set the
9 J D 0 1 7 2 0
system to disable the regeneration before
starting work to prevent fire hazards due to
highly heated exhaust gas.
See the operation and maintenance manual
for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
9 J D 0 1 7 2 1
follow the instructions in the operation and
• Fire caused by accumulation or attachment maintenance manual.
of flammable material
00-18 PC88MR-10
Actions if fire occurs (ALL-0000-17A-K-01-A)
• Turn the starting switch to OFF position to stop

the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature
environment).
When wearing cotton-work-gloves, wear rubber
gloves under them.
Dispose of waste materials (ALL-0000-99A-K-02-A)
To prevent pollution, pay full attention to the way to

dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce

poisonous gas harmful to human body when they
are burned.
• 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
How to read the shop manual (ALL-0320-010-A-01-A)
(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.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
00-20 PC88MR-10
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described.
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
indicated.
Tightening The tightening torques that require special attention during assembly
3 torque work are indicated.
The places to be coated with adhesives, grease, etc. during assembling
2 Coat
are indicated.
Oil, coolant The places where oil, coolant, etc. must be added and the quantity to be
5 added are indicated.
Places where oil, coolant, etc. must be drained and the quantity to be
6 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
Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)
(Rev. 2012/10)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance • When some parts are repaired, the value of
• To be accurate, the finished dimension of a part performance/function is set to the standard
is slightly different from one to another. value.
• The finished dimension of a part specifies the
allowable difference from the standard
dimension which is set first.
• The dimension set as the standard is called the
standard dimension and the range of difference
from this standard dimension is called the
"tolerance".
• An indication example of a standard dimension
and tolerance is shown in the following table.
(The standard dimension is entered on the left
side and the tolerance is entered with a positive
or negative symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
• An indication example of a shaft and hole is
shown in the following table.
Standard interference
(The standard dimension is entered on the left
• When the diameter of a hole of a part shown in
side and the tolerance of the shaft is entered
with a positive or negative symbol at the center the given standard dimension and tolerance
table is smaller than that of the shaft to be
and that of the hole on the right side)
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,
00-22 PC88MR-10
the parts can not be used any longer. This value

is called "repair limit".
• If a part is worn to the repair limit, it must be
replaced or repaired.
• The performance and function of the products
lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "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
Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)
(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.
Use care for working environment

• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.
How to clean parts when dirt is stuck

• 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)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.
00-24 PC88MR-10
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.
Be careful of working environment

• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
components which are removed, with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.
PC88MR-10 00-25
Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)
(Rev. 2012/10)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment

• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
Disassembly and maintenance work in the field

• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.
Plugging of opening (prevention of flowing out

of oil)
components which are removed (when plugs
are not prepared, seal with caps, tapes, vinyl
bags, etc.) to prevent entry of foreign material Replacing hydraulic oil while its temperature is
and flowing out of oil. Never leave the openings high
• When the hydraulic oil is warm, it flows easily. In
of the pipes and hoses without being covered or
addition, sludge can also be drained from the
plugged with cloth as foreign material may enter
them or environment may be polluted by the oil circuit together with the oil. So, it is better to
leaked. Do not discard the waste oil somewhere change the hydraulic oil while it is warm. When
or other. Hand it over to your customer for changing the hydraulic oil, the old oil must be
disposal, or dispose it by yourself. drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) 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
Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
PC88MR-10 00-27
Method of disconnecting and connecting of push-pull type coupler (ALL-

C930-001-P-00-A)
(Rev. 2012/01)
k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 (ALL-C930-925-P-01-A)
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
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
Type 2 (ALL-C930-925-P-02-A)
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (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
Type 3 (ALL-C930-925-P-03-A)
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)
00-30 PC88MR-10
Handling of electrical equipment (ALL-E000-2A4-P-01-A)
(Rev. 2012/11)
• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the wiring harness is pulled to disconnect the
occur because the male connector is not connector, or the components are lifted with a
properly inserted into the female connector,or crane while the wiring harness is still connected,
because one or both of connectors are or a heavy object hits the wiring harness, the
deformed or the position is not correctly aligned, crimping of the connector may separate, or the
or because there is corrosion or oxidization of soldering may be damaged, or the wiring
the contact surfaces. 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
blow it with compressed air and spray it with

electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.
High-pressure water entering connector

• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.
Entry of water, mud or dirt when disconnecting a

connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or
00-32 PC88MR-10
• Check that there is no oil, dirt or water stick

to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
• When removing a connector from a clip, pull harness with a dryer. But be careful not to
the connector in a parallel direction to the clip make it too hot as it causes short circuit.
for removing stoppers. a If there is any damage or breakage, replace
a If the connector is pried up and down or the connector.
to the right and left, the housing may 2. Fix the connector securely.
break. • Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.
3. Action to take after removing connectors

• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a 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
• If the connector clamp is removed, be sure to Drying wiring harness

return it to its original position. And check • If there is any oil or dirt on the wiring harness,
that it is securely installed. wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
Handling of Deutsch connector (DT8-pin, DT12-
pin)
Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
a Hot air from the dryer can be used, but
regulate the time to use hot air in order to
prevent the connector or related parts from
Connection becoming too hot, as it causes deformation
1. Push in female connector (2) horizontally until or damage to the connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the 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
2. While pressing lock (L2), pull out connector (1).

Handling of connectors used on engine
Slide, lock type

(FRAMATOME-3, FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).
Connection
1. Insert the connector securely until a click is Connection
heard.
1. Insert the connector securely until a click is
(FRAMATOME-24)
heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type
(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
Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
(AMP-3)
Push lock type
(BOSCH-3) Disconnection
Disconnection 1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
1. While pressing lock (C), pull out connector (3) in
• 114 series
Connection
heard.
• 107 series (SUMITOMO-2)
Disconnection
1. While pressing lock (E), pull out connector (5) in
a If the lock is located on the underside, use

flat-head screwdriver [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
(SUMITOMO-3)
Disconnection
1. While pressing lock (E), pull out connector (5) in
a Pull the connector straight up.
Connection
1. Insert the connector to the end while aligning its
grove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".
Connection
heard.
(SUMITOMO-4)
Disconnection
1. While pressing lock (D), pull out connector (4) in
Handling controller
• The electronic circuits for control including the
microcomputers are assembled in the controller.
These electronic circuits in the controller must
be handled with care as they control the
machine.
• Do not place objects on top of the controller.
Connection
heard.
Turn-housing type (Round green connector)
(CANNON-4)
Disconnection
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the • Cover the control connectors with tape or a vinyl
arrow. bag. Never touch the connector contacts.
a Housing (H1) is left on the wiring harness • During rainy weather, do not leave the controller
side. in a place where it is exposed to rain.
• 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
temperature even for a short period of time.

(Place it on a suitable dry stand.)
• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.
Precautions for troubleshooting electrical

circuits
• Be sure to turn the starting switch to "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.
00-38 PC88MR-10
How to read electric wire code (ALL-E500-030-P-00-A)

(Rev. 2012/10)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
(Type 2)
Heat- General wiring for extremely
resistant low- Heat-resistant cross cold weather specification
voltage wire AEX linked polyethylene -50 to +110
for Wiring at high ambient
automobile temperature place
PC88MR-10 00-39
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 —
Coating D
AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard — — — — — — — — —
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D
CAVS Standard — 1.6 — 1.8 — 2.1
a "f" of nominal No. denotes "flexible".
00-40 PC88MR-10
Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
a Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG — — — — R —
Ground B — — — — — B —
Start R — — — — — R —
Light RW RB RY RG RL — D —
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB — L —
Type of — — —
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Others Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —
PC88MR-10 00-41
Precautions when performing operation (ALL-1160-927-A-00-A)
(Rev. 2012/11)
• When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and
assembly" of the components, observe the following general cautions.
Precautions for removal and disassembly work

• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
a The O-rings in the table are emergency parts used for disassembly or transportation of the machine.
When assembling, confirm the part numbers in the parts book and use the parts conforming to the
using condition.
Disconnection of face seal type hoses and tubes
Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
00-42 PC88MR-10
Disconnection of taper seal type hoses and tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
Disconnection of split flange type hoses and tubes
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
04 38.1 17.5 07371-30400 07378-10400 07000-12021 01643-50823
00400 80825
07379- 01010-
05 42.9 19.8 07371-30500 07378-10500 07000-13022 01643-50823
00500 80830
07379- 07372-
06 47.6 22.2 07371-30640 07378-10600 07000-13025 01643-51032
00640 51035
07379- 07372-
10 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
12
07379- 01010-
66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232
01260 81245
07379- 07372-
14 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232
01460 51240
PC88MR-10 00-43
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445
01470 81455
07379- 07372-
77.8 42.8 07371-32076 07378-12000 07000-12060 01643-51232
02071 51240
20
07379- 01010-
96.8 44.5 07371-52080 07378-12010 07000-12060 01643-31845
02080 81865
07379- 07372-
24 88.9 50.8 07371-12484 07378-12400 07000-12070 01643-51232
02484 51240
07379- 07372-
30 106.4 62 07371-13010 07378-13000 07000-12085 01643-51645
03010 51650
07372-
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 01643-51645
51650
07379- 07372-
40 130.2 77.8 07371-14012 07378-14000 07000-12110 01643-51645
04012 51650
07372-
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 01643-51645
51655
Removal of pipe joints of O-ring boss type
Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
Removal of pipe joints of taper pipe thread type
00-44 PC88MR-10
Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R 1/ 8 07042-00108 07043-00108
02 R 1/ 4 07042-00211 07043-00211
03 R 3/ 8 07042-00312 07043-00312
04 R 1/ 2 07042-00415 07043-00415
06 R 3/ 4 07042-00617 07043-00617
10 R1 07042-01019 07043-01019
12 R1 1/4 07042-01222 07043-01222
14 R1 1/2 07042-01422 07043-01422
20 R2 07042-02026 07043-02026
Precautions for installation and assembly work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded
part.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded part of each taper male
screws which receives pressure.
However, if the threaded part is difficult to degrease, you may use a seal tape.
• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing
direction of the threads, seeing from the screw end and starting at the third thread.
a 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
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start the engine, and run it at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end 4 to 5 times.
3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
Precautions at the time of completing work

Refilling of coolant, oil and grease
• 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.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Testing of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Cooling system for water leakage.
Fuel system for fuel leakage.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
00-46 PC88MR-10
Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)

(Rev. 2012/10)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX

• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice as well for the user and operator.
How to use KOMTRAX practically

With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
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
Standard tightening torque table (ALL-M140-03B-P-01-A)
(Rev. 2012/10)
Table of tightening torque for bolts and nuts

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6.0 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10.0 to 12.5}
(*1, *2) 17
14 22 157 to 196 {16 to 20}
24
16 245 to 309 {25 to 31.5}
(*1) 22
18 27 343 to 427 {35 to 43.5}
20 30 490 to 608 {50 to 62}
22 32 662 to 829 {67.5 to 84.5}
24 36 824 to 1,030 {84 to 105}
27 41 1,180 to 1,470 {120 to 150}
30 46 1,520 to 1,910 {155 to 195}
33 50 1,960 to 2,450 {200 to 250}
36 55 2,450 to 3,040 {250 to 310}
39 60 2,890 to 3,630 {295 to 370}
*1: Split flange bolt.
*2: Flanged bolt.
00-48 PC88MR-10
a Tighten the following flanged bolt on which "7" is stamped on its top to the tightening torque shown in the
following table.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-20UNC 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
3/4-10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
7/8-9UNC 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
1-8UNC 883 to 1,196 {90 to 122} 1,040 {106} 245 to 333 {25 to 34} 284 {29}
1 1/8-7UNC 1,187 to 1,608 {121 to 164} 1,393 {142} 333 to 451 {34 to 46} 392 {40}
1 1/4-7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54}
1 1/2-6UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79}
PC88MR-10 00-49
Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-28UNF 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4} 37.3 {3.8} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.6 {6}
5/8-18UNF 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
7/8-14UNF 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
1-14UNF 1,020 to 1,373 {104 to 140} 1,196 {122} 284 to 382 {29 to 39} 333 {34}
1 1/8-12UNF 1,353 to 1,844 {138 to 188} 1,598 {163} 382 to 520 {39 to 53} 451 {46}
1 1/4-12UNF 1,804 to 2,432 {184 to 248} 2,118 {216} 510 to 686 {52 to 70} 598 {61}
1 1/2-12UNF 2,707 to 3,658 {276 to 373} 3,177 {324} 765 to 1,030 {78 to 105} 892 {91}
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})

Nominal No. diameter across flats
(mm) (mm) Range Target
02 14 Varies 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 depending 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 on type of 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 connector. 128 to 186 {13.0 to 19.0} 157 {16.0}
00-50 PC88MR-10

10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
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
Tightening torque (Nm {kgm}) Taper seal Face seal

Width
Nominal across Nominal No. - Thread root
No. of flats Thread size threads per diameter
Range Target
hose (mm) (mm) inch, type of (mm)
thread (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16-18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16-16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13 /16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1 3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Tightening torque (Nm {kgm}) Face seal

Outside Width
diameter of across flats Nominal No. - Thread root
pipe (mm) (mm) Range Target threads per inch, diameter (mm)
type of thread (reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1 3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})
6 10 ± 2 {1.02 ± 0.20}
8 24 ± 4 {2.45 ± 0.41}
10 43 ± 6 {4.38 ± 0.61}
12 77 ± 12 {7.85 ± 1.22}
14 —
00-52 PC88MR-10
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to
the torque shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})

6 8 ± 2 {0.81 ± 0.20}
8 10 ± 2 {1.02 ± 0.20}
10 12 ± 2 {1.22 ± 0.20}
12 24 ± 4 {2.45 ± 0.41}
14 36 ± 5 {3.67 ± 0.51}
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe
thread (NPT))
a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107,
and 114 series engines to the torques shown in the table below.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
1/16 15 ± 2 {1.53 ± 0.20} 5 ± 1 {0.51 ± 0.10}
1/ 8 20 ± 2 {2.04 ± 0.20 15 ± 2 {1.53 ± 0.20}
1/ 4 25 ± 3 {2.55 ± 0.31} 20 ± 2 {2.04 ± 0.20}
3/ 8 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31}
1/ 2 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41}
3/ 4 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51}
PC88MR-10 00-53
List of abbreviation (ALL-0360-005-A-00-A)

(Rev. 2015/01)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text (marked with a).
• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the shop manual

Purpose of use (major
Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
With this function, when the tires skid (wheels
Anti-skid Brake Travel and brake stop rotating), the brakes are released, and
ABS System when the wheels start to rotate, the brakes are
(HD, HM)
applied again.
Automatic Idling This function automatically sets the idle
AISS Engine
Setting System speed.
A lever is used to perform the steering
Advanced Joystick Steering operations instead of a steering wheel.
AJSS Steering System Moreover, it shifts gear and changes direction
(WA)
(FORWARD or REVERSE).
When the accelerator pedal is released while
Automatic Retarder Travel and brake the machine is traveling downhill, this function
ARAC automatically applies the retarder with a
Accelerator Control (HD, HM)
constant braking force.
When the accelerator pedal is released while
Travel and brake the machine is traveling downhill, this function
Automatic Retarder
ARSC automatically applies the retarder to ensure
Speed Control (HD, HM) that the machine speed does not accelerate
above the speed set by the operator.
Travel and brake When the tires spin on soft ground surfaces,
Automatic Spin
ASR this function automatically uses the optimum
Regulator (HD, HM) braking force to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake When the retarder is not being used, this
Brake cooling oil valve bypasses part of the brake cooling oil to
BCV
control valve (HD) reduce the load on the hydraulic pump.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine.
A regulator valve which is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and it is
Regulator
not used independently.
This system can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Hydraulic system
Sensing System (provides better combined operation than O.L.
S.S.).
Engine controller electronically controls
supply pump, common rail, and injector. This
CRI Common Rail Injection Engine
function maintains optimum fuel injection
amount and fuel injection timing.
Electronic control device uses the signals
Electronic Control from the sensors on the machine. This signal
ECM Electronic control system
Module indicates the optimum actuation to the
actuators. (Same as E.C.U.)
00-54 PC88MR-10

Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
Electronically This system ensures smooth high-speed
Travel travel by absorbing vibration of machine
ECSS Controlled Suspension
System (WA) during travel with hydraulic spring effect of
accumulator.
Electronic control device uses the signals
from the sensors on the machine. This signal
ECU Electronic Control Unit Electronic control system indicates the optimum actuation to the
actuators. (Same as E.C.M.)
This function recirculates part of exhaust gas
Exhaust Gas Engine to combustion chamber in order to reduce
EGR
Recirculation combustion temperature, controls emission of
NOx.
Equipment This system allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on the monitor.
Electromagnetic This mechanism allows actuators to be
EPC Hydraulic system
Proportional Control operated in proportion to the current supplied.
This structure protects the operator's head
from falling objects. (Falling Object Protective
Falling Object Cab and canopy Structure)
FOPS
Protective Structure
This performance is standardized as ISO
3449.
Forward-Neutral- Operation
F-N-R Forward-Neutral-Reverse
Reverse
Global Navigation A general term for positioning system using
GNSS Satellite System Communication satellites such as GPS, GALILEO, etc.
Communication
Global Positioning This system uses satellites to determine the
GPS System (KOMTRAX, KOMTRAX current location on the earth.
Plus)
This function uses a combination of hydraulic
Steering motor and bevel shaft to control difference in
Hydrostatic Steering
HSS travel speed of right and left tracks.
System (D) Accordingly machine can turn without using
steering clutch.
Transmission This function uses a combination of hydraulic
Hydro Static pump and hydraulic motor to shift the speed
HST
Transmission (D, WA) range steplessly without using gears.
Information and A general term for the engineering and its
Communication Intelligent Machine socially applied technology of information
ICT
Technology Control processing and communication.
This valve is installed at inlet port of pump,
Inlet Metering Actuator Engine and it adjusts fuel intake amount in order to
IMA
control fuel discharge of supply pump. Same
as I.M.V.
This is a device to detect the angular velocity
Inertial Measurement Intelligent Machine
IMU and acceleration of the 3 axes that control
Unit Control
motions.
This valve is installed at inlet port of pump,
and it adjusts fuel intake amount in order to
IMV 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.
PC88MR-10 00-55

Komatsu Catalyzed This filter captures soot in exhaust gas.
KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine This is built in KDPF or assembled with the
Oxidation Catalyst
muffler.
This component is used to purify the exhaust
gas. KDOC (catalyst) and KCSF (filter to
Komatsu Diesel Engine capture soot) are built-in it.
KDPF
Particulate Filter
It is installed in place of the conventional
muffler.
This function recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
VGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Image display equipment such as a monitor
LCD Liquid Crystal Display Machine monitor which assembles in the liquid crystal element.
It refers to semiconductor element that emits
LED Light Emitting Diode Electronic parts light when the voltage is applied in forward
direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Hydraulic system pump and controls discharge amount
corresponding to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
This indicates engine intake air flow.It is not
Engine used independently but it is used as combined
MAF Mass Air Flow
with sensor.Mass air flow sensor can be called
as MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Electric and hydraulic Device actuated to open electric or hydraulic
NC Normally Closed circuits that are normally closed if not
systems
actuated.
Electric and hydraulic Device actuated to close electric or hydraulic
NO Normally Open
systems circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Hydraulic system actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Hydraulic system A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
This valve is installed at inlet port of pump and
Pre-stroke Control Engine it adjusts fuel intake amount in order to control
PCV
Valve fuel discharge amount of supply pump.
00-56 PC88MR-10

Used for controlling proportional pressure.
Proportional Pressure Hydraulic system This system moves actuators in proportion to
PPC
Control the oil pressure.
Piston Pump and Hydraulic system
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and power Work equipment This function performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)
If a machine tips over, this structure protects
the operator with the seat belt fastened from
Roll-Over Protective being crushed. (Operator Protective Structure
ROPS Cab and canopy When Tipping)
Structure
This performance is standardized as ISO
3471.
Le Systeme Abbreviation for the "International System of
International d’ Unites Units". It is the universal unit system and "a
SI (International unit Unit single unit for a single quantity" is the basic
system) principle applied.
It refers to an actuator consisting of a solenoid
and an iron core that is moved by the
SOL Solenoid Electric system
magnetic force when the solenoid is
energized.
Hydraulic and electric Solenoid valve that switches over direction of
TWV 2-Way Valve
systems flow.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
PC88MR-10 00-57
Abbreviation Actual word spelled out

SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
00-58 PC88MR-10
Conversion table (ALL-2150-931-A-00-A)

(Rev. 2012/10)
Method of using the conversion table

• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from
millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
PC88MR-10 00-59
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilograms to pounds
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
l to U.S. Gallons
1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00-60 PC88MR-10
l to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1,005
140 1,013 1,020 1,027 1,034 1,042 1,049 1,056 1,063 1,071 1,078
150 1,085 1,092 1,099 1,107 1,114 1,121 1,128 1,136 1,143 1,150
160 1,157 1,165 1,172 1,179 1,186 1,193 1,201 1,208 1,215 1,222
170 1,130 1,237 1,244 1,251 1,259 1,266 1,273 1,280 1,288 1,295
180 1,302 1,309 1,316 1,324 1,331 1,338 1,345 1,353 1,360 1,367
190 1,374 1,382 1,389 1,396 1,403 1,410 1,418 1,425 1,432 1,439
PC88MR-10 00-61
kg/cm2 to lb/in22
1 kg/cm2 = 14.2233 lb/in22
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
00-62 PC88MR-10
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
PC88MR-10 00-63
00-64 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
01 Specification
2 01 Specification
PC88MR-10 01-1
01 Specification
Table of contents
Table of contents (ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1
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
01 Specification
Specification drawing
Specifications (ALL-2111-001-A-00-A)
Specification drawing (ALL-2110-001-A-00-A)
PC88MR-10 (PC88MR-2110-931-A-01-A)
PC88MR–10
Item Unit
1,650 mm arm 2,100 mm arm
Machine weight
With blade kg 8,600 8,640
(8,460) (8,500)
Bucket capacity m3 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}
• ISO 14396 kW {HP}/min- 50.7 {68.0} / 1,950 {1,950}
1{rpm}
• ISO 9249 / SAE
48.8 {65.5} / 1,950 {1,950}
J1349 (net)
A Overall length mm 6,255 6,430
B Overall height 2,760
mm
(2,730)
C Overall width mm 2,330
D Shoe width mm 450
E Tail swing radius mm 1,485
Overall length of the mm 2,890
F
track
(2,840)
Distance between mm 2,235
G
tumbler centers
Min. ground clearance mm 410
Travel speed (Lo/Hi) km/h 2.8 / 5.0
Continuous swing speed min-1 {rpm} 10.0
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated
horsepower measured on the basic engine unit. While, net denotes the value measured of an engine
under the condition essentially the same as that when it is installed on a machine.
a The dimensions of the machine are for the road liner specification. The dimensions in ( ) are for the steel
shoe specification.
PC88MR-10 01-3
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 mm 6,935 7,345
B Max. digging depth mm 4,110 4,565
C Max. digging height mm 6,620 6,800
Max. vertical wall
D mm 2,850 3,115
digging depth
E Max. dumping height mm 4,565 4,770
Min. swing radius of
2,755 2,900
F work equipment mm
(2,395) (2,545)
(When boom swings)
Max. digging reach at
G mm 6,710 7,135
ground level
Max. blade lift above
H mm 550 550
ground
Max. blade drop below
I mm 390 390
ground
a Dimensions when road liner is installed
01-4 PC88MR-10
01 Specification
Specifications
Specifications (ALL-2111-001-A-01-A)
PC88MR-10 (PC88MR-2111-931-A-02-A)
PC88MR–10
Machine model
Unit 1,650 mm arm 2,100 mm arm
Serial No. 7001 and up
Bucket capacity m3 0.28 0.20
Machine weight kg 8,600 (8,460) 8,640 (8,500)
Performance
Working ranges
Max. digging depth mm 4,110 4,565
Max. vertical wall digging depth mm 2,850 3,115
Max. digging reach mm 6,935 7,345
Max. digging reach at ground level mm 6,710 7,135
Max. digging height mm 6,620 6,800
Max. dumping height mm 4,565 4,770
Bucket offset amount
mm 785/815 785/815
(Left/Right)
Boom swing angle
deg. 53/67 53/67
(Left/Right)
Max. blade lift above ground mm 550 550
Max. blade drop below ground mm 390 390
Max. digging force (bucket) kN {kg} 61.3 {6,250} 61.3 {6,250}
Continuous swing speed rpm 10.0 10.0
Swing operation max. slope angle deg. 19 20
Travel speed (Lo/Hi) km/h 2.8/5.0 2.8/5.0
Gradeability deg. 35 35
Ground pressure kPa {kg/cm2} 38.2 {0.39} 38.2 {0.39}
Dimensions
Overall length (for transport) mm 6,255 6,430
Overall width mm 2,330 2,330
Overall height (for transport) mm 2,760 (2,730) 2,760 (2,730)
Overall height (for operation) mm 2,760 (2,710) 2,760 (2,710)
Ground clearance of upper structure mm 785 (735) 785 (735)
Min. ground clearance mm 410 (360) 410 (360)
Tail swing radius mm 1,485 1,485
Min. swing radius of work equipment 2,755 2,900
mm
[When boom swings] [2,395] [2,545]
Max. height of work equipment in min.
mm 5,260 (5,210) 5,285 (5,235)
swing radius posture
Overall width of track mm 2,320 2,320
Overall length of track mm 2,890 (2,840) 2,890 (2,840)
Distance between tumbler centers mm 2,235 2,235
Track gauge mm 1,870 1,870
Machine cab height mm 1,885 (1,835) 1,885 (1,835)
Blade width x height mm 2,320 x 470 2,320 x 470
The above values are for the machine equipped with the road liner.
Values in ( ) are for the machine equipped with the steel shoes.
PC88MR-10 01-5
01 Specification
Specifications
PC88MR–10
Machine model
Engine
Model — SAA4D95LE-6
4-cycle, water-cooled, in-line, vertical, direct
Model — injection, with variable geometry turbocharger
and air-cooled aftercooler
No. of cylinders - bore x stroke mm 4 - 95 x 115
Total piston displacement l {cc} 3.260 {3,260}
Performance
Rated horsepower
• SAE J1995 (gross) 50.7 {68}/ 1,950 {1,950}
kW {HP}/min-1
• ISO 14396 50.7 {68}/ 1,950 {1,950}
{rpm}
• ISO 9249/SAE J1349 (net) 48.8 {65.5}/ 1,950 {1,950}
Nm {kgm}/min-1
Max. torque 319 {32.5}/ 1,400 {1,400}
{rpm}
Fuel consumption ratio at rated
g/kWh {g/Hph} 227 {169}
horsepower
Max. speed with no load min-1 {rpm} 2,050 {2,050}
Min. speed with no load min-1 {rpm} 1,150 {1,150}
Starting motor — 24 V, 4.5 kW
Alternator — 24 V, 35 A
Battery (*1) — 12 V, 55 Ah x 2 pieces
Radiator core type — Aluminum V-fin
Type of aftercooler core — Corrugated aluminum
*1: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated
horsepower measured on the basic engine unit. While, net denotes the value measured of an engine
under the condition essentially the same as that when it is installed on a machine.
Undercarriage
Carrier roller — 1 (each side)
Track roller — 5 (each side)
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
• Rubber shoe — One-piece rubber shoe
01-6 PC88MR-10
01 Specification
Specifications
PC88MR–10
Machine model
Hydraulic system
Hydraulic pump
Variable displacement piston type x 1 pc.
Type x quantity —
Gear type x 1 pc.
Capacity cm3/rev 44 x 2 + 36.6
Set pressure
Work equipment, travel MPa {kg/cm2} 26.5 {270}
Swing, blade 21.1 {215}
Control valve
Type x quantity — 9-spool type x 1 pc.
Operating method — Hydraulic assist type
Travel motor
Variable displacement swash plate piston type
Type x quantity — x 2 pcs.
(with brake valve and parking brake)
Swing motor
Fixed displacement, swash plate, piston type x
Type x quantity — 1 pc.
(with safety valve and pivot shaft brake)
Hydraulic tank — Box-shaped sealed type
Hydraulic oil filter — Tank return side
Hydraulic oil cooler — Air cooled
Boom cylinder
Model — Double-acting piston type
Cylinder bore mm 115
Piston rod diameter mm 65
Stroke mm 988
Max. distance between pins mm 2,393
Min. distance between pins mm 1,405
Arm cylinder
Model — Double-acting piston type
Stroke mm 861
Bucket cylinder
Type — Double-acting piston type
Cylinder bore mm 90
Stroke mm 710
PC88MR-10 01-7
01 Specification
Specifications
PC88MR–10
Machine model
Boom swing cylinder
Stroke mm 638.5
Max. distance between pins mm 1,712.5
Blade cylinder
Stroke mm 200
Max. distance between pins mm 785
Min. distance between pins mm 585
01-8 PC88MR-10
01 Specification
Weight table
Weight table (ALL-2120-001-A-01-A)
PC88MR-10 (PC88MR-2120-931-A-01-A)
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model PC88MR–10
Engine assembly (excluding coolant and oil) 522
• Engine (excluding coolant and oil) 419
• Engine mount 30
• PTO 6
• Main pump 67
Cooling assembly (excluding coolant, oil, and fuel) 69
• Radiator (excluding coolant) 10
• Oil cooler (excluding oil) 10
• Aftercooler 6
• Fuel cooler (excluding fuel) 1
Revolving frame 1,225
Operator's cab 330
Operator's seat 38
Fuel tank (excluding fuel) 47
Hydraulic tank (excluding hydraulic oil) 68
Control valve 66
Counterweight 805
Swing motor (including brake valve) 22
Swing circle 104
Swing machinery 62
Center swivel joint 17
Track frame assembly (excluding track shoes)
Steel shoe specification, road liner specification 1,375
Rubber shoe specification 1,356
• Track frame 805
• Idler assembly 54 x 2
• Recoil spring assembly 40 x 2
• Carrier roller 3.7 x 2
• Track roller 12.4 x 10
• Travel motor (including reduction gear) 83 x 2
• Sprocket 19 x 2
Track shoe assembly
Road liner (450 mm) 450 x 2
City pad shoe (450 mm) 410 x 2
Rubber shoe (450 mm) 385 x 2
Triple grouser shoe (600 mm) 495 x 2
PC88MR-10 01-9
01 Specification
Weight table
Unit: kg
Machine model PC88MR–10
Boom assembly 369
Swing bracket assembly 202
Arm assembly
1,650 mm 146
2,100 mm 202
Bucket link assembly 42
Bucket assembly
750 mm wide (including side cutter) 204
650 mm wide (including side cutter) 185
Blade assembly
Blade (welded edge type) 360
Wide blade (welded edge type) 370
Reinforced blade (BOC type, including BOC) 392
Boom cylinder assembly 92
Arm cylinder assembly 68
Bucket cylinder assembly 51
Boom swing cylinder assembly 71
Blade cylinder assembly 49
a BOC: Abbreviation for Bolt On Cutting edge
01-10 PC88MR-10
01 Specification
Table of fuel, coolant, and lubricants
Table of fuel, coolant, and lubricants (PC88MR-RA19-05A-K-01-A)
a 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 2.8 2.8
Final drive case (each of right and left) 1.1 1.1
PTO gear case 0.4 0.4
Hydraulic oil system 100 56
Cooling system 13 —
Fuel tank 125 —
PC88MR-10 01-11
01 Specification
Table of fuel, coolant, and lubricants
01-12 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
10 Structure and function

3 10 Structure and function
PC88MR-10 10-1
Table of contents

10 Structure and function ................................................................................................................... 10-1
Engine related parts ............................................................................................................. 10-3
PTO.................................................................................................................................... 10-5
Variable flow turbocharger .................................................................................................... 10-6
EGR system piping drawing ................................................................................................ 10-10
EGR system circuit diagram ................................................................................................ 10-12
EGR valve......................................................................................................................... 10-13
EGR cooler........................................................................................................................ 10-15
KCCV layout drawing ......................................................................................................... 10-17
KCCV ventilator ................................................................................................................. 10-20
KDOC muffler .................................................................................................................... 10-22
Cooling system .................................................................................................................. 10-24
Power train............................................................................................................................... 10-27
Power train system............................................................................................................. 10-27
Swing circle ....................................................................................................................... 10-29
Swing machinery ............................................................................................................... 10-31
Track frame ....................................................................................................................... 10-33
Idler cushion ...................................................................................................................... 10-35
Hydraulic component layout ................................................................................................ 10-36
Valve control...................................................................................................................... 10-38
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
Boom swing PPC valve .................................................................................................... 10-145
Solenoid valve ................................................................................................................. 10-147
Multi-control valve ............................................................................................................ 10-151
Anti-drop valve for boom ................................................................................................... 10-152
Anti-drop valve for arm ..................................................................................................... 10-156
Center swivel joint ............................................................................................................ 10-160
Accumulator .................................................................................................................... 10-161
Work equipment ..................................................................................................................... 10-163
Work equipment............................................................................................................... 10-163
Work equipment shim....................................................................................................... 10-164
Bucket play adjustment shim............................................................................................. 10-165
Cab mount and cab tipping stopper ................................................................................... 10-166
ROPS cab ....................................................................................................................... 10-168
Electrical control system ................................................................................................... 10-170
Machine monitor system ................................................................................................... 10-214
KOMTRAX system ........................................................................................................... 10-236
Sensor ............................................................................................................................ 10-238
10-2 PC88MR-10
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
Engine related parts
9. Rear engine mount (*2)

10.Engine controller
11.Front engine mount (*2)
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
PTO
PTO (PC88MR-D400-041-K-00-A)
a PTO: Abbreviation for Power Take Off
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) 0.4
PC88MR-10 10-5
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
1. Variable flow turbocharger motor

2. Flange bolt
3. Bracket
4. Thrust sleeve
PC88MR-10 10-7
5. Bracket
6. O-ring
7. Insert
8. Oil deflector
9. Thrust bearing
10. Thrust ring
11. Bearing housing
12. Bearing
13. Piston ring
14. Turbine wheel
15. Turbine insert
16. Turbine housing assembly
17. Pin
18. Seal ring
19. Snap ring
20. O-ring
21. Snap ring
22. Piston ring
23. Compressor cover assembly
24. Compressor wheel
25. Lock nut
26. Flange bolt
27. Flange bolt
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
Operation (ENG95-AA10-044-K-00-A)
1. Large scroll
2. Small scroll
3. Fixed vane
4. Flow control valve
A: When flow control valve is fully closed (small flow rate)
B: When flow control valve is fully open (large flow rate)
• The turbine housing of the variable flow turbocharger consists of large scroll (1) and small scroll (2).
• Fixed vane (3) is installed between large scroll (1) and small scroll (2) for flow rectification.
• 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
EGR system piping drawing
EGR system piping drawing (ENG95-A9J0-04D-K-00-A)
a EGR: Abbreviation for Exhaust Gas Recirculation


2. EGR valve
3. Intake air connector
4. Mixing connector
5. Exhaust manifold
6. EGR cooler
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
EGR system piping drawing
Cools the exhaust gas.

The engine coolant is used for cooling.
• Intake air connector
Returns the air from the air-cooled aftercooler and the exhaust gas from the EGR valve to the intake side.
• Sensors
Control the EGR according to the operating condition.
Troubleshoot the system.
• 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
EGR system circuit diagram
EGR system circuit diagram (ENG95-A9J0-052-K-00-A)
1. Air cleaner
2. KDOC muffler
3. Mass air flow and temperature sensor (MAF)
4. Electric actuator (variable flow turbocharger)
5. EGR cooler
6. EGR valve
7. Electric actuator (EGR valve)
8. Ambient pressure sensor
9. Aftercooler
10. Exhaust manifold
11. Air intake manifold
12. Charge (boost) pressure and temperature sensor
13. Engine controller
C: Blower impeller
T: Turbine impeller
Operation (ENG95-A9J0-044-K-00-A)
• The engine controller outputs signals so that EGR valve (6) opens properly according to the engine load to
realize both clean exhaust gas and low fuel consumption.
• 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
EGR valve
EGR valve (ENG95-A9K1-041-K-00-A)

1. DC motor assembly (brushless motor with built-in position sensor)

2. DC motor shaft
3. Rod
4. Filter
5. Housing
6. Valve seat
7. Valve
8. Seal
9. Spring
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
Structure
• 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
EGR valve
Operation (ENG95-A9K1-044-K-00-A)
A: EGR gas inlet (from EGR cooler)

B: EGR gas outlet (to air intake manifold)
• DC motor shaft (2) of the DC motor converts rotary motion into linear motion. Accordingly, valve (7) is
opened or closed by turning the motor.
Open valve: The DC motor is turned and DC motor shaft (2) is pushed out to push rod (3) and open valve (7).
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
EGR cooler
EGR cooler (ENG95-A9L0-041-K-00-A)

1. Tube
2. Shell
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
EGR cooler
• 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
KCCV layout drawing
KCCV layout drawing (PC88MR-A180-04D-K-00-A)
a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation


2. Breather
3. Crankcase pressure sensor
4. CDR valve
5. KCCV ventilator
6. Check valve
A: Blowby gas (from breather)
B: Blowby gas from which engine oil is removed (to variable flow turbocharger)
C: Engine oil from which blowby gas is removed (to oil pan)
• Blowby gas (A) has been emitted to the atmosphere so far. Since the emission regulation has become
strict and the blowby gas must be controlled now, the blowby gas intake recirculation system is employed.
• Blowby gas (A) contains ingredients of the engine oil. If it is recirculated to variable flow turbocharger (1)
as it is, it causes the following problems. To prevent this, a filter is installed to KCCV ventilator (5) to
remove the engine oil.
1. Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
2. Abnormal combustion in engine
3. Malfunction of each sensor caused by sticking engine oil
PC88MR-10 10-17
KCCV layout drawing
D: Engine coolant (from thermostat inlet)

E: Engine coolant (to radiator)
F: Engine coolant (from EGR cooler)
G: Engine coolant (to water pump)
• For the coolant in the basic engine, see Shop Manual.

Operation (ENG95-A180-044-K-00-A)
a 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
KCCV layout drawing
1. Air cleaner
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• 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
KCCV ventilator
KCCV ventilator (ENG95-A18H-041-K-00-A)
a KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

1. Case
2. Filter
3. CDR valve
4. Relief valve
A: Blowby gas inlet (from breather)
B: Blowby gas outlet (to variable flow turbocharger intake side)
C: Oil drain port (to oil pan)
Function (ENG95-A18H-042-K-00-A)
• If the blowby gas is returned to the intake side of the variable flow turbocharger, the crankcase pressure
becomes negative and dust may be sucked in through the crankshaft seal. To prevent this, the blowby
pressure is controlled by using the CDR valve (regulator valve) and crankcase pressure sensor.
• If the filter of the KCCV ventilator is clogged, the crankcase pressure increases to cause oil leakage. To
prevent this, the crankcase pressure sensor (installed separately) senses clogging of the filter.
• There are 2 types of the filter; one is the top load type (taken out upward) and the other is the bottom load
type (taken out downward).
Operation (ENG95-A18H-044-K-00-A)
• Blowby gas enters (A) and engine oil mist is separated when it flows through filter (2).
• The separated oil flows along the case wall to oil drain port (C), and then flows into the oil pan.
• When the crankcase pressure becomes negative, the CDR valve operates to prevent the crankcase
pressure from becoming excessively negative.
• The crankcase pressure sensor senses the blowby gas pressure (crankcase pressure).
• If the engine controller judges from the value sensed by the crankcase pressure sensor that the filter is
clogged, it displays failure code CA555 and then displays CA556 if the pressure increases further.
10-20 PC88MR-10
KCCV ventilator
• Relief valve (4) is installed inside case (1) and operates to protect the KCCV ventilator and engine when
filter (2) is blocked.
CDR valve (ENG95-A18A-041-K-00-A)
a CDR: Abbreviation for Crankcase Depression Regulator
1. Diaphragm
2. Spring
A: Crankcase side
B: Variable flow turbocharger side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
variable flow turbocharger side (intake side) (B).
• When intake air flow at the variable flow turbocharger side (intake side) (B) increases and crankcase
pressure (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
KDOC muffler
KDOC muffler (ENG95-A9H2-041-K-00-A)
a KDOC: Abbreviation for Komatsu Diesel Oxidation Catalyst

1. DOC unit
2. Silencer unit
3. Exhaust gas outlet piping
4. Exhaust gas inlet piping
5. Drain piping
Structure
• The KDOC muffler consists of inlet piping (4) to lead in the exhaust gas from the engine, DOC unit (1) to
store the oxidation catalyst, silencer unit (2) having silencing function and containing a "dam" to prevent
rain water from flowing into the DOC unit from exhaust gas outlet piping, outlet piping (3) to discharge the
exhaust gas, and drain piping (5) to drain water from the silencer unit. Those components are welded
together into one unit.
• DOC unit (1) consists of ceramic honeycomb with oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramic
under the vibrations from the engine and chassis.
10-22 PC88MR-10
KDOC muffler
Function (ENG95-A9H2-042-K-00-A)
A: Flow of exhaust gas

1. DOC unit
2. Silencer unit
• The KDOC muffler is installed to meet the latest very severe emission regulations. It oxidizes SOF
(soluble organic fraction in minute particle in exhaust gas), HC (hydrocarbon not combusted), and CO
(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
Cooling system
Cooling system (PC88MR-B000-041-K-00-A)
10-24 PC88MR-10
Cooling system
A: Hydraulic oil cooler inlet

B: Fuel cooler outlet
C: Fuel cooler inlet
D: Hydraulic oil cooler outlet
E: Radiator inlet
F: Aftercooler outlet
G: Aftercooler inlet
H: Radiator outlet
1. Reservoir tank
2. Aftercooler outlet hose
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
Cooling system
Specifications (PC88MR-B000-030-K-00-A)
Hydraulic oil
Radiator Aftercooler Fuel cooler
cooler
Core type Corrugated Drawn cup
Aluminum V-fin Aluminum V-fin
aluminum
Fin pitch (mm) 3.5/2 3.5/2 4.0/2 4.0/2
Total heat dissipation area (m2) 23.55 5.11 6.17 0.97
Cracking pressure of pressure valve 49.1 ± 14.7
- - -
(kPa {kg/cm2}) {0.5 ± 0.15}
Cracking pressure of vacuum valve -4.9 to 0
- - -
(kPa {kg/cm2}) {-0.05 to 0}
10-26 PC88MR-10
Power train system
Power train (ALL-C100-001-K-00-A)
Power train system (PC88MR-C100-041-K-00-A)
1. Idler
2. Control valve
3. Travel junction valve
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
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
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
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) 5.5
10-30 PC88MR-10
Swing machinery
Swing machinery (PC88MR-J130-041-K-00-A)
1. Swing pinion (number of teeth: 11)

2. Swing machinery case
3. No. 2 sun gear (number of teeth: 14)
4. Ring gear (number of teeth: 67)
5. No. 1 planetary carrier
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
Swing machinery
Reduction ratio (14 + 67) / 14 x (14 + 67) / 14 = 33.47

Swing reduction ratio 33.47 x 7.273 = 243.45
Swing speed (rpm) 10.0
10-32 PC88MR-10
Track frame
Undercarriage and frame (ALL-DT00-001-K-00-A)
Track frame (PC88MR-DT20-041-K-00-A)
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
Track frame
Specifications (PC88MR-DT20-030-K-00-A)
Model PC88MR–10
Number of carrier rollers (each side) 1
Number of track rollers (each side) 5
Standard shoe
• Shoe width (mm) 450
• Link pitch (mm) 154.3
• Number of shoes (each side) 39
10-34 PC88MR-10
Idler cushion
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 84
• Rubber shoe 208
PC88MR-10 10-35
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
Hydraulic component layout
8. Swing motor
9. Accumulator (for breaker)
10. Oil filter (for machine ready for installation of attachment)
11. Main pump
12. Hydraulic oil cooler
13. Travel motor
14. Accumulator (for PPC circuit)
15. Quadruple type solenoid valve
16. Multi-control valve (*1)
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
Valve control
Valve control (PC88MR-PK01-041-K-00-A)
1. R.H. work equipment control lever (for operation of boom and bucket)
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
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
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
Hydraulic tank
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) 70

Hydraulic oil in tank (l) 56
Bypass valve set pressure (MPa {kg/cm2}) 0.25 ± 0.05 {2.5 ± 0.5}
PC88MR-10 10-41
Hydraulic tank
Pressure valve (PC88MR-AD1C-041-K-00-A)
1. Filter element
2. Bottle plate
3. Gasket
4. Seam valve
5. Spring
Prevention of pressure rise in tank

• While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and
the temperature in the hydraulic tank rise corresponding to the operation of the hydraulic cylinders.
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 2})
10-42 PC88MR-10
Hydraulic tank
Breather (PC88MR-PM38-041-K-00-A)
1. Nut
2. Cover
3. Filter element
4. Case
5. Valve assembly
6. Body
Prevention of negative pressure in tank

• Since the hydraulic tank is pressurized and sealed, if the oil level in it decreases, negative pressure is
generated in it. 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/cm2})
PC88MR-10 10-43
CLSS
CLSS (ALL-PNJ1-001-K-00-A)
a CLSS: Abbreviation for Closed center Load Sensing System

Structure of CLSS (PC88MR-PNJ1-041-K-00-A)
a CLSS: Abbreviation for Closed center Load Sensing System
Features
• Fine controllability not influenced by load
• Control performance that allows digging even under fine control operation condition
• Easy combined operation ensured by the flow dividing performance that is determined by the opening
areas of spools during combined operations
• 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
CLSS
Basic principle
Pump swash plate angle control

• The pump swash plate angle (pump discharged volume) is so controlled that LS differential pressure
(dPLS), which is the differential pressure between pump discharged pressure (PP) and control valve
outlet LS pressure (PLS) (actuator load pressure), is kept constant.
• [LS differential pressure (dPLS) = Pump discharged pressure (PP) - LS pressure (PLS)]
• The pump swash plate shifts toward the maximum angle position when LS differential pressure (dPLS) is
lower than the set pressure of the 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
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
CLSS
• A pressure compensation valve is installed to the outlet port side of the control valve to balance the load.
• When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet
port) and downstream (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
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
Main pump
P2T: Travel deviation adjustment orifice

P3: Gear pump discharge port
P5: Gear pump pressure pickup port
PD: Drain port
PD2: Pump drain port (plug)
PEN: Control pressure pickup port
PEPC: EPC source pressure pickup port
PGS: Gear pump suction port
PLS: LS pressure input port (from control valve port LS)
PM: PC mode selector pressure pickup port
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
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
Main pump
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
• This pump consists of a variable capacity swash plate piston pump, gear pump (for blade and swing
operations), and servo valve.
Structure
• Cylinder block (7) is supported on shaft (1) through spline (a). Shaft (1) is supported on the front and rear
bearings.
• The tip of piston (6) is shaped as a concave sphere and is crimped with shoe (5). Piston (6) and shoe (5)
constitute a spherical bearing.
• Rocker cam (4) has flat surface (A) and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) is supported on flange (2) fixed to case (3) and ball (12).
• Shoe (5) leads high-pressure oil to flat surface (A) of rocker cam (4) and form a static pressure bearing for
its sliding.
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while blocking the pressurized oil and the oil pressure
is balanced properly on this plane.
• 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
Main pump
• It is possible to change the discharged volume by changing the swash plate angle.
• There are 2 pump discharge ports and each pump can supply pressurized oil separately.
Operation (PC88MR-C200-044-K-00-A)
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) pivots on ball (12), and accordingly angle (a) between center line (X) of rocker cam (4) and
the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
• Piston (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder
block (7).
• Oil in amount of (F) minus (E) goes in and out of each cylinder.
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.
• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (7) is zero.
• Suction and discharge of pressurized oil is not performed in this stage. Namely pumping action is not
performed. (Actually, however, a zero swash plate angle never occurs.)
• The pump discharged volume is in proportion to swash plate angle (a).
• 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
Main pump
Control of discharged volume

• When the swash plate angle (a) increases, the difference between volumes (E) and (F) increases and also
pump discharged volume (Q) increases.
• Swash plate angle (a) is changed by servo piston (11).
• 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
Main pump
Servo valve (PC88MR-C2B0-041-K-00-A)
P3: Gear pump pressure input port

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
Main pump
PMI: PC mode selector pressure pickup port

PPLS: LS pump pressure input port
T: Drain port
1. Lever
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
Main pump
Operation (PC88MR-C2B0-044-K-00-A)
Action of spring
• The spring force of spring (2) in the PC valve is determined by the angle of the swash plate.
• When servo piston (6) moves to the right, spring (2) is compressed by operation of lever (1) and the load
of the spring changes. The spring has characteristics that the spring constant changes into 2 stages
depending on the height of the spring.
When pump pressure (PAVE) is low

When load is light
• Weakening in the pressing force of spool (4) causes spool (3) to lean towards the right side. When port (C)
and (D) are connected, pressure which goes in the LS valve turns into drain pressure (PT)
• When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes drain pressure
(PT) and servo piston (6) moves to the left.
• Pump discharged volume increases.
• As servo piston (6) moves, lever (1) moves to the left and spring (2) expands and the spring force is
decreased. 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
Main pump
When pump pressure (PAVE) is high

When load is heavy
• The pressing force of spool (4) increases, and spool (3) leans towards the left side. At this time, ports (C)
and (B) are connected, and pressure which goes into the LS valve becomes pump pressure (PP).
• When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes pump pressure
(PP), and servo piston (6) moves to the right.
• The pump discharged volume goes to decrease.
• As servo piston (6) moves, lever (1) moves to the right and spring (2) is compressed and spring force is
increased. 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
Main pump
When the servo piston is balanced

When balanced
• The stop position (= pump discharged volume) of servo piston (6) is determined by the position where the
thrust caused by pressure (PAVE) applied to spool (4) is balanced with the force of spring (2).
When swing gear pump pressure increases and decreases

• The pressing force of spool (4) changes, and the pump discharged volume changes similarly to the
changes when (PAVE) increases or decreases.
When the PC-EPC valve is operating

• 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
Main pump
LS valve (PC88MR-C2J0-042-K-01-A)
• The LS valve controls the pump discharged volume according to the travel of the control lever, or the flow
demanded by the actuator.
• The LS valve detects the flow rate demanded by the actuator from differential pressure (dPLS) between
inlet pressure (PPLS) and outlet pressure (PLS) of the control valve and controls pump discharged
volume (Q). [(PPLS) is called LS pump pressure, (PLS) LS pressure, and (dPLS) LS differential pressure]
• In other words, pressure loss [= LS differential pressure (dPLS)], which occurs when the oil flows through
the passage in control valve spool, is detected, and pump discharged volume (Q) is controlled to maintain
the pressure loss at a constant level. Through this operation, the pump can discharge the proper volume
of oil as demanded by the actuator.
• Pump discharged pressure (PP), LS pump pressure (PPLS), and LS pressure (PLS) are applied to LS
valve. The relationship between LS differential pressure (dPLS) and pump discharged volume (Q)
changes as shown below.
PC valve (PC88MR-C2K0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depending on the discharged pressure) even if the travel
of the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed
the engine horsepower, when pump discharged pressure (PP) is high.
• The PC valve decreases the pump discharged volume when the work load is increased and the pump
discharged pressure rises, and increases it when the pump discharged pressure lowers.
• 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
Control valve
Control valve (PC88MR-C030-041-K-00-A)

10-spool valve
(EU specification)
10-60 PC88MR-10
Control valve
A1: To blade cylinder

A2: To swing motor
A3: To L.H. travel motor
A4: To R.H. travel motor
A5: To boom swing cylinder
A6: To boom cylinder
A7: To arm cylinder
A8: To bucket cylinder
A9: To attachment 1, actuator
B1: To blade cylinder
B2: To swing motor
B3: To L.H. travel motor
B4: To R.H. travel motor
B5: To boom swing cylinder
B6: To boom cylinder
B7: To arm cylinder
B8: To bucket cylinder
B9: To attachment 1, actuator
BP: From boom RAISE PPC valve
LS: To pump LS valve (LS pressure input)
LS1I: LS1 pressure pickup port
LS2I: LS2 pressure pickup port
P1: From pump discharge port
P1I: P1 pressure pickup port
P2I: P2 pressure pickup port
PR: To PPC valve source pressure
PA1: From blade RAISE PPC valve
PA2: From swing RIGHT PPC valve
PA3: From L.H. travel REVERSE PPC valve
PA4: From R.H. travel REVERSE PPC valve
PA5: From boom SWING L.H. PPC valve
PA6: From boom RAISE PPC valve
PA7: Arm OUT PPC valve
PA8: From bucket DUMP PPC valve
PA9: From attachment solenoid valve
PB1: From blade LOWER PPC valve
PB2: From swing LEFT PPC valve
PB3: From L.H. travel FORWARD PPC valve
PB4: From R.H. travel FORWARD PPC valve
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
PP: To pump LS valve (LS pressure input)
PC88MR-10 10-61
Control valve
PT: From pump merge-divider selector solenoid valve

PMAX: Pump pressure sensor mounting port
TB: To tank via bypass check valve
TC: To tank via bypass check valve
TS: To tank
TSW: To swing motor
1. Block
2. Blade valve
3. Swing valve
4. L.H. travel valve
5. R.H. travel valve
6. Boom swing valve
7. Merge-divider valve block
8. Boom valve
9. Arm valve
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
10-62 PC88MR-10
Control valve
(1/6)
1. Suction safety valve (blade)

2. Suction valve (left travel)
3. Suction valve (right travel)
PC88MR-10 10-63
Control valve
4. Suction valve (boom swing)

5. Main relief valve
6. Suction valve (boom)
7. Suction valve (arm)
8. Suction valve (bucket)
9. Port relief valve (service)
10. Safety valve
11. Port relief valve (service)
12. Suction valve (bucket)
13. Suction valve (arm)
14. Suction valve (boom)
15. Suction valve (boom swing)
16. Suction valve (right travel)
17. Suction valve (left travel)
18. Suction valve (blade)
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
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
Control valve
4. Merge-divider valve spool

5. Pressure compensation valve F (boom)
6. Pressure compensation valve F (arm)
7. Pressure compensation valve F (bucket)
8. Pressure compensation valve F (service)
9. Pressure compensation valve R (service)
10. Pressure compensation valve R (bucket)
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
Control valve
(3/6)
Block
1. Boom raise assist valve
Blade valve
3. Suction safety valve
4. Suction valve
5. Spool
PC88MR-10 10-67
Control valve
6. Check valve
Swing valve
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

10-68 PC88MR-10
Control valve
(4/6)
R.H. travel valve

2. Suction valve
3. Suction valve
4. Spool
6. Travel junction valve + LS check valve
PC88MR-10 10-69
Control valve
Boom swing valve

8. Suction valve
9. Suction valve
10. Spool
Merge-divider valve block

12. Merge-divider valve spool
13. Unload valve
14. Check valve
16. Unload valve
18. Check valve
19. Sequence valve

10-70 PC88MR-10
Control valve
(5/6)
Boom valve
1. Hydraulic drift prevention valve
2. Suction valve
3. Spool
6. Suction valve
PC88MR-10 10-71
Control valve
Arm valve
7. Suction valve
8. Suction valve
9. Spool
Bucket valve
12. Suction valve
13. Suction valve
14. Spool
Service valve
17. Port relief valve
18. Port relief valve
19. Spool

10-72 PC88MR-10
Control valve
(6/6)
1. Safety valve
2. Filter
3. Check valve
PC88MR-10 10-73
Control valve
9-spool valve
(North America specification)
A9: To attachment, actuator

B9: To attachment, actuator
1. Pressure compensation valve F (attachment)
2. Pressure compensation valve R (attachment)
3. Suction valve
10-74 PC88MR-10
Control valve
4. Suction valve
5. Spool (attachment)
PC88MR-10 10-75
Control valve
Hydraulic circuit diagram and names of valves (PC88MR-C030-054-K-00-A)
1. Block
2: Blade valve
10-76 PC88MR-10
Control valve
3. Swing valve
4. L.H. travel valve
5. R.H. travel valve
6. Boom swing valve
7. Merge-divider valve block
8. Boom valve
9. Arm valve
10. Bucket valve
11. Service valve
12. Cover
13. Assistant valve
14. Blade spool
15. Swing spool
16. L.H. travel spool
17. R.H. travel spool
18. Boom swing spool
20. Boom spool
21. Arm spool
22. Bucket spool
23. Service spool
24. Pressure compensation valve
25. Suction valve
26. LS bleed valve
27. Travel junction valve + LS bleed valve
28. Boom lock valve
30. Safety valve
Relief pressure: 9.8 MPa {100 kg/cm2}
31. Safety valve
Cracking pressure: 27.9 MPa {285 kg/cm2}
32. Safety valve
Relief pressure: 19.6 MPa {200 kg/cm2})
33. G/P relief valve
34. Relief valve
35. Unload valve
36. Equalizer valve
38. Sequence valve
39. LS bypass valve
PC88MR-10 10-77
Control valve
9-spool valve (North American specification)
40. Suction valve
10-78 PC88MR-10
Control valve
Unload valve (PC88MR-PQD5-041-K-00-A)

When control valve is in HOLD position
Function
• This valve drains discharged volume (Q) for the minimum pump swash plate angle into the tank circuit
when the control valve is held.
• Pump discharged pressures (PP1) and (PP2) are set to 2.45 MPa {25.0 kg/cm 2} by spring (2) in the valve.
[LS pressures (PLS1) and (PLS2) are 0 MPa {0 kg/cm2}]
• Since the merge-divider spool is at the merge position, pump discharged pressures (PP1) and (PP2) are
merged.
• LS pressures (PLS1), (PLS2), and (PLS3) are merged.
Operation
• Pump discharged pressures (PP1) and (PP2) act on the right side of unload spool (1), and LS pressures
(PLS1) and (PLS2) act on the left side. (PP1 = PP2, PLS1 = PLS2)
• When the control valve is held, only pump discharged pressures (PP1) and (PP2) are applied since LS
pressures (PLS1) and (PLS2) are 0 MPa {0 kg/cm2}.
• (PP1) and (PP2) are set only by the load at installed height of spring (2).
• Pump discharged pressures (PP1) and (PP2) increase and reach the load at installed height of spring (2)
(2.45 MPa {25.0 kg/cm2}).
• 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 2}.
PC88MR-10 10-79
Control valve
When fine control operation of work equipment is performed

Work equipment: Swing, boom, arm, bucket, boom swing, attachment
Function
• When the fine control operation of the work equipment is performed and the actuator demand flow is
below the flow at the pump minimum swash plate angle.
• Pump discharged pressures (PP1) and (PP2) are set to LS pressures (PLS1) and (PLS2) + 2.45 MPa
{25.0 kg/cm2}.
• The differential pressure between pump discharged pressure (PP1)/(PP2) and LS pressure (PLS1)/
(PLS2) becomes the load at installed height of spring (2) (2.45 MPa {25.0 kg/cm 2}).
• Unload spool (1) opens.
• LS differential pressure (dPLS) becomes 2.45 MPa {25.0 kg/cm2}.
• Since the merge-divider spool is at the merge position, pump discharged pressures (PP1) and (PP2) are
merged.
• LS pressures (PLS1), (PLS2), and (PLS3) are merged.
Operation
• When the work equipment is controlled finely, LS pressures (PLS1) and (PLS2) are generated and act on
the left side of spool (1). (PP1 = PP2, PLS1 = PLS2) Since the open area of the work equipment control
valve spool is small, the differential pressure between LS pressure (PLS1)/(PLS2) and pump discharged
pressure (PP1)/(PP2) is large.
(PLS2) reaches the load at installed height of spring (2) (2.45 MPa {25.0 kg/cm 2}).
• Pump circuits (PP1) and (PP2) are interconnected to tank circuit (T).
10-80 PC88MR-10
Control valve
• Pump discharged pressures (PP1) and (PP2) are set to the force of spring (2) (2.45 MPa {25.0 kg/cm 2}) +
pressure of LS pressures (PLS1) and (PLS2).
• LS differential pressure (dPLS) becomes 2.45 MPa {25.0 kg/cm2}.
When fine control operation of right and left travels are performed.
Function
• When the fine control operation of the right and left travels are performed and the demand flow is below
the pump maximum discharged volume.
• Pump discharged pressures (PP1) and (PP2) are set to LS pressures (PLS1) and (PLS2) + 2.45 MPa
{25.0kg/cm2}.
(PLS2) is the load at installed height of spring (2), which is (2.45 MPa {25.0 kg/cm 2}).
• Unload spool (1) opens.
• Excessive oil (maximum discharged volume - demand flow) flows into the tank circuit.
• Since the merge-divider spool is located at the divide position, pump discharged pressures (PP1) and
(PP2) are divided from each other.
• LS pressures (PLS1), (PLS2), and (PLS3) are divided.
• The swash plate angle becomes maximum and the discharged volume becomes maximum. (For details,
see "Merge-divider valve")
Operation
• 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
Control valve
• Since the open area of the right and left travel valve spool is small, the differential pressures between LS
pressures [(PLS1) and (PLS2)] and pump discharged pressures [(PP1) and (PP2)] are large.
(PLS2) reaches the load at installed height of spring (2) (2.45 MPa {25.0 kg/cm 2}).
• Pump circuits (PP1) and (PP2) are interconnected to tank circuit (T).
• Excessive oil (maximum discharged volume - demand flow) flows through.
• The excess oil other than the demand flow corresponding with the travel of the right and left travel valve
spools (pump maximum flow - demand flow) is drained into tank circuit (T).
When right and left travel valves are operated
Function
• When the right and left travels are operated and they demand the maximum flow, the drain into tank circuit
(T) is stopped and all of pump discharged volume (Q) is supplied to the right and left travel circuits.
see "merge-divider valve")
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
Control valve
• Since the open area of the right and left travel valve spool is large, the differential pressure between pump
discharged pressure (PP1)/(PP2) and LS pressure (PLS1)/(PLS2) is small.
(PLS2) does not reach the load at installed height of spring (2) (2.45 MPa {25.0 kg/cm 2}).
• Spring (2) pushes spool (1).
• Pump circuits (PP1) and (PP2) are disconnected from tank circuit (T) and all of pump discharged volume
(Q) flows to the actuator circuit.
When only one side operation of travel is performed
Function
• On the side of the travel operation being performed, the demand flow corresponding with the travel of the
travel valve spool is supplied to the travel circuit.
• On the side of the travel operation being not performed, all of pump discharged volume is drained into the
tank circuit.
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
Control valve
• LS pressure (PLS1) acts on the left side of unload spool (1).

• Since the open area of the left travel valve spool is large, the differential pressure between LS pressure
(PLS1) and pump discharged pressure (PP1) is small.
• The differential pressure between pump discharged pressure (PP1) and LS pressure (PLS1) does not
reach the load at installed height of spring (2) (2.45 MPa {25.0 kg/cm 2}).
• Spring (2) pushes spool (1) to the right.
• Pump circuit (PP1) is disconnected from tank circuit (T) and all of pump discharged volume (Q) on the
(PP1) side flows into the left travel circuit.
• Since the right travel valve is in HOLD, no LS pressure (PLS2) is generated in it.
• Only pump discharged pressure (PP2) is acting.
• Pump discharged pressure (PP2) reaches the load at installed height of the spring (2.45 MPa {25.0 kg/
cm2}). 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
Control valve
Introduction of LS pressure (PC88MR-C2A4-041-K-00-A)
Work equipment valve: Swing, boom, arm, bucket, boom swing, attachment
Function
• LS pressure is the actuator load pressure on the outlet side of the control valve.
• Actually, pump pressure (PP) is reduced with pressure reducing valve (3) of the pressure compensation
valve to actuator circuit pressure (A), and then it is supplied to LS circuit (PLS).
• In the travel valve, actuator circuit pressure (A) is supplied directly to LS circuit (PLS).
Operation
• When spool (1) is operated, pump discharged pressure (PP) flows from flow control valve (2) and notch
(a) in the spool through bridge passage (b) to actuator circuit (A).
• Since pressure reducing valve (3) moves to the right, so pump discharged pressure (PP) is reduced due
to the pressure loss at notch (c) and then transmitted through LS circuit (PLS) to spring chamber (PLSS).
• LS circuit (PLS) is connected to tank circuit (T) from LS bypass valve (4). (See "LS bypass valve".)
• The areas at both ends of pressure reducing valve (3) are the same [(SA) = (SLS)], and actuator circuit
pressure (PA) acts on the (SA) end. The reduced pump discharged pressure (PP) acts on (SLS) the other
end.
• 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
Control valve
Travel valve
Operation
• When spool (1) is operated, pump discharged pressure (PP) transmitted from notch (a) in the spool of flow
control valve (2) through bridge passage (b) to actuator circuit (A).
• Pressure reducing valve (3) is moved to the right by actuator circuit pressure (PA), and notches (c) and (d)
are connected respectively to travel interconnection circuit (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
Control valve
LS bypass plug (PC88MR-PNSH-041-K-00-A)

Function
• It releases the remaining pressure of LS pressure (PLS).
• While moderating increasing rate of LS pressure (PLS), this valve generates pressure loss in the throttle
part of the pressure reducing valve with this discarded throttle flow, decreasing the enabled LS differential
pressure and improving stability.
When work equipment valve is operated (including when work equipment and travel are operated
simultaneously)
• 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
Control valve
When right and left travel valves are operated (including when one side travel is operated)
• Since spool (1) is located the divided position, LS circuits (PLS1) and (PLS2) are divided from each other.
• 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
Control valve
Pressure compensation valve (PC88MR-L6D0-040-K-00-A)
Function
• When the load pressure of an actuator is lower than that of other actuator and the flow to the actuator is
going to increase during combined operation, this valve allows the load pressure to be compensated. [At
this time, the load pressure of the other actuator under combined operation (right side) is higher than that
of the actuator on this side (left side).]
Operation
• When the load pressure of the other actuator (right side) increases during combined operation, flow to the
actuator circuit (A) on this side (left side) is going to increase.
• In this case, LS pressure (PLS) of the other actuator is applied to spring chamber (PLSS) and pushes
pressure reducing valve (1) and flow control valve (2) to the left.
• Flow control valve (2) reduces the open area between pump circuit (PP) and spool upstream (PPA) to
generate a pressure loss between (PP) and (PPA).
• The flow control valve (2)and the pressure reducing valve (1) balance each other at the place where the
pressure difference between (PA) and (PLS) which applies to the both end surfaces of the pressure
reducing valve (1) becomes the same as the pressure loss between (PP) and (PPA) around the flow
control valve.
• 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
Control valve
Surface area ratio of pressure compensation valve
S1: Area of flow control valve (2) - Area of piston (3)

S2: Area of pressure reducing valve (1) - Area of piston (3)
Function
• The pressure compensation valve finely adjusts the ratio of area (S1) on the left side of flow control valve
(2) to area (S2) on the right side of pressure reducing valve (1) (S2/S1) to determine the compensation
characteristics corresponding to the characteristics of each actuator.
Surface area ratio (S1):(S2) and compensation characteristics

• When ratio is 1.00:
[Pump (discharged) pressure (PP) - Upstream pressure of spool notch (PPB)] ≈ [LS circuit pressure (PLS)
- Actuator circuit pressure (PA) = (A)], thus oil flow is supplied corresponding with the open area ratio of
the spool.
• When ratio is above 1.00:
[(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
Control valve
Boom regeneration circuit (PC88MR-L511-040-K-00-A)

When boom lowers under its own weight
Function
• While the boom is lowered, if bottom pressure (A) of cylinder (1) is higher than head pressure (B) and the
boom lowers by its own weight, the return flow on the bottom side is supplied to the head side to increase
the cylinder speed.
Operation
• If the boom lowers by its own weight during the boom LOWER operation, bottom pressure (A) of boom
cylinder (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
Control valve
When boom lowers by cylinder operation
Function
• During the boom LOWER operation, if head pressure (B) of cylinder (1) is higher than bottom pressure (A)
and the cylinder is loaded, check valve (2) closes to disconnect the head side and bottom side.
Operation
• 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
Control valve
Arm regeneration circuit (PC88MR-L911-040-K-00-A)

When cylinder bottom pressure is higher than the head pressure (during hydraulic drift, etc.)
Function
• During the arm "IN" operation, if head pressure (A) of arm cylinder (1) is higher than bottom pressure (B)
and the arm drifts hydraulically, regeneration circuit (a) increases the oil flow to the bottom side to increase
the cylinder speed.
Operation
• If the arm drifts hydraulically during the arm "IN" operation, head pressure (A) of arm cylinder (1) is higher
than bottom pressure (B).
• 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
Control valve
When cylinder head pressure is higher than the bottom pressure (when digging, etc.)
Function
• During the arm "IN" operation, if bottom pressure (B) of arm cylinder (1) is higher than head pressure (A)
and the arm is loaded, check valve (3) closes to disconnect the head side and bottom side.
Operation
• 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
Control valve
Merge-divider valve (PC88MR-PP30-040-K-00-A)

When control valve is in HOLD and when work equipment is operated (including when work
equipment and travel are operated simultaneously)
Function
• Merge-divider spool (3) merges pump discharged pressures (PP1) and (PP2), and merges LS pressures
(PLS1), (PLS2), and (PLS3).
Operation
• When the control valve is in HOLD, the right and left travel PPC pressure switches and the work
equipment PPC pressure switch make no output.
• The controller does not generate output signal and the merge-divider valve does not generate output
pressure.
• When the work equipment is operated, R.H. and L.H. travel PPC pressure switches do not generate
output, but only the work equipment PPC pressure switch generates output.
• 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
Control valve
When right and left travels are operated (Including when one side travel is operated)
Function
• Merge-divider spool (3) divides pump discharged pressures (PP1) and (PP2), and divides LS pressures
(PLS1), (PLS2), and (PLS3).
• Whichever is the higher of pump discharged pressures (PP1) and (PP2) is output as the LS pressure.
Operation
• When only R.H. and L.H. travels are operated, R.H. and L.H. travel PPC pressure switches generate
output, but work equipment PPC pressure switch does not generate output.
• The controller generates output signal and the merge-divider valve generates output pressure.
• When the output pressure reaches load at installed length of spring (4) (1.47 MPa {15 kg/cm 2}), spool (3)
is pushed to the left.
• Pump discharged pressures (PP1) and (PP2) are divided from each other and LS pressures (PLS1),
(PLS2), and (PLS3) are also divided from each other.
• (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
Control valve
Self-pressure reducing valve (PC138-PL30-042-K-00-A)

Function
• It reduces the main pump discharge pressure and provides it as control pressure to the solenoid valves,
EPC valves, etc.
Operation
If normal
• When pressure (PR) exceeds the set pressure, poppet (1) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (4), and then flows through the opening of
poppet (1) to seal drain port (TS).
• Differential pressure is generated over orifice (a) in spool (4) and spool (4) moves to close the opening
between ports (P) and (PR).
• Pressure (P) is reduced and adjusted to constant pressure (set pressure) by the opening area at this time
and supplied as pressure (PR).
When abnormal high pressure occurs

• 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
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
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
Control valve
• The flows to the right and left travel motors becomes almost the same rate during straight travel to reduce
travel deviation.
• The travel junction circuit is also open during steering operation, but it does not affect the steering
performance since open area (b) of travel junction spool (3) is small.
Operation
When traveling straight
• Since only R.H and L.H. travel valves are operated and the work equipment control valve is not operated,
pump discharge circuits (PP1) and (PP2) and LS circuits (PLS1) and (PLS2) are divided respectively by
the merge-divider spool (See "Merge-divider valve").
• When R.H. and L.H. travel spools (1) are operated, the oil delivered from the pump flows to actuator circuit
(B) through pump discharge circuits (PP1) and (PP2).
• When the machine is traveled straight, R.H. and L.H. pressure reducing valves (2) are pushed to the right
and notch (a) and the connection circuit (c) are opened.
• The right end of travel junction valve spool (3) is connected to the work equipment PPC pressure circuit.
However, since the work equipment control valve is not operated, no pressure occurs.
• When R.H. and L.H. actuator circuits (B) are connected by travel junction circuit (c), if a difference occurs
between the flows to R.H. and L.H. travel motors, that difference is corrected to reduce travel deviation.
When steering while traveling
• Since only R.H and L.H. travel valves are operated and the work equipment control valve is not operated,
pump discharge circuits (PP1) and (PP2) and LS circuits (PLS1) and (PLS2) are divided respectively by
the merge-divider spool (See "Merge-divider valve").
• Steering operation is performed by supplying the demand flow corresponding with the travels of the R.H.
and L.H. travel spools (1) to the actuator circuit (B) (See "Unload valve").
• 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
Control valve
Travel LS air bleeding circuit, travel junction valve (PC88MR-C600-042-K-01-A)

When normally operated
PC88MR-10 10-101
Control valve
When travel and another actuator are operated
10-102 PC88MR-10
Control valve
Function
• When the travel and another actuators are operated simultaneously, discarded throttled flow of LS
pressure (PLS) is increased to loosen the pressure compensation accuracy of the travel circuit and reduce
the decrease in the travel speed.
• The travel or another actuator is operated singly, the LS bleed circuit is closed.
• Also, travel junction valve spool (5) is changed from large opening (c) o small opening (b) so that the flow
rate different between the R.H. and L.H. travel circuits can be corrected easily.
Operation
When normally operated
• When boom spool (1) is operated, LS pressure (PLS) becomes the same as the pressure in boom circuit
(A).
• Since the work equipment valve is operated, pump discharge circuits (PP1) and (PP2) and LS circuits
(PLS1), (PLS2) and (PLS3) are merged respectively by the merge-divider spool (See "Merge-divider
valve").
• LS pressure (PLS) is also led to spring chamber (PLSS) of pressure reducing valve (2) of the travel valve.
• Since the travel spool is not operated, notch (a) of pressure reducing valve (2) is closed, and check valves
(3) and (4) of the bleed circuit are also closed.
• When the boom is operated singly, travel LS bleed circuit is closed.
When travel and another actuator are operated
• When boom spool (1) is operated, LS pressure (PLS) becomes the same as boom circuit pressure (A).
• Since the work equipment valve is operated, pump discharge circuits (PP1) and (PP2) and LS circuits
(PLS1), (PLS2) and (PLS3) are merged respectively by the merge-divider spool (See "MERGE-DIVIDER
VALVE").
• Since the boom RAISE pressure in the actuator circuit is normally higher than the travel pressure (A > B),
the pressure in spring chamber (PLSS) of pressure reducing valve (2) on the travel side is higher than
travel circuit pressure (PB).
• Pressure reducing valve (2) moves to the left and LS pressure (PLS) is transmitted through check valves
(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
Control valve
Boom hydraulic drift prevention valve (PC88MR-L6C0-042-K-00-A)

Function
• When the boom lever is not operated, this valve prevents the pressurized oil in the bottom side of the
boom cylinder from leaking through spool (1) to prevent hydraulic drift of the boom.
When boom RAISE operation is performed
• 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
Control valve
When boom is in NEUTRAL
• 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
Control valve
When boom LOWER operation is performed
• When the boom LOWER operation is performed, pilot spool (3) is pushed by pilot pressure (P1) from the
PPC valve and the pressurized oil in chamber (b) in the poppet is drained.
• The pressure in port (Ab) is increased by the pressurized oil from the bottom side of boom cylinder, but the
oil pressure in chamber (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
Control valve
Hydraulic oil cooler bypass valve (PC88MR-B8PB-041-K-00-A)
Function (PC88MR-B8PB-042-K-00-A)
• The oil cooler bypass valve prevents breakage of oil cooler (3) when the return oil flow from the control
valve increases and oil cooler inlet pressure (PB) increases consequently.
• The oil cooler bypass valve drains the return oil from the control valve directly to the tank without via oil
cooler (3).
Operation (PC88MR-B8PB-044-K-00-A)
• 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
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
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
Swing motor
10. Brake piston

11. Disc
12. Plate
13. Relief valve
14. Check valve
15. Shuttle valve
Model LMF30AEL
Motor capacity (cm3/rev) 30
Relief valve set pressure (MPa {kg/cm2}) 20.6 {210}
Rated speed (rpm) 2,287
Brake releasing pressure (MPa {kg/cm2}) 1.32 {13.5}
10-110 PC88MR-10
Swing motor
Swing parking brake (PC88MR-J6A0-044-K-00-A)

Operation
Solenoid valve is "de-energized"

• 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
Swing motor
Solenoid valve is "energized"

• When the swing parking brake solenoid valve is energized, the valve is changed.
• 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
Swing motor
Relief valve (PC220-J6B1-041-K-00-A)

• The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).
Function (PC220-J6B1-044-K-00-A)
• When the swing is stopped, control valve (6) blocks the motor outlet circuit, but the motor rotation is
continued by inertial force.
• If the pressure of motor outlet circuit becomes abnormally high, it may cause damage to the motor.
• In order to prevent the motor damage, the relief valve relieves the abnormally high pressure to port (S)
from the motor outlet (high-pressure side).
Operation (PC138-J6B1-044-K-00-A)
When starting swing
• When the control lever is operated to "Swing RIGHT", the pressurized oil from the pump is supplied
through control valve (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
Swing motor
When stopping swing
• When the control lever is returned from "Swing RIGHT" to "NEUTRAL", the pressurized oil from the pump
is not supplied to port (MA).
• Since the return circuit to the tank for the pressurized oil from the motor outlet is closed by control valve (6),
the pressure in port (MB) increases.
• Rotation resistance is generated in the motor and the brake starts to work.
• When the pressure in port (MB) exceeds that in port (MA), it pushes shuttle valve (4).
• The pressure in chamber (C) becomes the same with port (MB) and increases to the set pressure of relief
valve (1).
• High braking torque is applied to the motor to stop.
• While relief valve (1) is in operation, the relieved pressurized oil and the pressurized oil from port (S) are
supplied to port (MA) through check valve (3).
• 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
Swing motor
Operation (PC88MR-J6B3-044-K-00-A)
When circuit pressure is (P0)

• The relief valve does not operate.
When the circuit pressure rises abruptly

• When circuit pressure reaches (P1), pressure acts on the area difference between (D1) and (D3) [(D1 >
(D3)], and oil presses spring (4), thus valve (3) starts opening.
• At this time, pressure acts on the area difference between (D1) and (D2) [(D2) > (D1)], thus seat (1)
follows valve (3).
• 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
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
Swing motor
T1: To tank
T2 : To tank
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Figure to explain effect
Function (PC88MR-J6B2-042-K-00-A)
• When the swing operation is stopped, the upper structure may swing back. This is due to inertia of the
weight of the upper structure, the backlash and rigidity of the swing machinery system, or compression of
the hydraulic oil. 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
Swing motor
Operation (PC88MR-J6B2-044-K-00-A)
When port (MB) brake pressure is generated
• Pressure (MB) is transmitted to chamber (d) through notch (g).

• The circle area difference of spool (5) (φD1＞φD2) compresses spool (6) and moves spool (5) to the left.
• Port (MB) and chamber (e) are interconnected.
• Spool (2) does not move since the pressure (MA) is the set pressure of spring (3) or lower. The
pressurized oil is closed and the brake pressure is secured.
When the motor stops once
• The motor rotates in reverse by the closed pressure generated in port (MB). (First round reversal)
• The reverse pressure is generated in port (MA) side. Pressure (MA) transmitted to chamber (a).
• The circle area difference of spool (2) (φD3＞φD4) compresses spool (3) and moves spool (2) to the right.
• 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
Travel motor
Travel motor (PC88MR-C400-041-K-00-A)
L.H. travel motor

A: From center swivel joint (port C2)
B: From center swivel joint (port D2)
D1: To center swivel joint (port DR2)
D2: Plug
P: From center swivel joint (port G2)
R.H. 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
Travel motor
1. Regulator valve
2. Timing plate
3. Brake piston
4. Spindle
5. Floating seal
6. Swash plate
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
Travel motor
21. Flange
22. Counterbalance valve
23. Check valve
24. Check valve
Structure
Reduction gear system

• Reduction gear (1) consists of 2-stage planetary gear mechanism and reduces the high speed rotation of
hydraulic motor (2) into low-speed and high-torque rotation.
Hydraulic motor
• Hydraulic motor (2) is a swash plate type axial piston motor. It converts the energy of the pressurized oil
sent from the main pump into rotary motion.
Brake valve
• Brake valve (3) consists of valves of various types and has the following functions.
Function of stopping hydraulic motor (2) smoothly
Function of preventing running away of hydraulic motor (2)
Function of preventing generation of abnormal pressure when hydraulic motor (2) is stopped suddenly
2-stage travel speed selector mechanism

• 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
Travel motor
Specifications (PC88MR-C400-030-K-00-A)
Model GM10VA-B
Hi 30.5
Displacement (cm3/rev)
Lo 54.3
Hi 2,628
Rated speed (rpm)
Lo 1,507
Parking brake releasing pressure (MPa {kg/cm2}) 0.63 {6.42}
Speed selector pressure (MPa {kg/cm2}) 2.94 {30}
Reduction ratio 45.97
Operation of travel motor (PC88MR-C400-044-K-00-A)
At high travel speed (motor swash plate angle is minimum)

2. Regulator valve
3. Spring
4. Check valve
5. Regulator piston
6. Swash plate
7. Parking brake piston
8. Main pump
9. Travel control 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
Travel motor
• Regulator valve (2) is pressed to the left by the reaction force of spring (3).
• The main pressurized oil from the control valve passes through check valve (4) and blocks the circuit to
regulator piston (5) by using regulator valve (2).
• The oil in control chamber (C) is drained through oil passage (e) of regulator valve (2) and port (D).
• Swash plate (6) is set to the maximum angle, and consequently the motor capacity becomes maximum
and the machine travels at low speed.
At high travel speed (motor swash plate angle is minimum)

2. Regulator valve
3. Spring
4. Check valve
5. Regulator piston
6. Swash plate
7. Parking brake piston
8. Main pump
9. Travel control valve
12. Brake valve
• When 2nd travel speed selector solenoid valve (1) is energized, the pressurized oil from main pump (8)
flows into port (P).
• Regulator valve (2) is pushed to the right by the pressurized oil flowing into port (P).
• The pressurized oil from the control valve passes through check valve (4), then flows through oil passage
(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
Travel motor
Brake valve (PC88MR-C4Q0-044-K-00-A)
• The brake valve consists of check valves (1a), (1b) and counterbalance valve spool (2) as shown in the
figure below.
Function
• When the machine travels downhill, it tends to travel faster than the motor rotation because of its gravity.
• 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
Travel motor
Operation when travel lever is operated
• When steering lever is operated, the pressurized oil from the control valve is supplied to port (PA).
• The pressurized oil pushes open check valve (1a) and flows from motor inlet port (MA) to motor outlet port
(MB).
• At the same time, the pressurized oil flows into chamber (D) through orifice (c) of counterbalance valve
(2).
• 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
Travel motor
Operation when travel lever is in neutral
• When the travel lever is returned to NEUTRAL, the pressurized oil from the control valve is blocked.
• Counterbalance valve (2) is returned to the right by the reaction force of spring (3).
• The oil in chamber (D) flows into port (PA) through orifice (c). At this time, back pressure is generated by
the throttle effect of orifice (c), and it controls the speed of counterbalance valve (2) returning to the right.
• The motor is stopped smoothly by gradually controlling the returning oil from port (MB) with the changing
speed and shape of the notch of counterbalance valve (2).
• 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
Travel motor
Operation when traveling downhill
• If the machine runs away on a downhill, the motor runs idle and the pressure in the motor inlet port (MA)
decreases, and the pressure in chamber (D) also decreases through orifice (c).
• When the oil pressure in chamber (D) decreases below the reaction force of spring (3), counterbalance
valve (2) starts to return to the right.
• The oil in chamber (G) flows into port (PB) through orifice (f). At this time, back pressure is generated by
the throttle effect of orifice (f), and it controls the speed of counterbalance valve (2) returning to the right.
• Counterbalance valve (2) moves to a position where the force caused by the machine weight and the
hydraulic force of motor inlet port (MA) are balanced with the hydraulic force of motor outlet port (MB).
• 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
Travel motor
Parking brake (PC88MR-C4A0-041-K-00-A)

Operation when travel lever is operated
• When the travel lever is operated, the pressurized oil from the pump moves spool (1) to the left.
• The pressurized oil flows through port (E) to chamber (A) of brake piston (2).
• 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
Travel motor
Operation when travel lever is in neutral
• When the travel lever is returned to NEUTRAL, the pressurized oil from the control valve is blocked.
• The pressurized oil in chamber (A) of brake piston (2) is drained into the case.
• 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
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
L.H. work equipment control lever

P: From self-pressure reducing valve
P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
P3: To control valve (LEFT swing port)
P4: To control valve (RIGHT swing port)
T: To hydraulic tank
R.H. work equipment control lever

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
10-132 PC88MR-10
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter
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
When valve is in fine control range
(neutral to fine control range)
• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• Almost at the same time when fine control hole (f) is disconnected from drain chamber (D), it is connected
to pump pressure chamber (PP).
• The pilot pressure oil of main pump is transmitted from port (P1) to port (A) through fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the stroke of the control lever.
• The pressure in port (P1) also increases in proportion to the stroke of the control lever.
• 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
(when control lever is returned)
• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the pressure
in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• When the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber
(PP) almost at the same time.
• The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to
the lever position.
• 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
When control lever is fully operated
• Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1).
(PP).
• 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
Travel PPC valve
Travel PPC valve (PC88MR-C6V0-041-K-00-A)

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)
PC88MR-10 10-137
Travel PPC valve
1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper
10-138 PC88MR-10
Travel PPC valve
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
Travel PPC valve
(neutral to fine control range)
• When piston (4) is pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downwards.
• Almost at the same time when fine control hole (f) is disconnected from drain chamber (D), it is connected
to pump pressure chamber (PP).
• The pilot pressure of control pump is transmitted from port (P1) to port (A) through fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the stroke of the control lever.
• The pressure in port (P1) also increases in proportion to the stroke of the control lever.
• 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
Travel PPC valve
(when control lever is returned)
• When lever (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the
pressure in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• When the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
(PP) almost at the same time.
• The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to
the lever position.
• 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
Travel PPC valve
When control lever is fully operated
• Lever (5) pushes down piston (4), and retainer (9) pushes down spool (1).
(PP).
• 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
Blade PPC valve
Blade PPC valve (PC88MR-LTJ0-041-K-00-A)
a For explanation of operation, see "Work equipment and swing PPC valve".
P: From solenoid valve

P1: To blade and boom swing valve
T: To tank
1. Spool
2. Piston
3. Lever
PC88MR-10 10-143
Blade PPC valve
4. Plate
5. Retainer
6. Body
7. Filter
10-144 PC88MR-10
Boom swing PPC valve
Boom swing PPC valve (PC88MR-L518-041-K-00-A)
a For explanation of operation, see "Work equipment and swing PPC valve".
P: From solenoid valve

T: To tank
1. Spool
2. Piston
3. Lever
PC88MR-10 10-145
4. Plate
5. Retainer
6. Body
7. Filter
10-146 PC88MR-10
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
Solenoid valve
A2: To swing motor port B

A3: To center swivel joint port G1
A5: To control valve port PT
ACC: To accumulator (for PPC circuit)

4. Merge-divider solenoid valve
Check valve
5. Plug
6. Plunger
Solenoid valve
7. Coil (ON/OFF type)
8. Push pin
9. Valve spool
10. Sleeve
11. Stopper
12. Body
Operation (PC88MR-PQPT-044-K-00-A)
Operation of check valve
• This valve is installed between port (P) and PPC solenoid valve. When the engine is stopped, the reaction
force of spring (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
Solenoid valve
Operation of solenoid valve
When solenoid valve is "de-energized" (circuit is disconnected)
• Coil (1) is de-energized when the signal current does not flow to coil (1).
• Spool (2) is pushed back to the left with the reaction force of spring (3).
• Between port (P) and port (A) are disconnected and pilot pressure oil does not flow from port (A) to the
actuator. At the same time, port (T) opens and oil from actuator is drained to the hydraulic tank.
When solenoid valve is "energized" (circuit is interconnected)
• Coil (1) is energized when the signal current flows to coil (1).
• Accordingly, spool (2) is pushed to the right by push pin (4).
• 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
Solenoid valve
Oil flow adjuster EPC valve for attachment (PC88MR-PQJ6-041-K-00-A)
C1: To control valve port PA9

C2: To control valve port PB9
P: From 4-spool solenoid valve port A1
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
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
Anti-drop valve for boom
Anti-drop valve for boom (PC88MR-LA1Q-041-K-00-A)
Function (PC88MR-LA1Q-042-K-00-A)
This valve prevents the work equipment from sudden lowering by thwarting the counterflow of pressurized oil
from the work equipment when the piping between the control valve and the work equipment cylinder breaks.
Operation (PC88MR-LA1Q-044-K-00-A)
When work equipment is in NEUTRAL
When there is no damage in the piping

1. Holding pressure of the work equipment cylinder is led from port (CY) to chamber (b), and it closes check
valve (5).
2. The pilot pressure which is led from PPC valve to port (PI) is 0 MPa{0 kg/cm2} when work equipment is in
NEUTRAL.
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
6. When the pressure inside the work equipment cylinder is abnormally high, holding pressure of the work
equipment cylinder operates safety valve (4).
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,
chamber (a) and chamber (b) are disconnected.
2. The pressure of the work equipment is held to prevent the work equipment from sudden lowering.
When the pressurized oil flows from the control valve to the work equipment cylinder

1. The pressurized oil which is led from the control valve to chamber (a) becomes higher than the combined
force of the pressure of chamber (b) of work equipment cylinder circuit and spring (6).
2. Check valve (5) opens, and chamber (a) and chamber (b) are connected
3. The pressurized oil flows from the control valve to the work equipment cylinder.
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
2. The pressure of chamber (a) drops. The pressure of chamber (a) becomes lower than the combined force
of the pressure of chamber (b) and spring (6).
3. Check valve (5) closes, and chamber (a) and chamber (b) are disconnected.
When the pressurized oil returns from the work equipment cylinder to the control valve

1. Holding pressure of the work equipment cylinder is led to chamber (b), and it closes check valve (5).
2. The pilot pressure is led from PPC valve to port (PI). The pilot pressure is larger than the force of spring
(2) (area of circle "d").
3. Spool (1) moves rightward to the standby position. (The first stroke)
4. Chamber (a) and chamber (b) are not interconnected.
5. The pilot pressure rises further. The pilot pressure is larger than the force of spring (2) (area of circle "d").
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.
10-154 PC88MR-10
pressurized oil of chamber (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
Anti-drop valve for arm
Anti-drop valve for arm (PC88MR-LA1B-041-K-00-A)
Function (PC88MR-LA1B-042-K-00-A)
This valve prevents the work equipment from sudden lowering by thwarting the counterflow of pressurized oil
from the work equipment when the piping between the control valve and the work equipment cylinder breaks.
Operation (PC88MR-LA1B-044-K-00-A)
When work equipment is in NEUTRAL

1. Holding pressure of the work equipment cylinder is led from port (CY) to chamber (b), and it closes check
valve (5).
2. The pilot pressure which is led from PPC valve to port (PI) is 0 MPa{0 kg/cm2} when work equipment is in
NEUTRAL.
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
6. When the pressure inside the work equipment cylinder is abnormally high, holding pressure of the work
equipment cylinder operates safety valve (4).
1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder,
chamber (a) and chamber (b) are disconnected.
When the pressurized oil flows from the control valve to the work equipment cylinder

1. The pressurized oil which is led from the control valve to chamber (a) becomes higher than the combined
force of the pressure of chamber (b) of work equipment cylinder circuit and spring (6).
2. Check valve (5) opens, and chamber (a) and chamber (b) are connected
3. The pressurized oil flows from the control valve to the work equipment cylinder.
pressurized oil of chamber (a) leaks through the damaged part to the outside.
PC88MR-10 10-157
2. The pressure of chamber (a) drops. The pressure of chamber (a) becomes lower than the combined force
of the pressure of chamber (b) and spring (6).
3. Check valve (5) closes, and chamber (a) and chamber (b) are disconnected.
When the pressurized oil returns from the work equipment cylinder to the control valve

1. Holding pressure of the work equipment cylinder is led to chamber (b), and it closes check valve (5).
2. The pilot pressure is led from PPC valve to port (PI). The pilot pressure is larger than the force of spring
(2) (area of circle "d").
3. Spool (1) moves rightward to the standby position. (The first stroke)
4. Chamber (a) and chamber (b) are not interconnected.
5. The pilot pressure rises further. The pilot pressure is larger than the force of spring (2) (area of circle "d").
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.
10-158 PC88MR-10
pressurized oil of chamber (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
Center swivel joint
Center swivel joint (PC88MR-J8E0-041-K-00-A)
A1: From control valve (right travel "REVERSE")

B1: From control valve (right travel "FORWARD")
C1: From control valve (left travel "REVERSE")
D1: From control valve (left travel "FORWARD")
E1: From control valve (blade "RAISE")
F1: From control valve (blade "LOWER")
G1: From 2nd travel selector solenoid valve
DR1: To hydraulic tank
A2: To R.H. travel motor port B
B2: To R.H. travel motor port A
C2: To L.H. travel motor port A
D2: To L.H. travel motor port B
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
Accumulator
Accumulator (PC88MR-PL40-001-K-00-A)
PPC circuit accumulator (PC88MR-PL40-041-K-00-A)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
This accumulator is installed to the solenoid valve. Even if the engine is stopped while the work equipment is
raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of the
compressed nitrogen gas in the accumulator to operate the spool and lower the work equipment by its own
weight.
Specifications (PC88MR-PL40-030-K-00-A)
Gas to be used Nitrogen gas

Volume of gas (cc) 300
Charged pressure 1.18 {12}
(MPa {kg/cm2}) (at 80°C)
Max. pressure used
6.86 {70}
(MPa {kg/cm2})
PC88MR-10 10-161
Accumulator
Attachment circuit accumulator (for low pressure circuit) (PC138-PL40-041-K-01-A)
(Machines ready for installation of attachment)
1. Cap
2. Core
3. Ring
4. Lid
5. Bladder
6. Shell
Specifications (PC138-PL40-030-K-01-A)
Gas to be used Nitrogen gas

Volume of gas (cc) 480
Charged pressure 0.1 {1.0}
(MPa {kg/cm2}) (At 80°C)
Max. pressure used
6.86 {70}
(MPa {kg/cm2})
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
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
Work equipment shim
Work equipment shim (PC88MR-L413-040-K-00-A)

Structure
• There are 2 types of work equipment shims, the iron shim and plastic shim.
• The work equipment shims are inserted to adjust the clearance of each joint of the work equipment to the
standard value.
Function
Steel shim
• The purpose of the iron shim is to reduce the play in the right and left direction of the work equipment.
a Depending on the size of clearance, it may be required to insert the shim into either of the right and left
sides and insert no shim on the other side.
Plastic 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
Bucket play adjustment shim
Bucket play adjustment shim (PC88MR-LBKB-040-K-00-A)

Structure
• 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
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
2. Mount rubber (rear right)

3. Mount rubber (rear left)
Structure
• Mount rubbers (1), (2), and (3) are installed to 4 places in total to fix the cab and floor frame to the
revolving frame.
• Mount rubbers (1), (2), and (3) absorb vibration.
• The mounting bolts of mount rubbers (1), (2), and (3) also work as cab tipping stoppers, which fix the cab
when the machine tips over.
• As shown below, mount rubbers (1), (2), and (3) are different in diameter and thickness, depending on
their locations.
Mount rubber location Mount rubber diameter (mm) Mount rubber thickness (mm)
Front left, front right 72 18.5
Rear left 84 18.5
Rear right 97 25.5
PC88MR-10 10-167
ROPS cab
ROPS cab (PC88MR-K000-041-K-00-A)
a ROPS: Abbreviation for Roll-Over Protective Structure
1. Front window
2. Wiper
3. Headlamp
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
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
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
PC88MR-10 10-171
10-172 PC88MR-10
Engine control function (PC88MR-AK60-042-K-00-A)
1. Battery disconnect switch

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Engine shutdown secondary switch
9. Lock lever
10. PPC lock switch
11. Starting motor cut-off relay (for PPC lock)
12. Starting motor cut-off relay (for personal code)
13. Fuel control dial
14. Safety relay
15. Starting motor
16. Fuel supply pump
17. Various sensors
18. Machine monitor
19. KOMTRAX terminal
20. Pump controller
Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a The engine does not start while the lock lever is in a position other than "LOCK".
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal receives an engine cut command issued through external operation.
• 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
Accordingly, a fail-safe mechanism is provided, that is, the engine stops when the electrical system has
trouble.
• When starting switch (6) is turned to "START" position while lock lever (9) is in "LOCK" position, the
starting current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in "FREE" position, starting motor cut-off relay (11) operates to cut off the starting current
to starting motor (15) and the engine does not start, that is, a neutral safety mechanism.
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the
signal to machine monitor (18).
Machine monitor (18) operates starting motor cut-off relay (12) to cut off the starting current to starting
motor (15), thus the engine does not start.
Engine speed control

• Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8)
selects the lower throttle signal and sends the command current to fuel supply pump (16).
Fuel supply pump (16) adjusts the fuel injection rate to control the engine speed.
Stopping engine
• When starting switch (6) is turned to "OFF" position, the current from ACC terminal of starting switch (6) to
engine controller (8) is cut off, and consequently the command current to fuel supply pump (16) is cut off.
Fuel supply pump (16) stops supplying fuel and the engine speed decreases to stop.
Stopping engine with engine shutdown secondary switch

• If engine shutdown secondary switch (7) is turned to "Stop Engine" position, the current from the ACC
terminal of starting switch (6) to engine controller (8) is forcibly shut off.
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)

2. Battery
3. Battery relay
4. Fusible link
10-174 PC88MR-10
5. Fuse box
6. Resister for PC–EPC valve
7. Pump controller
9. Machine monitor
10. Pump secondary drive switch
13. Various sensors
14. Oil pressure sensor of pump
15. Oil pressure sensor
16. Oil pressure switch
17. Main pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
18a. Merge-divider valve
18b. Self-pressure reducing valve
19. PC-EPC valve
Input/output signal
a: CAN signal
b: PC-EPC valve drive signal
c: Solenoid valve GND
d: Oil pressure sensor signal
e: Oil pressure switch signal
f: Throttle signal
g: Fuel supply pump control signal
h: Various sensor signals
Function
• This function allows the operator to select one from the 6 working modes of P, E, L, B, ATT-P, and ATT-E
by using the working mode selector switch on machine monitor (9).
• The operator can select the most appropriate engine torque (T) and pump absorption torque according to
the contents of work.
• If "Without Attachment" is set for the attachment by "With/Without Attachment" in "Default" of the service
mode, the available modes are 4 of P, E, L, and B.
• Pump controller (7) calculates the pump absorption upper limit torque according to the engine speed set
with the working mode and fuel control dial (11) and the actual engine speed, and controls the pump so
that the engine speed is kept around the matching point set in each mode even when heavy load is
applied.
• When the engine speed decreases, the pump controller reduces the pump absorption torque to prevent
the engine from stalling.
PC88MR-10 10-175
Control method in each mode

P, E, ATT/P, ATT/E,B and L modes
Matching point
Working mode Matching point
P and ATT/P
• During travel 48.8 kW / 1,950 rpm {66.4 HP / 1,950 rpm}
• During work 44 kW / 1,850 rpm {59.8 HP / 1,850 rpm}
E, ATT/E 34.2 kW / 1,640 rpm {46.5 HP / 1,640 rpm}
L 24.3 kW / 1,510 rpm {33.1 HP / 1,510 rpm}
• In mode P, E, ATT/P, or ATT/E, the engine speed is kept around the matching point set in each mode.
• When the pump load increases and the pressure increases accordingly, engine speed (N) decreases. At
this time, the controller decreases pump discharged volume (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
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
Control function when pump secondary drive switch is "ON"

• If the controller has trouble and the main pump does not operate normally and the machine does not work,
the operator can operate the machine temporarily with the absorption torque equivalent to E mode by
operating pump secondary drive switch (1).
At this time, since a constant current flows from the battery to the PC-EPC valve, only the PC-EPC valve
senses oil pressure.
a: Emergency (when abnormal)
b: 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
Auto-deceleration function (PC88MR-AF60-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Various sensors
8. Oil pressure switch
9. Main pump
10. Control valve
Input/output signal
a. CAN signal
b. Oil pressure sensor signal
c. Oil pressure switch signal
d. Throttle signal
e. Fuel supply pump control signal
f. Various sensors signal
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
• If any control lever is operated, the engine speed returns immediately to the speed set with fuel control dial
(4).
Operation
When control lever is at NEUTRAL

• While the engine is running at approximately 1,175 rpm or higher speed, when all the control levers are
set to "NEUTRAL" positions (A) for 4 seconds or more (E), engine speed is decreased and kept to engine
control speed (D) until any control lever is "operated" (B).
When control lever is operated

• While the engine speed is kept at engine control speed (D), when any control lever is operated, the engine
speed increases immediately to fuel control dial set speed (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
Engine automatic warm-up function (PC88MR-AP13-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resister for PC–EPC valve
7. Pump controller
9. Machine monitor
10. Emergency pump drive switch
13. Various sensors
14. Hydraulic oil temperature sensor
15. Main pump
15a. Servo
15b. LS valve
15c. PC valve
16. Control valve
17. PC-EPC valve
Input/output signal
a. CAN signal
PC88MR-10 10-181
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
Function
• When the coolant temperature is low after the engine is started, the engine speed is increased
automatically to warm up the engine.
• The engine automatic warm-up function has 2 kinds; "Heater warm-up" and "Normal warm-up", either of
which is used according to the purpose.
• The purpose of the heater warm-up is to increase the coolant temperature to improve the effect of the
heat.
• The purpose of the normal warm-up is to heat the engine to prevent damage on the engine caused by low
temperature.
Operating conditions 1
Machine specification: Air conditioner specification
Air conditioner: Blower "ON"
Coolant temperature: Below 65ºC
Ambient temperature: Max. 5ºC
O O
When any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up is disabled (normal warm-up) Heater warm is enabled
Operating conditions 2
(Operates when all of the following conditions are O
satisfied)
Coolant temperature: Below 30ºC
O
Engine speed: Max. 1,300 rpm
O O
Operation Operation
Engine speed: 1,300 rpm Engine speed: Min. 1,300 rpm
O O
Canceling conditions Canceling conditions
(Canceled when any of the following conditions is (Canceled when any of the following conditions is
satisfied) satisfied)
Coolant temperature: Min. 30℃
Automat-
ic 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.
O O
Canceled
Engine speed: Any
PC88MR-10 10-183
Overheat prevention function (PC88MR-B717-042-K-00-A)
a For the system circuit diagram, see "Engine automatic warm-up function".
• When the coolant temperature or the hydraulic oil temperature increases too high during operation, the
pump load is reduced and the engine speed is lowered to prevent overheat and protect the engine and
hydraulic components.
Operating condition Operation and remedy Condition for cancellation

Working mode: P, ATT/P, ATT/E Engine speed: Kept as it is Coolant temperature: Below
Coolant temperature: Min. 95ºC • Pump absorption torque is 95ºC
or lowered and engine load is Hydraulic oil temperature:
Hydraulic oil temperature: Min. o reduced according to the o Below 95°C
95ºC torque control signal. • When above condition is
Travel judgment: OFF satisfied, state before
operation is restored
(automatic restoration).

Coolant temperature: Min. 98ºC • Travel speed: Decreased 98ºC
or Hydraulic oil temperature:
Hydraulic oil temperature: Min. o o Below 98℃
98ºC • When above condition is
Travel judgment: ON satisfied, state before

Coolant temperature: Min. • Pump absorption torque is 100ºC
100ºC lowered and engine load is Hydraulic oil temperature:
or o reduced according to the o 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
10-184 PC88MR-10

Working mode: P, E, ATT/P, Engine speed: Kept as it is Coolant temperature: Below
ATT/E, B • Pump absorption torque is 102ºC
Coolant temperature: Min. lowered and engine load is Hydraulic oil temperature:
102ºC o reduced according to the o Below 102°C
or torque control signal. • When above condition is
Hydraulic oil temperature: Min. • Caution lamp: Lights up satisfied, state before
102ºC operation is restored
Travel judgment: Any position (automatic restoration).

Working mode: All modes Engine speed: Low idle Coolant temperature: Below
Coolant temperature: Min. Caution lamp: Lights up 105ºC
105ºC Alarm buzzer: Sounds Hydraulic oil temperature:
or Below 105°C
Hydraulic oil temperature: Min. o o
Fuel control dial: Return to Low
105ºC idle (MIN) position.
Travel judgment: Any position • When above condition is
satisfied, state before
(manual restoration).
PC88MR-10 10-185
Turbocharger protection function (PC88MR-AA90-042-K-00-A)
a For the system circuit diagram, see "Engine automatic warm-up function".
• This function limits the engine speed to prevent seizure of the turbocharger when the engine speed is
increased suddenly just after the engine is started.
• The control time is controlled in accordance with the coolant temperature.
Operating condition Operation

o
Engine oil pressure: Below 50 kPa {0.51 kg/cm2} Limits engine speed (see figure below)
A: Starting of engine
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)
*1:
Working mode: P mode
Fuel control dial: High idle (MAX) position
Swing lever at full stroke
10-186 PC88MR-10
Swing control function (PC88MR-JA01-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Swing parking brake cancel switch
7. Pump controller
8. Machine monitor
10. Main pump
11. Control valve
12. Swing motor
Input/output signal
a. Swing parking brake cancel switch signal
b: Swing parking brake solenoid valve drive signal
c. CAN signal
d: Oil pressure sensor signal
Function
Swing parking brake function
• 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
Function Swing parking brake

• When L.H. work equipment control lever is set to NEUTRAL, the swing parking brake
works in approximately 5 sec.
Operation • Swing parking brake is released and the swing operation can be performed freely when L.
H. work equipment control lever is operated to swing or to arm IN, or the boom swing
pedal is operated.
A: L.H. work equipment control lever in "SWING" (Swing parking brake "RELEASED")
B: L.H. work equipment control lever in "NEUTRAL"
C: Swing parking brake "operates"
D: 5 seconds
Swing parking brake cancel function
• If the swing parking brake does not operate normally and the upper structure cannot swing because of
trouble in the controller, etc., the operator can swing by releasing the swing parking brake with swing
parking brake cancel switch (2).
a: Release (when abnormal)
Swing parking Cancel
brake Normal (When controller is normal)
(When controller is abnormal)
cancel switch
Swing brake Swing parking brake is released (*1) Swing parking brake operates
*1: Operation of hydraulic brake by safety valve
a While the swing parking brake is released, only the hydraulic brake by the safety valve is applied. If swing
is stopped on a slope, the hydraulic drift may occur. 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
Travel control function (PC88MR-C7H1-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Various sensors
7. Oil pressure sensor of pump
9. Travel alarm
10. Main pump
11. Control valve
12. Travel motor
13. 2-stage travel speed selector solenoid valve
14. Travel junction/ pump merge-divider solenoid valve
Input/output signal
a. 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
h. Fuel supply pump control signal

i. Various sensor signals
Function
Travel speed selector function
1. "Manual" change of travel speed
• The operator can change the travel speed by setting the travel speed selector switch to "Hi" or "Lo"
position to change the motor capacity.
Travel speed selector switch Lo (Low-speed) Hi (High-speed)
Motor capacity (cc/rev) 54.3 30.5
Travel speed (km/h) 2.8 5.0
Travel motor swash plate angle Max. Min.
2. "Automatic" change of travel speed
1) Automatic change in accordance with engine speed
• When the engine speed is set to 1,600 rpm or below with fuel control dial (4), the travel speed is set
to "Lo" automatically.
2) Automatic change in accordance with pump discharged pressure
• While traveling with the travel speed selector switch at "Hi" position, if the load increases on a slope,
etc., and the travel pressure is 25.5 MPa {260 kg/cm2} or higher for 0.02 seconds or more, the
motor capacity is changed automatically and the travel speed is changed to a low speed (a speed
equivalent to "Lo") (however, travel speed selector switch is kept at "Hi" position).
• While traveling at low speed set by the automatic travel speed change with load, when the load
decreases on a flat or downhill slope and the travel pressure is 13.7 MPa {140 kg/cm 2} or less for
0.1 seconds or more, the motor capacity is changed automatically and the travel speed is returned
to the set speed of "Hi".
A: 13.7 MPa {140 kg/cm2}

B: 25.5 MPa {260 kg/cm2}
C: 0.1 seconds or more
D: 0.02 seconds or more
Pump control function when traveling
a For details, see "Engine and pump combined control function".
Travel junction function

• This function senses the pilot pressure when the travel lever and work equipment control lever are
operated and judges if the travel and work equipment are operated simultaneously or only the travel is
operated.
• When the travel and work equipment are operated simultaneously, the signal to the merge-divider
solenoid valve is cutout to set the flow rates to the right and left travel motors to almost the same level to
prevent travel deviation and improve the straight travel performance.
• 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
Pump merge-dividing function

• The pump merge-divider function senses the pilot pressure when the travel lever and work equipment
control lever are operated and judges if the travel and work equipment are operated simultaneously or
only the travel is operated.
• When the travel is operated singly, a signal is sent to the merge-divider solenoid valves to divide the pump
discharge and improve the travel performance.
Merge-
Pattern Judgment of travel operation Judgment of work equipment operation divider
valve
• When no work equipment is operated
1 (work equipment PPC oil pressure Divide
Travel PPC pressure: Min. 0.49 MPa {5 kg/ switch is "OFF")
cm2} • When work equipment is operated
2 (work equipment PPC oil pressure Merge
switch is "ON")
PC88MR-10 10-191
PPC lock function (PC88MR-PX16-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Main pump
10. Control valve
12. Lock lever automatic lock cancel switch
13. Pump controller
14. PPC lock lever relay
15. 1st-line attachment flow adjustment EPC valve
Input/output signal
a: PPC lock switch signal
b: 1st-line attachment flow adjustment EPC valve signal
c: Lock lever automatic lock signal
Function
• PPC lock switch (8) is interlocked with lock lever (7). When lock lever (7) is set to "LOCK" position, PPC
lock switch (8) is turned to OFF position.
• 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
Automatic idle stop (PC88MR-AF87-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Pump controller
10. Machine monitor
12. KOMTRAX terminal
13. Hydraulic oil temperature sensor
14. Coolant temperature sensor
Input/output signal
a: Input and output signals of pump controller
b: CAN signal
c: PPC lock switch signal
d: Hydraulic oil temperature sensor signal
Function
• When the auto idle stop function is enabled and the conditions for operation are satisfied, the engine is
stopped after the set time.
• The auto idle stop function stops the engine when the pump controller sends the engine stop signal to the
engine controller.
• When the engine is stopped by the auto idle stop function while it is running at high speed, a message to
turn ON the auto-deceleration function is displayed on the machine monitor and the auto-deceleration
function is set to ON.
• 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
1. Engine is running
2. Lock lever is in "LOCK" position
3. Working mode is "P", "E", "ATT/P", "ATT/E", or "B". (Disabled when working mode is "L")
4. Engine automatic warm-up function is not in "Normal warm-up" mode.
5. Engine coolant is not overheating (below 102ºC).
6. Hydraulic oil is not overheating (below 102ºC)
7. Auto idle stop time on machine monitor is not reset.
8. Machine monitor is not set in service mode. (*1)
9. None of following failure codes is occurring.
Failure codes related to operating condition 9. are as follows.
Failure code Failure (Displayed on screen)
B@BCNS Engine Coolant Overheat
B@HANS Hydraulic Oil Overheat
CA144 Coolant Temp Sens High Error
CA145 Coolant Temp Sens Low Error
D8AQKR CAN 2 Defective Communication (KOMTRAX)
DA2RKR CAN 1 Defective Communication (Pump Con)
DA2QKR CAN 2 Defective Communication (Pump Con)
DAFQKR CAN 2 Defective Communication (Monitor)
DB2RKR CAN1 Defective Communication(Engine Con)
DB2QKR CAN 2 Defective Communication(Engine Con)
DGH2KA Hydraulic Oil Temp Sensor Open Circuit
DGH2KB Hydraulic Oil Temp Sensor Ground Fault
*1: See Setting time.
Setting time
• The set time for the auto idle stop function is set in the following menus.
For setting of each menu, see Testing and adjusting.
Setting auto idle stop (service menu)
Setting Contents of setting
The auto idle stop function does not operate, and the related items are not displayed on service
OFF
menu and user menu.
The minimum time selectable in auto idle stop time fixing menu and auto idle stop time setting
1 min.
menu is set to 1 minute.
The minimum time selectable in auto idle stop time fixing menu and auto idle stop time setting
3 min.
menu is set to 3 minutes.
Set the minimum menu selecting time of auto idle stop time fixing menu and auto idle stop time
5 min. setting menu to 5 minutes. (Default value)
Fixing auto idle stop time (service menu)
In auto idle stop time setting menu, operator can select OFF or minimum set time in auto idle
Variable stop setting to maximum time of 60 minutes. (Default)
The auto idle stop function does not operate, and the auto idle stop time setting menu is not
OFF displayed.
Fix to X In auto idle stop time setting menu, operator can select minimum set time in auto idle stop
min. setting to X minutes (set time at left). (Cannot select OFF)
Fixing auto idle stop time (user menu)
OFF Auto idle stop function does not operate. (Default)
Y min. Stop engine Y minutes (set time at left) after lock lever is set to LOCK position.
10-194 PC88MR-10
k When "Fix to X min." is selected in the Fixing auto idle stop time menu, the screen changes to the
operator screen automatically and the auto idle stop function operates 60 minutes after the lock
lever is set to LOCK position, even if the Service menu is being used.
When performing work with the Service menu, always check the set value of the auto idle stop
function.
"Sensing abrupt engine stop"

• When the engine is stopped by the auto idle stop function, if the auto-deceleration function is OFF and the
fuel control dial is at a position above MIN., abrupt engine stop is sensed and the failure code is sent.
• The failure code is recorded in the mechanical system abnormality record.
• If abrupt engine stop is sensed, the auto-deceleration function is turned ON automatically.
k If the auto-decelerator setting is "OFF", the auto-deceleration function is not turned ON
automatically and abrupt engine stop may be sensed constantly.
• The failure code displayed at abrupt engine stop varies with the number of occurrence, and the message
displayed on the machine monitor varies according to the failure code.
Action level Failure code Failure (Displayed on screen)
L00 A900N6 Abrupt Engine Stop by Auto Idle Stop 1
L01 A900NY Abrupt Engine Stop by Auto Idle Stop 2
L03 A900FR Abrupt Engine Stop by Auto Idle Stop 3
• When failure code "A900FR" of action level "L03" is sent, the turbocharger assembly must be replaced
since the durability of the engine may decrease.
• After replacing the turbocharger assembly, reset the number of occurrence by using "Reset number of
abrupt stops by auto idle stop" in "Inspection" on the service menu.
a 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
Work equipment and travel automatic lock function (PC88MR-L409-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Pump controller
10. Work equipment automatic lock relay
11. 1st-line attachment proportional switch
12. Breaker operating switch
14. Control valve
15. Main pump
16. Lock lever automatic lock cancel switch
Input/output signal
a: PPC lock signal
b: PPC lock signal
c: 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
Function
This function automatically sets the lock lever in the same state as when it is locked to prevent the work
equipment or the machine continues its operation when the lock lever is unlocked while the work equipment
control lever or the travel lever is operated.
Operation
When an oil pressure switch or a sensor detects pressure higher than specified pressure (D) or an attachment
drive signal is input within certain time (C) after the lock lever is unlocked (A), this function judges that the
operation is abnormal and the pump controller outputs the lock lever automatic lock relay drive signal to shut
off the current to PPC lock solenoid to lock the machine (B).
a When the hydraulic oil temperature is low or high-viscosity hydraulic oil used, the pressure may not
increase within time (C) and the lock lever automatic lock control may not operate.
A: PPC lock lever is canceled

B: Lock lever automatic lock operates
C: Within 0.4 sec
D: 5 kPa
Control when lock lever automatic lock cancel switch is "ON"
If PPC solenoid valve does not operate and the operator cannot work because of abnormality in the controller,
the operator can operate the machine by operating lock lever automatic lock cancel switch (1).
At this time, the lock lever automatic lock control function does not work.
a: Emergency (when abnormal)

a 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
System operating lamp function (PC138-AW1Q-042-K-00-A)

2. Battery
3. System operating lamp
4. Machine monitor
6. Pump controller
7. KOMTRAX terminal
Function
• You can prevent an abnormal end due to cut-off of the battery power supply circuit while the controllers are
in operation by checking the operating status of machine monitor (4), controllers (5), (6), and (7) with
system operating lamp (3).
a Before cutting off the battery power supply circuit, turn the starting switch to "OFF" position, and check that
system operating lamp (3) goes off, then turn battery disconnect switch (1) to "OFF" position.
a If you turn battery disconnect switch (1) to "OFF" position (battery power supply circuit is cut off) while
system operating lamp (3) is ON, data lost error of machine monitor (4), controllers (5), (6), and (7) can
occur. Do not operate battery disconnect switch (1) while system operating lamp (3) is ON.
a System operating lamp (3) goes off in 2 minutes after the starting switch is turned to "OFF" position.
a System operating lamp (3) may sometimes light up while the starting switch is turned to "OFF" position
because KOMTRAX terminal (7) may maintain its communication under this condition.
ON/OFF of system operating lamp

• Voltage of 24 V is always applied to one end of the system operating lamp (LED) (3).
• When any of machine monitor (4), controllers (5), (6), and (7) is in operation, the controller outputs low
voltage (0 V), and a current flows in the diode to turn ON system operating lamp (3).
• When all of machine monitor (4), controllers (5), (6), and (7) are stopped, the controller outputs high
voltage (24 V), and no current flows in the diode, thus system operating lamp (3) goes off.
a System operating lamp (3) may look slightly luminous in the dark after it is turned off. It is due to the minute
leakage of current and not an abnormal phenomenon.
• KOMTRAX terminal (7) performs communication periodically even if the starting switch is kept in "OFF"
position, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal (7) varies the conditions including the
communication status and machine stop time, and the lamp may keep lighting for up to approximately one
hour
a When you want to cut off the battery circuit for maintenance but system operating lamp (3) keeps on
lighting up, turn the starting switch to 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
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.

2. System operating lamp
(O): OFF position

(I): ON position
PC88MR-10 10-199
Function
• Usually, battery disconnect switch (1) is used instead of disconnecting the cable from the negative
terminal of the battery in the following cases.
1. When storing the machine for a long period (more than 1 month)
2. When servicing or repairing the electrical system
3. When performing electric welding
4. When handling the battery
5. When replacing the fuse, etc.
• When battery disconnect switch (1) is turned to OFF position (the contact is opened), all the continuous
power supplies for the components, including the starting switch B terminal and controllers, are all cut out,
and the condition is the same as the condition when the battery is not connected. Accordingly, all of the
electrical system of the machine does not operate.
• System operating lamp (2) lights up while the controller is in operation. It lights up when KOMTRAX
terminal is performing communication, even if the starting switch is set to OFF position.
Precautions for using battery disconnect switch

• Do not turn OFF battery disconnect switch (1) while system operating lamp (2) is lit.
If battery disconnect switch (1) is turned OFF while system operating lamp (2) is lit, the data in the
controller may be lost and the controller may be damaged seriously.
• Do not turn OFF battery disconnect switch (1) while the engine is running or immediately after the engine
is stopped.
If battery disconnect switch (1) is turned OFF while the alternator is generating power, the generated
current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may
cause serious damage to the electrical system, including the electric devices and controllers.
• 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
Oil flow adjuster function for attachment (PC88MR-PT24-042-K-00-A)
(Machines ready for installation of attachment)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Various sensors
7. Pump secondary drive switch
8. 1st-line attachment proportional switch
9. 2nd-line attachment proportional switch [European specification (if equipped)]
10. Breaker operating switch
11. Main pump
11a. Servo
11b. LS valve
11c. PC valve
12. Control valve
14. 1st-line attachment flow adjustment EPC valve
15. 2nd-line attachment flow adjustment EPC valve [European specification (if equipped)]
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
e. CAN signal
f. PC-EPC valve drive signal
g. Solenoid valve ground
h. Throttle signal
i. Fuel supply pump control signal
j. Various sensor signals
Function
• The flow to the attachment when the attachment proportional switch is operated fully is controlled by
selecting ATT/P or ATT\E mode on the machine monitor and setting the attachment flow.
System component parts (ALL-RA1C-001-K-00-A)
Engine controller (PC220-AP70-041-K-00-A)
Input and output signals of engine controller (PC88MR-AP70-03C-K-00-A)

• 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)]
Pin No. Signal name Signal classification
1 (*1) —
2 (*1) —
3 Crankcase pressure sensor B
4 (*1) —
5 Charge temperature sensor B
10-202 PC88MR-10

6 Mass air flow (MAF) temperature sensor B
7 (*1) —
8 CAN_B(+)(KOMNET/r) E
9 Bkup (camshaft) speed sensor (+) B
10 (*1) —
11 (*1) —
12 (*1) —
13 GND C
14 Coolant temperature sensor B
15 Charge pressure sensor B
16 Ambient pressure sensor B
17 (*1) —
18 CAN_B (–) (KOMNET/r) E
19 (*1) —
20 (*1) —
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow (MAF) sensor B
24 (*1) —
25 (*1) —
26 Ne (crankshaft) speed sensor (+) B
27 (*1) —
28 (*1) —
29 (*1) —
30 SCV (+) D
31 Engine oil pressure switch B
32 (*1) —
33 (*1) —
34 (*1) —
35 (*1) —
37 Ne (crankshaft) speed sensor (–) C
38 (*1) —
39 (*1) —
40 SCV (–) C
41 (*1) —
42 (*1) —
43 (*1) —
44 Injector #3 (-) D
47 (*1) —
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 (*1) —
54 Injector #3 (–) C
57 (*1) —
PC88MR-10 10-203

59 GND C
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26–60P(2) [ECM J2(CN-CE02)]
1 Variable flow turbocharger motor (V) B
2 Variable flow turbocharger motor (U) B
3 EGR valve motor (W) B
4 EGR valve motor (V) B
5 EGR valve motor (U) B
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 Variable flow turbocharger motor B
12 (*1) —
13 (*1) —
14 (*1) —
15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) C
19 (*1) —
20 (*1) —
21 GND C
22 (*1) —
23 (*1) —
24 CAN_B(+) E
25 CAN_B (–) E
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
32 (*1) —
33 (*1) —
34 (*1) —
35 (*1) —
36 (*1) —
37 (*1) —
38 (*1) —
39 (*1) —
40 (*1) —
41 EGR valve hall sensor (V) D
42 EGR valve hall sensor (W) D
43 Variable flow turbocharger hall sensor (V) D
44 (*1) B
45 (*1) —
10-204 PC88MR-10

46 (*1) —
47 GND C
48 (*1) —
49 (*1) —
50 (*1) —
51 EGR valve hall sensor (U) D
52 Variable flow turbocharger hall sensor (U) D
53 Variable flow turbocharger hall sensor (W) D
54 (*1) —
55 Common rail pressure sensor: B
56 (*1) —
57 (*1) —
58 (*1) —
59 (*1) —
60 (*1) —
DRC26–60P(3) [CN-CE03]
1 Continuous power supply (24 V) A
3 Starting switch ACC signal B
4 (*1) D
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 System operating lamp D
10 (*1) —
13 (*1) C
14 (*1) —
15 (*1) —
16 (*1) —
17 CAN_A(+) (KOMNET/c) E
18 CAN_A (–) (KOMNET/c) E
19 (*1) C
20 (*1) —
21 GND C
22 GND C
23 (*1) —
24 (*1) —
25 (*1) —
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
30 (*1) —
31 GND C
32 GND C
33 (*1) —
PC88MR-10 10-205

34 (*1) —
35 (*1) —
36 (*1) —
37 (*1) —
38 (*1) —
39 (*1) —
40 (*1) —
41 GND C
43 (*1) C
44 (*1) —
45 (*1) —
46 (*1) —
47 (*1) —
48 (*1) —
49 (*1) B
50 (*1) B
51 Throttle signal B
52 (*1) A
53 (*1) —
54 (*1) —
55 (*1) —
56 (*1) —
57 (*1) —
58 (*1) —
59 (*1) —
60 (*1) —
10-206 PC88MR-10
Pump controller (PC-C3V1-041-K-00-A)
Input and output signals of pump controller (PC88MR-C3V1-03C-K-00-A)

AMP-81P [CN-CP01]
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 Continuous power supply return Input
3 Window washer Output
5 Continuous power supply return Input
6 Potentiometer power supply (5 V) Output
7 CAN (R)_H Input/output
8 Service oil pressure sensor Input
9 (*1) —
10 1st-line attachment potentiometer 2 Input
11 Oil pressure sensor of pump Input
12 Swing RIGHT PPC oil pressure sensor Input
13 Boom "LOWER" PPC oil pressure sensor Input
14 Arm "IN" PPC oil pressure sensor Input
15 (*1) —
16 (*1) —
17 (*1) —
PC88MR-10 10-207

18 GND (analog signal) —
19 (*1) —
20 (*1) —
21 (*1) —
22 Lock lever automatic lock cancel switch Input
23 Breaker switch Input
24 Starting switch ACC signal Input
25 (*1) —
26 CAN (R)_L Input/output
27 (*1) —
28 Hydraulic oil temperature sensor Input
29 2nd-line attachment potentiometer 2 Input
30 (*1) —
31 Swing LEFT PPC oil pressure sensor Input
32 Boom "RAISE" PPC oil pressure sensor Input
33 (*1) —
34 (*1) —
35 (*1) —
36 Blade "LOWER" oil pressure switch Input
37 (*1) —
38 (*1) —
39 Swing parking brake cancel switch Input
40 (*1) —
41 PPC oil pressure solenoid valve Input
42 (*1) —
44 (*1) —
45 CAN (C)_H Input/output
47 (*1) —
48 1st-line attachment potentiometer 1 Input
49 (*1) —
50 Bucket "DUMP" PPC oil pressure sensor Input
51 Arm "OUT" PPC oil pressure sensor Input
52 Boom swing LEFT PPC oil pressure sensor Input
53 (*1) —
54 (*1) —
55 Blade "RAISE" PPC oil pressure switch Input
56 Wiper motor reverse (W) Input
57 (*1) —
58 Machine model selection 5 Input
59 (*1) —
60 (*1) —
61 Starting switch C signal Input
62 External starting signal Input
63 Potentiometer power supply (5 V) Output
64 CAN (C)_L Input/output
65 (*1) —
66 (*1) —
67 2nd-line attachment potentiometer 1 Input
68 (*1) —
69 Bucket "CURL" PPC oil pressure sensor Input
10-208 PC88MR-10

71 Boom swing RIGHT PPC oil pressure sensor Input
72 Travel PPC oil pressure sensor Input
73 (*1) —
74 (*1) —
75 Wiper motor stop (P) Input
76 Cab front window open limit switch Input
77 (*1) —
78 Work equipment lock lever switch 2 Input
79 Work equipment lock lever switch 1 Input
81 GND (digital signal) —
AMP-40P [CN-CP02]
82 (*1) —
83 (*1) —
84 (*1) —
85 Merge-divider solenoid valve Output
86 (*1) —
87 2nd-line attachment L.H. flow adjustment EPC Output
88 (*1) —
89 (*1) —
90 (*1) —
91 (*1) —
92 (*1) —
93 Travel speed increase solenoid valve Output
94 (*1) —
95 2nd-line attachment R.H. flow adjustment EPC Output
96 Pump PC-EPC valve Output
97 (*1) —
98 (*1) —
99 PPC lock relay Output
100 System-in-use signal Output
101 Swing parking brake solenoid valve Output
102 1st-line attachment L.H. flow adjustment EPC Output
103 (*1) —
104 (*1) —
105 (*1) —
106 (*1) —
107 Travel alarm Output
108 Battery relay drive Output
109 (*1) —
110 1st-line attachment R.H. flow adjustment EPC Output
111 (*1) —
112 (*1) —
113 (*1) —
114 Wiper motor (–) Output
115 GND (solenoid) Input
116 Solenoid power supply Input
PC88MR-10 10-209

119 Wiper motor (+) Output
Fuel control dial (PC-AGJ7-041-K-01-A)
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function (PC-AGJ7-042-K-00-A)
• This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate.
• 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
Resister for PC-EPC valve (PC138-C3VR-041-K-00-A)

a EPC: Abbreviation for Electromagnetic Proportional Control
1. Resistance
2. Connector
Specifications (PC138-C3VR-030-K-00-A)
Resistance: 30 z
Function (PC88MR-C3VR-042-K-00-A)
• 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
1. Connector (with built-in resistor)
Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z
Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.
Engine oil pressure switch (PC-ABK6-041-K-00-A)
1. Connector
2. Sensor
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
PPC oil pressure switch (PC88MR-E610-041-P-00-A)
1. Plug
2. Switch
3. Connector
Specifications (PC220-E610-030-P-00-A)
Contact type: Normally open
Operating (ON) pressure: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
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
Machine monitor system
Machine monitor system (PC88MR-Q170-042-K-00-A)
1. Machine monitor
2. Battery
3. Pump controller
5. Air conditioner controller
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
Function
• The monitor system keeps the operator informed of all the machine conditions, by monitoring them by
using the sensors and switches installed in various parts of the machine and processing them instantly to
display on the machine monitor.
The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has problem
2. Machine status display (coolant temperature, hydraulic oil temperature, fuel level, etc.)
3. Display of camera image
• The switches on the machine monitor have functions to control the machine.
Machine monitor (PC-Q180-042-K-01-A)
Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If a failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.
Precautions on the machine monitor display

• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this
is not a failure or a defect. Products having 10 or less black or bright spots conform the product
specification; such the condition is quite normal.
• When the engine is started, the battery voltage may drop suddenly, depending on the ambient
temperature and the condition of the battery. 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
Blue bright spots can never be a problem as the screen has usually blue or white background. (White in
the LCD is made up of red, green and blue.)
Input and output signals of machine monitor (PC88MR-Q180-03C-K-00-A)

070-18P [CN-CM01]
3 GND (continuous power supply) —
4 GND (continuous power supply) —
5 External starting signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) —
8 System operating lamp Input/Output
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 (*1) —
15 Fuel level sensor Input
16 Charge level (alternator terminal R) Input
17 (*1) —
18 (*1) —
070-12P [CN-CM02]
1 Seat belt alarm switch Input
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 CAN (C) terminating resistor terminal —
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 CAN (R) terminating resistor terminal —
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output
070-8P [CN-CM04]
1 Power supply for camera (8 V) Output
2 Camera NTSC signal 1 Input
3 (*1) —
4 (*1) —
5 GND (power supply for camera) —
6 (*1) —
7 (*1) —
8 GND (shield) —
10-216 PC88MR-10
Display (PC88MR-Q1LA-042-K-00-A)
When camera is not installed
A: Standard screen
B: Check before starting screen
C: Maintenance time warning screen
D: Warning screen
E: Guidance screen
1. Service pilot lamp
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
10.Fuel level caution lamp

11.Fuel consumption gauge
12.Engine oil pressure caution lamp
13.Seat belt caution lamp
14.Engine stop pilot lamp
15.Work equipment lock pilot lamp
16.Lock lever automatic lock cancel pilot lamp
17.Message pilot lamp
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
When camera is installed
A: Standard screen
B: Check before starting screen
C: Maintenance time warning screen
D: Warning screen
E: Guidance screen
1. Service pilot lamp
2. ECO gauge
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
11.Fuel consumption gauge

12.Charge level caution lamp
13.Seat belt caution lamp
14.Engine stop pilot lamp
15.Work equipment lock pilot lamp
16.Lock lever automatic lock cancel pilot lamp
17.Message pilot lamp
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
Gauges (PC88MR-Q1LA-042-K-03-A)
Gauge Item displayed Description Remarks

Temperature Monitor • Indicates
Range
(°C) background corresponding
(*1) W1 105 Red temperature range.
• The alarm buzzer
Engine coolant W2 102 Red
sounds at 105°C or
temperature W3 100 Blue higher.
gauge W4 80 Blue • If background color is
W5 60 Blue white, warm up
W6 30 White engine.
Temperature Monitor • Indicates
Range
(°C) background corresponding
H1 105 Red temperature range.
(*1) • The alarm buzzer
H2 102 Red
Hydraulic oil sounds at 105°C or
H3 100 Blue higher.
temperature
gauge H4 80 Blue • If background color is
H5 40 Blue white, warm up
hydraulic
H6 20 White components.
Monitor • Indicates
Range Quantity (l)
background corresponding level
F1 96 Blue range.
(*1) F2 78 Blue
Fuel level gauge F3 60 Blue
F4 41 Blue
F5 32 Blue
F6 23 Red
Segment Load level • Indicates
Light to instantaneous fuel
Green 1 to 8 consumption
medium
(average of fuel
(*2) consumption by 3
seconds) in 10 steps.
ECO gauge (Displays when "ECO
Orange 9, 10 Heavy 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 to clock
display.)
PC88MR-10 10-221
Gauge Item displayed Description Remarks

• Displays time.
• 12-hour system display (AM/PM) (Press F4 switch to
Clock • 24-hour system display change to service
meter display.)
• Indicates average
fuel consumption.
(Display can be
(*2) switched by selecting
• 1 Day another item in "ECO
Fuel
• Split Time Guidance"o"Confi-
consumption • None
gauge gurations"o"Average
Fuel Consumption
Display" on user
menu.)
*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
Caution lamps (PC88MR-Q1LA-042-K-01-A)

Description
Item Caution lamp
Symbol display Action level Remarks
displayed Range
(background monitor
color)
Min. 102ºC Lights up (Red) L02 • Background color
Min. 30ºC, changes depending
Lights up (Blue) — on the temperature
below 102ºC
(*1) detected.
Coolant • Alarm buzzer sounds
temperature Lights up at 105ºC or higher.
Below 30ºC — • If background color is
(White)
white, warm up
engine.
Min. 102ºC Lights up (Red) L02 • Background color
Min. 20ºC, changes depending
Lights up (Blue) — on the temperature
below 102ºC
(*1) detected.
• Alarm buzzer sounds
Hydraulic oil at 105ºC or higher.
temperature Lights up • If background color is
Below 20ºC —
(White) white, warm up
hydraulic
components.
Below 23 l Lights up (Red) — • Background color
(*1) changes depending
Min. 23 l Lights up (Blue) — on the remaining fuel
Fuel level
level.
When charge is • Monitor lights up and
defective alarm buzzer sounds
(*1)
(Charge voltage Lights up (Red) L03 when abnormality is
Battery < Battery detected while
charge voltage) engine is running.
When normal Goes out —
When abnormal • Monitor lights up and
(*1) (Below specified Lights up (Red) L03 alarm buzzer sounds
Engine oil pressure) when abnormality is
pressure detected while
When normal Goes out — engine is running.
When • The display changes
maintenance Lights up (Red) — depending on how
due time is over long it has been
since the
maintenance due
time was over
Maintenance (*2) • After starting switch
time warning When is turned to "ON"
Lights up —
maintenance (Yellow) position, monitor
notice time is lights up if condition
over for lighting it up is
satisfied, and then
goes out in 30
seconds.
PC88MR-10 10-223
Description
Item Caution lamp
Symbol display Action level Remarks
displayed Range
(background monitor
color)
When action • Monitor lights up
level "L04" or Lights up (Red) when abnormality is
L04 and L03
"L03" is detected in machine
State of detected system.
system • When the
When action Lights up (*3) background color is
level "L01" is (Yellow) L01 red, the alarm buzzer
detected
sounds.
L04 and L03
State of "L03" is detected in engine
engine detected system.
system • When the
detected
sounds.
L04 and L03
State of "L03" is detected in hydraulic
hydraulic detected system.
system • When the
detected
sounds.
level "L03" is Lights up (Red) L03 when abrupt engine
Abrupt stop detected stop by auto idle stop
by auto idle function is detected.
stop function When action Lights up (*3) When the
level "L01" is (Yellow) background color is
detected L01 red, the alarm buzzer
sounds.
• Monitor lights up and
Engine When engine alarm buzzer sounds
overspeed is Lights up (Red) L02 when engine
overspeed
detected overspeed is
detected.
• Monitor lights up
When air Lights up (*3) when abnormality is
State of air
conditioner is (Yellow) detected in air
conditioner L01
abnormal conditioner system.
level "L04" is Lights up (Red) L04 when abnormality is
detected detected in machine.
When action When the
level "L03" is Lights up (Red) L03 background color is
detected red, the alarm buzzer
Action level
When action sounds.
level "L02" is Lights up (Red) L02
detected
When action Lights up (*3)
level "L01" is (Yellow)
detected L01
*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
*3: Be lit for 2 seconds, and then goes out.
PC88MR-10 10-225
Pilot display (PC88MR-Q1LA-042-K-02-A)
Item
Symbol Description Remarks
displayed
• Operates automatically at low • Indicates the
Automatic temperature. (Be lit for approx.30 sec. at operation state of
preheating maximum.) preheater.
• Goes off after engine is started.
Elapsed time
after turning
starting switch
Pilot display
to "HEAT
Preheating
(preheat)"
Manual position
preheating 0 to 30 Lights up
seconds
30 to 40
Flashes
seconds
40 seconds or
longer Goes out
Swing parking brake cancel Pilot display • Indicates
switch operation state of
Swing lock OFF Goes out swing lock.
ON Flashes
INT: Intermittent operation • Displays the
operation state of
Wiper ON: Continuous operation front window
Monitor goes out: Stopped wiper.
• Displays the
Air Lights up: ON operation state of
conditioner Goes out: OFF air conditioner
and blower.
• Displays whether
Lights up: Not fastened the seat belt is
Seat belt fastened.
Goes out: Fastened
• Displays the
Stopping Lights up: When engine is stopped operation state of
engine Goes out: When the engine is running engine.
• Displays the state

Message Lights up: There is unread message. of the message.
(Unread) Monitor goes out: No message
Message • Displays the state

(No return of the message.
Lights up: There is a read message which has not been
message, replied.
already-
Goes out: No message
read
message)
10-226 PC88MR-10
Item
Symbol Description Remarks
displayed
A Work Lock lever • Displays lock
Lock lever equipment automatic lock Pilot display state of work
automatic lock cancel switch equipment.
LOCK — OFF A lights up
FREE No operation OFF Goes out
Lock lever
B FREE Operation OFF A lights up
LOCK — ON A lights up
FREE — ON B lights up
• Displays
Auto- Lights up: ON operation state of
deceleration Goes out: OFF auto-deceleration
function.
P: Heavy-duty operation • Indicates the set
E: Low-fuel consumption operation working mode.
L: Fine control operation
Working
mode B: Breaker operation
ATT/P: 2-way attachment operation
ATT/E: 2-way attachment operation with low fuel
consumption
• Indicates set
Travel Lo: Low-speed travel mode of travel
speed Hi: High-speed travel speed.
• Idling stop guidance • Indicates

• Deterrence guidance of hydraulic relief guidance to
ECO
• E-mode recommendation guidance support operation
guidance
• Reduce travel speed recommendation guidance of machine.
• Low fuel level guidance
PC88MR-10 10-227
Switches (PC88MR-Q1C0-042-K-00-A)
No. Name Function Operation

Switches between ON and OFF of • When the working mode is "L" and
Auto-deceleration after the engine is started, the auto-
the auto-deceleration.
1 switch deceleration function is kept "OFF".
Lights up: ON
[Numeral key pad: 1] OFF io ON
Goes off: OFF
P: Heavy-duty operation
E: Low-fuel consumption operation
(*1)
L: Fine control operation
Working mode selector Displays working mode selection
2 switch B: Breaker operation
screen.
[Numeral key pad: 2] ATT/P: 2-way attachment operation
ATT-E: 2-way attachment operation with
low fuel consumption
Travel speed selector Selects travel speed. • Changes as follows in order.
3 switch Lo lights up: Low-speed travel Lo (low speed) o Hi (high speed) o
[Numeral key pad: 3] Lo (low speed)
Hi lights up: High-speed travel
• The alarm buzzer stops sounding.
• When abnormality which turns on the
alarm buzzer is detected again, the
Stops the alarm buzzer. alarm buzzer sounds.
Buzzer cancel switch
4 (Some alarm buzzer does not stop
[Numeral key pad: 4]
even if the switch is pressed.)
Operates front window wiper. • Each time the switch is pressed,

(*2) operation of the wiper changes.
INT: Intermittent operation
5 Wiper switch INT (intermittent) o ON (continuous)
ON: Continuous operation o OFF (stopped) o INT (intermittent)
Goes out: Stopped
10-228 PC88MR-10
No. Name Function Operation

ON: Washer fluid spouts out and the
wiper operates continuously.
[When wiper is stopped]
(*2) OFF: When the switch is released, the
wiper continues to operate for 2 cycles,
6 Window washer switch Sprays washer fluid to the front
window. then stops.
[When wiper is intermittent operation]
OFF: When the switch is released, the
wiper continues to operate for 2 cycles,
then returns to intermittent operation.
Fan switch (Increase) • The air flow increases immediately
7a Adjusts the air flow of the air after the air conditioner adjustment
conditioner in six levels. screen appears.
(Low, Medium 1, Medium 2, • The air flow decreases immediately
7b Fan switch (Decrease) Medium 3, Medium 4, High) after the air conditioner adjustment
screen appears.
Temperature control • The preset temperature increases
8a switch (High) Adjusts the temperature inside the immediately after the air conditioner
[Numeral key pad: 8] air-conditioned cab. adjustment screen appears.
Temperature control (18.0ºC to 32.0ºC: Settable by • The preset temperature decreases
8b switch (low) 0.5ºC) immediately after the air conditioner
[Numeral key pad: 0] adjustment screen appears.
• Automatically controls the air flow, air
(*3) Operates the air conditioner and air vent, and FRESH/RECIRC air
blower with automatic operation. changeover according to the set
9 Auto switch
AUTO lights up: Automatic temperature, immediately after the air
[Numeral key pad: 9] operation conditioner adjustment screen
appears.
Switches between ON and OFF of • Switches to the air conditioner
(*4) the air conditioner. adjustment screen, and pressing it
10 A/C lights up: Manual operation again switches ON/OFF.
Air conditioner switch
OFF io ON
Goes out: Stopped
• Switches to the air conditioner
FRESH/RECIRC air adjustment screen, and pressing it
11 Selects FRESH/RECIRC air.
selector switch again switches FRESH/RECIRC.
RECIRC io FRESH
Selects air vent mode from 6 • Switches to the air conditioner
modes. adjustment screen, and pressing it
1. Front and rear again switches air vent mode.
1o2o3o4o5o1
12 Vent selector switch 2. Front, rear, and foot
3. Foot
4. Foot and defroster
5. Defroster
Stops fan and air conditioner. • The fan and air conditioner stop.
13 OFF switch
Goes out: OFF
14a Guidance icon
See "Guidance icon and function switch." section.
14b Function switch
*1: When the working mode is changed, the auto-deceleration function is turned "ON". (However, when L
mode is selected, the auto-deceleration is turned "OFF".
*2: Windshield wiper and window washer do not operate while the front window is open, even if the switch is
pressed.
*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
Guidance icon and function switch (PC88MR-Q1C1-042-K-00-A)

• The function of function switches varies according to the guidance icon displayed on top of the switch.
• When the guidance icon is not displayed on top of the function switch, it does not function even if the
switch is pushed.
• The kind and function of the guidance icon displayed on top of each function switch are as follows.
Guidance
Item Function
icon
Selects user menu screen.
Information transmitted can be checked with
background colors.
Select user menu screen • Gray: When condition is normal
• Red: When maintenance due time is over
• Yellow: When maintenance notice time is over
• Green: When there is any unread KOMTRAX
message
Select clock or service meter Selects clock or service meter.
Selects monitor display.

Select camera image (*1) Camera + gauge screen o Camera screen o Gauge
screen o Camera + Gauge screen
Enters selected item or set item.
background colors.
Enter
• Gray: When condition is normal
• Green: When Energy Saving Guidance is
displayed
Return Returns to the previous screen or state.
Moves to upper item. (Moves to bottom item when at

Move selected item top item)
Holds the monitoring.
Moves to lower item. (Moves to top item when at

Move selected item bottom item)
Cancels holding of the monitoring.
Green arrow: Moves to the right tab.

Move selected item White arrow: Moves to right. (Moves to leftmost item
when at rightmost item.)
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
Guidance
Item Function
icon
Moves to lower page. (Moves to top page when at

Move selected item bottom page.)
Clear Clears selected item or displayed item.
Returns selected item to default value. (Use for

Return to default setting
adjusting screen)
Set Executes setting.
Executes starting.
Start (Used for starting split fuel consumption
measurement for fuel consumption display)
Executes stopping.
Stop (Used for stopping split fuel consumption
measurement for fuel consumption display)
Save Saves setting.
Select name setting screen Selects name setting screen.
Selects the 1st-line attachment oil flow setting screen.

Select ATT1 oil flow setting screen (Effective only when installation of 2-lines attachment
systems is set.)
Selects the 2nd-line attachment oil flow setting

screen.
Select ATT2 oil flow setting screen
(Effective only when installation of 2-lines attachment
systems is set.)
Hold Holds value of monitoring item. (Use for monitoring)
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
Guidance
Item Function
icon
Change "Average Fuel Changes graph on "Average Fuel Consumption Logs"

Consumption Logs" screen screen.
Select oil flow setting screen Selects the attachment and breaker oil flow setting
screen.
Selects "Current Abnormality" screen.

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
Operator mode functions (PC88MR-Q193-042-K-00-A)

• The functions with which the operator can display or set by operating switches in normally displayed
screen.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Cate- Display order (*2)
gory Item
(*1) U V W X Y Z
Display of KOMATSU logo 1 1 1 1 1 1
Display of password input 2 2 — — — —
Display of service person identification state 3 — 2 — — —
Display of operator ID input screen 4 — 3 — — —
Display of Check before starting 5 3 4 2 2 2
A Display of warning after check before starting — — — — 3 —
Display of maintenance due time over — — — — — 3
Display to check working mode and travel speed 6 4 5 3 4 4
Display of standard screen 7 5 6 4 5 5
Display of engine shutdown secondary switch screen
Display of end screen
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Stop operation of alarm buzzer
Operation of windshield wiper
Operation of window washer
Operation of air conditioner
B Operation to display camera mode
Operation to display clock and service meter
Check of maintenance information
Setting and display of user menu
• ECO Guidance
• Machine Setting
• Maintenance
• Monitor Setting
• Display of message (including KOMTRAX messages for user)
Display of ECO guidance
C Display of caution monitor
Display of action level and failure code
Checking function by LCD (Liquid Crystal Display)
D Function to check service meter
Function of usage limitation setting/change password
*1: The operator mode items are classified as follows.
A: Display from the time when the starting switch is turned to "ON" position to the time when display changes
to the standard screen, and display after starting switch is turned to "OFF" position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special operations of switches
*2: Display sequence from the time when the starting switch is turned to ON position to the time when the
standard screen appears varies depending on the settings and conditions of the machine as follows.
U: When the engine start lock and operator ID No. input setting are enabled.
V: When the engine start lock is enabled and the operator ID No. input setting is disabled.
W: When the engine start lock is disabled and the operator ID No. input setting is enabled.
PC88MR-10 10-233
X: When the engine start lock and operator ID No. input setting are disabled.
Y: When any abnormality is detected by the Check before starting.
Z: When any item is detected as the maintenance due time is over.
a 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
Service mode functions (PC88MR-Q194-042-K-00-A)

• These functions are not displayed normally. A technician can display and set them special operation of
switches.
This function is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Pre-defined Monitoring
Self-define Monitoring
Mechanical Sys Abnormality Record
Abnormality Record
Electrical Sys Abnormality Record
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Key-on Mode
Unit
Default With/Without Attachment
Camera
Auto Idle Stop Timer Fixing
Cylinder Cutout Mode Operation
Diagnostic Tests
Reset Number of Abrupt Engine Stop by AIS
Pump Absorption Torque
Att Flow Adjust in Combined Ope
Attachment EPC2 Adjustent
Adjustment
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
KOMTRAX system
KOMTRAX system (PC-Q210-042-K-00-A)
• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
• This system transmits various machine information by use of the radio communication. This system allows
the KOMTRAX operator to refer the information and provide various services to the customers.
• Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
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
KOMTRAX system
4. Communication antenna connection
Function (PC88MR-Q220-042-K-01-A)
• This terminal uses the portable communication technology.
• This terminal is the wireless communication equipment which enables to transmit GPS locational
information and various machine information which is received from network signal or input signal. It can
transmit the information via communication antenna.
• The condition of this terminal can be checked on the "KOMTRAX Setting" screen in the service mode of
the machine monitor.
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• The terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a 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.
Input and output signals (PC220-Q220-03C-K-00-A)

070-18P[CN-CK01]
Pin No. Signal name Input/Output signal
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN (C)_H Input/Output
11 CAN (C)_L Input/Output
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P [CN-CK02]
Pin No. Signal name Input/Output signal
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
PC88MR-10 10-237
Sensor
Sensor (ALL-E700-001-P-00-A)
Ambient pressure sensor (ENG-AAP2-041-K-00-A)
1. Connector
2. Sensor
Function (ENG95-AAP2-042-K-00-A)
• This sensor is installed to the bracket on the side of the cylinder block, senses the ambient pressure, and
outputs it as a variable voltage.
Charge (boost) pressure and temperature sensor (ENG-AAM7-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-AAM7-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its
temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for
temperature.
a "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
Sensor
Output characteristics
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
Sensor
1. O-ring
2. Sensor
3. Connector
Function (ENG-AG42-042-K-00-A)
• This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to
the gear rotation.
Bkup (camshaft) speed sensor (ENG-AG62-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG95-AG62-042-K-00-A)
• This sensor, installed to the gear portion of camshaft on the engine front cover, outputs the pulse voltage
due to the gear rotation.
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
Sensor
Variable flow turbocharger motor (with built-in position sensor) (ENG95-AA56-041-K-00-A)
1. Variable flow turbocharger motor (brushless motor with built-in position sensor)
2. Turbine part
3. Connector
Function (ENG95-AA56-042-K-00-A)
• Controls the flow control valve with a DC motor.
• 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)

PC88MR-10 10-241
Sensor
1. EGR valve motor (with built-in position sensor)

2. Connector
3. Body
Function (ENG95-AA57-042-K-00-A)
• Small-sized EGR valve driven with a DC motor.
• The EGR valve motor has a position sensor in it to sense the valve position.
Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)
1. Connector
2. O-ring
3. Sensor
Function (ENG-A96H-042-K-00-A)
• 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
Sensor
Crankcase pressure sensor (ENG-A18C-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG95-A18C-042-K-00-A)
• 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
Sensor
Function (PC88MR-AD41-042-K-00-A)
• This sensor is installed on the side surface of the fuel tank.
• This sensor detects the fuel level and converts it into an electric signal, and outputs the corresponding
signal.
• The float moves up and down corresponding to the fuel level.
• The movement of the float activates the variable resistor through the arm.
Hydraulic oil temperature sensor (PC-PMT1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function (PC138-PMT1-042-K-00-A)
• This sensor is installed to the suction piping of the main pump and outputs a resistance change signal of
the thermistor for the temperature change.
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
Sensor
PPC oil pressure sensor (PC-E720-041-P-00-A)
1. O-ring
2. Sensor
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.
PC88MR-10 10-245
10-246 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
20 Standard value tables

4 20 Standard value tables
PC88MR-10 20-1
Table of contents

20 Standard value tables.................................................................................................................... 20-1
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
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
Item Measurement condition Unit for new Repair limit
machine
Maximum
1,950 ± 50 -
speed(*1)
• Coolant temperature: 75 to 94°C Minimum
speed • Hydraulic oil temperature: 45 to rpm 1150 (+50 / 0) -
speed
55°C
Rated speed
1,950 -
(*1)
At sudden Bosch
Max. 0.5 Max. 2.0
Exhaust gas • Coolant temperature: 75 to 94°C acceleration index
color At the max. Bosch
speed Max. 0.5 Max. 1.5
index
Intake valve 0.35 -
Valve • Coolant temperature: Normal
Exhaust mm
clearance temperature 0.50 -
valve
Compres- MPa Min. 2.9 2.0
• Engine oil temperature: 40 to 60°C
sion {kg/
• Engine speed: 320 to 360 rpm {Min. 30} {20}
pressure cm2}
kPa Max. 0.98 1.47
Blowby • Coolant temperature: 75 to 94°C
{mmH2-
pressure • Hydraulic oil temperature: 45 to 55°C {Max. 100} {150}
O}
0.34 to 0.59 0.25
High idle MPa
Engine oil • Coolant temperature: 75 to 94°C {3.5 to 6.0} {2.5}
{kg/
pressure • E015W40-LA oil Min. 0.18 0.15
Low idle cm2}
{Min. 1.8} {1.5}
Engine oil
Whole speed range (inside oil pan) °C 80 to 115 120
temperature
Automatic Automatic
Fan belt adjustment adjustment
- mm
tension (Auto- (Auto-
tensioner) tensioner)
Air • Between compressor pulley and fan pulley
conditioner • Deflection when pressed with finger at 60 N {6.2 mm 6 to 9 6 to 9
compressor kg}
belt tension
(*1): The maximum speed and rated speed are the values of the travel speed.
PC88MR-10 20-3
Standard value table for engine
Engine SAA4D95LE-6
Standard value
Item Measurement condition Unit for new Repair limit
machine
kPa
Fuel • Coolant temperature: 75 to 94°C 883 to 1,471 {9 883 to 1,471 {9
{kg/
pressure • Engine at high idle to 15} to 15}
cm2}
1,600 rpm - Max. 190
Fuel return • Coolant 1,700 rpm - Max. 200
rate from temperature: 75 to Engine speed 1,800 rpm ml/min - Max. 210
injector 94°C 1,900 rpm - Max. 220
2,000 rpm - Max. 230
Leakage
from • Coolant temperature: 75 to 94°C
• Leakage for 30 seconds ml/min 0 Max. 20
pressure
limiter
20-4 PC88MR-10
Standard value table for machine
Standard value table for machine (PC88MR-0000-033-K-00-A)

Engine speed
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 94 °C rpm 1,850 ± 100 1,850 ± 100
• Engine: High idle
• Power mode (P)
• Arm relieved at OUT end
Travel of control lever

for new machine
NEUTRAL
Boom control lever o RAISE/ 71 ± 7 71 ± 7
LOWER
NEUTRAL
Arm control lever o CURL/ 71 ± 7 71 ± 7
DUMP
NEUTRAL
Bucket control lever o CURL/ 71 ± 7 71 ± 7
DUMP
NEUTRAL
Swing control lever o Swing
71 ± 7 71 ± 7
LEFT/
RIGHT
• At center of NEUTRAL
lever knob o Boom
Boom swing control pedal • Tip of pedal swing 15 ± 2 15 ± 2
• Read max. LEFT/ mm
value through RIGHT
travel end NEUTRAL
Blade control lever • Stopping engine o RAISE/ 53 ± 5 53 ± 5
LOWER
NEUTRAL
o
FOR-
Travel control lever WARD/ 115 ± 12 115 ± 12
REVERSE
(Right and
left)
Work
equipment/
3 to 5 0 to 5
Play of control lever Swing
blade
Travel 10 ± 3 10 ± 5
PC88MR-10 20-5
Control effort of control lever

for new machine
15.7 ± 3.9 Max. 24.5
Boom control lever
{1.6 ± 0.4} {Max. 2.5}
15.7 ± 3.9 Max. 24.5
Arm control lever
{1.6 ± 0.4} {Max. 2.5}
• Hydraulic oil temperature: 45 13.7 ± 2.9 Max. 21.6
Bucket control lever
to 55°C {1.4 ± 0.3} {Max. 2.2}
• For control lever, measure by 13.7 ± 2.9 Max. 21.6
Swing control lever hooking push-pull scale to N {1.4 ± 0.3} {Max. 2.2}
center of grip
{kg} 27.5 ± 6.9 Max. 39.2
Blade control lever • For control pedal, measure
by hooking push-pull scale to {2.8 ± 0.7} {Max. 4.0}
pedal end 69.6 ± 17.4 Max. 104.4
Boom swing control pedal • Read max. value through {7.1 ± 1.8} {Max. 10.6}
travel end
24.5 ± 5.9 Max. 39.2
Travel control lever
{2.5 ± 0.6} {Max. 4.0}
74.5 ± 18.6 Max. 107.6
Travel pedal
{7.6 ± 1.9} {Max. 11}
20-6 PC88MR-10
Hydraulic pressure
for new machine
• Hydraulic oil temperature: 45 to
55°C
• Engine: High idle MPa
3.43 ± 0.98 3.43 ± 0.98
Unload pressure • Power mode (P) {kg/
• Hydraulic pump outlet pressure {35 ± 10} {35 ± 10}
cm2}
with all control levers in
NEUTRAL position
26.5 ± 0.98 26.5 ± 1.47
Boom relief pressure
{270 ± 10} {270 ± 15}
26.5 ± 0.98 26.5 ± 1.47
Arm relief pressure
{270 ± 10} {270 ± 15}
• Hydraulic oil temperature: 45 to 26.5 ± 0.98 26.5 ± 1.47
Bucket relief pressure
55 °C {270 ± 10} {270 ± 15}
• Engine: High idle MPa
20.5 ± 0.98 20.5 ± 1.47
Swing relief pressure • Power mode (P) {kg/
• Hydraulic pump outlet pressure {210 ± 10} {210 ± 15}
cm2}
with all measurement circuits 26.5 ± 0.98 26.5 ± 1.47
Boom swing relief pressure
relieved {270 ± 10} {270 ± 15}
Blade RAISE relief 12.7 ± 0.98 12.7 ± 1.47
pressure {130 ± 10} {130 ± 15}
Blade LOWER relief 21.1 ± 0.98 21.1 ± 1.47
pressure {215 ± 10} {215 ± 15}
• Hydraulic oil temperature: 45 to 26.5 ± 0.98 26.5 ± 1.47
Travel relief pressure 55 °C MPa {270 ± 10} {270 ± 15}
• Hydraulic pump outlet pressure {kg/
3.2 ± 0.5 3.2 ± 0.5
Control circuit oil pressure cm2}
with all measurement circuits {33 ± 5} {33 ± 5}
relieved
Work
equipment 0 0
control
• Hydraulic oil lever: {0} {0}
MPa
Outlet pressure of PPC temperature: 45 to NEUTRAL
55 °C {kg/
valve Work
• Engine: High idle equipment cm2}
3.14 ± 0.5 3.14 ± 0.5
control
lever: Full {32 ± 5} {32 ± 5}
stroke
• Oil temperature: 45 All control -

2.5 to 4.4
to 55 °C levers in
• Engine: High idle NEUTRAL {25 to 45} {-}
MPa
LS differential pressure a LS differential
{kg/
pressure = Bucket cm2}
Pump outlet CURL -
pressure – LS Lever 2.11 ± 0.1
{-}
pressure {21.5 ± 1}
moved
halfway
PC88MR-10 20-7

for new machine
• Hydraulic oil Pump 26.5 ± 0.98 26.5 ± 1.47
temperature: 45 to discharge
55 °C pressure {270 ± 10} {270 ± 15}
PC valve output pressure MPa
(servo piston inlet • Engine: High idle
{kg/
pressure) • Power mode (P)
• Work equipment Servo cm2} Above value x
control: Arm IN piston inlet approximately -
relief pressure 0.25
• Hydraulic oil temperature: 45 to MPa

PC-EPC valve source 55°C 3.2 ± 0.5 3.2 ± 0.5
pressure • Engine: High idle {kg/
{33 ± 5} {33 ± 5}
cm2}
• All control levers in NEUTRAL
• Hydraulic oil Approx. 1.06 -
temperature: 45 to High idle
55 °C {10.8} {-}
• Power mode (P) Low idle Approx. 2.21 -
• All control levers in MPa
PC-EPC solenoid output {22.6} {-}
pressure NEUTRAL {kg/
• Hydraulic oil cm2}
temperature: 45 to Approx. 0.47 -
55 °C High idle
{4.8} {-}
• Power mode (P)
• Arm IN relief
• Hydraulic oil
temperature: 45 to Solenoid: 0 0
55 °C OFF {0} {0}
• For ON/OFF MPa
Solenoid valve outlet
pressure conditions of the {kg/
solenoid, see cm2}
Testing and Solenoid: 3.14 ± 0.5 3.14 ± 0.5
adjusting, "Testing ON {32 ± 5} {32 ± 5}
outlet pressure of
solenoid valve".
20-8 PC88MR-10
Swing
for new machine
• Arm length: 1650 mm
Bucket: Rated load (451 kg)
• For measuring posture, see
"Swing 1"
• Engine: High idle deg. 49 ± 10 Max. 73.5
Overswing • Hydraulic oil temperature: 45
to 55 °C (mm) (-) (-)
• Overswing of swing circle
after 1 turn
• Bucket with no load
• Value inside ( ): Overswing at
outside of swing circle
• Arm length:
2100 mm
• For measuring 2.6 ± 0.3 Max. 3.2
posture, see 90 deg.
(3.0 ± 0.3) (Max. 3.6)
"Swing 1"
• Engine: High
idle
Time required to start • Hydraulic oil
temperature: 45 sec.
swinging
to 55 °C
• Time required to
pass 90° and 4.1 ± 0.4 Max. 4.7
180 deg.
180° points (4.5 ± 0.4) (Max. 5.1)
after starting
swing
• Value in ( ): With
rated load
"Swing 1"
Time required to finish • Engine: High idle sec. 30 ± 3 Max. 35
swinging • Hydraulic oil temperature: 45
to 55 °C
• Time required to complete 5
turns after 1 turn
"Swing 2"
• Stopping engine
to 55 °C
• Rated load of bucket (450 kg)
• Set machine on 15 deg. deg. 0 0
Swing drift on slope slope, and set upper
(mm) (0) (0)
structure at 45 deg. to uphill
side.
• Make matchmark between
swing circle outer race and
track frame
• Distance between
matchmarks made in 15
minutes
Leakage from swing motor l/min Max. 3.5 Max. 7.0
to 55 °C
• Relieve swing circuit
PC88MR-10 20-9
Travel
for new machine
• For measuring
posture, see
"Travel 1"
• Engine: High Lo 37± 4 Max. 44
idle
• Hydraulic oil
temperature: 45
Travel speed (idle running) to 55 °C sec.
• Time required to
complete 5
turns after 1 Hi 22± 2 Max. 26
turn with track
of one side
raised off
ground
• For measuring
posture, see
"Travel 2" Lo 26 ± 2 Max. 30
• Engine: High
idle
Travel speed (actual running) • Hydraulic oil sec.
temperature: 45
to 55 °C
• Time required to Hi 14 ± 2 Max. 18
travel 20 m after
running up 10 m
"Travel 2" and "Travel 3"
Travel deviation to 55 °C mm Max. 200 Max. 220
• Travel deviation in travel of
20 m after running up 10 m
and more on level ground
• Firm and level ground
"Travel 4"
• Stopping engine
to 55 °C
Machine drift on slope mm 0 0
• Place machine on slope of
12deg. with sprocket on
uphill side.
• Travel distance by machine
drift on slope for 5 minutes
Leakage from travel motor to 55 °C l/min Max. 1.1 Max. 1.65
• Lock shoes and relieve travel
circuit
20-10 PC88MR-10
Work equipment
Standard value for new Repair limit
machine
• Whole work • Arm length: 2100 mm
equipment • For measuring posture,
(Hydraulic drift of see "Work equipment 1" Max. 350 Max. 600
bucket tooth tip) • Measure extension
• Boom cylinder amount and retraction
(Retraction amount of each cylinder
amount of and hydraulic drift of Max. 8 Max. 12
cylinder) bucket tooth tip.
• Level and flat ground
• Bucket: With rated load
• Arm cylinder (450 kg)
(Extension
Hydraulic drift
• Lever in NEUTRAL Max. 41 Max. 62

amount of • Stopping engine
cylinder) • Hydraulic oil temperature: mm
45 to 55 °C
• Measure immediately
• Bucket cylinder after setting
(Retraction • Measure hydraulic drift
amount of Max. 25 Max. 38
every 5 minutes and
cylinder) judge at 15 minutes
• Stopping engine
• Hydraulic oil temperature:
• Blade 45 to 55 °C
(Hydraulic drift of • Measure hydraulic drift of Max. 30
Max. 20
blade tip) blade tip from max.
raising position for 15
minutes
PC88MR-10 20-11

machine
2.8 ± 0.3
Arm length: (To just
1650 mm before
• For measuring Max. 3.5
cushion)
• Boom posture, see RAISE (To just before
"Work 2.5 ± 0.3
Bucket tooth on cushion)
equipment 2" Arm length: (To just
ground
• Engine: High 2100mm before
IO cushion)
idle
Max. extension
• Hydraulic oil
of cylinder Arm length:
temperature: 3.1 ± 0.3
1650 mm
45 to 55 °C
LOWER Max. 3.7
Arm length:
2.4 ± 0.3
2100mm
Max. 3.9
• For measuring 3.1 ± 0.3
posture, see Pull-in (To just before
(To just before cushion)
• Arm "Work cushion)
Max. extension equipment 3"
of cylinder • Engine: High
Max. 3.2
IO idle 2.7 ± 0.3
Push-out (To just before
Work equipment speed
Max. retraction • Hydraulic oil (To just before cushion)

temperature: cushion)
45 to 55 °C
• For measuring
sec.
posture, see
• Bucket "Work CURL 3.2 ± 0.4 Max. 4.0
IO idle
Max. retraction • Hydraulic oil DUMP 2.3 ± 0.3 Max. 3.1
temperature:
45 to 55 °C
• For measuring
posture, see
• Boom swing "Work Right 6.7 ± 0.7 Max. 8.0
IO idle
Max. retraction • Hydraulic oil Left 6.7 ± 0.7 Max. 8.0
temperature:
45 to 55 °C
• For measuring
posture, see
• Blade "Work RAISE 1.3 ± 0.2 Max. 2.1
Max. retraction of equipment 6"
cylinder • Engine: High
IO idle
Blade on ground • Hydraulic oil Max. 2.1
LOWER 1.3 ± 0.2
temperature:
45 to 55 °C
20-12 PC88MR-10

machine
• For measuring posture,
see "Work equipment 7"
• Engine: Low idle
45 to 55 °C
• With arm and bucket
Boom cylinders extended fully, Max. 2 Max. 3.9
lower boom from max.
raising position and
measure time taken to
raise the machine after
bucket reaches ground
45 to 55 °C
• With arm top side
Arm 0 Max. 1.0
horizontal and bucket
cylinder retracted fully,
move arm IN and
measure time to start it
Time lag
again after it stops on sec.

lower side
45 to 55 °C
• With boom top side
Bucket 0 Max. 1.0
horizontal and arm
cylinder retracted fully,
CURL bucket and
measure time to start it
again after it stops on
lower side
45 to 55 °C
Blade • Lower blade from max. Max. 1.0 Max. 2
raising position and
measure time taken to
raise the machine after
blade reaches ground
Internal leakage
Each cylinder • Engine: High idle Max. 1.5 Max. 7.5

45 to 55 °C cc/min
• Relieve circuit to be
Center swivel joint Max. 10 Max. 50
measured
PC88MR-10 20-13
Pump performance
Discharged Discharged
volume volume
Standard Repair limit
value
• Pump speed (rpm): 1,850 rpm
• PC-EPC current value (mA): 350 mA
• Test pump discharged pressure (MPa {kg/
cm2})
: P1 Q Q
Performance of
• Other pump discharged pressure (MPa {kg/ l/min
hydraulic pump (See graph) (See graph)
cm2})
: P2
• Average discharged pressure (MPa {kg/
cm2})
: Pp = (P1 + P2) / 2
a Bring pump discharged pressure P1 and P2 as close as possible to the average pressure when measuring.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump discharged volume and the engine speed at
the time of measurement, and use them as a base for calculating the pump discharged volume at the
specified speed.
a Pump discharge Q in the graph indicates the discharge from one pump.
20-14 PC88MR-10
PC88MR-10 20-15
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
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
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
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
Work equipment 9: Bucket time lag
Work equipment 10: Blade time lag
20-20 PC88MR-10
Standard value table for electrical system
Standard value table for electrical system (D155-E000-001-P-00-A)
Controller (PC88MR-RA1E-033-K-00-A)
Equipment name Procedure, measuring location, criteria and remarks
a Check ground terminal T12 for looseness and rust.
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
Continuous 3. Disconnect connector CE03, and connect T-adapter to female side.
Engine power 4. Turn battery disconnect switch to ON position.
controller supply 5. Turn starting switch to ON position.
voltage
a If any trouble is found, perform troubleshooting for failure code [CA441].
Between CE03 (female) (1) and (21) 20 to 30 V
Voltage
Continuous 2. Turn battery disconnect switch to OFF position.
power 3. Disconnect connector CP01 and connect T-adapter to female side.
supply 4. Turn battery disconnect switch to ON position.
voltage 5. Turn starting switch to ON position.
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
HST Between CP01 (female) (4) and (5) 20 to 30 V
controller 1. Turn starting switch to OFF position.
Solenoid 3. Disconnect connector CP02 and connect T-adapter to female side.
power 4. Turn battery disconnect switch to ON position.
supply 5. Turn starting switch to ON position.
voltage Between CP02 (female) (116) and ground 20 to 30 V
Voltage Between CP02 (female) (118) and ground 20 to 30 V
Between CP02 (female) (121) and ground 20 to 30 V
Continuous 3. Insert T-adapter into connector CM01.
Machine power 4. Turn battery disconnect switch to ON position.
monitor supply 5. Turn starting switch to ON position (to connect ACC).
voltage Between CM01 (1) and (3) 20 to 30 V
Voltage Between CM01 (2) and (4) 20 to 30 V
Between CM01 (10) and (4) (ACC line) 20 to 30 V
Engine control (PC88MR-AG10-033-K-00-A)

2. Disconnect connector EGR V , and connect T-adapter to male side.
EGR valve solenoid Between EGR V (male) (6) and (7) 1 to 5 z
Resistance Between EGR V (male) (7) and (8) 1 to 5 z
Between EGR V (male) (8) and (6) 1 to 5 z
2. Disconnect connector VFT and connect T-adapter to male side.
solenoid
Between VFT (male) (6) and (7) 8 to 15 z
(In the monitor display
KVGT) Resistance Between VFT (male) (7) and (8) 8 to 15 z
Coolant temperature 2. Disconnect connector TWTR, and connect socket to male side.
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

0°C 30 to 37 kz
Between TWTR (male) (A) and
(B) 25°C 9.3 to 10.7 kz
Resistance 50°C 3.2 to 3.8 kz
a Coolant temperature- 80°C 1.0 to 1.3 kz
Resistance characteristics
95°C 700 to 800 z
2. Disconnect connector TMAP, and connect socket to male side.
a Regard charge temperature sensor as normal if its resistance is 80 z to 48
kz.
-40°C 41 to 48 kz
Charge temperature
sensor -20°C 14 to 16 kz
Between TMAP (male) (3) and
(4) 0°C 5.4 to 6.1 kz
Resistance 30°C 1.6 to 1.8 kz
a Charge temperature- 60°C 560 to 600 z
90°C 230 to 250 z
130°C 80 to 90 z
2. Disconnect connector P55 and connect T-adapter to male side.
-30°C 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
180 to 185 z
100°C
20-22 PC88MR-10

Charge (Boost) pressure 2. Insert T-adapter into connector J1.
sensor 3. Turn starting switch to ON position.
Voltage Between J1 (15) and (59) Sensor output 0.3 to 4.7 V
2. Insert T-adapter into connector J1.
Ambient pressure sensor 3. Turn starting switch to ON position.
Between J1 (16) and (59) or
Voltage Sensor output 0.3 to 4.7 V
between PAMB (3) and (2)
2. Insert T-adapter into connector PFUEL or J2
Common rail pressure 3. Turn starting switch to ON position.
sensor
Between PFUEL (2) and (3) or
between J2 (21) and (44)
2. Insert T-adapter into connector J1 or CCV.
Crankcase pressure 3. Turn starting switch to ON position.
sensor
Between J1 (3) and (59) or
between CCV (3) and (2)
2. Disconnect connector FP, and connect T-adapter to male side.
Throttle sensor (fuel dial) Between FP (male) (A) and (C) 4.0 to 6.0 kz
Resistance Between FP (male) (B) and (C) 3 to 7 kz
Between FP (male) (A) and (B) 3 to 7 kz
Engine oil pressure switch 2. Disconnect connector POIL , and connect T-adapter to male side.
Resistance Between POIL (male) (1) and ground Max. 1 z
Machine control (PC88MR-E000-033-P-00-A)
Travel speed selector 2. Disconnect connector V02, and connect T-adapter to male side.
solenoid Between V02 (male) (1) and (2) 20 to 60 z
Resistance
Between V02 (male) (1) and ground Min. 1 Mz
Swing holding brake 2. Disconnect connector V03, and connect T-adapter to male side.
solenoid Between V03 (male) (1) and (2) 20 to 60 z
Resistance
Attachment return 2. Disconnect connector V06, and connect T-adapter to male side.
selector solenoid Between V06 (male) (1) and (2) 20 to 60 z
Resistance
2. Disconnect connector V11, and connect T-adapter to male side.
PC-EPC solenoid
Between V11 (male) (1) and (2) 3 to 14 z
Resistance
Attachment oil flow 2. Disconnect connector V91, and connect T-adapter to male side.
adjustment EPC solenoid
1 Resistance
Attachment oil flow 1. Turn starting switch to OFF position.
adjustment EPC solenoid 2. Disconnect connector V92, and connect T-adapter to male side.
2 Resistance Between V92 (male) (1) and (2) 3 to 14 z
PC88MR-10 20-23

Hydraulic oil temperature Between P22 (male) (1) and (2) 10°C Approx. 80 kz
sensor 30°C Approx. 35 kz
Resistance a Temperature of oil
temperature sensor – 80°C Approx. 6.5 kz
Resistance characteristics 100°C Approx. 3.5 kz
2. Insert T-adapter into connector P25.
Pump pressure sensor
3. Turn starting switch to ON position.
Voltage Between P25 (2) and (1) Sensor output 0.5 to 4.5 V
Travel PPC pressure 2. Connect T-adapter to connector P26.
Bucket DUMP pressure 2. Insert T-adapter into connector P01.
Arm OUT pressure sensor
Boom RAISE pressure 2. Insert T-adapter into connector P03.
Bucket CURL pressure 2. Insert T-adapter into connector P04.
Arm IN pressure sensor
Boom LOWER pressure 2. Insert T-adapter in connector P06.
Boom swing right 2. Insert T-adapter into connector P07.
pressure sensor 3. Turn starting switch to ON position.
Boom swing left pressure 2. Insert T-adapter into connector P08.
Swing right pressure 2. Insert T-adapter into connector P10.
20-24 PC88MR-10

Swing left pressure 2. Insert T-adapter into connector P11.
Machine monitor (PC88MR-Q170-033-K-00-A)
Defective power 2. Insert T-adapter into connector E12.
generation of alternator 3. Start engine.
(when system is normal) Engine speed:
Voltage Between E12 (1) and ground Medium or 27.5 to 29.5 V
above
2. Insert T-adapter into connector CM01.
3. Disconnect heater relay terminal R16A.
Preheating a To prevent current from flowing through heater when starting switch is
turned to HEAT position
4. Turn starting switch to HEAT position.
Between P21 (male) (1) and FULL Approx. 10 z
Fuel level sensor
ground
Resistance Approx. 85 to
a Fuel level sensor EMPTY
95 z
characteristics
PC88MR-10 20-25
20-26 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
30 Testing and adjusting

5 30 Testing and adjusting
PC88MR-10 30-1
Table of contents

30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Testing engine speed ........................................................................................................... 30-8
Testing exhaust gas color ..................................................................................................... 30-9
Testing and adjusting valve clearance .................................................................................. 30-10
Testing compression pressure............................................................................................. 30-12
Testing blowby pressure ..................................................................................................... 30-14
Testing engine oil pressure ................................................................................................. 30-15
Testing fuel pressure .......................................................................................................... 30-16
Testing fuel return rate and leakage ..................................................................................... 30-17
Bleeding air from fuel system .............................................................................................. 30-20
Testing fuel circuit for leakage ............................................................................................. 30-22
Handling cylinder cutout mode operation.............................................................................. 30-23
Handling no-injection cranking operation.............................................................................. 30-24
Testing and adjusting air conditioner compressor belt tension ................................................ 30-25
Check fan belt, replace ....................................................................................................... 30-26
Check auto-tensioner, replace............................................................................................. 30-28
Writing compensation values at replacement of injector and engine controller ......................... 30-31
Power train............................................................................................................................... 30-35
Testing swing circle bearing clearance ................................................................................. 30-35
Testing and adjusting track tension ...................................................................................... 30-36
Releasing remaining pressure from hydraulic circuit .............................................................. 30-37
Testing and adjusting oil pressure in work equipment and travel circuits .................................. 30-42
Testing and adjusting swing and blade circuit oil pressure...................................................... 30-45
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
Testing PPC valve outlet pressure ....................................................................................... 30-56
Adjusting play of work equipment and swing PPC valves....................................................... 30-57
Isolating the parts causing hydraulic drift in work equipment................................................... 30-58
Testing and adjusting travel deviation................................................................................... 30-59
Testing oil leakage ............................................................................................................. 30-61
Bleeding air from hydraulic circuit ........................................................................................ 30-65
Testing, cleaning and lubricating slide door rail and roller ....................................................... 30-68
Adjusting mirrors ................................................................................................................ 30-69
Testing and adjusting hood catcher...................................................................................... 30-71
Electrical system ...................................................................................................................... 30-73
Special functions of machine monitor ................................................................................... 30-73
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
Related information on testing and adjusting
Related information on testing and adjusting (ALL-3831-001-A-00-A)
Tools for testing and adjusting (PC88MR-5320-304-A-00-A)
Testing/Adjusting item Sym-
Q'ty
Part No. Part name Remarks
bol
1 799-201-9002 Handy smoke checker 1
Testing exhaust gas
B Commercially Bosch index: 0 to 9
color 2 Smoke meter 1
available
Adjustment of valve Commercially Feeler gauge
C 1
clearance available
1 795-502-1590 Compression gauge 1 0 to 7 MPa
2 795-502-1800 Adapter 1 For SAA4D95LE-6 engine
Testing compression 3 6275-11-3880 Gasket 1
pressure D
4 6275-11-3890 O-ring 2
Commercially Inside diameter of hose:
5 Hose 1 Approximately 15 mm
available
1 799-201-1506 Blowby checker 1 0 to 10 kPa {0 to 1000 mmH2O}
Testing blowby 799T-201– Plug
E 2 1 Hose inside diameter: 24 mm
pressure 3210
799T-201– Cap
3 2 Pipe outside diameter: 25.4 mm
3220
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa}
1
Testing engine oil 790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa
pressure F Gauge
2 799-401-2320 1 Pressure gauge: 1.0 MPa
6732-81-3170 • Adapter 1
3
07002-11023 • O-ring 1
799-101-5002 Hydraulic tester 1
1 MPa
Testing fuel pressure G 790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa
795-471-1450 Adapter 1
2
07005-00812 Seal washer 1
1 6151-51-8490 Spacer 2
2 6206-71-1770 Joint 1
3 07005-01012 Seal washer 3
Commercially Inside diameter: Approximately
4 Hose 1
Testing fuel return available 6.5 mm
rate and leakage H Commercially Inside diameter: Approximately
5 Hose 1
available 12 mm
Commercially Measuring cylinder
6 1
available
Commercially Stopwatch
7 1
available
1 796–401–1300 Fixing jig 1
2 796–401–1330 • Collar 1
Check fan belt, • Bracket
replace U 3 796–401–1310 1
4 01583–13018 Nut 1 Size: M30 × 1.5 mm
Commercially
5 Wrench 1
available
1 796–401–1300 Fixing jig 1
2 796–401–1330 • Collar 1
Check auto-tensioner, • Bracket
replace U 3 796–401–1310 1
4 01583–13018 Nut 1 Size: M30 × 1.5 mm
Commercially
5 Wrench 1
available
Writing compensation Commercially Lap top type personal Windows XP SP2/VISTA/
values at replacement X 1 available computer 1
Windows7
PC88MR-10 30-3
Q'ty
bol
of injector and engine 2 Cu 3886388 INSITE ver. 7.4 –
controller 795-799-5730 INSITE 5 kit –
Commercially • Cable (USB) 1
3 available or
• Cable (RS232) 1
795-799-5740
795-799-5720 • Cable 1
4 799-601-4510 Cable (12P) 1
Testing swing circle Commercially
J Dial gauge 1
bearing clearance available
Developer for dye
Testing fuel circuit for Commercially penetrant (color
leakage Y 1
available checker)
Testing and adjusting 799-101-5002 Hydraulic tester 1
1 MPa
oil pressure in work 790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa
K
equipment and travel
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
circuits 2
07002-11023 O-ring 2
Testing and adjusting 1 MPa
swing and blade L 790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa
circuit oil pressure 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
1 MPa
Testing oil pressure of 790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa
M
control circuit
799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Measuring and 799-101-5002 Hydraulic tester 1
1 MPa
adjusting oil pressure 790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa
N
in pump PC control
799-101-5220 Nipple 3 Size: 10 x 1.25 mm
circuit 2
07002-11023 O-ring 3
1 MPa
790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa
Measuring and Differential pressure
adjusting oil pressure P 2 799-401-2701 gauge 1 50 MPa
in pump LS control
799-101-5220 Nipple 2 Size: 10 x 1.25 mm
3
07002-11023 O-ring 2
4 796T-440-1101 Sensor adapter 1 Pressure range: 50 MPa
Testing output 1 MPa
pressure of solenoid Q 790-261-1205 Digital hydraulic tester 1 Pressure gauge: 70 MPa
valve Size: 02
2 799-401-3100 Adapter 1
30-4 PC88MR-10
Q'ty
bol
Hydraulic tester Pressure gauge: 2.5, 6, 40, 60
799-101-5002 1
Measuring PPC valve 1 MPa
output pressure R 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 70 MPa
2 799-401-3100 Adapter 1 Size 02
Testing oil leakage Commercially Measuring cylinder
T 1
available
Testing coolant
temperature and oil — 799-101-1502 Digital thermometer 1 -99.9 to 1,299°C
temperature
Testing operating — 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
effort and depressing
— 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
effort
Testing stroke and Commercially
— Ruler 1
hydraulic drift available
Testing work Commercially
— Stopwatch 1
equipment speed available
Testing voltage and — Commercially
Multimeter 1
resistance available
Removal and
installation of engine 795T-981- 19 mm deep socket
— Socket 1 (MITOLOY 4ML-19 or equivalent)
coolant temperature 1010
sensor
PC88MR-10 30-5
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)
30-6 PC88MR-10
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
-: Socket
PC88MR-10 30-7
Engine and cooling system
Testing engine speed (PC88MR-A000-360-K-00-A)
a Check the engine speed with the monitoring 1) Start the engine, set the fuel control dial to
function of the machine monitor. high idle (MAX) position, and turn the auto-
deceleration function ON.
a Check this item under the following conditions.
2) Set all the levers and pedals for work
• Coolant temperature: 75 to 94°C equipment control, swing control, and travel
• Hydraulic oil temperature: 45 to 55°C in neutral and test the engine speed when
Testing (PC88MR-A000-388-K-00-A) the auto-decelerator operates.
1. Preparation a The engine speed automatically lowers to a

Operate the machine monitor so that it can certain level approximately 5 seconds after
monitor the engine speed. all the levers and pedals are set to
NEUTRAL position. This level is the auto-
a For the machine monitor operating method, deceleration speed.
see the section of "Special functions of
machine monitor".
a Monitoring code: 01002 "Engine speed"
2. Testing low idle speed

1) Start the engine, and set the fuel control dial
to low idle (MIN) position.
equipment control, swing control, and travel
in neutral, and test the engine speed.
3. Testing high idle speed
1) Start the engine, and set the fuel control dial
to high idle (MAX) position.
2) Set the working mode in Power Mode (P)
and set the auto-deceleration to OFF.
equipment control, swing control, and travel
in neutral, and test the engine speed.
4. Measuring engine speed at pump relief
1) Start the engine, and operate the arm to the
stroke end where the arm cylinder is fully
extended.
2) Set the fuel control dial to high idle (MAX)
position, and set the working mode to 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
Testing exhaust gas color (PC88MR-A900-360-K-01-A)
a Testing tools
Sym-
Part No. Part name
bol
1 799-210-9002 Handy smoke checker
B Commercially
2 Smoke meter
available
k Place the machine on a level ground and

lower the work equipment to the ground.
k Be careful not to touch any hot part when

installing or removing the testing tools.
a Check this item under the following conditions. 2) Connect the probe hose, receptacle of the
accelerator switch and air hose to smoke
• Coolant temperature: 75 to 94°C
meter B2.
a If an air source and an electric power source are
a The supplied air pressure must be 1.5
not available in the field, use handy smoke
MPa {15 kg/cm2} or below.
checker B1. When recording official data, use
3) Connect the power cable to an AC 100 V
smoke meter B2.
receptacle.
Testing (PC88MR-A900-385-K-00-A)
a Before connecting the power cable, make
1. Measuring by using handy smoke checker B1 sure that the power switch of the smoke
1) Place a sheet of filter paper to smoke meter is turned OFF.
checker B1. 4) Loosen the cap nut of the suction pump and
2) Insert the exhaust gas intake pipe into place the filter paper.
exhaust pipe (1).
a Place the filter paper securely so that the
3) Start the engine, accelerate it quickly and run
exhaust gas does not leak.
it at high idle, and operate the handle of
5) Turn ON the power switch of smoke meter
smoke checker B1 to absorb the exhaust gas
B2.
into the filter paper.
a Suction time: 1.4 ± 0.2 second
6) Start the engine, accelerate it quickly or run it

at high idle, and depress the accelerator
4) Remove the filter paper and compare it with pedal of smoke meter B2 to collect exhaust
the attached scale for judgment. gas on the filter paper.
5) After finishing the test, remove the testing 7) Place the contaminated filter paper on the
tools, and restore the machine. clean filter paper (at least 10 sheets) in the
2. Testing by using smoke meter B2 filter paper holder and read the indicated
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
Testing and adjusting valve clearance (PC88MR-A700-360-K-00-A)
a Tools for testing and adjusting

Sym-
Part No. Part name
bol
Commercially Feeler gauge
C
available

k Turn the battery disconnect switch to OFF

position, and remove the key.

• Coolant temperature: Normal temperature 4. Check the valve clearances marked with q in
the valve arrangement drawing.
Testing (PC88MR-A700-361-K-00-A)
1. Remove cylinder head cover. For details, see

Disassembly and assembly, "Removal and
installation of injector assembly".
2. Remove undercover (11) and turn the crankshaft
from the opening at the bottom of the crankshaft
pulley.
5. Insert feeler gauge C into the clearance between

rocker arm (14) and crosshead (15) to check the
valve clearance.
a For standard values, see "Standard value
table for engine".
3. Rotate crankshaft pulley (12) forward and match

compression top dead center mark (a) to large
slit (b) of ring (13).
a Rotate the crankshaft by using the crankshaft
pulley bolt (2) (width across flats: 27 mm).
a At the compression top dead center, the
rocker arm of No.1 cylinder can be moved by
valve clearance with hands. If the rocker arm
does not move, cylinder is not at the
compression top dead center, so rotate the
crankshaft further 1 turn.
6. After finishing the test, remove the testing tools,
and restore the machine.
Adjusting (PC88MR-A700-27D-K-00-A)
After testing, adjust the valve clearance according

to the following procedure, if necessary.
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
a With feeler gauge C inserted, turn adjustment

screw (16) until the feeler gauge C can move
lightly to adjust adjustment screw (16).
table for engine".
3. While fixing adjustment screw (16), tighten lock
nut (17).
3 Lock nut (17):
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.
3 Cylinder head cover mounting nut:
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
PC88MR-10 30-11
Testing compression pressure (PC88MR-A000-360-K-01-A)
a Testing tools 4. Loosen injector terminal nuts (16), and remove

Sym- the terminals from injector (15).
Part No. Part name
bol a Insulate the terminals with tape etc. so that
1 795-502-1590 Compression gauge they do not touch each other.
2 795-502-1800 Adapter
Remove the holder to remove injector (15).
3 6275-11-3880 Gasket
D
4 6275-11-3890 O-ring
Commercially Hose/inside diameter:
5 approximately 15 mm
available

k Turn the battery connect switch to OFF

k When testing the compression pressure, be

careful not to burn yourself by touching the
exhaust manifold or KDPF, or get caught in a
5. Install gasket D3 to the tip of adapter D2 and
rotating part.
insert them into the mounting part of injector
a Check this item under the following conditions. (15).
6. Fix adapter D2 with mounting holders (17) for
• Engine oil temperature: 40 to 60°C the injector.
Testing (PC88MR-A000-36B-K-00-A) 3 Mounting bolt:
1. Remove cylinder head cover, injector connector, 39 to 49 Nm {4.0 to 5.0 kgm}
and high-pressure pipes. For details, see
Disassembly and assembly, "Removal and a Tighten the mounting bolt while the fulcrum of
installation of injector assembly". the holder is seated perfectly.
2. Set the cylinders to check to the compression a Do not reuse the holder mounting bolt.
top dead center. For details, see "Testing and
adjusting valve clearance".
a Confirm the compression top dead center of
the cylinder by checking that you can move
both of the intake rocker arm exhaust rocker
arm by the distance equivalent to the valve
clearance.
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
8. Install hose D5 to the disconnected part of the

tube on the common rail side to drain the
injected fuel into a container.
9. Return the engine parts disconnected for testing
the compression pressure to their original
positions to enable cranking.
10.Set the machine monitor to "No-Injection
Cranking" operation.
k If the engine is not set to the "No-Injection

cranking" when performing the
compression pressure check, it may start
during measurement and cause personal 2) When inserting injector (15) into the head,
injury. Accordingly, be sure to set the apply engine oil to the O-ring and insertion
engine in this mode. hole on the head.
a Turn the battery disconnect switch to ON 3) Be sure to use a new injector holder bolt.
position, then turn the starting switch to ON a Do not reuse the injector holder bolt since
position. the engine oil may enter into the fuel
a For the method to set to "No-Injection return circuit.
Cranking", see "Special functions of machine
monitor".
11.Crank the engine by using the starting motor and

measure the compression pressure.
a Read the compression pressure when the
gauge pointer stands still.
12.After finishing the test, remove the testing tools,
a Install injector (15) and spill hose connector
according to the following procedure.
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
Testing blowby pressure (PC88MR-A000-360-K-02-A)
a Testing tools
Sym-
Part No. Part name
bol
1 799-201-1504 Blowby checker
E 2 799T-201-3210 Plug
3 799T-201-3220 Cap


• Coolant temperature: 75 to 94°C
• Hydraulic oil temperature: 45 to 55°C 8. After finishing the measurement, remove the
Testing (PC88MR-A000-36C-K-00-A)
1. Open the engine hood.

2. Loosen clamp (1).
3. Disconnect KCCV gas outlet hose (2), block the
hose by using plug E2, and block KCCV hose
insertion pipe by using cap E3.
4. Loosen clamp (3).
5. Disconnect KCCV gas inlet hose (4), block
KCCV hose insertion pipe by using cap E3,
install tool and adapter [1] of the blowby checker
to hose (4), and connect gauge [2].
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
Testing engine oil pressure (PC88MR-AB00-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
F 2 799-401-2320 Gauge
6732-81-3170 Adapter
3
07002-11023 O-ring

a Check this item under the following conditions. 3. Install the O-ring to adapter F3, and connect
• Coolant temperature: 75 to 94°C them to gauge F2 by using nipple [1] and hose
[2] of hydraulic tester F1.
Testing (PC88MR-AB00-362-K-00-A)
1. Remove covers (1) and (2).
4. Start the engine, and turn the auto-decelerator

OFF.
5. Measure the oil pressure with the engine at low
idle and high idle.
2. Remove oil pressure pickup plug (3) from the

engine block.
3 Oil pressure pickup plug:
20 to 22 Nm {2.0 to 2.2 kgm}
PC88MR-10 30-15
Testing fuel pressure (PC88MR-AE20-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
G Adapter
795-471-1450 (8 x 1.25 mm o R1/8)
2
07005-00812 Seal washer

k Check of the high-pressure circuit

connecting the supply pump, the common
rail, and the injector cannot be performed
due to the extremely high pressure
generated there.
k Before testing the fuel system or removing/

installing its parts, wait at least 30 seconds
after stopping the engine until the remaining
pressure in the fuel circuit is released. (Do
not start the work immediately after the
engine is stopped since remaining pressure
is still in the circuit.)
a Measure the fuel pressure in the low-pressure 3) Start the engine, and measure the pressure
circuit connecting the priming pump, supply in the fuel low-pressure circuit with the
pump and fuel main filter. engine at high idle.
Testing (PC88MR-AE20-362-K-00-A) a For standard values, see "Standard value

table for engine".
1. Check of pressure in fuel low-pressure circuit 4) After finishing the test, remove the testing
1) Open the engine hood,and remove fuel tools, and restore the machine.
pressure pickup plug (1) on the fuel main
3 Fuel pressure pickup plug:
filter.
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/cm2}.
30-16 PC88MR-10
Testing fuel return rate and leakage (PC88MR-AE20-360-K-01-A)
A: Measuring position of leakage from pressure a Testing tools

limiter Sym-
Part No. Part name
B: Measuring position of return rate from injector bol
1. Fuel tank 1 6151-51-8490 Spacer
2. Pre-filter 2 6206-71-1770 Joint
3 07005-01012 Seal washer
3. Priming pump
Commercially
4. Fuel filter 4 Hose
available
5. Feed pump H Commercially
5 Hose
available
6. SCV (Suction control valve)
Commercially Measuring cylinder
7. Common rail pressure 6
available
8. Injector Commercially Stopwatch
7
available
9. Pressure limiter
10. Supply pump k Place the machine on a level ground, and
11. Fuel cooler lower the work equipment to the ground.
k 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
Testing (PC88MR-AE20-363-K-00-A)
1. Preparation 8) Return the air compressor.

1) Remove the air compressor. Preparation is completed.
2) Remove injector return tube (3) and pressure 2. Testing leakage from pressure limiter
limiter return tube (4) connected to joint bolt 1) Arrange the route of test hose H4 so that it
(2) of return block (1). does not sag, and put its end in a oil pan
(container to catch the fuel).
2) Start the engine, and run it at 1,600 rpm with
no load.
3) After the engine speed is stabilized, measure
the leakage for 1 minute by using measuring
cylinder H6.
a Measuring duration can be 20 seconds if
the leaked amount is multiplied by 3 after
the measurement.
table for engine".
3) Insert spacers H1 (2 pieces) into the return

block side, and tighten the removed joint bolt
again.
a Be sure to install seal washers H3 (3
pieces) to each end of spacers H1.
4) Remove the joint bolt on the cylinder head
side of injector return tube (3), set joint H2,
and tighten the joint bolt again.
5) Connect test hose H4 to the end of joint H2.
4) Stop the engine after the measurement is

over.
3. Testing fuel return rate from injector
a While you are measuring the fuel return rate
from the injector, keep the hose on the
pressure limiter side connected and its end in
the oil pan (container to catch the fuel).
1) Start the engine, and run it at the rated
horsepower.
6) Set joint H2 to pressure limiter (5), and 2) After the engine speed is stabilized, measure
tighten the removed joint bolt again. the return rate for 1 minute by using
7) Connect test hose H4 to the end of joint H2. measuring cylinder H6.
a You may measure the return rate for 20
seconds and multiply it by 3 to judge.
a 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.
table for engine".
30-18 PC88MR-10
3) Stop the engine after the measurement is

over.
4. After finishing the measurement, remove the
3 Joint bolt:
3.6 to 6.9 Nm {0.4 to 0.7 kgm}
PC88MR-10 30-19
Bleeding air from fuel system (ALL-AD00-001-K-00-A)
a If fuel is used up or if a fuel circuit component is removed and installed, bleed air from the fuel circuit
k Place the machine on a level ground and lower the work equipment to the ground.
Bleeding air (PC88MR-AD00-231-K-00-A)
1. Fill the fuel tank with fuel.

a Supply fuel until the float of sight gauge
reaches to the highest position.
3. Loosen knob (1) of the feed pump and pull it out,
and move it back and forth.
a 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
a Air bleeding route of fuel circuit

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
Testing fuel circuit for leakage (PC138-AD00-360-K-00-A)
a Testing tools a Relieve the arm circuit at the arm IN stroke

Sym- end.
Part No. Part name 9. Check the fuel piping and devices for fuel
bol
Developer leakage.
Commercially
Y for dye penetrant check a Check the high-pressure circuit for fuel
available
(color checker) leakage focusing on the area where color
checker Y is sprayed.
k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel a If any fuel leakage is detected, repair it and
leaks while the engine is running, it presents perform the checks from step 1 again.
a serious danger that could result in a fire. a If no fuel leakage is detected, check is
After testing the fuel system and removing or complete.
installing the tools for the test, test it for fuel
leakage according to the following procedure.

a Clean and degrease the engine and the parts

around it in advance so that you can check it
easily for fuel leakage.
Testing (PC88MR-AD00-364-K-00-A)
1. Spray color checker (developer) Y to the fuel

supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,200 rpm or
below, and stop it when its speed is stabilized.
3. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area where color
a If any fuel leakage is detected, repair it and
perform the checks from step 1 again.
4. Start the engine, and keep it running at low idle.
leakage.
6. Start the engine, and keep it running at high idle.
leakage.
8. Start the engine and keep it running at high idle,
then apply a load to the engine.
30-22 PC88MR-10
Handling cylinder cutout mode operation (PC400-AD00-34F-K-00-A)
a The cylinder cut-out test mode operation means

to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for Cylinder Cut-out
Mode operation, if the engine speed and output
do not change from the normal operation (all-
cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.
PC88MR-10 30-23
Handling no-injection cranking operation (PC-A000-25L-K-00-A)
a No-injection cranking means to crank the engine

by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
No-injection cranking is performed to lubricate
the engine parts and to protect them from
seizure. 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
Testing and adjusting air conditioner compressor belt tension (ALL-K5A0-001-K-00-

A)
k Park the machine on a level ground and a When the V-belt is replaced, check and
lower the work equipment to the ground. adjust its tension again after running the
engine for an hour.
Testing (PC88MR-K5A0-285-K-00-A)
a After tightening the bolts, check the belt
1. Open the engine hood and remove fan guard again for the normal tension according to the
(1). procedure described in the above.
2. Press the belt at the intermediate point between 4. Restore the machine after finishing the
the fan pulley and compressor pulley with your adjustment.
finger and measure deflection (a).
• Belt pressing force: 60 N {6.1 kg}
• Belt deflection: 6 to 9 mm
3. Restore the machine after finishing the test.

Adjusting (PC88MR-K5A0-27C-K-00-A)
a If the belt deflection is improper, adjust it

1. Loosen mounting bolt (3) and clamping bolt (4)
of bracket (2).
2. Use a bar, etc. to slide bracket (2) and adjust the
belt tension, and tighten clamping bolt (4).
3. Tighten mounting bolt (3) of brackets (2).
a 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
Check fan belt, replace (PC138-B430-360-K-00-A)
a Replacing tools a If the belt is obviously worn, there is a

Sym- possibility that the auto-tensioner is also
Part No. Part name worn and the surface of the pulley is rough.
bol
1 796–401–1300 Fixing jig In that case, the newly replaced belt may be
2 796–401–1330 • Collar worn early if the pulley is continuously used.
Therefore, replacement of the belt and auto-
U 3 796–401–1310 • Bracket tensioner as a set is recommended.
4 01583–13018 Nut
Commercially
5 Wrench
available
a The auto-tensioner is provided for the fan belt.

Thus, usual checking and adjusting the belt is
not necessary.
a When replacing the fan belt, remove the air
conditioner compressor belt beforehand.
Testing (PC88MR-B430-280-K-00-A)
1. Remove cover (1).
Replace (PC88MR-B430-923-K-00-A)
1. Install guide collar U2 to spacer (3) of auto-

tensioner (2).
2. Insert holding bracket U3 into collar U2 and
2. Check the fan belt (4).
tighten it lightly with nut U4.
a Replace the fan belt (4) in the following
a At this time, fit hollow part "a" of holding
cases.
bracket U3 to protruding part "b" of auto-
• The alternator belt has a vertical scratch tensioner (2).
(b) which crosses the horizontal scratch
(a).
• The alternator belt has tears (c).
Need not to be replaced if it has only a
horizontal scratch (d).
a Possible causes of the damage on the belt
• Improper tension has been applied.
• 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
6. After replacement, remove holding bracket U3 in

reverse order of installation.
k Slowly and carefully return tensioner

assembly (2).
3. 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).
k Make sure that it is securely inserted into

part (C) of tensioner assembly (2) before
turning the wrench U5. (The spring of
tensioner assembly (2) is strong. If the
wrench is loosely inserted, the wrench U5
may accidentally come off while being
turned, and it is extremely dangerous.)
After removing fan belt (4), return
tensioner assembly (2) to its original
position slowly and carefully.
Be careful not to get your fingers caught
between the pulley and fan belt (4) during
work.
4. Tighten nut U4 at the position where the belt

tension was reduced.
a Check that holding bracket U3 is inserted
between protrusions (b) and (d) of auto
tensioner (2), and that the end surface of
collar U2 and that of nut U4 become flush at
this time.
k 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
Check auto-tensioner, replace (PC88MR-AT50-92E-K-00-A)
a Replacing tools
Sym-
Part No. Part name
bol
1 796–401–1300 Fixing jig
2 796–401–1330 • Collar
U 3 796–401–1310 • Bracket
4 01583–13018 Nut
Commercially
5 Wrench
available
a When replacing the fan belt, remove the air 4. Install guide collar U2 to spacer (3) of auto-
conditioner compressor belt beforehand. tensioner (2).
a The auto-tensioner is provided for the alternator 5. Insert holding bracket U3 into collar U2 and
belt. Thus, checking and adjusting the belt tighten it lightly with nut U4.
tension is usually not necessary. a At this time, fit hollow part "a" of holding
Testing (PC88MR-AT50-280-K-00-A) bracket U3 to protruding part "b" of auto-
tensioner (2).
2. Check that there is no crack on the arm (a),

pulley (b), arm stop part (c), and spring case
stop parts (d) and (e) of the auto-tensioner (2).
a Replace the auto-tensioner (2) if there is any
crack or damage.
3. Check with the fan belt installed that the arm
stop part (c) of the auto-tensioner does not
contact with the spring case stop parts (d) or (e).
a Replace the fan belt if the arm stop part (c)
contacts with the spring case stop parts (d)
or (e).
6. Apply the wrench U5 to portion (C) (width across
30-28 PC88MR-10
k Make sure that it is securely inserted into 13.Check that the arm (a) of the auto-tensioner (2)
part (C) of tensioner assembly (2) before is not moved by hand.
turning the wrench U5. (The spring of
a Replace the auto-tensioner (2) if the arm (a)
is moved by hand.
wrench U5 is loosely inserted, the wrench
14.Check that the arm stop part (c) contacts with
may accidentally come off while being
the spring case stop part (d) by using the wrench
U5.
After removing fan belt (4), return
tensioner assembly (2) to its original a If the arm stop part (c) does not contact with
position slowly and carefully. the spring case stop part (d), replace the
auto-tensioner (2).
Be careful not to get your fingers caught
between the pulley and fan belt (4) during a The auto-tensioner (2) is not needed to be
work. replaced if there is no abnormality in steps
12, 13, and 14.
7. Tighten nut U4 at the position where the belt

a Check that holding bracket U3 is inserted
collar U2 and that of nut U4 become flush at
this time.
k If holding bracket U3 is insufficiently

tighten nut U4.
Replace (PC88MR-AT50-923-K-00-A)
8. Replace fan belt (4). 1. Remove the bolt (5), and remove the auto-
9. Apply a wrench to portion (c) (width across flats: tensioner (2).
12.7 mm) of auto tensioner (2), and rotate it to
the opposite to the winding-up direction.
k Be sure that wrench is set securely to

portion (c) of auto tensioner assembly (2)
before rotating it. (Since the spring force
of auto tensioner assembly (2) is strong,
the wrench might come off and induce
personal injury if it is rotated when not
securely attached.)
10.Remove nut U4 , and disconnect holding
bracket U3. 2. Set the dowel pin (6) of the new auto-tensioner
11.Remove collar U2. (2) to be aligned with the groove (7) of the
12.Check that the arm stop part (c) of the auto- cylinder block.
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
3. Install the bolt (5).

3 bolt (5) :
43 ± 6 Nm {4.4 ± 0.6 kgm}
30-30 PC88MR-10
Writing compensation values at replacement of injector and engine

controller (PC400-AP70-001-K-00-A)
a Equipment needed for writing compensation a Service connector (1) (CN-N08) is installed in
values the panel in the rear left side of the cab.
Sym-
Part No. Part name
bol
Laptop computer:
Commercially
1 Windows XP SP2/ VISTA/
available
Windows 7
2 Cu3886388 INSITE ver 7.4
Cu4919416 INLINE 5 kit
X Commercially
available • Cable (USB)
3 • Cable (RS232)
or
795-799-5740
795-799-5720 • Cable
4 799-601-4510 Cable (12P)
a To install the INSITE program to the computer, Start INSITE

insert the software DVD-ROM into the DVD 1. Boot the PC.
drive of the computer and follow the menu. 2. Turn the starting switch to ON position and
supply power from the battery to the engine
a For writing, use INSITE v7.4 Feature Pack 1 or
controller.
after.
3. Double-click the icon on the PC shown in the
a If a problem (shutdown or open circuit) occurs in figure below.
the computer or cables, a serious error may
arise in the engine controller. Be careful when
connecting the cables.
a When connecting the INSITE system to the
engine controller, do not interrupt the battery
power supply to the engine controller. A power
loss breaks the connection with the INSITE
system.
Connecting PC (PC88MR-AP70-270-K-00-A)
1. Check that the starting switch is turned to OFF

position.
4. Establish communication with the engine
k The starting switch must be turned to controller.
OFF position when the personal computer
is connected or disconnected. 1) Select "Connect to ECM".
• 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
• Section B: Confirm that "None" is

displayed.
3) Input the new data to "New Barcode"

column.
a Replacement of the injector and engine
a C: Connection-in-process screen
controller is performed.
D: Screen after the connection is Replace injector.
complete (illustration does not move) • When the injector is replaced, write the
E: Communication status is displayed injector compensation value written on
(illustration moves during communication) the new injector in the engine controller.
• If the compensation value is not correctly
written, an engine trouble can result.
• The character string on the injector top
face is read.
Read from the top line, from left to right.
(Reading order of character string)
5. Execute the injector trim function and data

writing.
1) Select "Advanced ECM Data".
• Section F: Make sure that "Advanced
ECM Data" is indicated.
2) Select "High Pressure Common Rail Injector

Setup". Replacing engine controller
• Section G: Make sure that "High • When the engine controller is replaced,
Pressure Common Rail Injector Setup" is write the injector compensation value
indicated. written on the old engine controller to the
new engine controller.
30-32 PC88MR-10
• If the compensation value is not correctly

written, an engine trouble can result.
• Compensation value information provided
on the back of engine controller
a: String of characters
b: QR code
• Screen while data processing is

continued (wait for 30 seconds)
• Section H: "New Barcode" column
6) After data processing is over, turn the

starting switch to ON position and select
"OK".
• Section L: Select "OK."
4) Execute writing to the engine controller.

After entering the injector data, select "Apply".
• I: Entry of data of the target injector.
Examples)
Enter data of No.1 cylinder injector
corresponding to "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
8) Screen that appears when data writing ends 7. Turn the starting switch to OFF position, then
successfully. "Success" is displayed on the boot the PC again (turn the starting switch to ON
screen. position) to make sure that an error is not
• Section N: Make sure that "success" is present on the monitor.
indicated. a Related error code:
CA2765: Inj Trim Data Error
8. When replacing the injector, clear the values on
the compensation values sheet on the back of
the engine controller.
a Clear the former data characters of the
replaced injector on the compensation
values sheet that is provided on the back of
the controller. (Add strike-through.)
a Record the former data of the replaced
injector in the maintenance register.
9. When the engine controller is replaced,
inconsistency may result between the data
a Screen that appears for faulty data writing recorded on the sheet on the back of the
• Section P: Indicates that writing is controller and that recorded in the register when
faulty. replacement of an injector or engine controller
• If the following appears instead of the was done before. In such case, you must use
screen of item 8) after the operation of the compensation character strings contained in
item 7), it is suspected that the the maintenance record information or import
entered new data is inappropriate. the compensation value information described
(After rechecking data, perform the on the top face of every injector installed on the
operation again.) cylinders, in the same way as you did in the
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
Power train
Power train (ALL-C100-001-K-00-A)
Testing swing circle bearing clearance (PC88MR-J117-360-K-00-A)
a Testing tools 5. Under this condition, read dial gauge J.

Sym- a The value indicated by dial gauge J is the
Part No. Part name
bol bearing clearance.
Commercially Dial gauge
J
available
k Be careful not to put you hand or foot under

the undercarriage during the test.
Testing (PC88MR-J117-365-K-00-A)
1. Fix dial gauge J to outer race (1) or inner race

(2) of the swing circle and put the probe to inner
race (2) or outer race (1) on the opposite side.
a Set dial gauge J at the front or rear of the
machine.
6. Return the machine to the condition in step 2,

and check that dial gauge J indicates 0 point
again.
a If the dial gauge does not indicate 0 point,
repeat steps 3 to 5.
2. Set the work equipment in the maximum reach

posture, and set the bucket end to the height of
the under surface of the revolving frame.
a At this time, the front of the upper structure
lowers and the rear rises.
3. Set dial gauge J to the zero point.
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
Undercarriage and frame
Testing and adjusting track tension (ALL-DTL0-001-K-00-A)
Testing (PC88MR-DTL0-285-K-00-A) a The grease can be pumped in until

dimension (b) between the idler guide
1. Run the engine at low idle, drive the machine by
the length of track on ground, and slowly stop it. and the track frame end becomes 0 mm.
If the tension is still loose, the wear of
2. Put a bar [1] on the track shoe between the idler
pins and bushings is large. In such a
and the first carrier roller.
case, the pins and bushings need to be
a Use an L shape steel bar, etc. which has few turned 180 deg. or replaced.
bents for bar [1].
3. Measure maximum clearance (a) between bar
[1] and track shoe.
Standard max. clearance (a)
• Road liner, iron shoe specification: 10 to 30
mm
• Rubber shoe specification: 1 to 3 mm
2. When decreasing the tension

1) Loosen valve (1), remove the grease, and
tighten valve (1).
k There is a danger that the valve may

jump out by the internal high-pressure
grease. Do not loosen the valve more
Adjusting (PC88MR-DTL0-27C-K-00-A)
than 1 turn.
1. When increasing the tension
2) To check if the track tension is correct, run
1) Pump in grease through grease fitting (2) by the engine at low idle, move the machine
using a grease gun. slowly forward by an amount equal to the
2) To check if the track tension is correct, run length of track on ground, then stop the
the engine at low idle, move the machine machine.
slowly forward by an amount equal to the 3) After finishing adjustment, check that the
length of track on ground, then stop the tension is correct according to the preceding
machine. procedure.
3) After finishing adjustment, check that the
tension is correct according to the preceding
procedure.
1 2
T2 P0 2 8 0 0
30-36 PC88MR-10
Hydraulic system
Releasing remaining pressure from hydraulic circuit (ALL-C000-001-P-02-A)
Releasing remaining pressure (PC88MR- 3. Start the engine and run it at low idle for 5
C000-22A-K-00-A) seconds to increase the pressure in the
Releasing remaining pressure from hydraulic accumulator.
tank a The engine does not start unless the work
k Release remaining pressure from the equipment lock lever is set to LOCK
hydraulic tank according to the following position.
procedure since hydraulic tank is airtight and 4. Repeat above procedure 2) and 3) 2 to 3
pressurized when removing a hose or a plug times, and all remaining pressure is released
connected to the hydraulic tank. from the pipes completely.
• With anti-drop valve
1. Lower the work equipment to the ground in a Check function of PPC circuit accumulator
stable posture and stop the engine.
a Stop the machine on a level ground.
2. Loosen oil filler cap (1) of the hydraulic tank
gradually to release the air in the tank. 1. Hold the work equipment in the maximum
reach posture (arm OUT, bucket DUMP
stroke end) at height (a) from the ground.
a: 1.5 m
Releasing remaining pressure in hydraulic

cylinder circuit
• Without anti-drop valve
2. Keep the work equipment at the maximum
reach, turn the starting switch to OFF
k When disconnecting a pipes between a position, and stop the engine.
hydraulic cylinder and the control valve, 3. Turn the starting switch to ON position.
release the remaining pressure from the 4. Set the work equipment lock lever in FREE
piping according to the following position.
procedure. 5. Check that the work equipment is lowered to
1. Release the remaining pressure in the the ground by slowly operating the work
hydraulic tank. For details, see preceding equipment control lever to the boom LOWER
"Releasing remaining pressure in hydraulic direction fully to the stroke end.
tank". a If the work equipment is lowered down
a Leave the oil filler cap of the hydraulic under its weight to the ground, the
tank removed. accumulator is normal.
2. Turn the starting switch to ON position and a Pressure of accumulator drops gradually
set the work equipment lock lever to FREE after stopping the engine. Be sure to
position, and then operate the right and left perform this work (procedure 2 and 3) in
work equipment control levers forward and 15 seconds after stopping the engine.
backward, and to the right and left.
a If the work equipment is not lowered or
a The control valve is operated by the stops on the way lowering, pressure in
pressure in the accumulator. The the accumulator may be dropped.
pressure in the accumulator is used up, 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
Hydraulic system
a Accumulator is a periodic inspection item work equipment control levers forward and
and an important periodic replacement backward, and to the right and left.
part.
a The control valve is operated by the
pressure in the accumulator. But the
pressure in the accumulator is used up
after the work equipment control levers
are operated 2 to 3 times.
2) Start the engine and run it at low idle for 5
seconds to increase the pressure in the
accumulator.
a The engine does not start unless the work
equipment lock lever is set to LOCK
position.
3. Repeat above procedure 1) and 2) 4 to 5 times,
and all remaining pressure is released from the
Releasing remaining pressure from cylinder cylinders completely.
4. Loosen oil filler cap of the hydraulic tank
1. Operate the arm to the maximum arm IN side gradually to release the air in the tank.
and maximum arm OUT side, lower the work
equipment to the ground, and stop the engine. a Leave the oil filler cap of the hydraulic tank
removed.
a Since anti-drop valve is attached to boom
cylinder bottom side, remaining pressure a When disassembling the anti-drop valve,
drops due to less hydraulic pressure on perform releasing remaining pressure in
bottom side of boom cylinder when work cylinders, loosen anti-drop valve assembly
equipment is lowered to the ground. mounting bolts gradually. Check that
hydraulic oil pressure is released, remove it
as an assembly, and disassemble it.
• With anti-drop valve of arm
(Releasing remaining pressure with maximum arm
IN posture)
Check function of PPC circuit accumulator
a Stop the machine on a level ground.
1. Hold the work equipment in the maximum reach
posture (arm OUT, bucket DUMP stroke end) at
height (a) from the ground.
a: 1.5 m
2. Keep the work equipment at the maximum reach,

turn the starting switch to OFF position, and stop
2. Release remaining pressure in hydraulic
the engine.
cylinder circuit
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
Hydraulic system
5. Check that the work equipment is lowered to the 1) Turn the starting switch to ON position and
ground by slowly operating the work equipment set the work equipment lock lever to FREE
control lever to the boom LOWER direction fully position, and then operate the right and left
to the stroke end. work equipment control levers forward and
a If the work equipment is lowered down under
its weight to the ground, the accumulator is a The control valve is operated by the
normal. pressure in the accumulator. But the
a Pressure of accumulator drops gradually
after stopping the engine. Be sure to perform
are operated 2 to 3 times.
this work (procedure 2 and 3) in 15 seconds
after stopping the engine.
a If the work equipment is not lowered or stops accumulator.
on the way lowering, pressure in the
accumulator may be dropped. Pressure
equipment lock lever is set to LOCK position.
cannot be released with this procedure if the
3. Repeat above procedure 1) and 2) 4 to 5 times,
function of accumulator is deteriorated.
and all remaining pressure is released from the
a Accumulator is a periodic inspection item and cylinders completely.
an important periodic replacement part. 4. Loosen oil filler cap of the hydraulic tank
gradually to release the air in the tank.
a Leave the oil filler cap of the hydraulic tank
removed.
a When disassembling the anti-drop valve,
perform releasing remaining pressure in
cylinders, loosen anti-drop valve assembly
mounting bolts gradually. Check that
hydraulic oil pressure is released, remove it
as an assembly, and disassemble it.
• With anti-drop valve of arm
(Releasing remaining pressure with maximum arm
OUT posture)
Releasing remaining pressure from cylinder Check function of PPC circuit accumulator
1. Lower the work equipment to the ground with a Stop the machine on a level ground.
arm IN operation, and stop the engine. 1. Hold the work equipment in the maximum reach
a Since anti-drop valve is attached to arm posture (arm OUT, bucket DUMP stroke end) at
cylinder head side, remaining pressure drops height (a) from the ground.
due to less hydraulic oil on head side of arm a: 1.5 m
cylinder when work equipment is lowered to
the ground. Also, Remaining oil on head side
is reduced.
2. Keep the work equipment at the maximum reach,

turn the starting switch to OFF position, and stop
the engine.
2. Release remaining pressure in hydraulic 3. Turn the starting switch to ON position.
cylinder circuit
PC88MR-10 30-39
Hydraulic system
4. Set the work equipment lock lever in FREE

position.
5. Check that the work equipment is lowered to the
ground by slowly operating the work equipment
control lever to the boom LOWER direction fully
to the stroke end.
a If the work equipment is lowered down under
its weight to the ground, the accumulator is
normal.
a Pressure of accumulator drops gradually
after stopping the engine. Be sure to perform
this work (procedure 2 and 3) in 15 seconds
after stopping the engine. 2. Release remaining pressure in hydraulic
cylinder circuit
a If the work equipment is not lowered or stops
on the way lowering, pressure in the 1) Turn the starting switch to ON position and
accumulator may be dropped. Pressure set the work equipment lock lever to FREE
cannot be released with this procedure if the position, and then operate the right and left
function of accumulator is deteriorated. work equipment control levers forward and
a Accumulator is a periodic inspection item and
an important periodic replacement part. a The control valve is operated by the
pressure in the accumulator. But the
are operated 2 or 3 times.
accumulator.
equipment lock lever is set to LOCK position.
3. Repeat above procedure 1) and 2) 10 to 15
times, and all remaining pressure is released
from the cylinders completely.
4. Loosen oil filler cap of the hydraulic tank
Releasing remaining pressure from cylinder gradually to release the air in the tank.
1. Operate the arm to the maximum arm OUT side, a Leave the oil filler cap of the hydraulic tank
lower the work equipment to the ground, and removed.
stop the engine.
a When disassembling the anti-drop valve,
a Since anti-drop valve is attached to arm perform releasing remaining pressure in
cylinder head side, remaining pressure cylinders, loosen anti-drop valve assembly
increases due to more hydraulic oil applied to mounting bolts gradually. Check that
head side when work equipment is lowered hydraulic oil pressure is released, remove it
to the ground. If it is the case, perform more as an assembly, and disassemble it.
times of releasing of the remaining pressure Releasing remaining pressure from swing motor
from hydraulic piping. circuit
a 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
Hydraulic system
a The control valve spool of the travel motor circuit

is an open type circuit, so the remaining
pressure in the circuit can be released by
performing the same operation as that described
in preceding "Releasing remaining pressure in
hydraulic tank".
Releasing remaining pressure in swing cylinder
circuit
1. Release the remaining pressure in the hydraulic
tank. For details, see preceding "Releasing
remaining pressure in hydraulic tank".
removed.
2. Turn the starting switch to ON position, set the
work equipment lock lever to FREE position, and
operate the swing pedal to the right and left.
a The control valve is operated by the pressure
in the accumulator. But the pressure in the
accumulator is used up after the work
equipment control levers are operated 2 to 3
times.
3. Start the engine and run it at low idle for 5
seconds to accumulate the pressure in the
accumulator.
a 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.
Releasing remaining pressure in blade cylinder
circuit
1. Release the remaining pressure in the hydraulic
tank. For details, see preceding "Releasing
remaining pressure in hydraulic tank".
removed.
2. Turn the starting switch to ON position, set the
work equipment control lever to FREE position,
and operate the blade control lever to forward
and reverse.
a The control valve is operated by the pressure
in the accumulator. But the pressure in the
accumulator is used up after the work
equipment control levers are operated 2 to 3
times.
3. Start the engine and run it at low idle for 5
seconds to accumulate the pressure in the
accumulator.
a 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
Hydraulic system
Testing and adjusting oil pressure in work equipment and travel

circuits (PC88MR-C000-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
K
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
k Place the machine on a level ground, lower

the work equipment to the ground, and
release the remaining pressure in the
hydraulic circuit. For details, see "Releasing
remaining pressure in hydraulic circuit". 2) Install nipple K2 and connect oil pressure
gauge [1] of hydraulic tester K1.
Testing (PC88MR-C000-362-K-00-A)
a Use the oil pressure gauge of 60 MPa .
a The oil pressures (pump discharged pressures)
of the work equipment and travel circuits can be
checked with the monitoring function of the
machine monitor (For details, see SPECIAL
FUNCTIONS OF MACHINE MONITOR).
• Monitoring code: 01100 "Pump pressure"
• Hydraulic oil temperature: 45 to 55°C
1. Preparation
1) Remove cover (6) on the right side of the
control lever, and remove pressure pickup
plugs (1) and (2).
• (1): Pump discharged pressure port (1) 2. Testing unload pressure
pickup plug 1) Start the engine, set the working mode to
• (2): Pump discharged pressure port (2) power mode (P), and turn the auto
pickup plug deceleration OFF.
2) Run the engine at high idle, set all of control
levers and pedals of work equipment and
travel in neutral, and measure the oil
pressure.
a 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
Hydraulic system
2) Set the working mode to Power Mode (P). a For the setting method, see "Special
3) Run the engine at high idle, operate the right functions of machine monitor".
and left work equipment control levers to • ""Monitoring code: 01100 "Pump pressure"
relieve the cylinder, and measure the oil • "Pre-defined Monitoring (07/11)" screen
pressure.
a The pressure at the time when the main
relief valve of the control valve is relieved
is displayed.
4. Testing the travel relief pressure
1) Run the engine, and lock the travel
mechanism.
k Insert pin [2] between the sprocket

and the track frame to securely lock
the track.
• "Self-define Monitoring" screen
2) Set the working mode to Power Mode (P).

3) Run the engine at high idle, operate the
travel lever and pedal to relieve the travel
motor circuit, and measure the oil pressure.
2. Increase the hydraulic oil temperature to 45 to
k Before operating the travel lever 55°C and measure the pump discharged
(pedal), check the pin position and pressure.
locked direction of the travel again. a For the measuring procedure, see
a The pressure when the main relief valve "Measuring method by using oil pressure
of the control valve cracks is relieved is gauge".
displayed. The travel circuit is always Adjusting (PC88MR-C000-270-K-00-A)
relieved at high pressure.
5. Work after finishing test a The unload valve cannot be adjusted.
After finishing the test, remove the testing tools, Adjustment of work equipment and travel relief
and restore the machine. pressure
3 Oil pressure pickup plug: a If the work equipment and travel relief pressure
20 to 27 Nm {2.0 to 2.8 kgm} is not normal, adjust main relief valve (3) of the
control valve according to the following
Measuring method by using machine monitor procedure.
a The oil pressure in the work equipment and
travel circuits (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
Hydraulic system
1. Remove the left side cover of the control valve.

2. While fixing holder (4), loosen lock nut (5).
3. Turn holder (4) to adjust the set pressure.
a When the holder is
• turned clockwise, the set pressure
increases.
• turned counterclockwise, the set pressure
decreases.
a Quantity of pressure adjustment per turn of
holder:
Approximately 19.6 MPa {Approximately 200
kg/cm2}
4. While fixing holder (4), tighten lock nut (5).
3 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
Hydraulic system
Testing and adjusting swing and blade circuit oil pressure (PC88MR-C000-360-K-01-A)
a Testing tools
Sym-
Part No. Part name
bol
1
L
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

remaining pressure in hydraulic circuit". 2. Testing swing relief pressure
1) Remove left exterior cover (11), and
disconnect connector (12) of the swing
a The oil pressures (pump discharged pressures) parking brake solenoid valve.
of Swing and blade circuit oil pressure (pump
discharged pressure) can be checked with the
monitoring function of the machine monitor (For
details, see SPECIAL FUNCTIONS OF
MACHINE MONITOR).
• Monitoring code: 01100 "Pump Pressure"
1. Preparation
1) Open the right side inspection window, and
remove oil pressure pickup plug (1).
2) Install nipple L2 and connect it to oil pressure

gauge [1] of hydraulic tester L1. 2) Start the engine, and set the working mode
to power mode (P).
a Use the oil pressure gauge of 60 MPa
{600 kg/cm2}. a Action level L03 is displayed on machine
monitor.
3) Run the engine at high idle, operate the left
work equipment control lever to relieve the
swing motor oil circuit, and measure the oil
pressure.
a 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
Hydraulic system
1) Start the engine, and set the working mode

to power mode (P).
blade control lever to lower, and measure the
oil pressure when relieving.
4. Testing blade (RAISE) relief pressure
to power mode (P).
blade control lever to raise, and measure the
oil pressure when relieving.
3) After finishing the adjustment, check the oil
Adjusting (PC88MR-C000-270-K-01-A) pressure again according to the above
1. Adjustment of swing relief pressure procedure.
2. Adjusting blade (LOWER) relief pressure
a If the swing relief pressure is not normal,
adjust safety valve (2) of the swing motor a If the blade (LOWER) relief pressure is
according to the following procedure. abnormal, adjust main relief valve (5)
k Do not turn end cap (3) in a

counterclockwise more than once. More k Do not turn end cap (6) in a
turns may cause the cap to be jumped counterclockwise more than once . More
out. turns may cause the cap to be jumped
out.
1) Loosen lock nut (4) of safety valve (2) and
turn end cap (3) to adjust the pressure. 1) Loosen lock nut (7) of main relief valve (5)
and turn end cap (6) to adjust the pressure.
a Rotate the adjustment screw:
• turned clockwise, the set pressure
increases. • turned clockwise, the pressure is
• turned counterclockwise, the set increased.
pressure decreases. • turned counterclockwise, the pressure
is decreased.
a Quantity of pressure adjustment per turn
of adjustment screw: a Quantity of adjustment per turn of
adjusting screw:
4.8 MPa {49.3 kg/cm2}
2) After finishing the adjustment, tighten lock 19.6 MPa {200 kg/cm2}
nut (4). 2) After finishing the adjustment, tighten lock
nut (7).
3 Lock nut:
3 Lock nut:
93.2 to 117.7Nm {9.5 to 12kgm}
39 to 49 Nm {4 to 5 kgm}
30-46 PC88MR-10
Hydraulic system
3) After finishing the adjustment, check the oil 3) After finishing the adjustment, check the oil
pressure again according to the above pressure again according to the above
procedure. procedure.
3. Adjusting blade (RAISE) relief pressure
a If the blade (RAISE) relief pressure is
abnormal, adjust suction safety valve (blade)
(8) according to the following procedure.
k Do not turn end cap (9) in a

counterclockwise more than once . More
turns may cause the cap to be jumped
out.
1) Loosen lock nut (10) of suction safety valve
(blade) (8) and turn end cap (9) to adjust the
pressure.
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure
is decreased.
a Quantity of adjustment per turn of
adjusting screw:
19.6 MPa {200 kg/cm2}
2) After finishing the adjustment, tighten lock
nut (10).
3 Lock nut:
39 to 49 Nm {4 to 5 kgm}
PC88MR-10 30-47
Hydraulic system
Testing oil pressure of control circuit (PC88MR-C010-360-K-00-A)
a Testing tools a After finishing the test, remove the testing

Sym- tools, and restore the machine.
Part No. Part name
bol
1
M
799-101-5520 Nipple (10 x 1.25 mm)
2
07002–11023 O-ring

remaining pressure in hydraulic circuit".

a The control circuit pressure can be checked
1. Open the left front inspection window, and at oil pressure pickup plug (2) on the pump
remove pressure pickup plug (1). side.
2. Install nipple M2 and connect it to oil pressure

gauge [1] of hydraulic tester M1.
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.
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
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit (PC88MR-C2A3-360-K-

00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
N
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

remaining pressure in hydraulic circuit".
2) Install nipple N2 and connect it to oil
Testing (PC88MR-C2A3-362-K-00-A) pressure gauge [1] of hydraulic tester N1.
a Before testing the oil pressure in the pump PC a Use the oil pressure gauge of 60 MPa
control circuit, check that the oil pressure in the {600 kg/cm2}.
work equipment and travel circuits and the
source pressure of the control circuit are proper.
1. Measurement of PC valve output pressure
(servo piston inlet pressure)
a To measure the PC valve output pressure
(servo piston inlet pressure), measure the
pump discharge pressure simultaneously
and compare them.
1) Open the right side cover, open the engine
hood and remove oil pressure pickup plugs
(1) and (2).
• (1): Pump discharge pressure pickup
plug
• (2): PC valve output pressure pickup plug
3) Start the engine, and operate the arm

cylinder to arm 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
Hydraulic system

to power mode (P).
4) Run the engine at low idle and high idle, set
all of control levers and pedals of work
equipment and travel in neutral, and
measure the oil pressure.

table for machine".
a If the PC valve or servo piston is
abnormal, the PC valve output pressure
(servo piston inlet pressure) is the "same
as the pump discharge pressure" or
approximately "0". a For standard values, see "Standard value
6) After finishing the test, remove the testing table for machine".
tools, and restore the machine. 5) After finishing the test, remove the testing
2. Measuring PC mode selection pressure tools, and restore the machine.
1) Open the right side cover, and remove oil Adjusting (PC88MR-C2A3-270-K-00-A)
pressure pickup plug (3).
Adjustment of pump PC valve
• (3): PC mode selection pressure pickup
plug a If the following failure symptom occurs and PC
valve is suspected to be defective, adjust PC
valve (4) in the following procedure.
• When the working load increases, the engine
speed drops largely.
• The engine speed is normal but the work
equipment speed is low.
2) Install nipple N2, and connect it to oil

pressure gauge [1].
a Use the oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
a Before loosening the lock nuts, put a match

marks (a) on the end of the adjustment screw to
indicate the original position before adjustment.
(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
Hydraulic system
a Since the PC valve is a decentered type, the

rotating direction (clockwise or
counterclockwise) to increase the absorption
torque cannot be stable. Adjust it by
monitoring the engine speed.
3. Tighten lock nut (5).
3 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
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit (PC88MR-C2A4-360-K-

00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
Differential pressure
2 799-401-2701 gauge
P
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
4 796T-440-1101 Sensor adapter
5 796T-440-1200 Sensor adapter
2. Install nipple P3 to the test part of plug (1), and
connect them to oil pressure gauge [2] by using
hose of hydraulic tester P1.
hydraulic circuit. For details, see "Releasing a Use the oil pressure gauge of 60 MPa {600
remaining pressure in hydraulic circuit". kg/cm2}.
Testing (PC88MR-C2A4-362-K-00-A)
a Before testing the oil pressure in the pump LS

control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the source pressure of the control circuit are
proper.
Measuring LS valve output pressure (servo

piston inlet pressure)
a Check LS pressure (the load pressure of the 3. Install nipple P3 to the test part of plug (2), and
actuator) at the same time as the pump connect them to oil pressure gauge [2] by using
discharged pressure, and calculate the hose of hydraulic tester P1.
differential pressure. a Use the oil pressure gauge of 60 MPa {600
1. Open the right side cover, and remove oil kg/cm2}.
pressure pickup plugs (1) and (2).
• (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
Hydraulic system
1. Open the right side cover of the machine, and

connect service oil pressure connector (1) (P49)
to the connector of sensor adapter assembly P4
(Pressure range: 50 MPa {500 kg/cm2}).

table for machine".
2. Remove the oil pressure pickup plug of the
Testing oil pressure with sensor measurement part, install nipple P2, and
adapter (special tool) (PC88MR-TA11-362-P-00-A) connect it to sensor adapter assembly P4.
Select "Pre-defined Monitoring" or "Self-define
Monitoring" on the machine monitor to monitor the
service pressure.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".
a Monitoring code: 01141 "Service Pressure
Sensor"
• "Pre-defined Monitoring" screen
3. Start the engine to increase the hydraulic oil

temperature to the specified oil temperature.
4. Monitor the oil pressure with the engine at low
idle or high idle.
5. After finishing the test, remove the testing tools
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
Hydraulic system
1. While fixing adjustment screw (4), loosen lock

nut (5).
2. Turn adjustment screw (4) to adjust the
differential pressure.
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure is
decreased.
a Quantity of pressure adjustment (LS
differential pressure) per turn of adjustment
screw:
1.27 MPa {13 kg/cm2}
3. While fixing adjustment screw (4), tighten lock
nut (5).
3 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
Hydraulic system
Testing outlet pressure of solenoid valve (PC88MR-PQPT-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
Q 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)
k Lower the work equipment to the ground and

stop the engine. Operate the control levers
several times to release the remaining
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure. 4. Start the engine.
5. Run the engine at high idle, operate each control
a Before testing the solenoid valve outlet pressure, lever and switch, turn the solenoid valve ON or
check that the control circuit oil pressure is OFF, and measure the output pressure.
normal.
a The conditions for turning the solenoid valve
a Check this item under the following conditions. ON/OFF, see the operation table of each
• Hydraulic oil temperature: 45 to 55°C solenoid valve.
Testing (PC88MR-PQPT-362-K-00-A) a You can check the operating condition of the
1. Remove the left front testing cover and solenoid valve with the monitoring function of
disconnect outlet hoses (1) to (4) of the solenoid the machine monitor (For details, see
valves to be tested. SPECIAL FUNCTIONS OF MACHINE
MONITOR).
No. Solenoid valve to be tested
1 PPC lock solenoid valve • Monitoring code: 02300 solenoid 1
2 Travel speed selector solenoid valve a For standard values, see "Standard value
3 Swing parking brake solenoid valve table for machine".
4 Merge-divider valve 6. After finishing the test, remove the testing tools,
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].
kg/cm2}.
PC88MR-10 30-55
Hydraulic system
Testing PPC valve outlet pressure (PC88MR-PW11-360-K-00-A)
Connecting points of PPC piping a Check this item under the following conditions.
Testing (PC88MR-PW11-362-K-00-A)
1. Disconnect the hose of PPC circuit to be tested.

a For the hose to be disconnected, see
"Connecting points of PPC piping".
2. Install adapter R2 and connect the disconnected
hose again.
3. Install nipple [1] of hydraulic tester R1 and
connect them to oil pressure gauge [2].
kg/cm2}.
Circuit to be Circuit to be a The figure shows the testing tools installed to
No. No.
measured measured hose of the bucket CURL PPC circuit.
Service 1B (white/ Service 1A (white/
1 orange) 2 brown)
3 Bucket CURL (blue) 4 Bucket DUMP (red)
5 Arm IN (green) 6 Arm OUT (orange)
Boom LOWER Boom RAISE
7 (black) 8 (yellow)
Boom right SWING Boom left SWING
9 (white/red) 10 (white/black)
Right travel Right travel
11 FORWARD (black/ 12 REVERSE (yellow/
yellow) green)
Left travel Left travel
13 FORWARD (brown/ 14 REVERSE (yellow/
yellow) orange) 4. Start the engine, and set the working mode to
15 Left swing (white) 16 Right swing (brown) power mode (P).
Blade LOWER (red/ Blade RAISE 5. Run the engine at high idle, set the control
17 black) 18 (yellow/blue) levers in NEUTRAL and travel end, and
measure the oil pressure at each position.
a The above figure shows the connecting points of
PPC piping to the control valve of 1-attachment
specification.
The colors in ( ) are the colors of the bands
installed for piping identification.
a Testing tools
Sym-
Part No. Part name
bol
1
R 790-261-1204 Digital hydraulic tester
2 799-401-3100 Adapter (size: 02)

the work equipment to the ground, and a For standard values, see "Standard value
release the remaining pressure in the table for machine".
hydraulic circuit. For details, see "Releasing 6. After finishing the test, remove the testing tools,
remaining pressure in hydraulic circuit". and restore the machine.
a Before testing PPC valve output pressure, check

that the control circuit source pressure is normal.
30-56 PC88MR-10
Hydraulic system
Adjusting play of work equipment and swing PPC valves (ALL-PL28-001-K-00-A)
a If the right and left work equipment levers have

large play, adjust them according to the following
procedure.
a The play of the lever measured at a position of
200 mm from the pivot must be 0.5 to 3 mm.
Adjusting (PC-PL28-270-K-00-A)
1. Remove boot (1).

2. Loosen lock nut (2) and tighten disc (3) until it
comes in contact with the heads of pistons (4) (4
pieces).
a At this time, do not move the pistons.
3. While fixing disc (3), tighten lock nut (2) to the
specified torque.
3 Locknut: 68 to 88 Nm (7 to 9 kgm)
4. Apply gear oil and grease (G2–L1) to the rocking
portions of the joint.
Apply gear oil and grease (G2–L1) to the rocking
portions of the joint.
(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
Hydraulic system
Isolating the parts causing hydraulic drift in work equipment (ALL-L410-001-K-00-A)
a If the work equipment (cylinder) drifts 2) Operate the arm control lever to IN again to
hydraulically, perform check to see if the determine the test results.　
problem is in the cylinder seal or control valve • When the lowering speed is increased at
according to the following procedure. this time, the cylinder packing is
Testing (PC88MR-L410-360-K-00-A) defective.
• If the lowering speed does not change at
1. Testing boom cylinder and bucket cylinder this time, the control valve is defective.
1) Stop the engine with the same posture as the
a The control lever can be operated when
hydraulic drift measurement.
the starting switch is set to ON position.
a Apply rated load to the bucket inside or fill
a If the accumulator pressure is reduced,
the bucket with soil or sand.
run the engine for approximately 10
seconds to accumulate the pressure.
[Reference] Reasons why the lowering speed is
increased by the above operation when the
cylinder packing causes the hydraulic drift:
1) When the machine is set in the above
posture (where the holding pressure is
applied to the bottom side), the oil leaks from
the bottom side to the head side. Since the
volume on the head side is less than that on
the bottom side by the volume of the rod, the
pressure in the head side is increased by the
oil flowing in from the bottom side.
2) As the internal pressure on the head side
2) For boom, move the boom control lever to increases, both pressures come to balance
"RAISE" side. For bucket, move the bucket at a certain level of pressure (depending on
control lever to "CURL" side for judgment. leakage), and the lowering speed becomes
• When the lowering speed is increased at slower.
this time, the cylinder packing is 3) If the circuit on the head side is opened to
defective. the drain circuit by the above operation of the
• If the lowering speed does not change at lever (the bottom side is closed by the check
this time, the control valve is defective. valve at this time), the oil in the head side
flows in the drain circuit. As a result, the
a The control lever can be operated when
pressure is imbalanced and the lowering
the starting switch is set to ON position.
speed is increased.
a If the accumulator pressure is reduced, 3. Testing PPC valve
run the engine for approximately 10 Test the lowering volume of the work equipment
seconds to accumulate the pressure. when the work equipment lock lever is set to the
2. Testing arm cylinder LOCK position and FREE position with the
1) Operate the arm control lever to IN, and stop pressure accumulated in the accumulator.
the engine at the time when the arm cylinder a The control lever can be operated when the
extends to approximately 100mm front of the starting switch is set to ON position.
stroke end.
a 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
Hydraulic system
Testing and adjusting travel deviation (PC138-0000-360-K-00-A)
Testing (PC88MR-0000-347-K-00-A)
1. Start the engine, increase the hydraulic oil

temperature to the operating range, and set the
machine in the traveling posture.
a To set in the traveling posture, extend the
bucket cylinder and arm cylinder fully and
hold the boom angle at 45 deg.
2. Set the working mode in P-mode and the travel
speed in Lo.
3. Run the engine at high idle and measure travel
deviation (a) in travel of 20 m after running up 10
m.
a Install oil pressure gauge and check that
discharged pressures P1 and P2 of the
hydraulic pump are even.
PC88MR-10 30-59
Hydraulic system
Adjusting (PC88MR-0000-270-K-00-A)
a If travel deviation occurs, you can correct it by a If the lock nut is sealed with a vinyl seal,
draining a part of the discharge of the pump of remove the tape to work.
larger discharge into the tank circuit by using the
a Before loosening the lock nut, make a
adjustment plug. (Take care that the travel
matchmark between the lock nut and pump
speed, work equipment speed in combined
case.
operations, and relief pressure may decrease
since the pump discharge decreases if you use • Loosening angle of lock nut: Approximately
this method.) 90 to 180 deg.
a The following is the correction method

applicable when the machine deviates in the
same direction during both forward and reverse
travels (If the deviation direction in forward
direction and reverse direction differs, the cause
of failure may be something other than the
hydraulic pump. In this case, perform
troubleshooting).
a Only when it is 200mm or less, travel deviation
can be corrected with this method.
k If the adjustment plug is loosened more than
the adjustment limit, high-pressure oil may
spout out. Work with extreme care. 3. Loosen plug (1) or (2), and adjust the travel
deviation.
k Lower the work equipment to the ground and • Quantity of adjustment per turn of plug:
stop the engine. Operate the control levers 150mm (reference)
several times to release the remaining
a The plug is fully tightened when the machine
pressure in the piping, and then loosen the
is shipped. Adjust by the loosening angle
oil filler cap of the hydraulic tank slowly to
from that condition.
release the internal pressure.
a If the plug is dragged when the lock nut is
1. Check the travel deviation direction and the loosened, tighten the plug fully once, and
positions of adjustment plugs (1) and (2). then adjust it.
• (1): Right deviation adjustment plug (pump a The plug may be loosened up to 2 turns (720
P1 ) deg.) from the fully tightened condition.
• (2): Left deviation adjustment plug (pump P2) 4. Tighten lock nut (3) while fixing plug (1) or (2)
a Adjust by loosening only either plug. Do not with an hexagonal wrench.
loosen the opposite one. 3 Lock nut:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a After tightening the lock nut, seal the hole of
it with a vinyl seal.
5. After the adjustment, check the travel deviation
again according to the above test procedure.
a 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
Hydraulic system
Testing oil leakage (PC88MR-C000-360-P-00-A)
a Testing tools k Release the remaining pressure in the

Sym- piping on the arm cylinder head side
Part No. Part name (however, operate the lever only in the
bol
Commercially Measuring cylinder arm IN direction). For details, see
T "Releasing remaining pressure in
available
hydraulic circuit".
2) Disconnect hose (2) on the cylinder head
side and block the hose side by using a plug.
k Take care not to disconnect the hose
1. Testing oil leakage of boom cylinder
on the cylinder bottom side.
1) Set the boom cylinder at RAISE stroke end,
and stop the engine. a Use the following parts to block the hose.
07376-70422 (Plug #04)
k Release the remaining pressure in the
piping on the boom cylinder head side
(however, operate the lever only in the
boom RAISE direction). For details,
see "Releasing remaining pressure in
hydraulic circuit".

a Use the following parts to block the hose.
07376-70422 (Plug #04) 3) Start the engine, run it at high idle, and
perform the arm digging relief.
k Take care not to operate the lever to

"Arm OUT" side.
4) 30 seconds after starting relief, measure the
amount of oil leakage for 1 minute.
5) Restore the machine after finishing the test.
3. Testing oil leakage of bucket cylinder
1) Set the bucket cylinder at its extension stroke
end and stop the engine.

3) Start the engine, run it at high idle, and piping on the bucket cylinder head
relieve the circuit by raising the boom. side (however, operate the lever only
in the bucket CURL direction). For
details, see "Releasing remaining
k Be careful not to operate the lever to
pressure in hydraulic circuit".
"Boom LOWER" side.
2. Testing oil leakage of arm cylinder
1) Set the arm cylinder to arm IN operation side
to the end of its stroke, and stop the engine. a Use the following parts to block the hose.
07376-70422 (Plug #04)
PC88MR-10 30-61
Hydraulic system

5. Testing oil leakage of blade cylinder
1) Start engine and drive the machine so that
tracks (idler side) get onto the wooden blocks,
etc. to raise the front side of machine.
k Raise the front side of machine until

blade does not touch the ground even
when the blade lift cylinder is
extended to its LOWER stroke end.
3) Start the engine, run it at high idle, and
relieve the circuit by moving the bucket in k Set work equipment lock lever to
CURL direction. LOCK position and put blocks under
the rear of tracks.
k Be careful not to operate the lever to 2) Fully extend the blade cylinder to its LOWER
"Bucket DUMP" side. stroke end and stop the engine.
amount of oil leakage for 1 minute. k Release the remaining pressure in the
5) Restore the machine after finishing the test. piping on the blade cylinder head side
4. Testing oil leakage of boom swing cylinder (however, operate the lever only in the
1) Fully extend the swing cylinder to the right blade LOWER direction). For details,
SWING stroke end and stop the engine. see "Releasing remaining pressure in
hydraulic circuit".
k Release the remaining pressure in the 3) Disconnect hose (5) on the cylinder head
piping on the boom swing cylinder side and block the hose side by using a plug.
head side (however, operate the lever
only in the right SWING direction). For k Be careful not to disconnect the hose
details, see "Releasing remaining on the cylinder bottom side.
pressure in hydraulic circuit".
2) Disconnect hose (4) on the cylinder head 07376-70315 (Plug #03)
k Be careful not to disconnect the hose

07376-70315 (Plug #03)
4) Start the engine, run it at high idle, and

relieve the circuit by lowering the blade.
k Be careful not to operate the lever to

"Blade RAISE" side.
3) Start the engine, run it at high idle, and amount of oil leakage for 1 minute.
relieve the circuit by right swing. 6) Restore the machine after finishing the test.
6. Testing oil leakage of swing motor
k Be careful not to operate the lever to 1) Remove cover (6).
"Left SWING" side.
30-62 PC88MR-10
Hydraulic system
4) Start the engine, run it at high idle, relieve the

swing circuit, and measure the leakage at
this time.
a Action level L03 is displayed on machine
monitor.
a 30 seconds after starting relief, measure
the amount of leakage for 1 minute.
5) Swing 180 deg. and check the amount of
leakage again.
a Perform removal and installation of the
connectors after the engine is stopped.
2) Disconnect drain hose (7) and block the
a Check it after the connectors of the swing
hose side by using a plug.
parking brake solenoid valve have
a Use the following parts to block the hose. already been removed.
07376-70315 (Plug #03) 6) Restore the machine after finishing the test.
7. Testing oil leakage of travel motor
1) Remove travel motor cover.
2) Start the engine, lock the travel mechanism,
and stop the engine.
k Insert pin [1] between the sprocket

and the track frame to securely lock
the track.
3) Remove left exterior cover (11), and

disconnect connector (CN-V03) (12) of the
swing parking brake solenoid valve.
3) Disconnect drain hose (8) of the travel motor

and block the hose side by using a plug.
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
Hydraulic system
k Before operating the travel lever,

check the pin position and locked
direction of the travel again.
k Make signs and perform checks

securely, since a mistake in lever
operation can cause an accident.
a 30 seconds after starting relief, measure
the amount of leakage for 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).
30-64 PC88MR-10
Hydraulic system
Bleeding air from hydraulic circuit (ALL-C000-001-P-04-A)
q: Execution of work
o: Go to next procedure
Air bleeding procedure and item
1 2 3 4 5 6
Bleeding air Checking oil
from Starting the Bleeding air Bleeding air Bleeding air
level and
hydraulic engine from cylinder from swing from travel
operating
pump motor motor
machine
• Replacement of
hydraulic oil q q
q q q q
• Cleaning (See note) (See note)
strainer
• Replacing
return oil filter q o o o q
element
• Replacing or
repairing
hydraulic pump q q q o o q
• Removal of
suction piping
• Replacing or
repairing
control valve
q q o o q
• Removal of
Detail of work, remarks
control valve
piping
• Replacement
or repair of
cylinder q q o o q
• Removal of
cylinder piping
• Replacing or
repairing swing
motor
q o q o q
• Removal of
swing motor
piping
• Replacing or
repairing travel
motor
q o o q q
• Removal of
travel motor
piping
• Replacing or
repairing swivel
joint q o o o q
• Installing swivel
joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
Bleeding air (PC88MR-C000-231-P-00-A)
1. Bleeding air from hydraulic pump 2) When oil without air starts to flow out, tighten
air bleeder (1).
a Keep the oil filler cap of the hydraulic tank
loosened during air bleeding work of the 3 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
Hydraulic system
2. Starting the engine 5. Bleeding air from travel motor

When starting the engine after performing step 1, 1) Remove the travel motor cover and
keep it at low idle for 10 minutes. disconnect motor drain hose (3).
a When performing the automatic warm-up 2) Start the engine, and run it at low idle, and
operation while engine coolant temperature check that the oil flows out of nipple (4).
is low, stop the engine once and cancel the 3) Connect hose (3) and restore the machine.
automatic warm-up function with fuel dial.
(Turn the starting switch to ON position and
keep the fuel dial at MAX position for 3
seconds or more, and automatic warm-up
function will be canceled.)
3. Bleeding air from cylinders
a When the cylinder has been replaced, bleed
air from the cylinder before connecting the
work equipment. Especially, the LOWER
side of the boom cylinder does not operate to
the stroke end with the work equipment
installed.
1) Start the engine and run it at low idle for 6. Check of oil level and operation
approximately 5 minutes. 1) Start the engine, retract the arm and bucket
2) While running the engine at low idle, raise cylinders fully, lower the work equipment to
and lower the boom 4 to 5 times. the ground, and stop the engine.
a Stop the piston rod at approximately 100
mm before stroke end to avoid relieving.
3) While running the engine at high idle,
perform the operation in step 2).
4) While running the engine at low idle, move
the piston rod to the stroke end to relieve the
circuit.
5) Bleed air from the arm and bucket cylinders
according to steps 2) to 4).
4. Bleeding air from swing motor
a Bleed air only when the oil inside the swing
motor case is drained.
a If the air is not bled from the swing motor and 2) Check the oil level by sight gauge (5) at the
the machine is operated, the motor bearings rear of the hydraulic tank.
may be damaged.
a If the oil level is below line L, add new oil.
1) Run the engine at low idle, loosen drain hose
(2), and tighten it when oil flows out. a Since the oil level varies according to the
oil temperature, use the followings as a
a Do not perform the swing operation guide.
during this work.
2) Run the engine at low idle and slowly swing • Oil temperature 10 to 30°C: Halfway
at least 2 times to the right and left. between H and L
30-66 PC88MR-10
Hydraulic system
• Oil temperature 50 to 80°C: Around H

level
PC88MR-10 30-67
Cab and its attachments
Testing, cleaning and lubricating slide door rail and roller (PC88MR-K160-04D-K-00-A)
Testing (PC138-K160-360-K-01-A)
If the slide door does not open or close smoothly, check slide door rail (1) and rolling surface (2) for the roller
for dirt, mud, etc.
Cleaning method of door rail

Open and close the door and remove dirt and stain from slide door rail (1) and rolling surface (2) for the roller.
Lubrication method of door rail and roller

a Do not use high-viscosity lubricating oil.
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
Adjusting mirrors (PC88MR-K810-360-K-00-A)
1. Mirror installing positions
3. Adjusting mirror (B)

2. Adjusting mirror (A) a Adjust mirror (B) so that the operator can see
Adjust mirror (A) so that the operator can see a people standing on the ground within 1 m
person in the rear left end of the machine. around the machine.
a Install the mirror to the location shown in the (b): 1 m
following figure.
(a): 170 mm
a Fix mirror stay (1) while the mirror is opened
to the maximum position.
a If the mirror does not move smoothly when
adjusting, loosen mirror fixing bolt (2) and
stay mounting bolt (3).
3 Tightening torque of bolt (2):
15.7 to 19.6 Nm {1.6 to 2.0 kgm}
a If mirror (B) is hard to adjust, loosen mirror

fixing bolt (4).
3 Tightening torque of bolt (4):
15.7 to 19.6 Nm {1.6 to 2.0 kgm}
a 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
30-70 PC88MR-10
Testing and adjusting hood catcher (PC88MR-H540-360-K-00-A)
1. Press key lock (1) of the hood, hold handle (2),

and slowly lift it in the opening direction to check
for backlash.
2. If there is play, perform adjustment according to

the following procedure.
• Open the hood, and loosen nut (4) of hood
stopper (3) to shorten protrusion a of stopper
(3).
2) Adjusting installation of hook (5) in

longitudinal directions of machine
Loosen mounting bolt (7) of bracket (6),
adjust the mounting position, and tighten it
again.
Clearance b: 0 mm (target value)
Difference c: 0 ± 1 mm (target value)
a Close the hood, and repeat performing
this step until the play is eliminated. At
this time, check that the key lock
operating effort does not become heavy.
(If hook (5) of the key lock strongly hit
lock bar (8) of the bracket, the key lock
operating effort becomes heavy and an
obstacle to the open/close operation).
a Key lock operating effort: 68.6 N {7.0 kg}
or lower
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
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
Electrical system
Special functions of machine monitor (PC220-Q170-042-K-01-A)
PC88MR-10 30-73
Electrical system
Upper part of machine monitor (display portion)

(a): Multi-information display
a When the engine is started, the battery voltage
may drop suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the screen display of the machine
monitor may go off for a moment. This
phenomenon is not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated
by the icon which is displayed just above the
function switch on the screen of the multi-
information display panel (a).
a If the icon for a function switch is not displayed,
that function switch is not working.
Lower part of machine monitor (switch portion)

[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer stop
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals : Air conditioner switch
a 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
Electrical system
Ordinary functions and special functions of machine monitor (PC88MR-Q170-042-K-01-A)
The machine monitor has the ordinary functions and special functions to display the various types of
information on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches. (Display and setting of some items need special operations of the switches.)
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
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 Abnormality record (mechanical systems)(PAGE
A 30-78) 30-101)
Display of operator identification ID input screen Abnormality record (electrical systems)(PAGE
A (PAGE 30-78) 30-102)
A Display of Check before starting(PAGE 30-79) Maintenance Record(PAGE 30-103)
Display of warning after Check before starting
A Maintenance mode setting(PAGE 30-104)
(PAGE 30-79)
Display of maintenance due time over(PAGE 30-
A Phone number entry(PAGE 30-107)
79)
Display of working mode and checking travel
A Default (Key-on Mode)(PAGE 30-107)
speed(PAGE 30-79)
A Display of standard screen(PAGE 30-80) Default value setting (Unit)(PAGE 30-108)
Default (With/Without Attachment)(PAGE 30-
A Display of end screen(PAGE 30-80) 109)
(Special operation)
Display of operation screen for engine shutdown

A secondary switch(PAGE 30-80) Default (Camera)(PAGE 30-110)
Default (Auto Idle Stop Timer Setting)(PAGE 30-
B Selection of auto-deceleration(PAGE 30-80) 110)
B Selection of working mode(PAGE 30-81) Default (Auto Idle Stop Setting)(PAGE 30-111)
Testing (Cylinder Cut-out operation)(PAGE 30-
B Selecting travel speed(PAGE 30-81) 112)
Testing (Reset Number of Abrupt Engine Stop by
B Operation to cancel alarm buzzer(PAGE 30-82) o AIS)(PAGE 30-114)
Adjustment (Pump Absorption Torque)(PAGE 30-
B Operation of windshield wiper(PAGE 30-82) 114)
Adjustment (Attachment Flow Adjustment)(PAGE
B Operation of window washer(PAGE 30-82) 30-115)
Operation to display air conditioner settings
B (PAGE 30-82) No-Injection(PAGE 30-116)
KOMTRAX Settings (Terminal Status)(PAGE 30-
B Operation to display camera mode(PAGE 30-82) 117)
Operation to display clock and service meter KOMTRAX Settings (GPS and Communication
B (PAGE 30-83) Status)(PAGE 30-118)
KOMTRAX Settings screen (Modem Status)
B Check of maintenance information(PAGE 30-83) (PAGE 30-119)
Setting and display of user mode (including
B KOMTRAX messages for user)(PAGE 30-84) Service Message(PAGE 30-119)
C Display of ECO guidance(PAGE 30-84)
C Display function of alarm monitor(PAGE 30-85)
Display of action level and failure code(PAGE 30-
C 86)
PC88MR-10 30-75
Electrical system
O (Special operation)
Function of checking display of LCD (Liquid
D Crystal Display)(PAGE 30-87)
D Function of checking service meter(PAGE 30-87)
Function of Usage Limitation Setting/ Change
D Password(PAGE 30-87)
a Classification of operator mode

A: Display or function that is indicated or enabled from the time when the starting switch is turned to ON
position to the time when display changes to the standard screen, and display after starting switch is
turned to 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
Electrical system
Operator mode (outline) (PC88MR-Q193-042-K-01-A) Function of checking display of LCD (Liquid Crystal
Display)(PAGE 30-87)
a Only outline of the operator mode is described in Function of checking service meter(PAGE 30-87)
this section.
Function of Usage Limitation Setting/ Change
For details of each function and display, and Password(PAGE 30-87)
their operation, see "Structure and function ", or
the "Operation and Maintenance Manual". a Display pattern of operator mode
a In this section, the following displays or functions The contents of display from when the starting
of the operator mode are explained (including switch is turned to ON position to when the
some items which need special operations). standard screen appears depend on the settings
and conditions of the machine.
A: When the engine starting lock and the
Display pattern operator identification ID No. input setting are
A B C D E F enabled
B: When the engine starting lock is enabled and
Display of KOMATSU logo
(PAGE 30-77) 1 1 1 1 1 1 the operator identification ID No. input setting is
disabled
Password input(PAGE 30-77) 2 2 C: When the engine starting lock is disabled and
Display of technician the operator identification ID No. input setting is
identification status(PAGE 30- 3 2 enabled
78)
Display of operator identification D: When the engine starting lock and the
ID input screen(PAGE 30-78) 4 3 operator identification ID No. input setting are
Display of Check before starting disabled
(PAGE 30-79) 5 3 4 2 2 2
E: When any abnormality is detected by the
Display of warning after Check Check before starting
before starting(PAGE 30-79) 3
F: When the maintenance due time over is
Display of maintenance due
3 detected in Maintenance items
time over(PAGE 30-79)
Display of working mode and Display of KOMATSU logo (PC220-Q180-044-K-01-A)
checking travel speed(PAGE 6 4 5 3 4 4 When starting switch is turned to ON position,
30-79) KOMATSU logo is displayed for 2 seconds.
Display of standard screen
(PAGE 30-80) 7 5 6 4 5 5 a After the KOMATSU logo screen is displayed for
Display of end screen(PAGE 30-80) 2 seconds, the screen changes to "Password
input" screen, or "Check before starting" screen.
Display of operation screen for engine shutdown
secondary switch(PAGE 30-80)
Selection of auto-deceleration(PAGE 30-80)
Selection of working mode(PAGE 30-81)
Selecting travel speed(PAGE 30-81)
Operation to cancel alarm buzzer(PAGE 30-82)
Operation of windshield wiper(PAGE 30-82)
Operation of window washer(PAGE 30-82)
Operation to display air conditioner settings(PAGE
30-82)
Operation to display camera mode(PAGE 30-82)
Operation to display clock and service meter(PAGE
30-83)
Check of maintenance information(PAGE 30-83)
Setting and display of user mode (including Password input (PC220-Q180-044-K-02-A)
KOMTRAX messages for user)(PAGE 30-84) After the KOMATSU logo is displayed, the screen to
Display of ECO guidance(PAGE 30-84) input the engine start lock password is displayed.
Display function of alarm monitor(PAGE 30-85) a This screen is displayed only when the engine
Display of action level and failure code(PAGE 30- start lock function is enabled.
86)
a When correct password is input, the screen
O (Special operation)
changes to "Check before starting" screen.
PC88MR-10 30-77
Electrical system
a The machine monitor has some password

functions other than the engine start lock. Those
functions are independent from one another.
Display of operator identification ID input

screen (PC88MR-Q19G-100-K-10-A)
After displaying the identification of the technician,
the operator ID input screen is displayed.
a The following screen may sometimes be
displayed instead of the above "Password input" a The screen shown in the figure is displayed only
screen. when the operator ID No. input setting is
enabled.
a If this screen is displayed, call the person
responsible for the operation of KOMTRAX in a Before performing checking and adjusting,
your Komatsu distributor and ask for remedy. check in advance that the input setting of ID of
the operator identification function has already
been set by the customer.
a If the customer has set the ID input setting with
SKIP, press [F1] button after identifying the
technician, and the engine can be started.
a If they have set the ID input setting without SKIP,
the engine cannot be started as long as the
registered ID available for the technician is
informed by a person in charge of the machine
from the customer.
Display of technician identification

status (PC88MR-Q19G-100-K-00-A)
When the operator identification function is enabled,
turn the starting switch to ON position while
pressing the numeral input key "4", and the
following technician identification screen is
displayed for 2 seconds.
a This function is for identifying the testing and
maintenance work by service man from
operation status by operator.
a The screen moves to check-before-starting
screen by inputting ID or SKIP without pressing
any button on KOMATSU logo screen.
30-78 PC88MR-10
Electrical system
Display of Check before starting (PC88MR-Q180- Display of maintenance due time over (PC88MR-
044-K-00-A) Q180-044-K-02-A)
When the screen changes to the "check before If you find a maintenance item at check before
starting" screen, the check before starting is starting that it is near or overdue the set interval, the
performed for 2 seconds. maintenance monitor is displayed for 30 seconds to
urge the operator to perform maintenance.
a If any abnormalities are detected by the check
before starting, the screen changes to "Display a This screen is displayed only when the
of warning after check before starting" or maintenance function is enabled.
"Display of maintenance time over". If the remaining time of any item is 30 hours or
a If no abnormalities are detected by the check less, the yellow icon is displayed. If the
before starting, the screen changes to "Display remaining time of any item is 0 hour or less, the
of working mode and travel speed check". red icon is displayed.
a The monitors (6 monitors) on the screen shows a Perform setting and changing of the
the items currently subjected to the check before maintenance function in the service mode.
starting.
Display of working mode and checking travel

speed (PC88MR-Q180-044-K-03-A)
Display of warning after Check before
If the check before starting is finished normally, the
starting (PC88MR-Q180-044-K-01-A)
screen to check the working mode and travel speed
If any abnormalities are detected in "Check before
is displayed for 2 seconds.
starting", the alarm monitor is displayed on the
screen. a 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
Electrical system
Display of operation screen for engine

shutdown secondary switch (PC88MR-AKHL-100-K-00-
A)
When you turn the engine shutdown secondary
switch to ON position, the "Engine Shutdown
Secondary SW in Operation" screen is displayed on
every screen except the end screen.
a The engine shutdown secondary switch is
provided on the lower left side of the operator's
seat. It is used to stop the engine when you
cannot stop the engine by turning the starting
switch to OFF position.
Display of standard screen (PC88MR-Q180-044-K-04-A)

If the machine monitor starts normally, the standard
screen is displayed.
a Service meter (a) or the clock is displayed at the
lower left of the screen (Switch between the
service meter and clock with [F4]).
a 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 (PC88MR-AF6C-100-K-

00-A)
Press the acceleration switch while the standard
screen is displayed to display large monitor (a) of
the auto-deceleration for 2 seconds and then the
the auto-deceleration setting is switched.
a Auto-deceleration setting switches [ON] o [OFF]
Display of end screen (PC220-Q180-044-K-09-A) o [ON] in order by pressing switch.
When starting switch is turned to OFF position, the
a When the auto-deceleration is set to ON, auto-
end screen is displayed for 5 seconds.
deceleration monitor (b) is also displayed as
a Other messages may appear on the end screen soon as large monitor (a) is displayed.
due to KOMTRAX message display function.
a When the auto-deceleration is set to OFF, auto-
deceleration monitor (b) is disappears.
30-80 PC88MR-10
Electrical system
Selection of working mode (PC88MR-PT5W-100-K-00-A) 3. After returning to the standard screen, display
Select the working mode according to the following large motor (a) of the selected working mode for
procedure. 2 seconds to switch the working mode setting.
1. When the working mode selector switch is a As soon as large monitor (a) appears, the
pressed while the standard screen is displayed, display of working mode monitor (b) is also
the "Working mode selection" screen is changed.
displayed.
a The following figure shows the working mode
selection screen with the attachment
available (if not setting as service mode
available, the attachment mode "ATT/P" or
"ATT/E" does not appear).
<Caution for selecting breaker mode [B]>

• When breaker mode [B] is selected, the
hydraulic circuit setting is also changed as
soon as the hydraulic pump control is
changed.
• If an attachment other than the breaker is
2. Operate the function switch or working mode used, the machine may operate
selector switch to select and enter the working unexpectedly and may be not operated
mode to be used. correctly. In addition, the hydraulic
Function switch components may be damaged.
• [F3]: Moves selection downward.
• [F4]: Moves selection upward. Selecting travel speed (PC88MR-C6T7-100-K-00-A)
• [F5]: Cancels the selection and returns the Press the travel speed selector switch while the
display to the standard screen. standard screen is displayed to display large
• [F6]: Enters the selection and returns to the monitor (a) of the travel speed for 2 seconds and
standard screen. then the travel speed setting is switched.
Working mode selector switch a In setting of the travel speed, each time the
• Pressing: Moves selection downward. switch is pressed, sequential switching among
• Holding down: Enters the selection and [Lo] o[Hi]o[Lo] takes place in this order.
returns to the standard screen.
a As soon as large monitor (a) appears, the
a 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
Electrical system
Operation to cancel alarm buzzer (PC88MR-Q576-

100-K-00-A)
Press the buzzer cancel switch while the alarm
buzzer is sounding, then the alarm buzzer stops.
a Even if the buzzer cancel switch is pressed, the
display on the screen does not change.
Operation of windshield wiper (PC88MR-K751-100-K-

00-A)
Press the wiper switch while the standard screen is
displayed to display large monitor (a) of the wiper
for 2 seconds and then the wiper operates/stops.
a Wiper does not move while the window limit
switch is [ON]. Operation to display camera mode (PC88MR-
Q16A-100-K-00-A)
a In setting of the wiper, each time the switch is
When [F3] is pressed, the multi-display changes to
pressed, sequential switching among [INT] o
the camera image (Set the connection of the
[ON] o [OFF] o [INT] takes place in this order.
camera in the service mode).
a As soon as large monitor (a) appears, display of
wiper monitor (b) is also changed and hidden.
a When the wiper is set to OFF, large monitor (a)
does not appear.
Operation of window washer (PC220-K7DA-100-K-00-

A)
While the ordinary screen is displayed, if the
window washer switch is pressed, the washer fluid
is splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation to display air conditioner

settings (PC220-K500-100-K-00-A)
Operate the air conditioner switch while the
standard screen is displayed, and the air
conditioner setting screen will appear.
a 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
Electrical system
a When the standard screen is displayed during Operation to display clock and service
the camera connection setting, a warning meter (PC88MR-Q1MA-100-K-00-A)
message is displayed. When [F4] is pressed while the standard screen is
displayed, the display at section (a) is alternately
a The warning message is disappeared by switched between service meter display and clock
pressing [F5]. display.
a If the warning message is displayed for 10 a When selecting the clock display, perform the
seconds or longer, the standard screen (camera time adjustment, 12-hour or 24-hour display
used in combination) is displayed again. setting, and daylight saving setting by using the
user mode functions.
a If any caution occurs when the standard screen

(camera used in combination) is displayed, the Check of maintenance information (PC88MR-
corresponding caution monitor is displayed at Q1C2-100-K-00-A)
the top of the camera screen . You can check the maintenance information on the
a If no control lever is operated for 10 seconds maintenance screen displayed by pressing [F6]
while a failure enough to display user code is while the maintenance monitor is displayed.
occurring in the camera mode, the screen If the maintenance monitor is not displayed, press
returns to the standard screen (camera used in [F6] and then [F1] or [F2] to change the monitor to
combination). the maintenance screen. Then you can check the
information.
a To reset the remaining time after finishing the

maintenance, further operations are required.
PC88MR-10 30-83
Electrical system
Display of ECO guidance (PC88MR-Q1L3-100-K-00-A)

When the machine remains in a certain operating
condition, the "ECO Guidance" screen is displayed
automatically to urge the operator to perform
energy-saving operation.
a The ECO Guidance screen is displayed when
the following conditions are met while this
display function is set to be enabled in operator
mode.
a Conditions for display:
• Idle stop guidance
When no lever is operated for a period of at least
Setting and display of user mode (including 5 minutes and the engine keeps running at idle
KOMTRAX messages for user) (PC88MR-Q1C3-100- during this period, the guidance on idle stop is
K-00-A) displayed on the monitor. This function helps
To enter and display the user mode, press [F6] to reduce unnecessary fuel consumption by
display the "User Menu" screen while the standard alerting the operator to stop the engine while
screen is displayed. waiting for the next operation, or during a break.
a The lamp for the idle stop guidance goes out
automatically when the lever operation is
resumed, or if the function switch [F5] is
pressed.
a There are following items in the user menu.

"Energy Saving Guidance"
"Machine Setting"
"Maintenance"
• Deterrence guidance of hydraulic relief
"Monitor Setting" If relieving lasts for 3 or more seconds during
"Mail Checking" operation, deterrence guidance of hydraulic
[KOMTRAX message] relief is displayed on the monitor.
• There are two types of KOMTRAX message; a The lamp for the guidance on deterrence of
one is for the user and the other is for the hydraulic relief goes out automatically after
technician. 10 seconds has passed since it appeared, or
• For user: if the function switch [F5] is pressed.
It denotes the messages transmitted from the
KOMTRAX base station to users. Upon
receiving a message, the message monitor is
displayed on the standard screen. Operate this
"Check mail" when viewing contents of a
message.
• 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
Electrical system
• E-mode (recommended) guidance a The low fuel level guidance goes out
When light-load work continues for 10 minutes automatically after 10 seconds has passed
or more in P mode or ATT/P mode, E-mode since it appeared, or if the function switch
recommendation guidance is displayed. This [F5] is pressed.
function helps reduce unnecessary fuel
consumption in light-load work by alerting the
operator to switch to E-mode.
a The lamp for the E-mode recommendation
guidance goes out automatically after 10
seconds has passed since it appeared, or if
the function switch [F5] is pressed.
Display function of alarm monitor (PC88MR-Q1FC-

044-K-00-A)
If an abnormality that displays the alarm monitor of
action level "L01" occurs on the standard screen or
camera mode screen, the alarm monitor is
displayed in a large size for a while and then kept
displayed at (a) inside the screen.
• Reduce engine speed (recommended) guidance
a When a caution occurs while the camera mode
If travel condition continues for 2 or more
is displayed, the alarm monitor flashes at the
minutes when travel mode is Hi and fuel control
upper left of the screen.
dial is at MAX position, the reduce engine speed
(recommended) guidance is displayed. Throttle
the fuel control dial to reduce necessary fuel
consumption during travel for long time.
a The lamp for the reduce engine speed
(recommended) guidance goes out
automatically after 10 seconds passes, or if
the function switch [F5] is pressed.
If an abnormality that displays an alarm monitor of

action level "L02", "L03", or "L04" occurs, the alarm
monitor is displayed at the center of the monitor until
the abnormality is eliminated.
• Low fuel level guidance

If the operable time estimated from the current
fuel level and the latest average fuel
consumption is shorter than 8 hours, the low fuel
level guidance is displayed.
PC88MR-10 30-85
Electrical system
Display of action level and failure code (PC88MR-Q1FC-100-K-00-A)

If an abnormality that displays an action level and a a This screen appears when trouble (failure code)
failure code occurs on the standard screen or occurs only if its action level is set.
camera mode screen, the alarm monitor lights up.
a The telephone number is displayed only when
the telephone number is registered in Service
Mode.
a If multiple troubles occur simultaneously, all the
codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the "Abnormality Record" in
the service mode, check the details in the
service mode.
a "Current Abnormality" is replaced with the
standard screen automatically after 30 seconds.
a Since "Current Abnormality" cannot be displayed
If the alarm monitor lights up, press function switch from the screen on which the camera mode is
[F5] to display the "Current Abnormality". displayed, move to "Current Abnormality" from
• [F1]: Moves to next page (screen) (when the standard screen side.
displayed)
• [F2] Moves to previous page (screen) (when
displayed)
• [F5]: Returns to the standard screen
On "Current Abnormality" screen, the following
information is displayed.
(a): Alarm monitor
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a Remedies that displayed action levels require operator to do (The following table is an excerpt from the
Operation and Maintenance Manual)
Degree of Alarm Remedy
urgency Action level Buzzer
monitor
Stop immediately and perform checking and
High Q maintenance.
L04 Q
(Continuous) Ask your Komatsu distributor for testing and repair
services.
Stop the work, move machine to safe place, stop it, and
Q perform checking and maintenance.
L03 Q
(Intermittent) Ask your Komatsu distributor for testing and repair
I
services.
Stop the work once, and run the engine at medium
O Q speed with no load or stop the engine. If no improvement
L02 Q is seen, ask your Komatsu distributor for checking and
(Intermittent)
repair services.
L01 Some functions may be limited. However, you can
(For 2 perform the work. Perform the inspection and
- Q maintenance after completion of the work.
Low seconds
only) Please contact your KOMATSU distributor as needed.
30-86 PC88MR-10
Electrical system
Function of checking display of LCD (Liquid

Crystal Display) (PC-Q1LE-100-K-00-A)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
• Switch operations (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a To return to the former screen, press any one of
the function switches. Function of Usage Limitation Setting/ Change
Reference: An LCD panel, as one of its
Password (PC88MR-Q19X-100-K-00-A)
Selecting the Usage Limitation Setting displays the
characteristics, sometimes shows black spots
password input screen when you proceed to
(spots that remain unlit) and bright spots (spots that
breaker setting, attachment setting and
do not go off).
maintenance resetting. Observe the following
If the number of the bright points and black points procedure when using the Usage Limitation Setting.
does not exceed 10, the LCD panel is not faulty or
1. While the standard screen is displayed, perform
defective.
the following operation by using the numeral
input switches.
• Switch operation (Press the switches in order
while pressing [4])
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes elapse after the
starting switch is turned to ON position.
Function of checking service meter (PC-Q1MB-

100-K-00-A)
When checking the service meter with the starting
switch in OFF position, operate the numeral input
switches as follows to display only the service meter
section.
• Switch operations (simultaneous): [4] + [1]
a There is some time lag in start of the LCD, so 2. After the "Usage Limitation Password" screen is
hold down the switches until the service meter is displayed, input the current password by using
displayed. the numeral input switches and confirm it by
a If you release one of the switches, the monitor using the function switch.
goes off. • [F5]: Deletes input numbers/Returns to
Reference: After the machine monitor is used standard screen.
continuously over a long period of time, blue points • [F6]: Enters input password.
(points that remain lit) may appear on this screen. It a Default password: [000000]
does not indicate that the LCD panel is faulty or
defective. a When the input password is correct, the
screen changes to the next screen.
PC88MR-10 30-87
Electrical system
a When the input password is incorrect, the

screen displays message to request inputting
the password again.
a The password for the Usage Limitation and

the engine start lock password are not
identical.
3. After the "Usage Limitation Setting" screen is 4. Changing a password
displayed, select a setting by using the function After the "Usage Limitation New Password
switch. Input" screen is displayed, input the new
• [F3]: Moves selection downward. password by using the numeral input switches
• [F4]: Moves selection upward. and confirm it by using the function switch.
• [F5]: Cancels the selection and returns the • [F5]: Deletes input numbers/Returns the
display to the previous screen. display to the preceding screen.
• [F6]: Enters selection. • [F6]: Enters input password.
a Default password: [000000]
a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
screen displays message to request inputting
the password again.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
is not accepted).
Selection of use/non-use of Usage Limitation

After the "Usage Limitation ON/OFF" screen is
displayed, select a setting by using the function
switch.
• Non-use: Password input screen is not
displayed
• ON: The password input screen for setting of
the circuit breaker or attachment, or
maintenance resetting appears.
• [F3]: Moves selection downward.
• [F4]: Moves selection upward.
• [F5]: Cancels the selection and returns the After the "Usage Limitation New Password
display to the previous screen. Input" screen is displayed once more, input the
• [F6]: Enters selection. new password for the second time by using the
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
Electrical system
a 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
Electrical system
Service mode (PC88MR-Q194-100-K-00-A) a The following shows the items selectable with
To change the operator mode to the service mode, the service menu (including some items which
perform the following operation. need special operations).
This operation is always required when you use the 01 Monitoring/ Pre-defined(PAGE 30-91)
service mode. 02 Monitoring(PAGE 30-94)
1. Checking of display of screen, and switch Abnormality record (mechanical systems)
operation (PAGE 30-101)
03
While the standard screen is displayed, perform Abnormality record (electrical systems)(PAGE
the following operation with the numeral input 30-102)
switches. 04 Maintenance Record(PAGE 30-103)
• Switch operation (Press the switches in order 05 Maintenance mode setting(PAGE 30-104)
while pressing [4]) 06 Phone number entry(PAGE 30-107)
[4] + [1] o [2] o [3] Default (Key-on Mode)(PAGE 30-107)
a This switch operation is accepted only while Default value setting (Unit)(PAGE 30-108)
the standard screen is displayed. Default (With/Without Attachment)(PAGE 30-
109)
07
Default (Camera)(PAGE 30-110)
Default (Auto Idle Stop Timer Setting)(PAGE
30-110)
Default (Auto Idle Stop Setting)(PAGE 30-111)
Testing (Cylinder Cut-out operation)(PAGE 30-
112)
08
Testing (Reset Number of Abrupt Engine Stop
by AIS)(PAGE 30-114)
Adjustment (Pump Absorption Torque)(PAGE
30-114)
09
Adjustment (Attachment Flow Adjustment)
(PAGE 30-115)
10 No-Injection(PAGE 30-116)
2. Selecting the service menu KOMTRAX Settings (Terminal Status)(PAGE
When the "Service Menu" screen is displayed, 30-117)
the service mode is selected. Select a service KOMTRAX Settings (GPS and Communication
menu you use by using the function switches or 11 Status)(PAGE 30-118)
numeral input switches. KOMTRAX Settings screen (Modem Status)
• [F3]: Moves selection downward (PAGE 30-119)
• [F4]: Moves selection upward 12 Service Message(PAGE 30-119)
• [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
Electrical system
Monitoring/ Pre-defined (PC88MR-Q1S1-100-K-00-A)

The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
various parts of the machine and the information
from the controllers which is controlling switches,
etc.
In "Monitoring/ Pre-defined", frequently used
monitoring items in daily work are selected
beforehand.
1. Selecting menu
Select the "Pre-defined Monitoring" on the
"Service Menu" screen.
2. Checking Monitoring/Pre-defined information

After the "Pre-defined Monitoring" screen is
displayed, the items displayed in it can be
checked with the function switch.
• [F1]: Moves to next page (screen)
• [F2]: Moves to previous page (screen)
• [F4]: Selects hold or releasing hold
(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
Electrical system
List of Pre-defined Monitoring items

(SI unit is the default value)
Pre-defined Monitoring screen (1/11) Machine basics
Unit (SI) Applicable
No. ID Item name component
SI Metric Imperial
1 01002 Engine Speed r/min rpm rpm ENG
2 04107 Coolant Temperature °C °C °F ENG
3 37212 Engine Oil Pressure Switch — — — ENG
4 18400 Intake Temperature °C °C °F ENG
5 04401 Hydr. Oil Temperature °C °C °F PUMP
6 03203 Battery Power Supply V V V ENG
Pre-defined Monitoring screen (2/11) Fuel injection system
SI Metric Imperial
2 36400 Rail Pressure MPa kg/cm2 psi ENG
3 36200 Rail Pressure Command MPa kg/cm2 psi ENG
4 48000 IMV Current A A A ENG
5 48001 IMV Command Current A A A ENG
6 18600 Inject Fueling Command mg/st mg/st mg/st ENG
Pre-defined Monitoring screen (3/11) EGR, VFT actuator
SI Metric Imperial
2 18105 EGR Opening % % % ENG
3 19000 VFT Opening % % % ENG
4 48200 MAF kg/min kg/min kg/min ENG
5 36500 Charge Pressure kPa kg/cm2 psi ENG
Pre-defined Monitoring screen (4/11) Engine temperature system
SI Metric Imperial
2 04107 Coolant Temperature °C °C °F ENG
3 18400 Intake Temperature °C °C °F ENG
4 18500 Charge Temperature °C °C °F ENG
5 18105 EGR Opening % % % ENG
6 19000 VFT Opening % % % ENG
Pre-defined Monitoring screen (5/11) Intake and exhaust pressure system
SI Metric Imperial
2 37400 Ambient Pressure kPa kg/cm2 psi ENG
4 48200 MAF kg/min kg/min kg/min ENG
30-92 PC88MR-10
Electrical system
Pre-defined Monitoring screen (6/11) Engine

SI Metric Imperial
2 37212 Engine Oil Pressure Switch — — — ENG
3 48400 Crankcase Pressure kPa kg/cm2 psi ENG
Pre-defined Monitoring screen (7/11) Pump
SI Metric Imperial
2 01100 Pump Pressure MPa kg/cm2 psi PUMP
3 01141 Service Pressure Sensor MPa kg/cm2 psi PUMP
4 01300 PC-EPC Sol Current mA mA mA PUMP
5 13113 Main Pump Absorb Torque Nm kgm lbft PUMP
6 04401 Hydraulic Oil Temperature °C °C °F PUMP
Pre-defined Monitoring screen (8/11) PPC pressure switch
SI Metric Imperial
2 07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
3 07500 Boom Lower PPC Pressure MPa kg/cm2 psi PUMP
4 07200 Arm IN PPC Pressure MPa kg/cm2 psi PUMP
5 07600 Arm OUT PPC Pressure MPa kg/cm2 psi PUMP
Pre-defined Monitoring screen (9/11) PPC pressure switch
SI Metric Imperial
2 09002 Swing Right PPC Pressure MPa kg/cm2 psi PUMP
3 09001 Swing Left PPC Pressure MPa kg/cm2 psi PUMP
4 07300 Backet CURL PPC Pressure MPa kg/cm2 psi PUMP
5 07301 Bucket DUMP PPC Pressure MPa kg/cm2 psi PUMP
Pre-defined Monitoring screen (10/11) PPC pressure
SI Metric Imperial
2 07900 Boom Swing left PPC Pressure MPa kg/cm2 psi PUMP
3 07901 Boom Swing right PPC Pressure MPa kg/cm2 psi PUMP
4 01901 Pressure Switch 2 MPa kg/cm2 psi PUMP
Pre-defined Monitoring screen (11/11) PPC pressure
SI Metric Imperial
2 07101 Travel PPC Pressure MPa kg/cm2 psi PUMP
PC88MR-10 30-93
Electrical system
Monitoring (PC88MR-Q19L-100-K-00-A) a 6 monitoring items at maximum can be

The machine monitor can monitor the condition of selected at the same time. However, it may
the machine in real time by receiving signals from not be possible to set up to 6 items
various switches, sensors, and actuators installed to depending on the display pattern of the
various parts of the machine and the information selected items.
from the controllers which is controlling switches,
etc. The monitoring item can be selected freely in
the monitoring.
1. Selecting menu
Select "Monitoring/Custom" on "Service Menu"
screen.
3. Deciding monitoring items

After selecting monitoring items, execute
monitoring with the function switch or numeral
input switch.
a Execution with function switch: Double click
or keep pressing [F6] (for approximately 2
2. Selecting monitoring item seconds).
After the "Monitoring Selection Menu" screen is
displayed, select items to be monitored by using a Execution with numeral input switch: Input
the function switches or numeral input switches. [99999] and press [F6].
• [F1]: Moves selection leftward a When monitoring only two items, for example,
• [F2]: Moves selection rightward select them and confirm with [F6]. If [F6] is
• [F3]: Moves selection downward pressed once more at this time, monitoring is
• [F4]: Moves selection upward executed.
• [F5]: Clears input numbers/ Returns the
display to the service menu screen a If monitoring items are selected up to the limit
• [F6]: Enters selection number, monitoring is executed
automatically.
a In setting of the monitoring, each time
function switch [F2] is pressed, sequential
switching among [ENG]o[PUMP]o[MON]o
[ENG] takes place in this order. (When [F1] is
pressed, sequential switching takes place in
the reverse order.)
a Selection with function switches: Select an
applicable equipment by using [F1] or [F2],
select an item by using [F3] or [F4], and then
enter it by using [F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is
selected directly. Enter that item by using
[F6]. 4. Executing monitoring
After "Monitoring" screen is displayed, perform
a 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
Electrical system
a The unit of display can be selected in SI unit,

metric unit, or inch unit with the Default
function in the service mode.
7. Saving of monitoring item

A function switch lets you save and delete the
selected monitoring item.
5. Holding monitoring information • [F1]: MEMORY
You can hold and release holding of the • [F2]: CLEAR
monitoring information by using the function
switches.
• [F4]: Selects hold or releasing hold
(If the Hold is selected, a diagonal line is
drawn on the HOLD portion.)
• [F5]: Returns the display to monitoring
selection menu screen
a When a monitoring item is saved, a

confirmation screen appears asking whether
the saved item should be displayed or not,
when "Monitoring" is selected again.
a When an item is saved, it can be displayed
as many times as required unless it is
6. Changing machine setting mode cleared.
To change the setting of the working mode, a If another item is saved while having the
travel speed, or auto-deceleration during previous item saved, the previously saved
monitoring, operate the corresponding switch item is overwritten by the latest one.
under the current condition, and the
corresponding mode is selected. a The saved monitoring item is cleared by
using [F2]. It is also cleared when the
a If the setting is changed during monitoring, selection is entered by using [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
Electrical system
30-96 PC88MR-10
Electrical system
Table of monitoring items (PC88MR-Q19L-208-K-00-A)
Unit (Default: SI) Applic-

Code Monitoring item (Display on screen) able
Remarks
No. SI Metric Imperial compo-
nent
01002 Engine Speed r/min rpm rpm ENG
04107 Coolant Temperature °C °C °F ENG
48000 IMV Current A A A ENG
48001 IMV Command Current A A A ENG
03203 Battery Power Supply V V V ENG
37212 Engine Oil Pressure SW ON, OFF ENG
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure MPa kg/cm2 psi ENG
18400 Intake Temperature °C °C °F ENG
18500 Charge Temperature °C °C °F ENG
Display of
absolute value
36500 Charge Pressure kPa kg/cm2 psi ENG (including
ambient pressure)
48200 MAF kg/min kg/min lb/min ENG
48400 Crankcase Pressure kPa kg/cm2 psi ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Throttle Position Sensor Voltage V V V ENG
04105 Coolant Temperature Sensor Volt V V V ENG
37401 Ambient Pressure Sensor Voltage V V V ENG
18401 Intake Temperature Sensor Volt V V V ENG
18501 Charge Temperature Sensor Volt V V V ENG
36501 Charge Pressure Sensor Voltage V V V ENG
36401 Rail Pressure Sensor Voltage V V V ENG
48401 Crankcase Pressure Sensor Volt V V V ENG
17500 Engine Power Mode Selection — ENG
48900 Engine Operation Mode — ENG
08402 Droop SW Selection — ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Pressure Command mg/st mg/st mg/st ENG
37300 Instantaneous Fuel Consumption l/h l/h gal/h ENG
19000 VFT Opening % % % ENG
18105 EGR Opening % % % ENG
20216 Engine Controller Build Version — ENG
20217 Engine Con Calibration Data Ver — ENG
18900 Engine Con Internal Temperature °C °C °F ENG
20400 Engine Controller S/N — ENG
01601 2nd Engine Speed Command r/min rpm rpm PUMP
07101 Travel PPC Pressure MPa kg/cm2 psi PUMP
01100 Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07500 Boom Lower PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm IN PPC Pressure MPa kg/cm2 psi PUMP
07600 Arm OUT PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket CURL PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket DUMP PPC Pressure MPa kg/cm2 psi PUMP
PC88MR-10 30-97
Electrical system

Remarks
nent
09001 Swing Left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing Right PPC Pressure MPa kg/cm2 psi PUMP
07900 Boom Swing left PPC Pressure MPa kg/cm2 psi PUMP
07901 Boom Swing right PPC Pressure MPa kg/cm2 psi PUMP
04401 Hydraulic Oil Temperature °C °C °F PUMP
01300 PC-EPC Sol Current mA mA mA PUMP
01701 Attachment Sol 2 Current mA mA mA PUMP
42008 Lever Main Potentiometer 1 Volt V V V PUMP
42009 Lever Sub Potentiometer 1 Voltage V V V PUMP
42012 Lever Potentiometer 1 Stroke % % % PUMP
03200 Battery Voltage V V V PUMP
04402 Hydraulic Oil Temp Sensor Volt V V V PUMP
01602 2nd Engine Speed Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP
01141 Service Pressure Sensor MPa kg/cm2 psi PUMP
Swing ON, OFF PUMP
Travel ON, OFF PUMP
Boom Lower ON, OFF PUMP
01900 Pressure SW 1
Boom Raise ON, OFF PUMP
Arm IN ON, OFF PUMP
Arm OUT ON, OFF PUMP
Bucket CURL ON, OFF PUMP
Bucket DUMP ON, OFF PUMP
01901 Pressure SW 2 Service ON, OFF PUMP
Blade Up ON, OFF PUMP
Blade Down ON, OFF PUMP
Boom Swing Left ON, OFF PUMP
01902 Pressure SW 3
Boom Swing Right ON, OFF PUMP
Swing Brake ON, OFF PUMP
Solenoid Valve Merge- divider ON, OFF
02300 PUMP
1
Travel Speed ON, OFF PUMP
Solenoid Valve PPC Lock Relay ON, OFF
02301 PUMP
2
SW Input 1 Swing P Brake ON, OFF
02200 PUMP
Release SW
Model Selection 1 ON, OFF PUMP
02201 SW Input 2
Overload Alarm ON, OFF PUMP
02202 SW Input 3 Key SW (ACC) ON, OFF PUMP
Lock Lever SW ON, OFF PUMP
Lock Lever SW 2 ON, OFF PUMP
02203 SW Input 4 PPC Lock Solenoid ON, OFF PUMP
State
Lever Auto Lock ON, OFF PUMP
Release SW
30-98 PC88MR-10
Electrical system

Remarks
nent
Breaker SW ON, OFF PUMP
Window Limit SW ON, OFF PUMP
02204 SW Input 5 P Limit SW ON, OFF PUMP
W Limit SW ON, OFF PUMP
20229 Pump Controller Assembly P/N — PUMP
20403 Pump Controller S/N — PUMP
20230 Pump Controller Program P/N — PUMP
20212 Pump Controller Program Version — PUMP
04300 Battery Charge Voltage V V V PUMP
04200 Fuel Level Sensor Voltage V V V MON
Key SW ON, OFF MON
Start ON, OFF MON
04500 Monitor Input 1
Preheat ON, OFF MON
Light ON, OFF MON
Battery Charge
04501 Monitor Input 2 ON, OFF MON
Voltage
Engine Shutdown ON, OFF MON
04502 Monitor Input 3 2nd SW
Seat Belt SW ON, OFF MON
F1 ON, OFF MON
F2 ON, OFF MON
Monitor F3 ON, OFF MON
04503
Function SW F4 ON, OFF MON
F5 ON, OFF MON
F6 ON, OFF MON
SW1 ON, OFF MON
SW2 ON, OFF MON
Monitor 1st & SW3 ON, OFF MON
04504
2nd Row SW SW4 ON, OFF MON
SW5 ON, OFF MON
SW6 ON, OFF MON
SW7 ON, OFF MON
SW8 ON, OFF MON
Monitor 3rd & SW9 ON, OFF MON
04505
4th Row SW SW10 ON, OFF MON
SW11 ON, OFF MON
SW12 ON, OFF MON
SW13 ON, OFF MON
Monitor 5th ON, OFF
04506 SW14 MON
Row SW
SW15 ON, OFF MON
20227 Monitor Assembly P/N — MON
20402 Monitor S/N — MON
20228 Monitor Program P/N — MON
20200 Monitor Program Version — MON
55300 A/C Compressor State ON, OFF MON
55000 A/C Fresh Air Temp Code — MON
55100 A/C Recirc Air Temp Code — MON
55200 A/C Mode Data (Monitor) — MON
55201 A/C Mode Data (A/C ECU) — MON
PC88MR-10 30-99
Electrical system

Remarks
nent
Only when
20260 KOMTRAX Assembly P/N — MON KOMTRAX is
used
Only when
20418 KOMTRAX S/N — MON KOMTRAX is
used
Only when
20261 KOMTRAX Program P/N — MON KOMTRAX is
used
Only when
20273 KOMTRAX ProgramVersion — MON KOMTRAX is
used
Only when ID key
20262 ID Key Controller Assembly P/N — MON
is used
Only when ID key
20419 ID Key Controller S/N — MON
is used
Only when ID key
20263 ID Key Controller Program P/N — MON
is used
a Listing order in table

The monitoring items are listed in the order of the display on the monitoring item selection menu screen.
a Unit
The display unit can be set to SI, Metric, or Imperial as required (select a desired unit from "Unit" of
"Default" in the service menu).
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
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
Electrical system
Abnormality record (mechanical (a): Occurrence order from latest one/Total

systems) (PC88MR-Q1S2-100-K-00-A) number of records
The machine monitor logs the past and currently (b): Failure code
occurring failures classifying them into the (c): Detail of failure
mechanical system abnormality and electrical (d): Number of occurrences (displayable range:
system abnormality. 0 to 65,535 times)
To check the mechanical system abnormality record, (e): Service meter reading at the first occurrence
perform the following procedures. (f): Service meter reading at the last occurrence
• [F1]: Move to next page (screen) (This
a For the failure code list, see "Chapter 40 Failure function key is available when more than 1
code list for troubleshooting". page is needed for display.)
1. Selecting a menu • [F1]: Return to previous page (screen) (This
Select "Abnormality Record" on "Service Menu" function key is available when more than 1
screen. page is needed for display.)
• [F5]: Returns to the "Abnormality Record"
screen.
a If no abnormality is recorded, "No Error" is
displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrence is 1 (first
occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
2. Selecting a sub menu When the latest service meter reading is
After the "Abnormality Record" screen is recovered, the value at the recovery time is
displayed, select "Mechanical Sys Abnormality displayed, thus the above readings may not
Record" by using the function switch or numeral be the same.
input switches. a If [E] is displayed on the left of a failure code,
• [F3]: Moves selection downward. the abnormality is still occurring or correction
• [F4]: Moves selection upward. of it is not confirmed.
• [F5]: Returns to "Service Menu" screen.
• [F6]: Enters selection. a For all of the failure codes that the machine
monitor can record, see the failure code list.
a When you input a 2-digit code by using the
numeral input switches, the corresponding a If the characters in the failure are many, the
item is directly selected. Accordingly, you character strings display is scrolled.
4. Clearing abnormality record

3. Information displayed on "Abnormality Record" The contents of an abnormality record of the
screen mechanical system cannot be deleted.
On "Mechanical Sys Abnormality Record"
screen, the following information is displayed.
PC88MR-10 30-101
Electrical system
Abnormality record (electrical (a) Occurrence order of abnormalities from latest

systems) (PC88MR-Q1S3-100-K-00-A) one/ Total number of records
The machine monitor records the past and currently (b): Failure code
occurring failures classifying them into the (c): Detail of failure
mechanical system abnormality and electrical (d): Number of occurrences (displayable range:
system abnormality. 0 to 65,535 times)
To check the electrical system abnormality record, (e): Service meter reading at the first occurrence
perform the following procedures. (f): Service meter reading at the last occurrence
• [F1]: Move to next page (screen) (This
a For the failure code list, see "40 Failure code list function key is available when more than 1
for troubleshooting". page is needed for display.)
1. Selecting menu • [F2] Return to previous page (screen) (This
Select "Abnormality Record" on "Service Menu" function key is available when more than 1
screen. page is needed for display.)
• [F3]: Moves selection downward
• [F4]: Moves selection upward
• [F5]: Returns to "Abnormality Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a On the electrical systems abnormality record
screen, up to 20 cases currently stored are
displayed.
If the number of abnormality records
increases to 21 or beyond, the latest
occurrence code is displayed and the oldest
one is deleted.
2. Selecting sub menu
After the "Abnormality Record" screen is a If the number of occurrence is 1 (first
displayed, select "Electrical Sys Abnormality occurrence), the service meter reading at the
Record" by using the function switch or numeral first occurrence and that at the last
input switches. occurrence are the same.
• [F3]: Moves selection downward a If [E] is displayed on the left of a failure code,
• [F4]: Moves selection upward the abnormality is still occurring or correction
• [F5]: Returns to "Service Menu" screen of it is not confirmed.
a For all of the failure codes that the machine
a When you input a 2-digit code by using the monitor can record, see the failure code list.
numeral input switches, the corresponding
item is directly selected. Accordingly, you a If the characters in the failure are many, the
may enter the selection by using [F6]. character strings display is scrolled.
3. Information displayed on "Abnormality Record" 4. Clearing abnormality record

screen 1) While the "Electrical Sys Abnormality
On "Electrical Sys Abnormality Record" screen, Record" screen is displayed, perform the
the following information is displayed. following operation by using the numeral
input switches.
30-102 PC88MR-10
Electrical system
• Switch operation (Press the switches in • [F5]: Returns to Electrical Systems

order while pressing [4]) screen (clear mode)
[4] + [1] o [2] o [3] Return
• [F6]: Executes clearing
a The following figure shows the screen
when an individual item is cleared (it is
slightly different from the screen when all
the item are cleared at once).
2) Check that the display on the screen

becomes the clear mode, then clear the
individual information one by one or all
together by using the function switches.
a If the screen is set in the clear mode,
graphic mark [CLEAR] is indicated above 4) If the screen to notify completion of clearing
[F2]. is displayed and then "Electrical System
• [F2]: Clears all items Abnormality Record" (clear mode) screen is
• [F3]: Moves selection downward displayed, the clearing of the abnormality
• [F4]: Moves selection upward record is completed.
• [F5]: Returns to "Abnormality Record" a After a while, the screen returns to the
screen "Electrical Sys Abnormality Record"
• [F6]: Clears items one by one screen.
a To clear items one by one: Select the item
to be cleared with [F3] or [F4] and press
[F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.
Maintenance Record (PC88MR-Q19Z-100-K-00-A)

The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
When the maintenance is performed, if the data are
reset in the operator mode, the number of the times
of maintenance is recorded in this section.
1. Selecting menu
Select "Maintenance Record" on "Service Menu"
3) After "Electrical Systems Abnormality Record screen.
Reset" screen is displayed, operate the
function switches.
PC88MR-10 30-103
Electrical system
(a): Maintenance items

(b): Number of replacements up to now
(c): Service meter reading (SMR) at the last
replacement
2. Selecting maintenance record item

After the "Maintenance Record" screen is
displayed, select an item of which the setting is
to be checked by using the function switches or
numeral input switches.
• [F1]: Moves to next page (screen) Maintenance mode setting (PC88MR-Q1F1-100-K-00-A)
• [F2]: Moves to previous page (screen) The actuating condition of the maintenance
• [F3]: Moves selection downward reminder function in the operator mode can be set
• [F4]: Moves selection upward and changed by using this menu.
• [F5]: Returns to "Service Menu" screen • To enable or disable the function
a You may enter a 2-digit code by using the • Change replacement interval setting (by item)
numeral input switches to select the item of • To initialize all of replacement interval setting
that code. 1. Selecting menu
Select "Maintenance Mode Setting" on "Service
Menu" screen.
a The following items can be selected in the

maintenance record.
"49 Air Cleaner Cleaning or Change"
After the "Maintenance Mode Setting" screen is
"60 Coolant Change" displayed, select an item of which the setting is
"41Fuel Prefilter Change" to be changed by using the function switches or
"01 Engine Oil Change" numeral input switches.
"02 Engine Oil Filter Change" • [F1]: Moves to next page (screen)
"05 Hyd Oil Tank Breather Change" • [F2]: Moves to previous page (screen)
"03 Fuel Main Filter Change" • [F3]: Moves selection downward
"04 Hydraulic Oil Filter Change" • [F4]: Moves selection upward
"07 Damper Case Oil Check/Refilling" • [F5]: Returns to "Service Menu" screen
"09 Swing Machinery Case Oil Change"
"08 Final Dribe Case Oil Change" a When you input a 2-digit code by using the
"47 KCCV Filter Change" numeral input switches, the corresponding
"10 Hydraulic Oil Change" item is directly selected. Accordingly, you
3. Items displayed on Maintenance Record screen
The following information is displayed.
30-104 PC88MR-10
Electrical system
4. Setting of Maintenance Notice Time Setting

a The following items can be selected on the
After selecting "Maintenance Notice Time
"Maintenance Mode Setting" screen.
Setting", if the screen is displayed, set with the
"00 Maintenance Mode Change" function switches.
"49 Air Cleaner Cleaning or Change Interval"
"60 Coolant Change Interval"
"41 Fuel Prefilter Change Interval"
"01 Engine Oil Change Interval"
"02 Engine Oil Filter Change Interval"
"05 Hydraulic Oil Tank Breather Change Interval"
"03 Fuel Oil Tank Breather Change Interval"
"04 Hydraulic Oil Filter Change Interval"
"07 Damper Case Oil Check or Refilling Interval"
"09 Swing Machinery Case Oil Change Interval"
"08 Final Drive Case Oil Change Interval"
"10 Hydraulic Oil Change Interval"
"99 All Default Value" • Default value: Maintenance notice time set
3. Setting of maintenance mode change on the machine monitor (Recommended by
After selecting "Maintenance Mode Change" the manufacturer and not changeable).
and the screen is displayed, select the desired • Set value: Maintenance time that can be
setting by using the function switches. freely set. Maintenance reminder function
• ON: All of functions of maintenance items works according to this set time in operator
become effective in operator mode. mode (the time increases or decreases in
• OFF: All of functions of maintenance items multiples of 10 hours).
becomes ineffective in operator mode. • [F3]: Decreases set value
• [F3]: Moves selection downward • [F4]: Increases set value
• [F4]: Moves selection upward • [F5]: Cancels contents of setting before entry
• [F5] Cancels selection and returns to the and returns to the "Maintenance Mode
"Maintenance Mode Change" screen Change" screen
• [F6]: Enters selection and returns to • [F6]: Enters setting and returns to
"Maintenance Mode Change" screen Maintenance mode setting 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
Electrical system
5. Setting of each maintenance item • [F5]: Cancels contents of setting before entry
Select each maintenance item. After the screen and returns to the "Maintenance Mode
is displayed, set the item by using the function Change" screen
switches. • [F6]: Enters setting and returns to
• ON: Function of the selected individual "Maintenance Mode Change" screen
maintenance item becomes effective in
a When you enter by using [F6] and return to
operator mode.
the "Maintenance Mode Setting" screen by
• OFF: Function of the selected individual
using [F5] , your setting is validated.
maintenance item becomes ineffective in
operator mode. a If the set value of an item of which
• [F3]: Moves selection downward maintenance reminder function is set to "ON"
• [F4]: Moves selection upward is changed after 1 operating hour or more
• [F5]: Cancels selection and returns to the from the setup, the change is recognized as
"Maintenance Mode Change" screen a reset of the remaining time.
• [F6]: Enters selection and returns to
"Maintenance Mode Change" screen
7. Function to return all of the values to default

values
6. Setting of set value of each maintenance item After selecting "All Default Value" and the screen
Select the set value of each maintenance item. is displayed, select the desired setting by using
After the screen is displayed, set the value by the function switches.
using the function switches.
• If the operation for this function is executed,

• Default value: Maintenance notice time set the set values of all the maintenance items
on the machine monitor (Recommended by are returned to the default values.
the manufacturer and not changeable). • [F5]: Returns the display to "Maintenance
• Set value: Maintenance time that can be Mode Setting" screen
freely set. Maintenance reminder function • [F6]: Executes initialization
works according to this set time in operator a 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
Electrical system
Phone number entry (PC88MR-Q19A-110-K-00-A) a Up to 14 digits can be input from the left.
The telephone number, which is displayed together Leave the surplus places without inputting.
with the "Occurred error list" in the operator mode, a If an input numeral is wrong, move the cursor
can be input and changed according to the following (orange background) to that digit and
procedure. overwrite it with the correct numeral.
If a telephone number is not input with this function,
a If [F6] is pressed without inputting a digit,
no telephone number is displayed in Operator mode.
there is not information of telephone No.
1. Selecting a menu Accordingly, no telephone No. is displayed in
Select "Phone Number Entry" on "Service the operator mode.
Menu" screen.
2. Registering and changing phone number Default (Key-on Mode) (PC88MR-Q1F2-100-K-00-A)

After the "Phone Number Entry" screen is Use the menu of "Default" to check or change
displayed, register or change the phone number various settings of the machine monitor and
by using the function switch or numeral input machine.
switches.
Use the sub menu of "key-on Mode" to set the
• [F2]: Deletes all input digits
working mode selected and displayed on the
• [F3]: Moves the input position to the next left
machine monitor when the starting switch is turned
place (if not blank)
to ON position.
• [F4]: Moves the input position to the next
right place (if not blank) 1. Selecting a menu
• [F5]: Resets input digit/ Returns the display Select "Default" on the "Service Menu" screen.
to the service menu screen
• [F6]: Validates the entry
PC88MR-10 30-107
Electrical system
• [F6]: Enters selection and returns the display

to Default screen
a Factory default is, "Mode at Previous Key-
off".
a If "With Attachment" is not selected, selection
of the Attachment/P-Mode and Attachment/
E-mode is disabled.
a If you change the setting to "Without
attachment" when Attachment/P-mode [P] or
Attachment/E-mode is selected, Power
mode [P] is displayed when the starting
2. Selecting a sub menu switch is turned to ON position.
After the "Default" screen is displayed, select
"Key-on Mode" by using the function switch or
a Selecting method is the same as on the
Default value setting (Unit) (PC88MR-Q1F3-100-K-00-A)

Use the menu of "Default" to check or change
various settings of the machine monitor and
machine.
The unit selecting function is used to select the unit
3. Selecting mode of the data to be displayed in monitoring, etc.
After the "Key-on Mode" screen is displayed,
1. Selecting menu
select the mode by using the function switches
Select "Default" on the "Service Menu" screen.
to set it.
• Power mode: [P] is displayed when the
starting switch is set to ON position
• Economy mode: [E] is displayed when the
starting switch is set to ON position
• Lifting Operation Mode: [L] is displayed when
the starting switch is turned to ON position.
• Breaker Mode: [B] is displayed when the
starting switch is turned to ON position.
• Attachment/P-mode: [ATT/P] is displayed
when the starting switch is set to ON
position.
• Attachment/E-mode: [ATT/E] is displayed
when the starting switch is set to ON
position. 2. Selecting a sub menu
• Mode at Previous Key-off: Final mode in After the "Default" screen is displayed, select
previous operation is displayed when the "Unit" by using the function switch or numeral
starting switch is turned to ON position. input switches.
• [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
Electrical system
3. Selecting unit 2. Selecting a sub menu

After the "Unit" screen is displayed, select the After the "Default" screen is displayed, select
unit to be set by using the function switches. "With/Without Attachment" by using the function
• [F3]: Moves selection downward switch or numeral input switches.
• [F5]: Cancels selection and returns the
display to Default screen
to Default screen
a Factory default is the “SI Unit”.
3. Selecting With/Without
After the "With/Without Attachment" screen is
switch.
• Without Attachment: An attachment is not
Default (With/Without Attachment) (PC88MR-Q1F4- installed.
100-K-00-A)
• With Attachment 1: An attachment is
Use the menu of "Default" to check or change installed.
various settings of the machine monitor and • [F3]: Moves selection downward
machine. • [F4]: Moves selection upward
Use the sub menu of "With/Without Attachment" to • [F5]: Cancels selection and returns the
configure attachment setting when the attachment display to Default screen
is installed or removed. • [F6]: Enters selection and returns the display
1. Selecting a menu to Default screen
Select "Default" on the "Service Menu" screen. a 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
Electrical system
• "Use": Images from connected camera are

displayed as a normal image.
• [Я]: Reverse images (mirror images if it is
used for rear view monitor) are displayed.
• [R]: Normal images (visual images if it is
used for front or side monitor) are displayed.
• [F4]: Moves selection upward.
• [F5] Cancels contents of setting before entry
and returns to "Default" screen
• [F6]: Enters selection in each line
a You cannot switch camera 1 between [Я] and
[R].
Default (Camera) (PC88MR-Q1F6-100-K-00-A)
a Enter selection in each line with [F6], and
return to the "Default" screen with [F5], and
then your setting is validated.
machine.
Camera setting is for setting of camera when the a Unless setting is normally set with this
camera is installed or removed. function when the camera is connected, the
graphic mark of camera is not displayed at
1. Selecting a menu
[F3] in the operator mode. Accordingly, the
Select "Default" on "Service Menu" screen.
image of the camera cannot be used.
a When the camera is installed, check that the
right and left portions of the displayed image
are correct.
2. Selecting a sub menu

After the "Default" screen is displayed, select
"Camera" by using the function switch or
Default (Auto Idle Stop Timer Setting) (PC88MR-

Q1GE-100-K-00-A)
3. Selecting camera setting Use the menu of "Default" to check or change
After the "Camera" screen is displayed, select a various settings of the machine monitor and
setting by using the function switch. machine.
• Not Use: Camera is not used
30-110 PC88MR-10
Electrical system
Use the auto idle stop time fixing setting function to

set the time selectable by using the auto idle stop
time setting in the operator mode.
1. Selecting menu
Select "Default" on the"Service Menu" screen.
Default (Auto Idle Stop Setting) (PC88MR-Q1C9-110-

K-00-A)
machine.
2. Selecting a sub menu Use the auto idle stop setting function to set the
After the "Default" screen is displayed, select shortest time selectable by using the auto idle stop
"Auto Idle Stop Time Fixing" by using the time setting.
function switch or numeral input switches. 1. Selecting menu
a Selecting method is the same as on the Select "Default" on the "Service Menu" screen.

3. Setting selectable time After the "Default" screen is displayed, input "50"
After the "Auto Idle Stop Time Fixing" screen is by using the numeral input switches and press
displayed, select a setting by using the function "F6".
switch. a This function is required if the setup time
• Variable: Selection from OFF to 60 minutes needs to be shorter than the initial setting "5
is allowed. minutes" by laws and regulations or if the
• OFF: Auto idle stop function is not used. auto idle stop setting by the specifications is
• X-minute fixing: OFF setting and setting the not allowed to operate. Accordingly, this
time longer than the selected time are function is not displayed in the menu list.
unselectable.
This function allows you to set the time
shorter than the initial setting "5 minutes".
However, setting the shorter time may result
in lower durability of the starting motor due to
increase in frequency of engine start.
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
Electrical system
3. Setting selectable time

After the "Auto Idle Stop Setting" screen is Testing (Cylinder Cut-out operation) (PC88MR-
AD00-34F-K-00-A)
On the machine monitor, the cylinder cutout mode
switch.
operation can be performed.
• OFF: Auto idle stop function is not used.
• 1 minute: When selection from "1-minute fix" Cylinder cutout mode operation means to run the
to "60-minute fix" is allowed or when engine with one or more fuel injectors disabled
"Variable" is selected in "Auto Idle Stop electrically to reduce the number of effective
Setting", selection from "1 minute" to "60 cylinders. This operation is used to identify a
minutes" is allowed in "Auto Idle Stop cylinder that does not output power normally
Setting". (combustion in it is abnormal).
• 3 minutes: When selection from "3-minute 1. Selecting menu
fix" to "60-minute fix" is allowed or when Select "Diagnostic Tests" on "Service Menu"
"Variable" is selected in "Auto Idle Stop Time screen.
Fixing", selection from "3 minutes" to "60
minutes" is allowed in "Auto Idle Stop
Setting".
• """"5 minutes: When selection from "5-minute
fix" to "60-minute fix" is allowed or when
"Variable" is selected in "Auto Idle Stop Time
Fixing", selection from "5 minutes" to "60
minutes" is allowed in "Auto Idle Stop
Setting".
• [F6]: Enters selection and returns the display 2. Selecting sub menu
to Default screen After the "Diagnostic Tests" screen is displayed,
a When this setting is "OFF", the auto idle stop select "Cylinder Cutout Mode Operation" using
does not operate. Accordingly, the auto idle the function switch or numeral input switches.
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
Electrical system
out cylinder to be reset with the function

switches.
a This operation can be performed while the
engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue, the
cylinder is reset.
a If the machine monitor releases a cutout
cylinder but the engine controller cannot
release the cutout cylinder, the background
(a) of the cylinder number becomes red.
3. Selecting cylinder to be cut-out a The cutout cylinder mode operation is not
After the "Cylinder Cutout Mode Operation" automatically released after the screen
screen is displayed, select a cylinder to be cut returns to the operator mode. Accordingly, be
out by using the function switches. sure to perform the releasing operation after
• [F1]: Moves selection leftward the cylinder cutout mode operation is
• [F2]: Moves selection rightward finished.
• [F4]: Selects hold or releasing hold 5. Holding displayed data
(If the Hold is selected, a diagonal line is Each time [F4] is pressed during the cylinder
drawn on the HOLD portion.) cutout operation, the displayed data is newly
• [F5]: Returns the display to "Diagnostic held (c) (the real-time data is kept displayed on
Tests" screen the left side).
• [F6]: Enters selection While the data is held, if [F4] is pressed, the data
a This operation can be performed while the holding function is reset.
engine is running. a The holding function is available for a
a If background (a) of the selected cylinder cylinder, regardless of whether it is cut out or
number becomes white after you press [F6], not.
the cylinder is cut out.
a If the machine monitor cuts out a cylinder but
the engine controller cannot cutout that
cylinder, the background (a) of the cylinder
number becomes yellow.
a One or more cylinders can be cut out.
a Auto-deceleration function can be selected in
the cylinder cutout mode operation. When
turning auto-deceleration ON, auto-
deceleration monitor (b) is displayed.
[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur.
1) Lowering of engine speed
2) Fuel Inject Command (quantity)
increases.
• If the engine is running at near high idle,
however, the engine speed may not lower for
the reason of engine control.
• 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
Electrical system
Testing (Reset Number of Abrupt Engine Stop

by AIS) (PC88MR-AF87-360-K-00-A)
On the machine monitor, the cylinder cutout mode
operation and reset of sudden stop numbers can be
executed.
Reset number of abrupt stops by auto idle stop is
used to reset the counter that counts the high
engine speed status when stopping the engine by
the auto idle stop function memorized in the
machine. The reset is performed after replacing the
turbocharger.
1. Selecting a menu
Select the "Diagnostic Tests" on the "Service
Menu" screen. a Perform the sudden stop number reset after
replacing the turbocharger.
Adjustment (Pump Absorption

Torque) (PC88MR-C201-27E-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
The sub menu of Pump Absorption Torque is used
to finely adjust the absorption torque of the
hydraulic pump.
1. Selecting menu
Select "Adjustment" on the "Service Menu"
screen.

After the "Diagnostic Tests" screen is displayed,
select "Reset Number of Abrupt Engine Stop by
AIS" using the function switch or numeral input
switches.

After the "Adjustment" screen is displayed,
select "Pump Absorption Torque" by using the
function switch or numeral input switches.
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
Electrical system
The sub menu of "Attachment Flow Adjustment" is

used to finely adjust the oil flow rate to the
attachment in combined operations.
1. Selecting a menu
Select "Adjustment" on the"Service Menu"
screen.
3. Selecting pump absorption torque setting

After the "Pump Absorption Torque" screen is
displayed, select the desired value at the right
side by using the function switches.
• Set value: For actual torque adjustment
value, see table
• [F4]: Decreases set value 2. Selecting a sub menu
• [F6]: Checks and enters setting. Returns to After the "Adjustment" screen is displayed,
the "Adjustment" screen select "Att Flow Adjust in Combined Ope" by
using the function switch or numeral input
a The 3-digit number in the left column does switches.
not change since it is the code of this
function. a Selecting method is the same as on the
a Relationship between set value and torque 3. Selecting distribution of oil flow
adjustment value After the "Att Flow Adjust in Combined Ope"
Code Set Value Torque adjustment value screen is displayed, select the desired value at
+39.2 Nm {+4 kgm} the right side by using the function switches.
000
• Set value: For actual distribution of oil flow,
001 +29.4 Nm {+3 kgm}
see table
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm} • [F4]: Decreases set value
021 004 0 Nm {0 kgm} • [F6]: Checks and enters setting. Returns to
005 -9.8 Nm {-1 kgm} the"Adjustment" screen
006 -19.6 Nm {-2 kgm}
a The 3-digit number in the left column does
007 -29.4 Nm {-3 kgm} not change since it is the code of this
008 -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
Electrical system
a Relationship between set value and current

value to ATT EPC
Code Set Value
000 +35 mA
001 +30 mA
002 +25 mA
003 +20 mA
004 +15 mA
005 +10 mA
006 +5 mA
007 0 mA
008 -5 mA
a Relationship between set value and 009 -10 mA
distribution of oil flow to attachment 010 -15 mA
Distribution of flow to 011 -20 mA
Code Set Value 012 -25 mA
attachment
000 50% 013 -30 mA
001 70% 014 -35 mA
037
002 100%
003 40% No-Injection (PC88MR-AD00-25L-K-00-A)
If the engine is operated after long storage of the
Adjustment (Attachment EPC machine, it may be worn or damaged because of
Adjustment) (PC88MR-PT24-270-K-00-A) insufficient lubrication with oil. To prevent this, the
After the "Attachment EPC Adjustment" screen is machine monitor has a function to crank the engine
displayed, select the desired value at the right side without injecting fuel to lubricate the engine before
by using the function switches. starting it.
• Set value: For actual current value, see table Set No Injection cranking while the engine is
• [F3]: Increases set value stopped.
• [F4]: Decreases set value 1. Selecting a menu
• [F6]: Confirms setting and returns to Adjustment Select "No Injection" on "Service Menu" screen.
screen
a The 3-digit number in the left column does not
change since it is the code of this function.
Adjustment item Default

Code
value
Attachment EPC 2
Adjustment 049
Attachment EPC 3
Adjustment 048
007
Attachment EPC 4
Adjustment 165
Attachment EPC 5
Adjustment 164
2. Displaying check screen
When the "No Injection" screen is displayed, the
message to ask if "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
Electrical system
a This function can be selected even when the

engine is running. However, if you execute
no-injection cranking, a message "Engine is
operating Please turn the key off once" is
displayed on the screen.
3. Starting No Injection cranking

If No Injection cranking (no fuel injection to every
cylinder) is enabled, a message "No Injection is
possible" is displayed on the screen. Under this
condition, crank the engine with the starting
motor.
Also, if no-injection cranking is operated
a While the screen is changing to the following while "Check" screen appears, the function
screen, the screen of "Getting Ready" is does not become effective in the following
displayed. case.
a Do not crank the engine for 20 seconds or • The communication between the monitor
longer to protect the starting motor. and engine controller is not normal.
• Perform an engine start operation before
the message "No injection is possible" is
displayed.
4. Finishing No Injection cranking

After the cranking is over, turn the starting switch
to OFF position.
a You cannot change the screen described KOMTRAX Settings (Terminal Status) (PC220-
above to another screen. Q210-110-K-00-A)
5. Prohibiting No Injection cranking The setting and operating conditions of KOMTRAX
Even if the operator tries to perform the No can be checked on the display of KOMTRAX
Injection cranking while the engine is running, Settings.
the message "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
Electrical system
KOMTRAX Settings (GPS and Communication

Status) (PC220-Q210-110-K-01-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of KOMTRAX
Settings.
GPS & Communication Status is for checking the
positioning and communication condition of the
KOMTRAX terminal.
1. Selecting a menu
screen.

After the "KOMTRAX Settings" screen is
displayed, select "Terminal Status" by using the
a Selecting method is the same as ot on the

displayed, select "GPS & Communication
Status" by using the function switch or numeral
input switches.
a Selecting method is the same as it on the
3. Contents displayed on Terminal Status screen
On "Terminal Status" screen, the following items
of information are displayed.
• "Terminal Type": Model name of the
KOMTRAX communication modem
• "KOMTRAX Communication": Status of radio
station establishment underway
• "GMT Time": Greenwich Mean Time (add 9
hours to it for Japan time)
• [F5]: Returns the screen to "KOMTRAX
Settings" screen
3. Contents of display of GPS & Communication

Status
On "GPS & Communication Status" screen, the
following items of information are displayed.
• "Positioning": GPS positioning status
• "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
Settings" screen
30-118 PC88MR-10
Electrical system
IP addresses (2 systems) of the modem are

displayed.
Settings" screen
a IP address is a unique number assigned to
each modem that is used when
communication between the modem and
server is established.
KOMTRAX Settings screen (Modem

Status) (PC220-Q210-110-K-02-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of KOMTRAX
Settings.
Modem information is used to check the IP address
of the KOMTRAX communication modem.
1. Selecting a menu
Service Message (PC220-Q210-100-K-00-A)
screen.
Special messages for the technician sent from
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If a received message includes a setting operation,
a return mail can be sent by using the numeral input
switches as well.
1. Selecting a menu
Select "Service Message" on "Service Menu"
screen.

displayed, select "Modem Status" by using the
2. Displaying message (read only)

If there is a message, the contents are displayed.
If there is no message, "No message." is
displayed.
• [F5]: Returns to "Service Menu" screen
a 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
3. Details displayed on Modem Status screen machine monitor in the operator mode.
PC88MR-10 30-119
Electrical system
3. Display of message (with return mail function)

If Numeric Input is displayed under the message,
input a proper number by using the numeral
input switches and enter it by using the function
switch, and the information is returned to the
KOMTRAX base station.
• [F5]: Returns to "KOMTRAX Settings" screen
• [F6]: Enters input value and sends it back
a 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
Electrical system
KOMTRAX terminal start-up procedure (PC88MR-Q210-110-K-00-A)
Observe the following procedure when using 1. Our technician provides a new terminal, and
KOMTRAX. records the part number and serial number.
• Inside Japan: Our technician notifies KOMTRAX-
KOMTRAX-Keyperson performs "Machine Keyperson of the new terminal information.
Registration" by using KOMTRAX client PC. 2. KOMTRAX-Keyperson performs "Terminal
Replacement" and operation related to
a For details, see "KOMTRAX-Keyperson communication startup by using KOMTRAX
operation manual". client PC.
• Outside Japan: 3. Select the country where the terminal is used
1. KOMTRAX-Keyperson performs "Machine in "Terminal start setting" screen, and press
Registration" by using KOMTRAX client PC. the "Apply" button.
2. After "Machine registration", select the 4. KOMTRAX-Keyperson fills in required items
country where the terminal is used in on "Terminal Replacement Sheet", and send
"Terminal setting"screen, and press the it by email to KOMTRAX support center via
"Apply" button. KOMTRAX administrator in the subsidiary.
3. After the notification of completion of opening 5. KOMTRAX-Keyperson confirms that
is received from KOMTRAX support center communication has started on KOMTRAX
and the "Start" button is displayed in the screen, and notifies to the site that the
"Terminal start setting" screen, press the terminal has been replaced.
button. 6. Our technician replaces the terminal, and
perform "Machine side inspection for
a Completion of opening may take a few days.
KOMTRAX Communication opening". Our
a After pressing the "Start" button, the technician notifies KOMTRAX-Keyperson of
communication starts normally in a few days. the completion of inspection of the work.
7. After the notification of completion of opening
a For details, see "Global KOMTRAX Web
is received from KOMTRAX support center
Reference Manual (For Key Person)".
and the "Start" button is displayed in the
a Operating the KOMTRAX client PC requires "Terminal start setting" screen, press the
the KOMTRAX operation administrator button.
authority at each distributor. Therefore you
a Completion of opening may take a few days.
must consult the KOMTRAX-Keyperson
before using it. a After pressing the "Start" button, the
When KOMTRAX terminal is replaced. communication starts normally in a few days.
Observe the following procedure when using a For details, see "Global KOMTRAX Web
KOMTRAX after replacement of KOMTRAX Reference Manual (For Key Person)".
terminal.
a Operating the KOMTRAX client PC requires the
• Inside Japan: KOMTRAX operation administrator authority at
1. Our technician provides a new terminal, and each distributor. Therefore you must consult the
records the part number and serial number. KOMTRAX-Keyperson before using it.
2. Our technician replaces the terminal, and Machine side inspection for KOMTRAX
perform "Machine side inspection for Communication opening
KOMTRAX Communication opening". Our
When the KOMTRAX terminal is replaced,
technician notifies KOMTRAX-Keyperson of
KOMTRAX Communication opening must be done
the completion of inspection work and new
to check whether normal communication is
terminal information.
available from the terminal.
3. KOMTRAX-Keyperson performs "Terminal
Replacement" by using KOMTRAX client The above KOMTRAX Communication opening can
PC. be performed on the machine monitor.
4. KOMTRAX-Keyperson fills in required items a GPS and data communication are checked
on "End of the Use Sheet", and send it to during the inspection of KOMTRAX
KOMTRAX support center. Communication opening. Accordingly, it is
a For details, see "KOMTRAX-Keyperson preferable to park the machine outdoors. The
operation manual". opening may not be completed when the
• Outside Japan: machine is placed indoor where radio wave from
the satellite is blocked.
PC88MR-10 30-121
Electrical system
1. Selecting a menu opening. Answer affirmatively to it and start

Select "KOMTRAX Settings" on the "Service the operation.
Menu" screen. Return switch: Returns the display to the
GPS & Communication Status screen
Enter switch: Executes the establishment
inspection.
a When KOMTRAX Communication
opening is already completed, this screen
does not appear.

displayed, select "GPS & Communication
Status."
3) The screen displays the state of KOMTRAX

Communication opening. Check on this
screen that all item are "OK".
Modem: "OK" is displayed when the system
enters the communication range.
GPS: "OK" is displayed when it acquires
GPS data.
Transmission: "OK" is displayed when it
transmits data correctly.
Inspection status: The inspection completes
when the modem, GPS and transmission are
3. Implementation of KOMTRAX Communication all "OK".
opening
1) After the "GPS & Communication Status" a It takes 90 seconds to 15 minutes to
screen is displayed, perform the following approve all items.
operation. a While waiting for the approval, you may
Switch operation: While pressing numeral do what you want to do like displaying
input switch "4", press the buttons in the other screens, turning the starting switch
sequence of "1"o"2"o"3". to OFF position or starting the engine.
If there is nothing abnormal, KOMTRAX
Communication opening finishes
automatically. Select "KOMTRAX
Settings" o "Terminal Status" of "Service
Menu" to make sure that "Already Open."
is indicated for the item in "KOMTRAX
Settings, "KOMTRAX Communication".
a The opening may not be completed when
the machine is placed indoor where radio
wave from the satellite is blocked.
a 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
Electrical system
a If "GPS" does not become "OK", check

the communication antenna and cable for
external failure. 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. If "GPS &
Communication Status" appears, the
machine side opening is completed.
PC88MR-10 30-123
Electrical system
30-124 PC88MR-10
Electrical system
Adjusting rearview camera angle (PC88MR-Q162-360-K-00-A)
a Adjust the camera so that persons in area (W) of

1 meter around the rear of the machine can be
seen by the machine monitor in the operator's
cab.
If the image displayed on the monitor is out of
position, adjust the installation angle of camera (1).
4. Loosen mounting bolts (5) of camera (1), and

adjust camera installing angle (A) so that the
side of camera matches the edge of bracket (B).
Angle (A): 48 deg. (+2 deg. /0)
Adjusting (PC88MR-Q162-270-K-00-A)
1. Remove cover (3) by inserting flat-head

screwdriver [1] in the hole in cover (3) and
pressing the internal claw.
a A part of the machine is displayed on the

monitor screen.
Adjust the image area of the counterweight
displayed on the monitor screen to 10 to 15%.
a The claw of cover (3) is made of plastic, so

be careful not to break it when removing.
5. After adjusting, tighten bolts (5).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
2. Remove bolts (4) (2 places).

PC88MR-10 30-125
Electrical system
6. Install covers (2) and (3).
30-126 PC88MR-10
Electrical system
Handling voltage circuit of engine controller (PC220-AP40-2A4-K-00-A)
1. Disconnecting or connecting work of the

connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in OFF
position and the system operating lamp goes
out.
k Before connecting the wiring harness

connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
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
Electrical system
Handling battery disconnect switch (PC88MR-AW1P-100-K-00-A)
1. When the battery disconnect switch is turned to

"OFF (O)" position, be sure to remove switch
key (1).
kA hazard can result if an unauthorized

person turns switch key (1) to ON position
carelessly.
a The battery disconnect switch is installed
inside the rear left cover of the machine.
2. The operating condition of each controller can
be checked with the system operating lamp (2)
to prevent the abnormal end of the
disconnection of the battery power supply circuit
while the controllers are in operation.
1) Before shutting off the battery power supply
circuit, turn the starting switch to "OFF"
position, and check that system operating
lamp (2) goes off, then turn the battery
disconnect switch to "OFF (O)" position.
2) If the battery disconnect switch is turned to
"OFF (O)" position (battery power supply
circuit is OFF) while system operating lamp
(2) is lit, data loss error of controller may
occur. Never operate the battery disconnect
switch while system operating lamp (2) is lit.
3) System operating lamp (2) goes off in 2
minutes after the starting switch is turned to
"OFF" position.
4) System operating lamp (2) may sometimes
light up while the starting switch is turned to
"OFF" position because KOMTRAX terminal
may maintain its communication under this
condition.
5) System operating lamp (2) may look slightly
luminous in the dark after it is turned off. It is
due to the minute leakage of current and not
an abnormal phenomenon.
• After the starting switch is turned to
"OFF" position, KOMTRAX terminal
repeats the start and stop to maintain the
periodic communication.
• The start and stop cycle (sleep cycle) of
KOMTRAX terminal varies depending on
the factors including the communication
state and machine stop time. So the lamp
can be lit as long as approximately 1
hour.
6) When you want to cut off the battery circuit
for maintenance but the system operating
lamp (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
Electrical system
Testing diodes (ALL-E300-001-P-00-A)
a Test the diode array (8-pin) and the single diode

(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.
2. When using analog tester

1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to
a The continuity direction of the single diode is the anode (P) side of the diode and apply
indicated on the surface of the diode. the black (-) lead to the cathode (N) side.
Testing (PC220-E300-36J-P-00-A) 2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
1. When using a digital tester apply the black (-) lead to the anode (P)
1) Select the diode range screen to check the side.
displayed values. 3) Evaluate the condition of the diode by the
a When an ordinary circuit tester is used, movement of the pointer.
the voltage of the internal battery is • The pointer does not move by the above
indicated. 1] connection, but it does by the 2]
2) Apply the red (+) lead of the multimeter to the connection: Normal (however, the
anode (P) side of the diode and apply the movement of the pointer (resistance)
black (-) lead to the cathode (N) side and varies by type of tester, or selection of
check the indicated value. measuring range).
3) Evaluate the condition of the diode by the • The pointer moves by either connection
indicated value. of the above 1], and 2]:
• Indicated value does not change: No Defective (internal short circuit)
continuity (defective) • The pointer moves by neither connection
• Indicated value changes: Continuity the above 1], nor 2]: Defective (internal
(normal) (note) open circuit)
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
0:
The diode has internal short circuit
(defective).
PC88MR-10 30-129
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 h
User name Date of inspection Inspector
Specification
Main parts Attachment Shoe width
T Standard
( )
Boom T Breaker T 450 mm T( )
T Standard
Arm T( ) T 600 mm
( )
Bucket T( )
T Standard
( )
Check of oil and coolant levels
T Radiator coolant When necessary T Machinery case oil
T Engine oil T Damper case oil T( )
T Hydraulic oil T Final drive case oil
Ambient temperature Altitude
°C m
Operator's comment
Result of visual inspection
Abnormality record in mechanical systems Abnormality record in electrical systems

A900FR Times/First time h/Latest h Times/First time h/Latest h
A900N6 Times/First time h/Latest h Times/First time h/Latest h
A900NY Times/First time h/Latest h Times/First time h/Latest h
AB00KE Times/First time h/Latest h Times/First time h/Latest h
B@BAZG Times/First time h/Latest h Times/First time h/Latest h
B@BCNS Times/First time h/Latest h Times/First time h/Latest h
CA234 Times/First time h/Latest h Times/First time h/Latest h
30-130 PC88MR-10
Pm clinic
Max. range of engine coolant temperature gauge
Coolant temperature gauge level Coolant temperature Color of monitor light (a)
6 105°C
Red
5 102°C
4 100°C
3 80°C Blue
2 60°C
1 30°C White
Max. range of hydraulic oil temperature gauge
Oil temperature level Hydraulic oil temperature Color of monitor light (a)
6 105°C
Red
5 102°C
4 100°C
3 80°C Blue
2 40°C
1 20°C White
PC88MR-10 30-131
Pm clinic
Check sheet (PC88MR-2160-033-A-00-A)
a Perform the checks after sufficient warm-up operation of the engine.

Date of
Model Serial No. Service meter User name Inspector
inspection
PC88MR-10 / /
Engine
Engine SAA4D95LE-6 No
Go-
Standard Mea- goo-
od
Item Testing conditions Unit value for new Repair limit sured d
machine item
• Coolant temperature: 75 to 94°
C
Engine high 55°C 1,900 to 1,900 to
idle speed • Fuel control dial: MAX
2,000 2,000
(*1) • Working mode: P mode
• Auto-deceleration switch: OFF
• Work equipment, swing, travel
control lever: All NEUTRAL rpm
C
Engine low • Hydraulic oil temperature: 45 to
55°C 1,150 to 1,150 to
idle speed
• Fuel control dial: MIN 1,200 1,200
(*1)
• Auto-deceleration switch: OFF
control lever: All NEUTRAL
C
• Fuel control dial: MAX 0.34 to 0.59 Min. 0.25
• Working mode: P mode {2.5}
• Auto-deceleration switch: OFF {3.5 to 6.0}
Engine oil • Work equipment, swing, travel MPa

pressure control lever: All NEUTRAL {kg/cm2}
C
• Fuel control dial: MIN Min. 0.18 Min. 0.15
• Auto-deceleration switch: OFF {1.8} {1.5}
*1: Items that can be inspected in Special functions of machine monitor.
30-132 PC88MR-10
Pm clinic
Work equipment speed

Go-
Standard Mea- go-
od
Item Testing conditions Unit value for new Repair limit sured od
machine item
55°C Arm length:
• Engine: High idle 1650 mm
• Working mode: P mode
• Measurement range: Between 2.5 to 3.1
Boom ground touch point of bucket
and RAISE stroke end Max. 3.5
RAISE
• Measurement posture: See Arm length:
chapter 20, "Work equipment 2" 2100mm
in "Machine posture and
procedure for measuring 2.2 to 2.8
performance".
55°C
• Measurement range: Between
arm OUT stroke end and arm IN
Arm IN stroke end 2.8 to 3.4 Max. 3.9
• Measurement posture: See
chapter 20, "Work equipment 3"
procedure for measuring
performance".
sec.
55°C
arm IN stroke end and arm OUT
Arm OUT stroke end 2.4 to 3.0 Max. 3.2
performance".
55°C
Bucket bucket DUMP stroke end and
bucket CURL stroke end 2.8 to 3.6 Max. 4.0
CURL
performance".
PC88MR-10 30-133
Pm clinic

Go-
Standard Mea- go-
od
machine item
55°C
bucket CURL stroke end and
Bucket bucket DUMP stroke end 2.0 to 2.6 Max. 3.1
DUMP • Measurement posture:
Horizontal boom top face (See
performance".)
55°C
Boom • Measurement range: Between
swing LEFT stroke end and RIGHT
stroke end 6.0 to 7.4 Max. 8.0
LEFT o
RIGHT • Measurement posture: See
performance".
30-134 PC88MR-10
Pm clinic

Go-
Standard Mea- go-
od
machine item
55°C
Boom • Measurement range: Between
swing RIGHT stroke end and LEFT
stroke end 6.0 to 7.4 Max. 8.0
RIGHT
oLEFT • Measurement posture: See
performance".
55°C
ground touch point of blade and
Blade RAISE stroke end 1.1 to 1.5 Max. 2.1
RAISE • Measurement posture:
performance".)
55°C
RAISE stroke end and ground
Blade touch point of blade 1.1 to 1.5 Max. 2.1
LOWER • Measurement posture:
performance".)
Swing speed
Go-
Standard Mea- goo-
od
machine item
swing RIGHT
45 to 55°C
• Working mode: P mode 27 to 33 Max. 35
Time • What to measure: Time
required to required to complete 5 turns
sec.
finish after 1 turn of swing
swing LEFT
swinging • Measurement posture: See

chapter 20, "Swing 1" in
"Machine posture and 27 to 33 Max. 35
performance".
PC88MR-10 30-135
Pm clinic
Travel speed
Go-
Standard Mea- goo-
od
machine item
Reverse Forward Reverse Forward

• Hydraulic oil
temperature: 45 to 55°C 33.0 to 41.0 Max. 44.0
• Working mode: P mode Lo
• What to measure: Time
required for 5 turns after 33.0 to 41.0 Max. 44.0
Travel
1 idle turn of track off
speed (idle sec.
ground
running)
• Measurement posture:
See chapter 20, "Travel 20.0 to 24.0 Max. 26.0
1" in "Machine posture
and procedure for Hi
measuring
performance". 20.0 to 24.0 Max. 26.0
Hydraulic drift of work equipment

Go-
Standard Mea- goo-
od
machine item
55°C
• Engine: Stopped
• Load: Bucket rated load (320
kg)
• Work equipment control lever:
NEUTRAL
Whole work • Measurement posture: See
equipment chapter 20, "Work equipment 1"
(Hydraulic in "Machine posture and mm/15
drift Max. 350 Max. 600
procedure for measuring min.
measured performance".
at tooth tip) • Measure extension amount and
retraction amount of each
cylinder and hydraulic drift of
bucket tooth tip.
• Start measuring immediately
after setting.
• Measure hydraulic drift every 5
minutes and judge at 15
minutes.
30-136 PC88MR-10
Pm clinic
Hydraulic circuit
Go-
Standard Mea- goo-
od
machine item
55°C
Control • Engine: High idle 2.7 to 3.7 2.7 to 3.7
MPa
circuit oil • Working mode: P mode {kg/cm2} {28 to 38} {28 to 38}
pressure • Auto-deceleration switch: OFF
Unload • Hydraulic oil temperature: 45 to
pressure 55°C
(pump • Engine: High idle MPa 1.8 to 3.8 1.8 to 3.8
discharge • Working mode: P mode {kg/cm2}
• Auto-deceleration switch: OFF {18 to 38} {18 to 38}
pressure)
(*1) • Work equipment, swing, travel
Work
55°C 25.52 to 25.03 to
equipment
• Engine: High idle MPa 27.48 27.97
(arm) relief
• Working mode: P mode {kg/cm2}
pressure {260 to 280} {255 to 285}
(*1)
Arm digging relief
55°C
• Disconnect connector (CN-V03) 19.52 to 19.03 to
Swing relief
of parking brake solenoid. MPa 21.48 21.97
pressure
• Engine: High idle {kg/cm2}
(*2) {200 to 220} {195 to 225}
Swing relief
• R.H.
Travel
locked 25.52 to 25.03 to
• Right 27.48 27.97
forward
• Hydraulic oil or {260 to 280} {255 to 285}
Travel relief temperature: 45 to reverse

55°C relief MPa
pressure
• Engine: High idle • L.H. {kg/cm2}
(*1)
• Working mode: P Travel
mode locked 25.52 to 25.03 to
• Left 27.48 27.97
forward
or {260 to 280} {255 to 285}
reverse
relief
55°C
LS
• Working mode: P mode 2.5 to 4.4 2.1 to 2.3
differential MPa
• Work equipment operation:
pressure {kg/cm2} {25 to 45} {21.5 to 23.5}
Bucket CURL full stroke, lever in
(*2)
NEUTRAL
• LS differential pressure = Pump
pressure - LS pressure
PC88MR-10 30-137
Pm clinic

Go-
Standard Mea- goo-
od
machine item
Front pump
25.5 to 27.5 25.0 to 28.0
discharge
{260 to 280} {255 to 285}
pressure
• Hydraulic oil Above value Above value
temperature: 45 to Pump
PC valve x x
55°C control
output approximate- approximate-
• Engine: High idle pressure
pressure MPa ly 0.25 ly 0.25
• Working mode: P
(Servo Rear pump {kg/cm2}
piston inlet mode 25.5 to 27.5 25.0 to 28.0
discharged
pressure) • Work equipment {260 to 280} {255 to 285}
pressure
control: Arm IN
relief Above value Above value
Pump
x x
control
approximate- approximate-
pressure
ly 0.25 ly 0.25
*1: Items that can be inspected in Special functions of machine monitor.
*2: Items that can be checked in Special functions of machine monitor by using service connector
30-138 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
40 Troubleshooting
6 40 Troubleshooting
PC88MR-10 40-1
40 Troubleshooting
Table of contents

40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting......................................................................................... 40-8
Troubleshooting points ......................................................................................................... 40-8
Sequence of events in troubleshooting................................................................................. 40-10
Checks before troubleshooting ............................................................................................ 40-12
Inspection procedure before troubleshooting ........................................................................ 40-14
Preparation for troubleshooting of electrical system............................................................... 40-31
Classification and procedures for troubleshooting ................................................................. 40-36
Symptom and troubleshooting numbers ............................................................................... 40-39
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 40-44
Connector list and layout .................................................................................................... 40-46
Connector contact identification........................................................................................... 40-55
T-branch box and T-branch adapter table ............................................................................. 40-94
Fuse location table ............................................................................................................. 40-99
Failure codes table........................................................................................................... 40-101
Troubleshooting by failure code (Display of code) ...................................................................... 40-108
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit............................................ 40-108
Failure code [879AKB] A/C Recirc Air Temp Sens Short ...................................................... 40-109
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit............................................. 40-110
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit ..............................................40-111
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-112
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-113
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-114
Failure code [879EMC] Ventilation Damper Malfunction ...................................................... 40-115
Failure code [879FMC] Air Mix Damper Malfunction ............................................................ 40-116
Failure code [879GKX] Refrigerant Press Input Sig Out of Range......................................... 40-117
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-118
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-119
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-120
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3............................................ 40-121
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 ............................................ 40-122
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2............................................ 40-123
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-124
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-126
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
Failure code [CA131] Throttle Sensor High Error................................................................. 40-133
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-135
Failure code [CA144] Coolant Temperature Sensor High Error ............................................. 40-137
Failure code [CA145] Coolant Temperature Sensor Low Error.............................................. 40-139
Failure code [CA153] Charge Air Temperature Sensor High Error......................................... 40-141
Failure code [CA154] Charge Air Temperature Sensor Low Error ......................................... 40-143
Failure code [CA187] Sensor 2 Supply Voltage Low Error.................................................... 40-145
Failure code [CA221] Ambient Pressure Sensor High Error ................................................. 40-147
Failure code [CA222] Ambient Pressure Sensor Low Error .................................................. 40-149
Failure code [CA227] Sensor 2 Supply Voltage High Error ................................................... 40-151
Failure code [CA234] Engine Overspeed ........................................................................... 40-152
Failure code [CA238] NE Speed Sensor Supply Voltage Error ............................................. 40-153
Failure code [CA239] NE Speed Sensor Supply Voltage High Error...................................... 40-154
Failure code [CA271] PCV1 Short Circuit Error ................................................................... 40-155
Failure code [CA272] PCV1 Open Circuit Error ................................................................... 40-156
40-2 PC88MR-10
40 Troubleshooting
Table of contents
Failure code [CA343] Engine Controller Internal Failure....................................................... 40-165
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-166
Failure code [CA352] Sensor1 Supply Voltage Low Error..................................................... 40-167
Failure code [CA356] MAF Sensor High Error..................................................................... 40-169
Failure code [CA357] MAF Sensor Low Error ..................................................................... 40-171
Failure code [CA386] Sensor1 Supply Voltage High Error .................................................... 40-173
Failure code [CA435] Engine Oil Pressure SW Error ........................................................... 40-174
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-175
Failure code [CA442] Battery Voltage High Error................................................................. 40-177
Failure code [CA451] Common Rail Pressure Sensor High Error.......................................... 40-179
Failure code [CA452] Common Rail Pressure Sensor Low Error .......................................... 40-181
Failure code [CA466] KVGT Motor Driver Position Error ...................................................... 40-183
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error........................................... 40-185
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error............................................ 40-187
Failure code [CA559] Common Rail Pressure Low Error 1 ................................................... 40-192
Failure code [CA689] Engine NE Speed Sensor Error ......................................................... 40-195
Failure code [CA691] Intake Air Temperature Sensor High Error .......................................... 40-197
Failure code [CA692] Intake Air Temperature Sensor Low Error ........................................... 40-199
Failure code [CA697] Engine Con Internal Temp Sens High Error......................................... 40-201
Failure code [CA698] Engine Con Internal Temp Sens Low Error ......................................... 40-202
Failure code [CA731] Engine Backup Speed Sensor Phase Error ........................................ 40-203
Failure code [CA778] Engine Backup Speed Sensor Error................................................... 40-205
Failure code [CA1117] Engine Controller Partial Data Lost Error........................................... 40-209
Failure code [CA1695] Sensor 5 Supply Voltage High Error ................................................. 40-210
Failure code [CA1696] Sensor 5 Supply Voltage Low Error .................................................. 40-211
Failure code [CA1843] Crankcase Pressure Sensor High Error ............................................ 40-212
Failure code [CA1844] Crankcase Pressure Sensor Low Error............................................. 40-214
Failure code [CA1896] EGR Valve Stuck Error.................................................................... 40-216
Failure code [CA1942] Crankcase Pressure Sensor In Range Error ..................................... 40-217
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error............................................. 40-218
Failure code [CA2185] Throttle Sensor Supply Voltage High Error........................................ 40-219
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error......................................... 40-221
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
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error ............................................ 40-229
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-231
Failure code [CA2765] Injector Trim Data Mismatch ............................................................ 40-232
Failure code [CA3419] MAF Sensor Supply Voltage High Error ............................................ 40-233
Failure code [CA3421] MAF Sensor Supply Voltage Low Error............................................. 40-235
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error........................................ 40-237
Failure code [CA3918] KVGT Stuck Error........................................................................... 40-239
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................ 40-240
Failure code [CA3921] KVGT Servo Error 2........................................................................ 40-241
Failure code [CA3922] KVGT Motor Driver Open Error ........................................................ 40-242
Failure code [CA3923] KVGT Motor Driver Short Error ........................................................ 40-244
Failure code [D110KB] Battery Relay Output Short Circuit ................................................... 40-246
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
40 Troubleshooting
Table of contents
Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX)................................ 40-256

Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-258
Failure code [DA22KK] Pump Con Solenoid Power Volt Low Error ....................................... 40-259
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error ............................................. 40-261
Failure code [DA29KQ] Model Selection Sig Mismatch (Pump Con) ..................................... 40-263
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-265
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-267
Failure code [DA2QKR] CAN 2 Defective Communication (Pump Con)................................. 40-268
Failure code [DA2RKR] CAN 1 Defective Communication (Pump Con)................................. 40-270
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-271
Failure code [DAF0MC] Monitor Malfunction....................................................................... 40-272
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-273
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor) ..................................... 40-274
Failure code [DAFGMC] GPS Module Malfunction .............................................................. 40-275
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-276
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-278
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) ..................................... 40-279
Failure code [DAZ9KQ] Model Selection Sig Mismatch (A/C) ............................................... 40-280
Failure code [DAZQKR] CAN2 Defective Communication (A/C ECU) ................................... 40-281
Failure code [DB2QKR] CAN2 Defective Communication (Engine Con)................................ 40-285
Failure code [DB2RKR] CAN1 Defective Communication (Engine Con) ................................ 40-289
Failure code [DDNRKA] WE Lever Lock SW Open Circuit ................................................... 40-293
Failure code [DDNRKY] WE Lever Lock SW Short Circuit ................................................... 40-295
Failure code [DDNS00] Lock Lever Auto Lock Release SW On............................................ 40-297
Failure code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault ........................................ 40-299
Failure code [DHPAMA] Front Pump Press Sens Defective Function .................................... 40-301
Failure code [DHS3MA] Arm IN PPC Press Sensor Def Function ......................................... 40-303
Failure code [DHS4MA] Bucket CURL PPC Press Sens Def Function .................................. 40-305
Failure code [DHS5MA] Travel PPC Sensor Abnormality..................................................... 40-307
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function .................................... 40-309
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function.................................... 40-311
Failure code [DHSAMA] Swing Right PPC Press Sens Def Function .................................... 40-313
Failure code [DHSBMA] Swing Left PPC Press Sensor Def Function.................................... 40-315
Failure code [DHSCMA] Arm OUT PPC Press Sens Def Function........................................ 40-317
Failure code [DHSDMA] Bucket DUMP PPC Press Sens Def Function ................................. 40-319
Failure code [DHSPMA] Boom Swing LH PPC Press Sensor Abnormality............................. 40-321
Failure code [DHSQMA] Boom Swing RH PPC Press Sensor Abnormality............................ 40-323
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
Failure code [DW43KB] Travel Speed Solenoid Short Circuit ............................................... 40-335
Failure code [DW43KY] Travel Speed Sol Hot Short Circuit ................................................. 40-337
Failure code [DW45KA] Swing Parking Brake Solenoid Open Circuit .................................... 40-338
Failure code [DW45KB] Swing Parking Brake Solenoid Short Circuit .................................... 40-341
Failure code [DW45KY] Swing Brake Sol Hot Short Circuit .................................................. 40-343
Failure code [DW4CKY] PPC lock Sol Hot Short Circuit....................................................... 40-345
Failure code [DWJ0KA] Merge-divider Sol Open Circuit....................................................... 40-347
Failure code [DWJ0KB] Merge-divider Sol Short Circuit....................................................... 40-349
Failure code [DWJ0KY] Merge-divider Sol Short Circuit....................................................... 40-351
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit .................................... 40-352
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit..................................... 40-354
Failure code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit ............... 40-356
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
40 Troubleshooting
Table of contents
Failure code [DXEAKY] Service Current EPC5 Hot Short Circuit .......................................... 40-366
Failure code [DY20KA] Wiper Motor Open Circuit ............................................................... 40-368
Failure code [DY20MA] Wiper Motor Defective Function...................................................... 40-370
Failure code [DY2CKB] Washer Motor Short Circuit ............................................................ 40-372
Failure code [DY2DKB] Wiper Motor (Normal) Short Circuit ................................................. 40-374
Failure code [DY2EKB] Wiper Motor (Reverse) Short Circuit................................................ 40-376
Troubleshooting of electrical system (E-mode) .......................................................................... 40-378
E-1 Engine does not start (Engine does not crank) .............................................................. 40-378
E-2 Manual preheating system does not work..................................................................... 40-384
E-3 While preheating is working, preheating monitor does not light up .................................. 40-387
E-4 When starting switch is turned to ON position, machine monitor displays nothing............. 40-389
E-5 Engine coolant temperature monitor lights up in white while engine is running ................. 40-392
E-6 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-393
E-7 Charge level monitor lights up while engine is running ................................................... 40-394
E-8 Fuel level monitor lights up in red while engine is running .............................................. 40-395
E-9 Engine coolant temperature monitor lights up in red while engine is running .................... 40-396
E-10 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-397
E-11 Engine oil pressure monitor lights up in red while engine is running............................... 40-398
E-12 Fuel gauge display does not move from minimum or maximum .................................... 40-399
E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-400
E-14 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-401
E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full
nor empty).......................................................................................................... 40-402
E-16 Hydraulic oil temperature gauge does not move from minimum or maximum ................. 40-403
E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor
empty) ............................................................................................................... 40-405
E-18 Some areas of machine monitor screen are not displayed............................................ 40-406
E-19 Function switch does not work................................................................................... 40-407
E-20 Automatic warm-up system does not operate (in cold season)...................................... 40-408
E-21 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration
switch is operated ............................................................................................... 40-409
E-22 Auto-deceleration function does not operate or is not canceled while lever is
operated ............................................................................................................ 40-410
E-23 Working mode selection screen is not displayed while working mode selector switch is
operated ............................................................................................................ 40-412
E-24 Setting of engine and hydraulic pump is not changed while working mode is
changed............................................................................................................. 40-413
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
E-29 Service mode cannot be selected .............................................................................. 40-418
E-30 Any of work equipment, swing and travel does not work............................................... 40-419
E-31 Any of work equipment, swing and travel cannot be locked .......................................... 40-421
E-32 Upper structure does not swing while swing parking brake cancel switch is set to
CANCEL position................................................................................................ 40-423
E-33 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position .............................................................................................................. 40-425
E-34 Work equipment does not operate while lock lever automatic release switch is in release
position .............................................................................................................. 40-427
E-35 Alarm does not sound during travel ............................................................................ 40-429
E-36 Alarm does not stop sounding while machine is stopped.............................................. 40-430
E-37 Horn does not sound ................................................................................................ 40-431
E-38 Horn does not stop sounding..................................................................................... 40-433
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
40 Troubleshooting
Table of contents
E-42 Boom LOWER is not displayed correctly with monitoring function ................................. 40-438
E-43 Arm OUT is not displayed correctly with monitoring function......................................... 40-439
E-44 Arm IN is not displayed correctly with monitoring function ............................................ 40-440
E-45 Boom RAISE is not displayed correctly with monitoring function ................................... 40-441
E-46 Bucket CURL is not displayed correctly with monitoring function................................... 40-442
E-47 Bucket DUMP is not displayed correctly with monitoring function.................................. 40-443
E-48 Boom swing left is not displayed correctly with monitoring function ............................... 40-444
E-49 Boom swing right is not displayed correctly with monitoring function ............................. 40-445
E-50 Swing is not displayed correctly with monitoring function.............................................. 40-446
E-51 Travel is not displayed correctly with monitoring function ............................................. 40-447
E-52 Blade RAISE ON is not displayed correctly with monitoring function ............................. 40-448
E-53 Blade LOWER ON is not displayed correctly with monitoring function ........................... 40-450
E-54 KOMTRAX system does not operate normally ............................................................ 40-452
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-454
Information described in troubleshooting table (H-mode) ..................................................... 40-454
System chart of hydraulic and mechanical systems............................................................. 40-455
Failure mode and cause table ........................................................................................... 40-457
H-1 All of work equipments, swing and travel operations lack speed or power ....................... 40-465
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-467
H-3 Any of work equipment, swing and travel does not work ................................................ 40-468
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-469
H-5 Fine control performance or response is poor ............................................................... 40-470
H-6 Boom speed or power is low ....................................................................................... 40-471
H-7 Arm speed or power is low .......................................................................................... 40-474
H-8 Bucket speed or power is low...................................................................................... 40-476
H-9 Boom swing speed or power is low .............................................................................. 40-478
H-10 Blade speed or power is low...................................................................................... 40-480
H-11 Work equipment does not move in single operation ..................................................... 40-482
H-12 Hydraulic drift of boom is large .................................................................................. 40-483
H-13 Hydraulic drift of arm is large ..................................................................................... 40-484
H-14 Hydraulic drift of bucket is large ................................................................................. 40-485
H-15 Hydraulic drift of blade is large................................................................................... 40-486
H-16 Time lag of work equipment is large ........................................................................... 40-487
H-17 In combined operation of work equipment , equipment having heavier load moves
slower................................................................................................................ 40-489
H-18 In combined operation of swing and boom RAISE, boom rising speed is low ................. 40-490
H-19 In combined operation of work equipment or swing and travel, travel speed drops
largely................................................................................................................ 40-491
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
H-24 One of tracks does not run ........................................................................................ 40-501
H-25 Upper structure does not swing to the right or left ........................................................ 40-503
H-26 Upper structure swing only to the right or left .............................................................. 40-504
H-27 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-505
H-28 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-506
H-29 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-507
H-30 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-508
H-31 Shock is large when upper structure stops swinging.................................................... 40-509
H-32 Large unusual noise is heard when upper structure stops swinging .............................. 40-510
H-33 Swing drift on a slope is large while swing parking brake is applied............................... 40-511
H-34 Swing drift on a slope is large while swing parking brake is released............................. 40-512
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
40 Troubleshooting
Table of contents
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-516

S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-517
S-4 Engine startability is poor ............................................................................................ 40-518
S-5 Engine does not pick up smoothly ............................................................................... 40-520
S-6 Engine stops during operation ..................................................................................... 40-522
S-7 Engine runs rough or is unstable ................................................................................. 40-524
S-8 Engine lacks power .................................................................................................... 40-525
S-9 Exhaust smoke is black .............................................................................................. 40-527
S-10 Engine oil consumption is excessive .......................................................................... 40-529
S-11 Oil becomes contaminated quickly ............................................................................. 40-530
S-12 Fuel consumption is excessive .................................................................................. 40-531
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-532
S-14 Oil pressure drops .................................................................................................... 40-533
S-15 Fuel mixes into engine oil.......................................................................................... 40-534
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
40 Troubleshooting
Related information on troubleshooting
Related information on troubleshooting (ALL-5100-001-A-00-A)
Troubleshooting points (ALL-5130-42A-A-00-A)
(Rev. 2012/11)
k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.
k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.
k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
k Drain approximately 10l

l of coolant beforehand, because you may get scalded by hot water
spurting out from mounting location of coolant temperature sensor when removing radiator cap
during checking and replacing coolant temperature sensor.
k When performing checking and replacement of engine oil pressure sensor (switch), open oil filler
port, and check that engine oil temperature cools down enough not to get scalded.
k Loosen the oil filler cap of the hydraulic tank to release the pressure in the hydraulic tank. For
details, see Testing and adjusting "Releasing remaining pressure in hydraulic circuit" when
checking and replacing oil temperature sensor and oil pressure sensor. Check the code with
monitoring function and display the hydraulic oil temperature, then check that the temperature is
40°C or lower and cool enough not to burn.
Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before the failure?
4) Under what conditions did the failure occur?
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
40 Troubleshooting
3) Make checks of other items.

4) Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
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
40 Troubleshooting
Sequence of events in troubleshooting (ALL-5140-42A-A-00-A)
(Rev. 2011. 7)
40-10 PC88MR-10
40 Troubleshooting
PC88MR-10 40-11
40 Troubleshooting
Checks before troubleshooting (PC138-5150-208-A-00-A)
Judge-
No. Role ment Remedy
value
1 Check for unusual noise and smell - Correct
2 Check for dirt around engine - Remove
3 Check for water leakage around engine - Correct
4 Check for oil leakage around engine - Correct
5 Check for leakage from fuel line - Correct
6 Check of radiator for clogging - Remove
a: Engine, lubricating oil and coolant
7 Check of level and type of fuel - Refilling of oil

8 Check for foreign material in fuel - Clean and drain
9 Check of fuel pre-filter - Replace
10 Check of fuel main filter - Replace
Between
11 Check of level (in oil pan) and type of engine oil Refilling of oil
H and L
Between
12 Check of coolant level (in sub tank) Refilling of coolant
H and L
The red
piston is
not
projected
13 Check of air cleaner clogging at the Clean or replace
transpar-
ent part
of dust
indicator
14 Check for dirt around KDOC muffler - Remove
15 Check for gas leakage around KDOC muffler - Correct
1 Check for unusual noise and smell - Correct
Check for oil leakage -
b: Hydraulic and mechanical equipment
2 Correct
Between
3 Check of hydraulic oil level Refilling of oil
H and L
4 Check of hydraulic oil strainer - Clean and drain
5 Check of hydraulic oil filter - Replace
Between
6 Check of swing machinery case oil level Refilling of oil
H and L
Between Refilling of oil
7 Check of damper case oil level
H and L
8 Check of final drive case oil level - Refilling of oil
Bleed air from

9 Air bleeding - cylinder
40-12 PC88MR-10
40 Troubleshooting
Judge-
No. Role ment Remedy
value
1 Check of battery terminal for looseness and corrosion - Retighten or replace
2 Check of alternator terminal for looseness and corrosion - Retighten or replace
3 Check of starting motor terminal for looseness and corrosion - Retighten or replace
20 to 30 Charge or replace
4 Check of battery voltage (with engine stopped)
V
Between
5 Check of battery electrolyte level Add or replace
H and L
Check of wiring harness for discoloration, burnt areas and cover
6 peeling - Repair or replace
Check for coming off of wiring harness clamp and sagging of wiring -
7 Correct
harness
c: Electrical parts
8 Check of grounding - Correct

9 Check for loose connector and damaged lock - Repair or replace
10 Check of connector pin for corrosion, bends and deformation - Repair or replace
Dry, clean or
11 Check for water and foreign material in connector -
replace
12 Check of wiring harness for open circuit and short circuit - Repair or replace
13 Check of fuse for blowout and corrosion ― Replace
After few
minutes
Check of alternator voltage (when engine speed is medium or of
14 higher) Replace
operation:
27.5 to
29.5 V
Check of battery relay operation sound (When the starting switch is
15 turned to ON or OFF position) - Replace
16 Check and cleaning of rear view camera - Clean or repair
1 Check of undercarriage - Correct
d: Exterior parts
2 Check of handrails and steps - Correct
3 Check of rear view mirrors - Clean or repair
1 Check of gauges and monitors - Clean or replace

e: Interior parts
2 Check of seat belt - Replace
PC88MR-10 40-13
40 Troubleshooting
Inspection procedure before troubleshooting (ALL-5150-001-A-00-A)
Walk-around check (D37-5150-289-A-00-A)
Before starting the engine, look around and under Check piping between the turbocharger and KDOC
the machine to check for any loose nuts or bolts, muffler and joints of KDOC muffler for gas leakage
leakages of oil, fuel or coolant, and check the (sticking soot, etc.) If any abnormality is found,
condition of the work equipment and hydraulic repair.
system. b2. Check of work equipment, cylinders, linkage
Check the connectors for looseness, the wiring and hoses for breakage, wear and clearance
harnesses for play, and the hot parts for Check the work equipment, cylinders, linkage and
accumulated dust. hoses for cracks and excessive wear, check that
k Accumulated combustibles around hot each clearance is within the normal range, and then
engine parts such as the engine,KDOC repair any unusual parts.
muffler, and turbocharger, etc. and fuel or oil b3. Check of hydraulic equipment, hydraulic
leakages may cause a machine fire. Be sure tank, hoses and joints for oil leakage
to check thoroughly and repair any failures. Check and repair any oil leaks.
a1. and b1. Check for unusual sounds and c1. Check around battery and dirt removal
smells Check and remove any accumulated dirt and
Check for unusual sounds and smells. combustibles (dead leaves, twigs, etc.) around the
battery.
Some causes of unusual sounds and smells can
damage the machine if they are left as they are. c16. Check and cleaning of rear view camera
Therefore, stop the machine immediately when you Check the rear view camera for any defect, and
find any unusual sounds and smells. repair any failures.
a2. Check around engine and dirt removal d1. Check of undercarriage (tracks, sprockets,
Check and remove any accumulated dirt around the idlers and guards) for defect, wear, loose bolts
engine and any combustibles (dead leaves, twigs, and oil leakage from roller
etc.) on hot engine parts such as the KDOC muffler, Repair any unusual parts.
turbocharger, etc. d2. Check of handrails and steps for unusual
a3. Check for water leakage around engine conditions and loose bolts
a4. Check for oil leakage around engine Repair any unusual conditions and retighten any
Check any oil leaks from the engine and any water loose bolts.
leaks from the coolant system. If any of them is d3. Check and cleaning of rear view mirrors
unusual, perform a repair. Check and repair any unusual conditions and
a5. Check for leakage from fuel line breakage of the rear view mirrors.
Check the hoses and tubes for any fuel leaks and Clean the mirror surfaces and adjust their angles so
damages. If any of them is abnormal, perform a that the operator can see the area behind him at the
repair. operator's seat.
a6. Check of radiator and dirt removal e1. Check of gauges and monitors for unusual
Check and remove any accumulated dirt and conditions
combustibles (dead leaves, twigs, etc.) around the Check the gauges and monitors inside the operator
radiator. cab. If any of them is unusual, replace it.
For removal of dirt from the radiator, see the Clean up the surfaces.
Operation and Maintenance Manual, "Cleaning and e2. Check of seat belt and mounting hardware
testing of radiator fins, oil cooler fins, aftercooler fins,
Check the hooks, locks and hook fittings for
fuel cooler fins and air conditioner condenser fins
damage. 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
40 Troubleshooting
Testing in accordance with testing procedure (PC88MR-5150-280-A-00-A)
a. Engine, lubricating oil, and coolant

a7. Check of fuel level and type
k Fuel is highly flammable and dangerous.
Never bring open flames near fuel.
k When adding fuel, never spill it or let it

overflow.
k Wipe off any spilled fuel. If fuel spills over

soil or sand, remove all the fuel and soil or
sand together.
1. Turn the starting switch to ON position, and

check the fuel level with fuel level gauge (1) on • If breather hole (3) in the oil filler cap is
the monitor panel. clogged, the pressure in the tank decreases
After checking, turn the switch back to OFF and fuel may not be supplied. To prevent this,
position. clean the breather hole.
2. If the fuel level is low, open the soil cover, open a9. Check of fuel prefilter
fuel filler cap (F) of the fuel tank and add fuel k Immediately after the engine is stopped, its
through the fuel filler port to the necessary level, parts and oil are still very hot, and may cause
referring to the position of float gauge (G). burn injury. Accordingly, wait until all parts
3. After adding fuel, push float gauge (G) straight have cooled down before starting the work.
down with fuel filler cap (F) and tighten fuel filler
cap (F) securely while taking care the float k High pressure is generated inside the engine
gauge (G) will not be caught in tab (2) of fuel fuel piping system when the engine is
filler cap (F). running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter.
k 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 40-15
40 Troubleshooting
a 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. Do no use substitute parts.
a During testing or maintenance of the fuel system,
take extreme care not to allow any foreign
material to enter the fuel system. If any dust or
other material sticks to any part, wash the part
thoroughly with clean fuel.
• Prepare a container to receive drained oil. 2. Turn valve (6) at the bottom of the main valve to
• Prepare a filter wrench. CLOSE position (S).
The water separator inspection, and drainage of
water and sediments
• The water separator is integrated with fuel
prefilter (1).
2. Through the transparent cup (2), water quantity
or sediments can be visually checked. If they are
accumulated, place a container to receive water
under the drain hose (3).
3. Loosen drain valve (4) to drain the water.
4. If drain hose (3) starts to discharge fuel, close
drain valve (4) immediately.

4. Place a container under the fuel prefilter
cartridge to receive the fuel.
5. Loosen drain valve (4) and drain the water and
sediments from transparent cup (2), and also
drain all the fuel from filter cartridge (1).
6. Turn transparent cup (2) counterclockwise by
using filter wrench, and remove it. (This cap is to
be reused.)
7. Turn filter cartridge (1) counterclockwise by
using the filter wrench, and remove it.
8. Install currently removed transparent cup (2) to
the bottom of the new filter cartridge.
a If water in transparent cup (2) is frozen, drain a At this time, replace O-ring (7) with a new
the water only after confirming that it has one.
completely melted.
a If you cannot visually identify the presence of
water due to stains on transparent cup (2),
clean transparent cup (2) when replacing fuel
prefilter cartridge (1).
a When you have removed drain valve (4) for
the above cleaning process, coat the O-ring
with grease and tighten drain valve until it
touches the bottom.
Replace fuel prefilter cartridge
1. Open inspection cover (5).
9. When installing the transparent cup, thinly apply

oil to the packing surface, contact it to the
40-16 PC88MR-10
40 Troubleshooting
sealing surface of filter cartridge (1), and then 2) Loosen the knob of fuel feed pump (8), pull it
tighten it 1/4 to 1/2 turn. out, then pump it in and out until the
movement becomes heavy.
a If the transparent cup is fastened too much,
15.After bleeding air, push in the knob of fuel feed
the O-ring will be damaged and this leads to
pump (8) and tighten it.
leakage of fuel. If it is too loose, fuel will also
16.After replacing filter cartridge (1), start the
leak from gaps of the O-ring. Therefore, be
engine and run it at low idle for 10 minutes.
sure to observe the fastening angle.
17.Check the filter seal surface and the mounting
10.Clean the filter head, fill the new filter cartridge
face of the transparent cap for fuel leakage. If
with clean fuel, thinly apply oil to the packing
there is any leakage of fuel, check the fastening
surface, then install it to the filter head.
condition of the filter cartridge. If the fuel still
a Be sure to add fuel through 8 small holes (A) leaks, follow Steps 3) to 7) to remove the filter
on the dirty side without removing center cap cartridge, then check the packing surface for
(B). damage or foreign material. If any damage or
foreign material is found in the packing, replace
a After adding fuel, remove cap (B) and install
the cartridge with a new one, then repeat steps
the fuel filter.
8) to 16).
a Fuel for adding should be clean fuel. Be a10. Check of main filter
careful to prevent any dirt or dust form
k Immediately after the engine is stopped, its
entering into it. In particular, center portion is
parts and oil are still very hot, and may cause
the clean side, so do not remove cap (B)
burn injury. Accordingly, wait until all parts
when adding fuel. Be careful to prevent dirt
have cooled down before starting the work.
or dust from entering into the center clean
side part.
k High pressure is generated inside the engine
fuel piping system when the engine is
running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter.
k 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.
a The common rail fuel injection system used on
this machine consists of more precise parts than
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
a If the filter cartridge is fastened too much, the material may enter, and it may cause problems
packing will be damaged and this leads to in the injection system. Do no use substitute
leakage of fuel. If the filter cartridge is too parts.
loose, fuel will also leak from the packing. a During testing or maintenance of the fuel system,
Therefore, be sure to observe the fastening take extreme care not to allow any foreign
angle. material to enter the fuel system. If any dust or
a When using a filter wrench for tightening, other material sticks to any part, wash the part
take care not to leave flaws or dents on the thoroughly with clean fuel.
filter. • Prepare a container to receive drained oil.
12.Make sure that drain valve (4) is securely • Prepare a filter wrench.
closed. 1. Open inspection cover (1).
13.Set valve (6) to OPEN position (O).
14.After completing the replacement of filter
cartridge (1), bleed air according to the following
procedure.
1) Fill up the fuel tank with fuel (to the level
where the float is at the highest position).
PC88MR-10 40-17
40 Troubleshooting
2. Turn valve (2) at the bottom of the main valve to 7. When installing the filter cartridge, tighten it until
CLOSE position (S). the packing surface contacts the sealing surface
of the filter head, then tighten it more than 2/3
turn.
a If the filter cartridge (3) is fastened too much,
the packing will be damaged and this leads
to leakage of fuel. If the filter cartridge is too
loose, fuel will also leak from the packing.
Therefore, be sure to observe the fastening
angle.
When using a filter wrench for tightening,
take care not to leave flaws or dents on the
filter.
8. Turn valve (2) at the bottom of the main valve to
OPEN position (O).
3. Open the engine hood. 9. Bleed air according to the following procedure.
4. Place a container under the filter cartridge (3) to
receive the fuel. 1) Fill up the fuel tank with fuel (to the level
5. Turn filter cartridge (3) counterclockwise by where the float is at the highest position).
using the filter wrench, and remove it. 2) Loosen fuel feed pump knob (4) and draw it
out once, then push and pull several times
until its movement becomes stiff.
• There is no need to remove the plugs at
the head of the fuel prefilter and fuel main
filter.
• When the engine runs out of fuel, use the
same procedure to operate fuel feed
pump (4) and bleed the air.
6. Clean the filter head, thinly apply oil to the

packing surface of the new filter cartridge, then
install it to the filter head.
a Do not add fuel to the new filter cartridge (3).
a 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
40 Troubleshooting
11.Check for fuel leakage on filter seal surface. If 6. If the oil level is above H mark, remove
the fuel leaks, check filter cartridge if it is undercover (1), drain the extra engine oil
tightened. If the fuel still leaks, follow steps 1) to through drain plug (P) at the bottom of the
5) to remove the filter cartridge, then check the engine oil pan, and check the oil level again.
packing surface for damage or foreign material. 7. If the oil is at the correct level, tighten the oil filler
If any damage or foreign material is found in the cap securely and close the engine hood.
packing, replace the cartridge with a new one,
then repeat steps 6) to 10).
a11. Check of engine oil level (in oil pan) and
type
a When checking the oil level after the engine has

been operated, wait at least 15 minutes after
stopping the engine.
a If the machine is at an angle, make it level
a12. Check of coolant level (in reservoir tank)
before checking.
k There is no need to open the radiator cap at
a When the ambient temperature is low, water or
emulsified matter may stick to the oil level gauge, the usual checks. When checking the coolant
oil filler cap, etc. or the drained oil may be milky level, check it in reservoir tank when the
white because of water vapor in the blowby gas. engine is cooled down.
However, if the coolant level is normal, it is not a
k Immediately after the engine is stopped, the
problem.
coolant is still very hot and the pressure is
1. Stop the engine. accumulated in the radiator.
If the cap is opened under these conditions,
3. Remove dipstick (G) and wipe off oil on it with a
you may be scalded. If you need to remove
cloth.
the radiator cap, wait until the temperature
4. Insert dipstick (G) fully and pull it out.
drops before you do. Then turn the cap
slowly to release the pressure and remove it
with care.
1. Open the soil cover, check the coolant level is

within FULL - LOW range at reservoir tank (1)
(shown in the figure below). If coolant is
insufficient, add coolant up to FULL level
through water filler port at reservoir tank (1).
2. After refilling with coolant, tighten the cap
securely.
a If the reservoir tank is empty, coolant may be
leaking. If any abnormality is found in the
check for leakage, repair it immediately. If no
5. If the oil level is between H mark and L mark on
abnormality is found, check the level of the
dipstick (G), it is appropriate.
coolant in the radiator. If it is low, add coolant
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
40 Troubleshooting
Cleaning of outer element

a When the outer element is cleaned 6 times or
used for 1 year, replace it. When replacing it,
replace the inner element at the same time.
a Even when the number of cleanings of the outer
element is less than 6 times, it must be replaced
along with the inner element if dust indicator (1)
indicates the red zone immediately after
cleaning.
1. Open the battery cover on the rear left of the
machine, remove clips (2) (3 places), and
remove cover (3).
a13. Check of air cleaner for clogging
k When using compressed air for cleaning, put
on personal protective items such as
protective eyeglasses, gloves, dust mask,
etc. to protect yourself from dirt that will fly
out.
k When removing the outer element from the

air cleaner body, do not forcibly pull it out,
otherwise it can be dangerous.
Be careful not to fall from a high location on
unsafe scaffolding as a reaction when pulling
out the outer element.
2. Remove outer element (6).
Testing
a Never remove inner element (7). Dust may
Open the engine hood, and check if the red piston is enter and it may lead to failure of the engine.
protruding into the transparent part of dust indicator
(1). If it is protruding, clean the air cleaner element.
a Do not clean the element before the red piston is
projected into the transparent part of dust
indicator (1).
a 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
40 Troubleshooting
a Do not remove vacuator valve (4) when

cleaning cover (3).
a Do not hit the element or bump it against
nearby things when cleaning it.
6. Install cover (3) according to the following

procedure.
a When installing cover (3), check O-ring (5)
for scratches, and replace it with a new one if
any.
1) Set the outer element (6) which has been
4. Blow dry compressed air (0.2 MPa {2.1kg/cm2} cleaned.
or less) from the inside of the outer element (6) 2) Align the match marks of air cleaner body (8)
along the pleats. and cover (3).
5. Then blow it from outside along the pleats, and

finally blow it from the inside again.
3) Install cover (3), and fix it with clip (2).
• Peel off a seal after cleaning the element
7. Press the button of dust indicator (1) to return
each time.
the red piston.
a After clearing the element, throw light on its Replacement of element

inside by using a light bulb to check it. 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
40 Troubleshooting
2. Remove the outer element (6). 3) Install cover (3) and fix it with clip (2).
6. Replace the seal stuck to cover (3) with a new
a Do not remove inner element (7) at this time.
one.
3. Clean the inside of the air cleaner body and 7. Press the button of dust indicator (1) to return
cover (3). the red piston.
a Do not remove vacuator valve (4) when
cleaning cover (3).
b. Hydraulic and mechanical equipment

b3. Check of hydraulic oil level
4. Remove inner element (7), and immediately
install a new inner element. k Immediately after the engine is stopped, its
5. Install cover (3) according to the following parts and oil are still very hot, and may cause
procedure. burn injury. Accordingly, wait until all parts
a When installing cover (3), check O-ring (5)
for scratches, and replace it with a new one if
k 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
40 Troubleshooting
1. Set the work equipment in the posture A or B a Be careful not to add oil any higher than H
shown in the below figure, and stop the engine, mark since it can damage the hydraulic
check the oil level, and add new oil if necessary. circuit or allow spurt of oil.
a State A a If oil level is above H mark, stop the engine,
1) Start the engine, run it at low idle. wait for the oil temperature to cool down,
2) Lower the blade end to the ground. discharge excessive oil from drain plug (P)
3) Retract the cylinder for arm and bucket. under the hydraulic tank.
4) Set the boom at the center position.
5) Lower the boom so that the bucket tooth
contacts to the ground.
6) Stop the engine.
a State B
1) Start the engine, run it at low idle.
2) Lower the blade end to the ground.
3) Extend the arm and bucket cylinder.
4) Set the boom at the center position.
5) Set boom at full RAISE position.
6) Stop the engine.
2. Check the oil level with sight gauge (G) on the

inspection window of the R.H. cover.
The oil level changes corresponding to the oil
If the oil level is within the range shown below, it
temperature, use the followings as a guide when
is correct.
checking it.
State A: Within range a
• Before staring operation (oil temperature: 10
State B: Within range b
to 30°C), the oil level should be near L mark.
If the oil level is below L mark, open the soil
• During normal operation (oil temperature: 50
cover, and add oil through the oil filler port (F)
to 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
40 Troubleshooting
a The pump may suction the air if the 6. Remove any dirt stuck to strainer (6), then wash
pressurization is not performed for the it in clean flushing oil. If strainer (6) is damaged,
hydraulic tank, and it may have harmful replace it with a new one.
effect to the devices. 7. Insert strainer (6) in projected portion (7) of the
1) Fully extend the cylinders for boom, arm, and tank to install.
bucket. 8. Install the bolts while pressing down spring (4)
2) Remove the oil filler cap. with the projection at the bottom of cover (3).
3) Install the oil filler cap. Tighten the mounting bolts.
b4. Check of hydraulic oil strainer a Check O-ring installed to cover (3), and
k Immediately after the engine is stopped, its replace it if it has any scratches.
parts and oil are still very hot, and may cause b.5 Check of hydraulic oil filter
burn injury. Accordingly, wait until all parts k Immediately after the engine is stopped, its
have cooled down before starting the work. parts and oil are still very hot, and may cause
k When you remove the oil filler cap, oil may have cooled down before starting the work.
spurt out. Be careful to rotate it slowly, and
release inner pressure gradually. k When you remove the oil filler cap, oil may
spurt out. Be careful to rotate it slowly, and
1. Lower the work equipment to the ground.
release inner pressure gradually.
2. Stop the engine, open the soil cover, loosen bolt
(1), and then remove plate (2) on the upper 1. Lower the work equipment to the ground.
surface of hydraulic tank oil filler port (F). 2. Stop the engine, open the soil cover, loosen bolt
(1), and then remove plate (2) on the upper
surface of hydraulic tank oil filler port (F).
3. Remove the cap of oil filler port (F) of the

hydraulic tank, and release the internal
pressure. 3. Remove the cap of oil filler port (F) of the
4. Remove the bolts to remove cover (3). hydraulic tank, and release the internal
When removing the bolts, keep pressing down pressure.
cover (3) since it may jump out by spring (4). 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
40 Troubleshooting
5. Remove spring (4) and valve (5) , and then 5. Pull out dipstick (G) and check the oil level. If the
remove element (6). oil level is between H mark and L mark on the
6. Clean the removed parts using cleaning oil. dipstick, it is appropriate.
7. Install outer element (6).
8. Check O-ring to be installed between hydraulic
tank and cover (3), and replace it if it has any
scratches.
9. Set valve (5) and spring (4) to element (6).
10.Set cover (3) and install it with the mounting
bolts while pressing it by hand.
11.Tighten the mounting bolts.
12.Install the cap of oil filler port (F).
13.Install plate (2) on the top surface of oil filler port
(F), and fix it with bolt (1).
14.To bleed air, run the engine at low idle for 10
minutes.
15.Stop the engine. 6. If the oil level does not reach L mark on dipstick
b6. Check of swing machinery case oil level (G), add oil through oil filler (F).
k Immediately after the engine is stopped, its 7. If the oil level is above H mark of dipstick (G),
parts and oil are still very hot, and may cause loosen drain valve (P) to drain the excessive oil.
burn injury. Accordingly, wait until all parts 8. After checking oil level or adding oil, insert
have cooled down before starting the work. dipstick (G) into the insertion hole.
b7. Check of final drive case oil level
1. Swing the upper structure so that drain plug (P)
k Since the oil may spurt out due to internal
is in the middle between the right and left tracks.
pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.

• Prepare a container to receive drained oil.

• Prepare a hexagonal wrench.
1. Be sure that plug (P) is at the right below.
2. Place a container under drain plug (P) on the

bottom side of the machine to receive the oil.
3. Remove dipstick (G) and wipe off oil on it with a
cloth.
2. Place a container under drain plug (P) to receive

the oil.
3. Remove plugs (P), (G), and (F) by using the
hexagonal wrench, and drain oil.
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
40 Troubleshooting
6. If oil flows out of the plug (G) hole, install the

plug (G) and (F).
b8. Bleeding air
• For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel
circuit".
• For bleeding air from the hydraulic system, see
Testing and adjusting, "Bleeding air from
hydraulic circuit".
c. Electric equipment
c1. Check of battery terminal for looseness and
corrosion
• Check alternator terminal B (3) for open circuit,
1. Open the battery cover on the machine and
looseness and corrosion.
remove nut (1) from 2 places at the battery top
surface to remove rubber covers (2) from 2
places.
2. Check the battery cable terminals for looseness
and corrosion.
c3. Check of starting motor terminal for

looseness and corrosion
• Check starting motor terminal B (1) and terminal
C (2) for open circuit, looseness and corrosion.
c2. Check of alternator terminal for looseness
and corrosion
• Remove covers (1) and (2).
c4. Check of battery voltage (with engine

stopped)
• Check the battery voltage by using the battery
tester while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k 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
40 Troubleshooting
k Since the battery produces combustible gas battery fluid) to the UPPER LEVEL (U.L.) line
that can explode, do not bring any open immediately.
flame near it. 4. After adding the purified water, tighten cap (2)
securely.
k Battery electrolyte is dangerous. Take care
that it does not come in contact with your
eyes or skin. If it does, wash it away with
water and contact your doctor.
a Do not add the electrolyte to the battery

exceeding UPPER LEVEL line. If the electrolyte
level is too high, it may leak and cause damage
to the paint surface or corrode other parts.
a To avoid freezing, add the purified water (such
as a commercial battery fluid) before starting the
work in the next day.
• When checking the electrolyte level through the
side face of the battery a If the purified water is added to above
1. Open the battery room door and roll up rubber UPPER LEVEL (U.L.) line, remove the fluid
cover (1) installed above the battery. by using a syringe to lower the level to
UPPER LEVEL (U.L.) line. Neutralize the
removed fluid with baking soda (sodium
bicarbonate), then flush it away with a large
amount of water.
• When electrolyte level cannot be checked
through the side face of the battery
1. Remove cap (2) on the top of battery. (described
previously)
2. Look into filler port (3) and check the surface of
fluid. If the fluid level is below sleeve (4), always
add the purified water (such as a commercial
battery fluid) until it reaches the bottom of sleeve
(the UPPER LEVEL).
2. Wipe and clean the battery surface, especially • (A) Correct level: Since the electrolyte level
around the battery level lines with a wet cloth, reaches to the sleeve bottom, the shape of
and check to see that the battery fluid is the electrode plates will appear distorted due
between the UPPER LEVEL (U.L.) and LOWER to the surface tension.
LEVEL (L.L.) lines. • (B) Low level: Electrolyte level does not
a Do not clean the battery with a dry cloth reach the bottom of sleeve, so pole plates
since static electricity may cause an appear straight and not bent.
explosion. 3. After adding fluid, tighten cap (2).
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
40 Troubleshooting
a If the purified water is added to above

UPPER LEVEL (U.L.) line, remove the fluid
by using a syringe to lower the level to
UPPER LEVEL (U.L.) line. Neutralize the
removed fluid with baking soda (sodium
bicarbonate), then flush it away with a large
amount of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
• Check the wiring harness and cables for
discoloration and burn.
a If discolored or burnt, the circuit may be shorted
or grounded.
• Check the wiring harnesses and cables for
damage and peeling of the covers.
• If any abnormality is found, repair or replace the
wiring harness or cables.
c7. Check for coming off of wiring harness
clamp and sagging of wiring harness
• Check wiring harness for sagging and looseness
due to coming off of harness clamp
a In particular, carefully check the wiring harness
around the hot and movable parts.
• If removed from the clamp, secure it with the • Check the connection of ground terminals (T08)
clamp. to (T11), and (T14).
c8. Check of grounding • Check the connection of ground terminals (T12)

and (T13).
a 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
40 Troubleshooting
• Check the connection of engine controller (EC) • Disconnect the connectors, and check their pins
ground (T15A) and between engine controller for corrosion, bending, sinking than other pins,
mounting bracket and frame (2). and extension of female pins.
• If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for entering of water
and foreign material inside the connector
• Disconnect connectors, and check them for
entering of water or foreign material inside the
connector.
c9. Check for loose connector and damaged

lock
• Check the connection of male and female
connectors by pulling them by hand.
• If the connection is loose, secure it.
a If there is entering of water or foreign material

inside connector, the seals may be damaged.
Check the seals for damage.
• If the seal is defective, repair or replace it.
• Dry the inside of the connector with a dryer.
• Check the connectors for unlocking, and check
the lock and connector housing for cracking.
• Check lock screws (L) of engine controller (EC)
for looseness.
a 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
40 Troubleshooting
Open the rear left cover to gain access to fusible

c12. Check of wiring harness for open or short
links (F02), (F03), (F05), and (F06).
circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.
c14. Check of alternator voltage (when engine

speed is medium or higher)
1. Remove the cover on the machinery and
inspection cover.
2. Connect the positive (+) lead of the multimeter to
• Visually check wiring harnesses for peeling of alternator terminal (B) and connect the negative
harness covers and the pins for contact with (-) lead to the chassis ground.
adjacent pins due to defective crimping. 3. Start the engine, warm it up, and measure the
c13. Check of fuse for breakage and corrosion voltage while running the engine at a medium or
a When replacing a fuse, be sure to turn off the a higher speed.
power (turn the starting switch to OFF position) • If the voltage is abnormal, repair or replace
and turn the battery disconnect switch to OFF the alternator.
position. c15. Check of battery relay operation sound
• A fusible link is a large-capacity fuse. 1. Open the rear left side cover.
• If a fuse is corroded and coated with white 2. Turn the starting switch to the ON and OFF
powder, or there is any play between the fuse positions, and check whether the battery relay
and fuse holder, replace the fuse. operation sound is heard or not.
• Replace each fuse with the one of the same • If the operation sound is not heard, check the
capacity. related circuits, referring to the description of
Remove the cover at the rear right of the operator troubleshooting for E-1 described in the E
seat, and the fuse holder is seen. mode troubleshooting.
• If the relating circuit is normal, replace the
battery relay.
40-30 PC88MR-10
40 Troubleshooting
Preparation for troubleshooting of electrical system (PC88MR-C050-001-K-00-A)
a When performing troubleshooting of electrical

system of machine monitor, engine controller,
pump controller and KOMTRAX communication
modem related, expose applicable connector
portion according to the following procedure.
a For connectors whose lock method is special,
perform disconnection and connection.
Preparation
1. Machine monitor
1) Remove 3 mounting screws of cover (1).
a One of the 3 screws is covered with cap
4) Insert or connect troubleshooting T-adapters
(2).
to connectors CM01, CM02, and CM04 on
a Disconnect connector P31 of sunlight machine monitor (7).
sensor and remove cover (1).
2) Remove a mounting bolt and duct (6). 1) Open the engine hood.
3) Insert a flat-head screwdriver in slit (3) and
pull it upward to remove cover (5) while a The engine controller is mounted on the
releasing lug (4). engine.
2) Insert or connect troubleshooting T-adapters
into or to connectors 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.
3 Screw:3 ± 1 Nm {0.3 ± 0.1 kgm}
PC88MR-10 40-31
40 Troubleshooting
3. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove cover (1).
4. Reference
• Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2) Move lever (3) upward.
3) Connect test adapters to connectors CP01
and CP02 of pump controller (2).
3) Lightly press part (A) on both sides of

connector cover (1) to release tabs (B).
4) Remove connector cover (1) around tab
a The operating voltage cannot be (C).
measured by inserting T-adapter because
it is not designed to accept 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
40 Troubleshooting
3) Set tab (C) to the connector and place

connector cover (1).
a Take care that wiring harness (5) is
not caught.
• Procedure for installing connector cover

1) Push in right and left sliders (4) as far as
they go.
4) Put tabs (B) in to install connector cover

(1).
a Right and left sliders (4) pushed in as

far as they go (left in the following
figure)
2) Move lever (3) on connector cover (1) 5) Replace the cut cable ties with new ones
from the top position to the left position to bind connector cover (1) and the wiring
(locked position) as shown in the harness together.
following figure. 5. KOMTRAX communication module
a (B), (C): Tab 1) Referring to steps (1) to (5) in 3. Pump
controller, expose KOMTRAX
a If the sliders and lever are not set as
communication module.
shown in the following figure, the
2) Connect troubleshooting T-adapters to
connector is not disconnected or
connectors 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
40 Troubleshooting
Engine oil pressure switch (POIL)

Crankcase pressure sensor (CCV)
Mass air flow sensor (MAF)
a Disconnection and connection of connectors
Since the connectors of the ambient
pressure sensor, engine Ne speed sensor,
engine Bkup speed sensor and engine oil
pressure switch have a special lock
mechanism, disconnect them in the order of
(a) to (c), and connect them in the order of
(d) to (f) as shown in the following figure.
Disconnection: (a) Slide the lever, (b) unlock,
and (c) disconnect the connectors. a Removal and installation of sensor body
Connection: (d) Connect the connectors, (e) Since a TORX wrench is necessary when
engage the lock, and (f) slide the lever. removing and installing the charge (boost)
pressure and temperature sensor, see "Tools
for testing, adjusting, and troubleshooting".
8. Supply pump IMV solenoid (SCV)
The connector of the supply pump IMV
solenoid has a special locking mechanism.
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
a Removal and installation of sensor body (d) engage the lock.
Since a deep socket is necessary when
performing removal and installation of engine
oil pressure switch, see "Tools for testing,
adjusting, and troubleshooting".
7. Boost pressure and temperature sensor
(TMAP)
The connector of the boost pressure
temperature sensor has a special locking
mechanism. 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 9. Common rail pressure sensor (PFUEL)
the connectors. a Disconnection and connection of connectors
Connection: (c) Connect the connectors and The connector of the common rail pressure
(d) engage the lock. sensor has a special locking mechanism.
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
40 Troubleshooting
10.Engine coolant temperature sensor (TWTR)

a Precautions for disconnection of connectors
The direction of the lock for connector may a Disconnection and connection of connectors
be changed toward the difficult direction The connector of the engine coolant
(facing to the bottom or to the engine side) temperature sensor has a special locking
for unlocking depending on the position mechanism. Disconnect it according to steps
where the sensor is screwed in. (a) to (b), and connect it according to steps
In such a case, turn the lock to the direction (c) to (d) as shown below.
(a) by using the needle nose pliers with Disconnection: (a) Unlock and (b) disconnect
curved tip (commercially available) [1], then the connectors.
the lock can be canceled easily. Connection: (c) Connect the connectors and
Since the lock is canceled with "click" sound, (d) engage the lock.
listen the sound and disconnect the
connectors.
a Removal and installation of sensor body

Since a deep socket is necessary when
a Precautions for connecting connectors
removing and installing the engine coolant
When connecting connectors, pay attention temperature sensor, see "Tools for testing,
not to connect the connectors reverse. adjusting, and troubleshooting".
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
40 Troubleshooting
Classification and procedures for troubleshooting (PC88MR-5160-40D-A-00-A)

Classification of troubleshooting
Mode Content
Display of Troubleshooting by failure code
code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
S-mode Troubleshooting engine
Procedure for troubleshooting

If a problem occurs in the machine, go to the corresponding troubleshooting section according to the following
procedure.
1. Troubleshooting procedure to be taken when action level and failure code are displayed on
machine monitor:
If an action level and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding [Display of code] according to the displayed failure code.
a If multiple problems occur simultaneously, all the failure codes for the problems are displayed
repeatedly in order. Record all the failure codes.
2. Troubleshooting procedure to be taken when action level and failure code are not displayed on
normal screen of machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1])
1) If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and
then see if the trouble is still detected. (See [*2])
a A failure code of the mechanical system cannot be deleted.
a If abnormality related to air conditioner is displayed in electrical system abnormality record, perform
"Check with self-diagnosis" in "Air conditioner".
2) If no failure code is recorded in the abnormality record, a failure that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the problem which seems to be a failure again and select the same problem from
the table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out
troubleshooting corresponding to that problem in the [E-mode], [H-mode], or [S-mode].
3. Actions to take after failure is repaired
Referring to following page, delete all failure codes in electrical system abnormality record.
[*1],[*2]
1. On the normal operation screen, while pressing number key [4] in the panel switch section, press [1], [2],
and [3] in this order.
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
40 Troubleshooting
4. Press switch [F6] in the panel switch section to confirm, and then enter the "Mechanical system failure
record" screen.
5. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a A failure code of the mechanical system cannot be deleted.
6. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
7. Similarly to 2 and 3, enter the "Electrical system abnormality record" screen.
8. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a If [E] is displayed on the left of a failure code, that failure code is "active" (the failure is still occurring or
normal resetting is not confirmed yet). If [E] is not displayed on the left of a failure code, that failure
code is "non-active" and disappears in the following clearing step. Accordingly be sure to take record
of that failure code.
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
40 Troubleshooting
12.Press switch [F5] (return) in the panel switch section to return to the "Electrical system abnormality record"
screen. Check if there is any failure code still displayed and take record.
13.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
14.Take record of information of all columns.

a Similarly to the electrical system abnormality record, if "E" is displayed on the left of a failure code, that
failure code is "active"
(the failure is still occurring or normal resetting is not confirmed yet).
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
40 Troubleshooting
Symptom and troubleshooting numbers (PC88MR-5540-441-A-00-A)
Problem and troubleshooting number

Troubleshooting
No. Problem
Index
Action level, failure code
Action level is displayed on machine monitor. If function key [F5] is pressed,
1 occurring failures list is displayed. Take actions by
The failure code is displayed on the mechanical system abnormality record screen following the
2
failure code.
3 The failure code is displayed on the electrical system abnormality record screen
Troubleshooting
No. Problem
Index
Phenomena related to engine
4 Starting performance is poor. S-4
5 Engine does not start E-1, S-1
6 When starting switch is turned to "START" position, engine is not rotated S-1, E-1
7 Engine is cranked but exhaust gas does not come out S-2
8 Fuel is injected but engine does not start S-3
9 Engine does not pick up smoothly S-5
10 Engine stops during operation S-6, H-2
11 Engine runs rough or is unstable S-7
12 Engine lacks power S-8
13 Exhaust gas color is black S-9
14 Oil consumption is increased. S-10
15 Oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Oil pressure drops S-14
19 Fuel in oil S-15
20 Oil is mixed with water (milkiness) S-16
21 Coolant temperature rises too high (overheating) S-17
22 Unusual noise is heard S-18
23 Vibration is excessive S-19
24 Manual preheater does not operate. E-2
25 While preheater is operating, preheating monitor does not light up. E-3
26 Automatic warm-up system does not work (in cold weather). E-21
When auto-decelerator switch is operated, auto-decelerator monitor does not light
27 up or does not go off. E-22
28 Auto-decelerator is not operated or canceled with lever. E-23
Symptom related to work equipment, swing and travel
29 Any of work equipment, swing, and travel does not work. E-31, H-3
30 All of work equipment, swing, and travel mechanism do not lock. E-32
31 Speed or power of all work equipment, swing and travel is low. H-1
32 Engine speed lowers extremely or engine stalls. H-2, S-6
When working mode switch is operated, working mode selection screen is not
33 displayed. E-24
When working mode is changed, setting of engine and hydraulic pump is not
34 changed. E-25
35 Abnormal sound comes out from around hydraulic pump H-4
36 Fine control performance or response is low H-5
Problems related to work equipment
37 Speed or power of boom is low. H-6
38 Speed or power of arm is low. H-7
PC88MR-10 40-39
40 Troubleshooting
Troubleshooting
No. Problem
Index
39 Speed or power of bucket is low H-8
40 Boom swing speed or power is low. H-9

41 Blade speed or power is low. H-10
42 Work equipment does not move in single operation. H-11
43 Hydraulic drift of boom is large. H-12
44 Hydraulic drift of arm is large. H-13
45 Hydraulic drift of bucket is large. H-14
46 Flow rate of attachment circuit cannot be adjusted H-16
47 Oil flow in attachment circuit cannot be controlled H-35
Problems related to combined operation
In combined operation of work equipment , equipment having heavier load moves
48 H-17
slower.
49 In combined operation of swing and boom RAISE, boom rising speed is low. H-18
In combined operation of work equipment or swing and travel, travel speed drops
50 largely. H-19
Problems related to travel
51 Machine does not travel straight. H-20
52 Travel speed is slow. H-21
53 Machine is hard to steer or travel power is low. H-22
54 Travel speed does not change, or travel speed is too slow or fast. H-23, E-25, E-26
55 One of tracks does not run. H-24
56 Alarm does not sound during travel. E-35
57 Alarm does not stop sounding while machine is stopped. E-36
Problems related to swing
58 Upper structure does not swing to the right or left. H-25
59 Upper structure swing only to the right or left. H-26
60 Swing acceleration or swing speed is low in both directions (right and left). H-27
Swing acceleration performance is poor or swing speed is slow in only one
61 H-28
direction.
62 Upper structure overruns excessively when it stops swinging (both right and left). H-29
63 Upper structure overruns excessively when it stops swinging (either right or left). H-30
64 Shock is large when upper structure stops swinging. H-31
65 Large unusual noise is heard when upper structure stops swinging. H-32
66 Swing drift on a slope is large while swing parking brake is applied. H-33
67 Swing drift on a slope is large while swing parking brake is released. H-34
Upper structure does not swing while swing parking brake cancel switch is set to
68 CANCEL position. E-32
Swing brake does not operate while swing parking brake cancel switch is set to
69 NORMAL position. E-33
Problems related to machine monitor
70 When starting switch is turned to ON position, machine monitor displays nothing E-4
71 Engine coolant temperature monitor lights up in white while engine is running. E-5
72 Hydraulic oil temperature monitor lights up in white while engine is running. E-6
73 Charge level monitor lights up while engine is running. E-7
74 Fuel level monitor lights up in red while engine is running. E-8
75 Engine coolant temperature monitor lights up in red while engine is running. E-9
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
40 Troubleshooting
Troubleshooting
No. Problem
Index
78 Fuel gauge display does not move from minimum or maximum. E-12
79 Fuel gauge indicates incorrect amount (indicates neither full nor empty). E-13
Engine coolant temperature gauge display does not move from minimum or
80 E-14
maximum.
Engine coolant temperature gauge indicates incorrect temperature (indicates
81 neither full nor empty). E-15
82 Hydraulic oil temperature gauge does not move from minimum or maximum. E-16
Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither
83 full nor empty). E-17
84 Some areas of machine monitor screen are not displayed. E-18
85 Function switch does not work. E-19
86 Alarm buzzer does not stop sounding. E-27
87 Service meter is not displayed, while starting switch is in OFF position. E-28
88 Service mode cannot be selected. E-29
89 Horn does not sound. E-37
90 Horn does not stop sounding. E-38
91 Wiper monitor does not light up, or does not go out, while wiper switch is operated. E-39
92 Wiper does not operate while wiper switch is operated. E-40
93 Window washer does not operate while window washer switch is operated. E-41
"Testing and
Air conditioner does not operate normally (including failure code related to air troubleshooting
94 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
40 Troubleshooting
Information in troubleshooting table (ALL-5170-421-A-01-A)
(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit head bolt or bolt hole which has no rust, etc.
• Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
6 • Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
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
40 Troubleshooting

<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
• When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
• When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
7 Defective controller female connector.
• "Male and female" means male and female of connector pins, not
connector housings.
• Male and female of connector pins and housing in DT series, etc, are
opposite to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to
troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The "/" in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• The arrow (io) indicates a rough installation
position on the given machine.
• NO: Normally Open
• NC: Normally Closed
• Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
• 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
40 Troubleshooting
Troubleshooting method for open circuit in wiring harness of pressure

sensor system (D65-E720-42A-P-00-A)
a Since the pressure sensors consist of not only resistor but also electronic circuit components such as
amplifiers they have variation in measured value and their own polarities. So troubleshooting must be
performed carefully.
Failure codes applicable to this diagnosis
• CA123: Charge air pressure sensor low error
Procedure
1. Measure and record resistance of pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the sensor side connector.
2) Measure resistances R1 and R2 between pins.
a If the polarities of multimeter probes to apply are reversed, measured values may change.
Therefore, when measuring the resistances in steps 1 and 2, apply the multimeter probes to the
pressure sensor connector so that their polarities match those of the sensor.
a If the measured value is infinite, take measurements by applying the probes of the opposite
polarities and record the finite value obtained as a measured value.
a Since the measured values may be dispersed, take several measurements.
The cause of this dispersion appears to be an electric charge in a sensor. Take measurements
several times in steps 1 and 2. Consider this dispersion when judging whether or not the wiring
harness is open in step 3.
2. Measure and record the resistance of the wiring harness between the pressure sensor and engine
controller connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) With the pressure sensor to measure connected, disconnect connector (3) on the engine controller
side, and connect T-adapter (4) to the wiring harness side connector.
3) Connect T-box (5) to T-adapter (4) and measure resistances R1' and R2' between respective pins.
3. Judging open circuit
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
40 Troubleshooting
List of pressure sensor measuring locations and reference values
Measuring location at Measured internal

Sensor sensor pin resistance of sensor Remarks
(reference)
Charge pressure R2: between (2) and (4) Approx. 100 z Sensor is common to engine
sensor R1: between (1) and (4) Approx. 200 z models 107 and 114
*: When measuring R2', disconnect the following: (See the circuit diagram related to each failure code)
• When measuring R2' of charge pressure sensor (CA123):
Connectors of ambient air pressure sensor, CAM sensor and boost pressure sensor
Measurement record (For measuring locations, see circuit diagram related to each failure code.)
Sensor + Wiring harness
Sensor unit (Measuring location on
Sensor (Measuring location on Measured value wiring harness side Measured value
sensor pin side connetor) connector of engine
controller)
R2': Between (60) and
R2: between (2) and (4)
Charge pressure (59) (*)
sensor R1': Between (15) and
R1: between (1) and (4)
(59)
PC88MR-10 40-45
40 Troubleshooting
Connector list and layout (PC88MR-C050-055-K-00-A)
Connector Connector type Number Equipment name

of pins Address
No.
A08 DT 6 Intermediate connector (boom working lamp) A-4
A40 DT 4 Camera K-9
AB Terminal 1 Alternator terminal B G-9
AC01 YAZAKI 10 Air conditioner unit W-5
AC02 SUMITOMO 4 Air conditioner unit W-5
AC03 DT 2 Air conditioner compressor solenoid clutch I-9
CAM FRAMATOME 3 CAM sensor (Bkup) AJ-1
CCV FRAMATOME 3 Crankcase pressure sensor AE-4
CE03 DRC 60 Engine controller J-9
CK01 070 18 KOMTRAX controller S-9
CK02 070 12 KOMTRAX controller S-9
CM01 070 18 Machine monitor N-5
CN1 DT 4 Injector (#1 and #2) AG-9
CN2 DT 4 Injector (#3 and #4) AI-9
CP01 AMP 81 Pump controller T-9
CP02 AMP 40 Pump controller U-9
D01 SWP 8 Diode V-8
D02 SWP 8 Diode T-9
D03 SWP 8 Diode V-8
E01 Terminal 1 Ribbon heater I-9
E12 SUMITOMO 3 Alternator (G and L terminals) H-9
E24/OEM Intermediate connector (OEM BREAKOUT) H-9, AF-7
DT 6
BREAKOUT
EGR V SUMITOMO 8 EGRV AH-9
F01 Terminal 20 Fuse W-7
F02 L 2 Fusible link L-8
F03 L 2 Fusible link L-7
F04 Terminal 1 Fuse L-7
Intermediate connector (speaker) W-3, AC-
H08 M 4
2
Intermediate connector (cab roof) W-4, AD-
H09 M 8
3
H15 090 22 Intermediate connector (R.H. console wiring harness) Q-1
H16 090 22 Intermediate connector (L.H. console wiring harness) W-3
J01 SUMITOMO 20 Junction connector S-1
J03 SUMITOMO 20 Junction connector V-2
J05 SUMITOMO 20 Junction connector V-2
J06 SUMITOMO 20 Junction connector W-6
J07 SUMITOMO 20 Junction connector W-5
J1(CE01) DRC 60 Engine controller AF-6
J2(CE02) DRC 60 Engine controller AF-6
K01 M 2 Pump (PC) resistor U-9
K02 DT 3 CAN terminating resistor J-9
L01 DT 2 Working lamp (boom) A-4
L03 M 2 Room lamp AC-9
40-46 PC88MR-10
40 Troubleshooting
Connector Number
Connector type Equipment name Address
No. of pins
L05 YAZAKI 4 Intermediate connector AD-6
L19 DT 2 System operating lamp K-1
M01 PA 9 Radio U-1
M01A — 3 Radio U-1
W-6, AD-
M01B M 3 Intermediate connector
5
M01C — 3 AUX jack AD-4
M02 M 2 L.H. speaker AD-9
M03 M 2 R.H speaker AB-9
M04 YAZAKI 2 Cigarette lighter T-9
M05 M 6 Wiper motor N-3
M06 YAZAKI 2 Window washer tank C-7
M07 090 2 Horn (treble tone) G-1
M09 X 2 Optional power supply (1) S-1
M10 X 2 Optional power supply (2) V-2
M11 DT 6 DC/DC converter V-8
M12 X 2 12 V optional power supply T-9
M13A M 2 12 V socket S-9
M13B M 2 12 V socket T-9
M14 DT 2 Travel alarm L-2
M1A X 2 Optional power supply (continuous power supply) S-1
M22 DTM 12 R.H. knob switch O-2
M23 DTM 12 L.H. knob switch T-1
M40 X 2 Headlamp Y-7
M41 X 2 Headlamp Y-6
N08 DT 12 Service connector W-8
NE FRAMATOME 3 Engine speed sensor AJ-2
P01 AMP 3 Bucket DUMP pressure sensor D-8
P02 AMP 3 Arm OUT pressure sensor D-8
P03 AMP 3 Boom RAISE pressure sensor D-8
P04 AMP 3 Bucket CURL pressure sensor F-9
P05 AMP 3 Arm IN pressure sensor E-9
P06 AMP 3 Boom LOWER pressure sensor F-9
P07 AMP 3 Boom swing (right) pressure sensor E-8
P08 AMP 3 Boom swing (left) pressure sensor C-7
P10 AMP 3 Swing (right) pressure sensor B-6
P11 AMP 3 Swing (left) pressure sensor E-8
P12 X 2 Blade RAISE pressure switch A-6
P13 X 2 Blade LOWER pressure switch B-7
P17 S090 2 Air conditioner Hi/Lo pressure switch I-1
Air conditioner outer sensor (outside air temperature
P18 090 2 sensor) L-5
P20 M 3 Fuel control dial P-8
P21 X 1 Fuel level sensor A-5
P22 DT 2 Hydraulic oil temperature sensor G-9
P25 AMP 3 Pump pressure sensor C-7
P26 AMP 3 Travel pressure sensor H-1
P31 050 2 Sunlight sensor N-6
P49 AMP 3 Service pressure sensor A-6
P55 FRAMATOME 4 MAF sensor K-8
PAMB FRAMATOME 3 Ambient pressure sensor AJ-6
PFUEL AMP 3 Common rail pressure sensor AJ-7
PC88MR-10 40-47
40 Troubleshooting
Connector Number
Connector type Equipment name Address
No. of pins
POIL FRAMATOME 2 Engine oil pressure switch AJ-3
R01 Terminal 1 Battery relay terminal E L-3
R02 Terminal 1 Battery relay terminal BR L-4
R03 Terminal 1 Battery relay terminal M L-4
R04 Terminal 1 Battery relay terminal B L-5
R05 Relay 5 Lamp relay W-8
R06 Relay 5 Starting motor cut-off relay (PPC lock) U-9
R07 Relay 5 Starting motor cut-off relay (personal code) U-9
R08 Relay 5 Horn relay V-8
R10 Relay 5 Optional lamp relay W-8
R12 Relay 5 PPC lock lever relay V-9
R15 Terminal 1 Ribbon heater relay N-1
R16A Terminal 1 Ribbon heater relay N-2
R16B Terminal 1 Ribbon heater relay N-2
R17 X 2 Intermediate connector (starting motor safety relay) M-2
R21 Relay 5 Compressor relay U-9
R28 Terminal 1 Starting motor safety relay (terminal C) M-2
R29 Terminal 1 Starting motor safety relay (terminal B) M-1
S01 Terminal 6 Starter switch P-7
S02 SWP 6 Light switch Q-8
S14 M 3 PPC oil pressure lock switch W-4
S18 SWP 6 Engine shutdown secondary switch T-1
S19 DT 2 Seat belt monitor switch W-4
S21 Terminal 6 Pump secondary drive switch W-7
S22 Terminal 6 Swing parking brake cancel switch W-7
S23 Terminal 2 Lock lever automatic lock cancel switch W-7
S25 090 10 Secondary operation switch W-6
SB Terminal 1 Starter B terminal I-9
SC Terminal 1 Starter C terminal H-9
SCV SUMITOMO 2 Supply pump flow sensor AI-5
T01 Terminal 1 Ground (floor frame) K-2
T02 Terminal 1 Ground (cab) AD-3
T08 Terminal 1 Ground (revolving frame) B-2
T09 Terminal 1 Ground (revolving frame) A-3
T12 Terminal 1 Ground (engine controller) A-3
T13 Terminal 1 Ground (revolving frame) C-2
T15A Terminal 1 Ground (engine controller enclosure) J-9
T15B Terminal 1 Ground (engine controller enclosure) I-1
TMAP SUMITOMO 4 Intake air temperature sensor AJ-8
TWTR DELPHI 2 Coolant temperature sensor AE-2
V01 DT 2 PPC source pressure solenoid valve I-1
V02 DT 2 Travel Hi/Lo selecting solenoid J-1
V03 DT 2 Swing parking brake solenoid valve J-1
V04 DT 2 Travel operation/Merge-divider valve J-1
V11 DT 2 PC-EPC valve G-9
V91 DT 2 IATT (LH) EPC H-1
V92 DT 2 IATT (RH) EPC G-1
VFT SUMITOMO 8 Variable flow turbocharger AE-3
W03 X 2 Rear limit switch AD-7
40-48 PC88MR-10
40 Troubleshooting
Layout of connectors (1/6)
PC88MR-10 40-49
40 Troubleshooting
40-50 PC88MR-10
40 Troubleshooting
PC88MR-10 40-51
40 Troubleshooting
40-52 PC88MR-10
40 Troubleshooting
PC88MR-10 40-53
40 Troubleshooting
40-54 PC88MR-10
40 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
40 Troubleshooting
40-56 PC88MR-10
40 Troubleshooting
PC88MR-10 40-57
40 Troubleshooting
40-58 PC88MR-10
40 Troubleshooting
PC88MR-10 40-59
40 Troubleshooting
40-60 PC88MR-10
40 Troubleshooting
PC88MR-10 40-61
40 Troubleshooting
40-62 PC88MR-10
40 Troubleshooting
PC88MR-10 40-63
40 Troubleshooting
40-64 PC88MR-10
40 Troubleshooting
PC88MR-10 40-65
40 Troubleshooting
40-66 PC88MR-10
40 Troubleshooting
PC88MR-10 40-67
40 Troubleshooting
40-68 PC88MR-10
40 Troubleshooting
PC88MR-10 40-69
40 Troubleshooting
40-70 PC88MR-10
40 Troubleshooting
PC88MR-10 40-71
40 Troubleshooting
40-72 PC88MR-10
40 Troubleshooting
PC88MR-10 40-73
40 Troubleshooting
40-74 PC88MR-10
40 Troubleshooting
PC88MR-10 40-75
40 Troubleshooting
40-76 PC88MR-10
40 Troubleshooting
PC88MR-10 40-77
40 Troubleshooting
40-78 PC88MR-10
40 Troubleshooting
PC88MR-10 40-79
40 Troubleshooting
40-80 PC88MR-10
40 Troubleshooting
PC88MR-10 40-81
40 Troubleshooting
40-82 PC88MR-10
40 Troubleshooting
PC88MR-10 40-83
40 Troubleshooting
40-84 PC88MR-10
40 Troubleshooting
PC88MR-10 40-85
40 Troubleshooting
40-86 PC88MR-10
40 Troubleshooting
PC88MR-10 40-87
40 Troubleshooting
40-88 PC88MR-10
40 Troubleshooting
PC88MR-10 40-89
40 Troubleshooting
40-90 PC88MR-10
40 Troubleshooting
PC88MR-10 40-91
40 Troubleshooting
40-92 PC88MR-10
40 Troubleshooting
PC88MR-10 40-93
40 Troubleshooting
T-branch box and T-branch adapter table (ALL-5330-305-A-00-A)
(Rev. 2014. 05)
a The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of
harness checker assemblies are listed in the horizontal line.
T-adapter kit
Not included in kit

Number of pins
Identifi-
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name cation
Symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14 pins) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
ECON-
799-601-2750 Adapter for ECONO 2 q q
O2P
ECON-
O3P
ECON-
O4P
ECON-
O8P
ECON-
O12P
799-601-2810 Adapter for DLI 8 DLI-8P q q
Extension cable (ECONO ECON-
799-601-2840 type) 12 q q q
O12P
799-601-2850 Case q
T-box (for DRC60,
799-601-4350 ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
40-94 PC88MR-10
40 Troubleshooting
T-adapter kit
Not included in kit

Number of pins
Identifi-
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Symbol

799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (white) 10 S10P q q q q
799-601-7160 Adapter for S (blue) 12 S12P q q q
799-601-7170 Adapter for S (blue) 16 S16P q q q q
799-601-7330 Adapter for S (white) 16 S16PW q
799-601-7350 Adapter for S (white) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short socket adapter for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (gray) 8 DT8GR q q
799-601-9070 Adapter for DT (black) 8 DT8B q q
799-601-9080 Adapter for DT (green) 8 DT8G q q
799-601-9090 Adapter for DT (brown) 8 DT8BR q q
799-601-9110 Adapter for DT (gray) 12 DT12GR q q
799-601-9120 Adapter for DT (black) 12 DT12B q q
799-601-9130 Adapter for DT (green) 12 DT12G q q
PC88MR-10 40-95
40 Troubleshooting
T-adapter kit
Not included in kit

Number of pins
Identifi-
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Symbol
799-601-9140 Adapter for DT (brown) 12 DT12BR q q

799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24 pins) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-
T2)
799-601-9420 Adapter PFUEL for engine 3 A3 q q
(CRI-T3)
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* Socket PCV for engine 2 P q q
(CRI-T3)
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* Socket TIM for engine 2 A q q
(CRI-T3)
795-799-5460 Cable for engine (HPI-T2) 3 q
Adapter PIM for engine
799-601-4110 (140-T3) 4 ITT3N q q
Adapter NE, CAM for
799-601-4130 engine (CRI-T3) 3 FCIN q q
799-601-4140 T3) 3 FCIG q q
Ambient pressure
Adapter POIL for engine
799-601-4150 (CRI-T3) 3 FCIB q q
799-601-4160 T3) 2 4160 q q
40-96 PC88MR-10
40 Troubleshooting
T-adapter kit
Not included in kit

Number of pins
Identifi-
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Symbol
Oil pressure switch

Adapter PEVA for engine
799-601-4180 (CRI-T3) 3 4180 q q
799-601-4190* 3 1, 2, 3 L q q
Common rail pressure
1, 2, 3, 4
799-601-4230* Intake pressure/ 4 q q
C
temperature
Socket PAMB for engine
799-601-4240* 3 1, 2, 3A q q
(CRI-T3)
Socket PIM for engine
799-601-4250* 3 1, 2, 3B q q
(CRI-T3)
Socket G for engine (CRI- 1, 2, 3,
799-601-4330* T3) 3 q q
G
799-601-4340* 2 2, PA q q
Pump actuator
(95) 1, 2, 3,
799-601-4380* 4 q
Intake pressure/ 4T
temperature
Adapter for controller
799-601-4260 (ENG) 4 DTP4 q q
799-601-4211 (ENG) 50 DRC50 q
799-601-4220 (ENG) 60 DRC60 q
Socket for controller
799-601-4390* (95ENG) 60 q
12-
799-601-4280* Box for controller (PUMP) q
1
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for DT 2 to 4,
799-601-9890 DTM 2 pins 3, q
4
T-adapter for ICT control
799-902-9600 26 q
box
799-902-9700 T-box 26 q
*: These are not T-adapters but sockets.
PC88MR-10 40-97
40 Troubleshooting
T-adapter kit
Not included in kit

Number of pins
799-A65-4600
Identification
799-902-9300
Part No. Part name
Symbol
799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 q

799-902-9310 Adapter for control box 19 799-902-9310 q
799-902-9320 Adapter for IMU 10 799-902-9320 q
799-902-9330 Adapter for MS cylinder 6 799-902-9330 q
KDPF differential pressure sensor
799T-601-4611 short socket adapter 4 799T-601-4611 q
KDPF outlet pressure sensor short
799T-601-4670 socket adapter 4 799T-601-4670 q
799T-601-4680 KDPF dummy temperature sensor 4 799T-601-4680 q
40-98 PC88MR-10
40 Troubleshooting
Fuse location table (PC88MR-5530-04D-A-00-A)

Connection table of fuse box
a This connection table shows the fuse box and the devices which receive the power from the fuse box ( A
switched power supply is the power which is supplied while the starting switch is in ON position and an
unswitched power supply is the power which is supplied while the starting switch is in OFF and ON
positions).
a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see
if the power is supplied properly.
Type of Power Fuse
power supply to Fuse No. Destination of power
capacity
supply fuse
1 5A Working lamp relay, emergency switch
2 30 A Solenoid valve
3 5A PPC oil pressure lock solenoid valve
4 10 A Window washer motor, cigarette lighter
5 10 A Horn
6 5A Spare
Fusible link
Switched 7 10 A –
F02 (65 A)
power 8 10 A Radio and speaker
supply 9 20 A Working lamp
10 20 A Air conditioner unit
11 10 A Headlamp (if equipped)
12 10 A Optional power supply (1)
13 20 A Optional power supply (2), power supply of 12 V
Starting 14 5A Air conditioner controller power supply
switch 15 5A Key ACC signal
16 10 A Radio backup, room lamp, system operating lamp
Continu- 17 20 A Machine monitor, pump controller
Fusible link
ous power 18 30 A Engine controller
F03 (45 A)
supply 19 5A Engine controller backup
20 10 A Optional power source (continuous power supply)
Fusible link
– 120 A Alternator (60 A)
F05 (120 A)
–
Fusible link – Preheating
120 A
F06
Locations of fusible links
* Fusible links F02, F03, F04, and F05 are accessible when the rear left cover is opened.
PC88MR-10 40-99
40 Troubleshooting
Locations of fuse boxes and fuse No.
40-100 PC88MR-10
40 Troubleshooting
Failure codes table (PC88MR-5520-441-A-00-A)

Applicable History
Failure Failure (Displayed on screen) Action
compo- category Remarks
code level
nent
Failure code [879AKA] A/C Recirc Air Temp Electrical
879AKA Sens Open Circuit(PAGE 40-108) MON -
system
Failure code [879AKB] A/C Recirc Air Temp Electrical
879AKB Sens Short(PAGE 40-109) MON -
system
Failure code [879BKA] A/C Fresh Air Temp Sens Electrical
879BKA Open Circuit(PAGE 40-110) MON -
system
Failure code [879BKB] A/C Fresh Air Temp Sens Electrical
879BKB Short Circuit(PAGE 40-111) MON -
system
Failure code [879CKA] Ventilating Sensor Open Electrical
879CKA Circuit(PAGE 40-112) MON -
system
Failure code [879CKB] Ventilating Sensor Short Electrical
879CKB Circuit(PAGE 40-113) MON -
system
Failure code [879DKZ] Sunlight Sensor Open or Electrical
879DKZ Short Circuit(PAGE 40-114) MON -
system
Failure code [879EMC] Ventilation Damper Electrical
879EMC Malfunction(PAGE 40-115) MON L01 system
Failure code [879FMC] Air Mix Damper Electrical
879FMC Malfunction(PAGE 40-116) MON L01 system
Failure code [879GKX] Refrigerant Press Input Electrical
879GKX Sig Out of Range(PAGE 40-117) MON L01 system
Failure code [989L00] Engine Controller Lock Electrical
989L00 Caution 1(PAGE 40-118) MON -
system
Failure code [989M00] Engine Controller Lock Electrical
989M00 Caution 2(PAGE 40-119) MON -
system
Failure code [989N00] Engine Controller Lock Electrical
989N00 Caution 3(PAGE 40-120) MON -
system
Failure code [A900FR] Abrupt Engine Stop by Mechanical
A900FR Auto Idle Stop 3(PAGE 40-121) MON L03 system
Failure code [A900N6] Abrupt Engine Stop by Mechanical
A900N6 Auto Idle Stop 1(PAGE 40-122) MON -
system
Failure code [A900NY] Abrupt Engine Stop by Mechanical
A900NY Auto Idle Stop 2(PAGE 40-123) MON L01 system
Failure code [AB00KE] Charge Voltage Low Mechanical
AB00KE (PAGE 40-124) MON L03 system
Failure code [B@BAZG] Eng Oil Press Low Mechanical
B@BAZG ENG L03
(PAGE 40-126) system
B@BCN- Failure code [B@BCNS] Eng Water Overheat Mechanical
(PAGE 40-127) ENG L02 system
S
Failure code [CA115] Eng Ne and Bkup Speed Electrical
CA115 Sens Error(PAGE 40-128) ENG L04 system
Failure code [CA122] Charge Air Pressure Electrical
CA122 Sensor High Error(PAGE 40-129) ENG L03 system
Failure code [CA123] Charge Air Pressure Electrical
CA123 Sensor Low Error(PAGE 40-131) ENG L03 system
Failure code [CA131] Throttle Sensor High Error Electrical
CA131 (PAGE 40-133) ENG L03 system
Failure code [CA132] Throttle Sensor Low Error Electrical
Failure code [CA144] Coolant Temperature Electrical
Failure code [CA145] Coolant Temperature Electrical
Failure code [CA153] Charge Air Temperature Electrical
PC88MR-10 40-101
40 Troubleshooting
Applicable History
code level
nent
Failure code [CA154] Charge Air Temperature Electrical
Failure code [CA187] Sensor 2 Supply Voltage Electrical
CA187 Low Error(PAGE 40-145) ENG L03 system
Failure code [CA221] Ambient Pressure Sensor Electrical
CA221 High Error(PAGE 40-147) ENG L03 system
Failure code [CA222] Ambient Pressure Sensor Electrical
Failure code [CA234] Engine Overspeed(PAGE Mechanical
CA234 40-152) ENG L02 system
Failure code [CA238] NE Speed Sensor Supply Electrical
CA238 Voltage Error(PAGE 40-153) ENG L01 system
Failure code [CA239] NE Speed Sensor Supply Electrical
CA239 Voltage High Error(PAGE 40-154) ENG L01 system
Failure code [CA271] PCV1 Short Circuit Error Electrical
Failure code [CA272] PCV1 Open Circuit Error Electrical
Failure code [CA322] Injector #1 (L#1) Open or Electrical
CA322 Short Circuit(PAGE 40-157) ENG L03 system
Failure code [CA343] Engine Controller Internal Electrical
CA343 Failure(PAGE 40-165) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
CA351 Error(PAGE 40-166) ENG L03 system
Failure code [CA352] Sensor1 Supply Voltage Electrical
Failure code [CA356] MAF Sensor High Error Electrical
Failure code [CA357] MAF Sensor Low Error Electrical
Failure code [CA386] Sensor1 Supply Voltage Electrical
Failure code [CA435] Engine Oil Pressure SW Electrical
Failure code [CA441] Battery Voltage Low Error Electrical
Failure code [CA442] Battery Voltage High Error Electrical
Failure code [CA449] Common Rail Pressure Electrical
CA449 High Error 2(PAGE 40-178) ENG L03 system
Failure code [CA466] KVGT Motor Driver Electrical
CA466 Position Error(PAGE 40-183) ENG L03 system
40-102 PC88MR-10
40 Troubleshooting
Applicable History
code level
nent
Failure code [CA515] Rail Pressure Sensor Sup Electrical
CA515 Volt High Error(PAGE 40-185) ENG L03 system
Failure code [CA516] Rail Pressure Sensor Sup Electrical
CA516 Volt Low Error(PAGE 40-187) ENG L03 system
CA553 High Error 1(PAGE 40-189) ENG L01 system
Failure code [CA555] Crankcase Pressure High Electrical
CA555 Error 1(PAGE 40-190) ENG L01 system
Failure code [CA556] Crankcase Pressure High Electrical
CA556 Error 2(PAGE 40-191) ENG L03 system
CA559 Low Error 1(PAGE 40-192) ENG L01 system
Failure code [CA689] Engine NE Speed Sensor Electrical
Failure code [CA691] Intake Air Temperature Electrical
Failure code [CA692] Intake Air Temperature Electrical
Failure code [CA697] Engine Con Internal Temp Electrical
CA697 Sens High Error(PAGE 40-201) ENG L01 system
Failure code [CA698] Engine Con Internal Temp Electrical
CA698 Sens Low Error(PAGE 40-202) ENG L01 system
Failure code [CA731] Engine Backup Speed Electrical
CA731 Sensor Phase Error(PAGE 40-203) ENG L01 system
Failure code [CA778] Engine Backup Speed Electrical
CA778 Sensor Error(PAGE 40-205) ENG L01 system
Failure code [CA1117] Engine Controller Partial Electrical
CA1117 Data Lost Error(PAGE 40-209) ENG L04 system
Failure code [CA1843] Crankcase Pressure Electrical
Failure code [CA1896] EGR Valve Stuck Error Electrical
CA1942 Sensor In Range Error(PAGE 40-217) ENG L01 system
Failure code [CA1961] EGR_Motor Driver IC Electrical
CA1961 Over Temp Error(PAGE 40-218) ENG L03 system
Failure code [CA2185] Throttle Sensor Supply Electrical
Failure code [CA2186] Throttle Sensor Supply Electrical
CA2186 Voltage Low Error(PAGE 40-221) ENG L03 system
CA2249 Low Error 2(PAGE 40-223) ENG L03 system
Failure code [CA2272] EGR Valve Position Electrical
Failure code [CA2311] IMV Solenoid Error Electrical
Failure code [CA2349] EGR Valve Solenoid Electrical
CA2349 Open Circuit Error(PAGE 40-227) ENG L03 system
PC88MR-10 40-103
40 Troubleshooting
Applicable History
code level
nent
Failure code [CA2353] EGR Valve Solenoid Electrical
CA2353 Short Circuit Error(PAGE 40-229) ENG L03 system
Failure code [CA2357] EGR Valve Servo Error Electrical
Failure code [CA2765] Injector Trim Data Electrical
CA2765 Mismatch(PAGE 40-232) ENG L01 system
Failure code [CA3419] MAF Sensor Supply Electrical
Failure code [CA3421] MAF Sensor Supply Electrical
CA3421 Voltage Low Error(PAGE 40-235) ENG L03 system
Failure code [CA3724] EGR/KVGT Motor Driver Electrical
CA3724 Power Low Error(PAGE 40-237) ENG L03 system
Failure code [CA3918] KVGT Stuck Error(PAGE Electrical
CA3918 40-239) ENG L03 system
Failure code [CA3919] KVGT Motor Driver IC Electrical
CA3919 Over Temp Error(PAGE 40-240) ENG L03 system
Failure code [CA3921] KVGT Servo Error 2 Electrical
Failure code [CA3922] KVGT Motor Driver Open Electrical
Failure code [CA3923] KVGT Motor Driver Short Electrical
Failure code [D110KB] Battery Relay Output Electrical
D110KB Short Circuit(PAGE 40-246) PUMP L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Open or Short(PAGE 40-248) MON L03 system
Failure code [D811MC] KOMTRAX Malfunction KOM- Electrical
D811MC (PAGE 40-251) -
TRAX system
Failure code [D862KA] GPS Antenna Open KOM- Electrical
D862KA Circuit(PAGE 40-252) -
TRAX system
Failure code [D8ALKA] Operating Lamp Open KOM- Electrical
D8ALKA Circuit (KOMTRAX)(PAGE 40-253) -
TRAX system
Failure code [D8ALKB] Operating Lamp Short KOM- Electrical
D8ALKB Circuit (KOMTRAX)(PAGE 40-255) -
TRAX system
Failure code [D8AQKR] CAN 2 Defective Electrical
D8AQKR Communication (KOMTRAX)(PAGE 40-256) MON -
system
Failure code [DA20MC] Pump Controller Electrical
DA20MC Malfunction(PAGE 40-258) PUMP -
system
Failure code [DA22KK] Pump Con Solenoid Electrical
DA22KK Power Volt Low Error(PAGE 40-259) PUMP L03 system
Failure code [DA25KP] 5V Sensor 1 Power Electrical
DA25KP Voltage Low Error(PAGE 40-261) PUMP -
system
Failure code [DA29KQ] Model Selection Sig Electrical
DA29KQ Mismatch (Pump Con)(PAGE 40-263) PUMP L01 system
Failure code [DA2LKA] Operating Lamp Open Electrical
DA2LKA Circuit (Pump Con)(PAGE 40-265) PUMP -
system
Failure code [DA2LKB] Operating Lamp Short Electrical
DA2LKB Circuit (Pump Con)(PAGE 40-267) PUMP -
system
Failure code [DA2QKR] CAN 2 Defective Electrical
DA2QKR Communication (Pump Con)(PAGE 40-268) MON L03 system
Failure code [DA2RKR] CAN 1 Defective Electrical
DA2RKR Communication (Pump Con)(PAGE 40-270) MON L04 system
Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB Abnormality(PAGE 40-271) MON -
system
40-104 PC88MR-10
40 Troubleshooting
Applicable History
code level
nent
Failure code [DAF0MC] Monitor Malfunction Electrical
DAF0MC (PAGE 40-272) MON -
system
Failure code [DAF8KB] Camera Power Supply Electrical
DAF8KB Short Circuit(PAGE 40-273) MON L03 system
Failure code [DAF9KQ] Model Selection Signal Electrical
DAF9KQ Mismatch (Monitor)(PAGE 40-274) MON L03 system
Failure code [DAFGMC] GPS Module KOM- Electrical
DAFGMC Malfunction(PAGE 40-275) -
TRAX system
Failure code [DAFLKA] Operating Lamp Open Electrical
DAFLKA Circuit (Monitor)(PAGE 40-276) MON -
system
Failure code [DAFLKB] Operating Lamp Short Electrical
DAFLKB Circuit (Monitor)(PAGE 40-278) MON -
system
Failure code [DAFQKR] CAN 2 Defective KOM- Electrical
DAFQKR Communication (Monitor)(PAGE 40-279) -
TRAX system
Failure code [DAZ9KQ] Model Selection Sig Electrical
DAZ9KQ Mismatch (A/C)(PAGE 40-280) MON -
system
Failure code [DAZQKR] CAN2 Defective Electrical
DAZQKR Communication (A/C ECU)(PAGE 40-281) MON L01 system
Failure code [DB2QKR] CAN2 Defective Electrical
DB2QKR Communication (Engine Con)(PAGE 40-285) MON L03 system
Failure code [DB2RKR] CAN1 Defective Electrical
DB2RKR Communication (Engine Con)(PAGE 40-289) MON L04 system
Failure code [DDNRKA] WE Lever Lock SW Electrical
DDNRKA Open Circuit(PAGE 40-293) PUMP L03 system
Failure code [DDNRKY] WE Lever Lock SW Electrical
DDNRKY Short Circuit(PAGE 40-295) PUMP L03 system
Failure code [DDNS00] Lock Lever Auto Lock Electrical
DDNS00 Release SW On(PAGE 40-297) PUMP -
system
Failure code [DGH2KB] Hydraulic Oil Temp Electrical
DGH2KB Sensor Ground Fault(PAGE 40-299) PUMP L01 system
Failure code [DHPAMA] Front Pump Press Sens Electrical
DHPAMA Defective Function(PAGE 40-301) PUMP L01 system
Failure code [DHS3MA] Arm IN PPC Press Electrical
DHS3MA Sensor Def Function(PAGE 40-303) PUMP L01 system
Failure code [DHS4MA] Bucket CURL PPC Electrical
DHS4MA Press Sens Def Function(PAGE 40-305) PUMP L01 system
Failure code [DHS5MA] Travel PPC Sensor Electrical
DHS5MA Abnormality(PAGE 40-307) PUMP L01 system
Failure code [DHS8MA] Boom Raise PPC Press Electrical
DHS8MA Sens Def Function(PAGE 40-309) PUMP L01 system
Failure code [DHS9MA] Boom Lower PPC Press Electrical
DHS9MA Sens Def Function(PAGE 40-311) PUMP L01 system
Failure code [DHSAMA] Swing Right PPC Press Electrical
DHSAMA Sens Def Function(PAGE 40-313) PUMP L01 system
Failure code [DHSBMA] Swing Left PPC Press Electrical
DHSBMA Sensor Def Function(PAGE 40-315) PUMP L01 system
Failure code [DHSCMA] Arm OUT PPC Press Electrical
DHSCMA Sens Def Function(PAGE 40-317) PUMP L01 system
Failure code [DHSDMA] Bucket DUMP PPC Electrical
DHSDMA Press Sens Def Function(PAGE 40-319) PUMP L01 system
Failure code [DHSPMA] Boom Swing LH PPC Electrical
DHSPMA Press Sensor Abnormality(PAGE 40-321) PUMP L01 system
Failure code [DHSQMA] Boom Swing RH PPC Electrical
DHSQMA Press Sensor Abnormality(PAGE 40-323) PUMP L01 system
PC88MR-10 40-105
40 Troubleshooting
Applicable History
code level
nent
Failure code [DKULKA] PPC Lock Relay Open Electrical
DKULKA Circuit(PAGE 40-325) PUMP L03 system
Failure code [DKULKB] PPC Lock Relay Short Electrical
DKULKB Circuit(PAGE 40-327) PUMP L03 system
Failure code [DKULKY] PPC Lock Relay Hot Electrical
DKULKY Short Circuit(PAGE 40-329) PUMP L03 system
Failure code [DV20KB] Travel Alarm Short Electrical
DV20KB Circuit(PAGE 40-331) PUMP L01 system
Failure code [DW43KA] Travel Speed Solenoid Electrical
DW43KA Open Circuit(PAGE 40-333) PUMP L01 system
Failure code [DW43KB] Travel Speed Solenoid Electrical
DW43KB Short Circuit(PAGE 40-335) PUMP L01 system
Failure code [DW43KY] Travel Speed Sol Hot Electrical
DW43KY Short Circuit(PAGE 40-337) PUMP L01 system
Failure code [DW45KA] Swing Parking Brake Electrical
DW45KA Solenoid Open Circuit(PAGE 40-338) PUMP L03 system
Failure code [DW45KB] Swing Parking Brake Electrical
DW45KB Solenoid Short Circuit(PAGE 40-341) PUMP L03 system
Failure code [DW45KY] Swing Brake Sol Hot Electrical
DW45KY Short Circuit(PAGE 40-343) PUMP L03 system
Failure code [DW4CKY] PPC lock Sol Hot Short Electrical
DW4CKY Circuit(PAGE 40-345) PUMP L03 system
Failure code [DWJ0KA] Merge-divider Sol Open Electrical
DWJ0KA Circuit(PAGE 40-347) PUMP L01 system
Failure code [DWJ0KB] Merge-divider Sol Short Electrical
DWJ0KB Circuit(PAGE 40-349) PUMP L01 system
Failure code [DWJ0KY] Merge-divider Sol Short Electrical
DWJ0KY Circuit(PAGE 40-351) PUMP L01 system
Failure code [DXA8KA] Front Pump PC-EPC Electrical
DXA8KA Solenoid Open Circuit(PAGE 40-352) PUMP L03 system
Failure code [DXA8KB] Front Pump PC-EPC Electrical
DXA8KB Solenoid Short Circuit(PAGE 40-354) PUMP L03 system
Failure code [DXE7KA] Attachment Flow
Electrical
DXE7KA Regulating EPC 2 Solenoid Open Circuit(PAGE PUMP -
system
40-356)
Failure code [DXE7KB] Att Flow Regulating EPC Electrical
DXE7KB 2 Short Circuit(PAGE 40-358) PUMP -
system
Failure code [DXE7KY] Attachment Flow
Electrical
DXE7KY Regulating EPC 2 Solenoid Hot Short Circuit PUMP -
system
(PAGE 40-360)
Failure code [DXEAKA] Att Flow Regulating Electrical
DXEAKA EPC 5 Open Circuit(PAGE 40-362) PUMP -
system
Failure code [DXEAKB] Att Flow Regulating Electrical
DXEAKB EPC 5 Short Circuit(PAGE 40-364) PUMP -
system
Failure code [DXEAKY] Service Current EPC5 Electrical
DXEAKY Hot Short Circuit(PAGE 40-366) PUMP -
system
Failure code [DY20KA] Wiper Motor Open Electrical
DY20KA Circuit(PAGE 40-368) PUMP -
system
Failure code [DY20MA] Wiper Motor Defective Electrical
DY20MA Function(PAGE 40-370) PUMP -
system
Failure code [DY2CKB] Washer Motor Short Electrical
DY2CKB Circuit(PAGE 40-372) PUMP -
system
Failure code [DY2DKB] Wiper Motor (Normal) Electrical
DY2DKB Short Circuit(PAGE 40-374) PUMP -
system
Failure code [DY2EKB] Wiper Motor (Reverse) Electrical
DY2EKB Short Circuit(PAGE 40-376) PUMP -
system
40-106 PC88MR-10
40 Troubleshooting
a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
a Applicable component is the controller or machine monitor which checks the system.
MON: Machine monitor
ENG: Engine controller
PUMP: pump
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(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
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Troubleshooting by failure code (Display of code) (ALL-3840-001-A-00-A)
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit (PC88MR-879AKA-
441-A-Z0-A)
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
40 Troubleshooting
Failure code [879AKB] A/C Recirc Air Temp Sens Short (PC88MR-879AKB-441-A-Z0-A)
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
40 Troubleshooting
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
40 Troubleshooting
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
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Open Circuit (PC400-879CKA-441-A-Z0-A)
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
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit (PC400-879CKB-441-A-Z0-A)
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
40 Troubleshooting
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
40 Troubleshooting
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
40 Troubleshooting
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
40 Troubleshooting
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
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution 1 (PC88MR-989L00-400-A-Z0-A)
Action level Failure code Engine Controller Lock Caution 1

Failure
– 989L00 (Machine monitor system)
Detail of • Engine controller lock up is detected (Factor 1).
failure
Action of • None in particular
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to the password which had been set before replacement.
information • Method of reproducing failure code: Turn starting switch to ON position.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
40-118 PC88MR-10
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution 2 (PC88MR-989M00-400-A-Z0-A)

Failure
– 989M00 (Machine monitor system)
failure
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to the password which had been set before replacement.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
If this failure code is displayed while machine monitor is not replaced,
2 Defective machine monitor machine monitor may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
PC88MR-10 40-119
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution 3 (PC88MR-989N00-400-A-Z0-A)

Failure
– 989N00 (Machine monitor system)
failure
Action of • Tries automatic recovery.
monitor
Problem on
machine
Related • Method of reproducing failure code: Failure code cannot be reproduced since machine
information recovers when cause of failure disappears.
If this failure code is generated repeatedly, engine controller may be
1 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
40-120 PC88MR-10
40 Troubleshooting
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3 (PC88MR-A900FR-
400-A-Z0-A)
Action level Failure code Abrupt Engine Stop by Auto Idle Stop 3
Failure
L03 A900FR (Machine monitor system)
Details of • Durability of turbocharger is degraded because engine speed just before the engine is
failure stopped by auto idle stop function is high, causing abrupt engine stops frequently.
Action of • Turns the auto-deceleration setting ON.
machine • Auto idle stop sudden stop monitor is displayed in red on machine monitor.
monitor • Resets when next auto idle stop countdown starts or starting switch is turned OFF.
Problem on • Turbocharger may get damaged.
machine
• This failure code is displayed when activation of failure code [A900N6] exceeds 2,000
times.
• This failure code will be cleared after replacing the turbocharger assembly and resetting
Related
the auto idle stop sudden engine stop counter.
information
• Method of reproducing failure code: Before resetting the auto idle stop sudden engine
stop counter, let the engine stop by auto idle stop function with auto-deceleration turned
OFF and fuel dial set at maximum.
No. Cause Procedure, measuring location, criteria, and remarks
If this repeatedly occurs even when the auto idle stop function is OFF,
PC88MR-10 40-121
40 Troubleshooting
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 (PC88MR-A900N6-
400-A-Z0-A)
Failure
— A900N6 (Machine monitor system)
Details of • Engine speed just before the engine is stopped by auto idle stop function is high.
failure
Action of
machine • Turn the auto-deceleration setting ON.
monitor
Problem on
machine
• This failure code is displayed if auto-deceleration is not OFF and fuel dial is not at
minimum when auto idle stop function commands engine stop.
• Engine speed can be checked with monitoring function.
Related (Code: 01002 Engine speed)
information • Accumulated counts can be checked with auto idle stop sudden stops counter reset
menu.
• Method of reproducing failure code: Let the engine stop by auto idle stop function with
auto-deceleration turned OFF and fuel dial set at maximum.
40-122 PC88MR-10
40 Troubleshooting
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2 (PC88MR-A900NY-
400-A-Z0-A)
Failure
L01 A900NY (Machine monitor system)
Details of • Accumulated count of abrupt engine stops is high because engine speed just before the
failure engine is stopped by auto idle stop function is high.
Action of • Turns the auto-deceleration setting ON.
machine • Auto idle stop sudden stop monitor is displayed in yellow on machine monitor.
monitor • Resets when next auto idle stop countdown starts or starting switch is turned OFF.
Problem on • Turbocharger may get damaged.
machine
• This failure code is displayed when activation of failure code [A900N6] exceeds 1,000
times.
• This failure code will be cleared after replacing the turbocharger assembly and resetting
Related
the auto idle stop sudden engine stop counter.
information
• Method of reproducing failure code: Before resetting the auto idle stop sudden engine
stop counter, let the engine stop by auto idle stop function with auto-deceleration turned
OFF and fuel dial set at maximum.
PC88MR-10 40-123
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low (PC138-AB00KE-400-A-Z0-A)
Action level Failure code Charge Voltage Low

Failure
L03 AB00KE (Machine monitor system)
Detail of • While engine is running, voltage from alternator drops, and machine monitor detects that
failure battery charge voltage is low (below 7.8 V).
Action of • Displays charge level monitor red on machine monitor.
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • If machine continues to be operated, battery may not be charged.
machine
• Signal voltage of alternator can be checked by using monitoring function.
Related (Code: 04300)
information • Method of reproducing failure code: Start engine.
Loose alternator
1 terminal or open circuit 1. Turn starting switch to OFF position.
at terminal 2. Check terminal.
Defective power 1. Turn starting switch to OFF position.

generation of alternator 2. Insert T-adapter into connector E12.
2 3. Start engine.
(When system works
properly.) Between E12 (1) and Engine speed: Medium 27.5 to 29.5
Voltage
ground or above V
2. Disconnect diode D01 and connect T-adapters to male side.
3 Defective diode a Measure it with diode range of multimeter.

No
Between D01 (male) (2) (+) and (6) (-)
Continuity continuity
Between D01 (male) (6) (+) and (2) (-) Continuity
Defective wiring 2. Insert T-adapter into connector CM01.
4 harness or machine 3. Start engine.
monitor
Voltage Between CM01 (16) and ground 20 to 30 V
Open circuit in wiring a If no failure is found by check on cause 2, this check is not required.
harness
5 (wire breakage or 2. Disconnect connectors CM01 and E12, and connect T-adapter to each
defective contact of female side.
connector) Resistance Between CM01 (female) (16) and E12 (female) (1) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
harness
6 2. Disconnect connectors CM01 and E12, and connect T-adapter to either
(contact with ground female side.
circuit) Between CM01 (female) (16) or E12 (female) (1)
Resistance and ground Min. 1 Mz
Defective machine If no failure is found by above checks, machine monitor is defective.

7
monitor (Since this is an internal defect, troubleshooting cannot be performed.)
40-124 PC88MR-10
40 Troubleshooting
Circuit diagram related to charge
PC88MR-10 40-125
40 Troubleshooting
Failure code [B@BAZG] Eng Oil Press Low (PC400-BaBAZG-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Low

Failure
L03 B@BAZG (Engine controller system)
Detail of • While engine is running, signal voltage from engine oil pressure sensor drops, so engine
failure controller determines that engine oil pressure is low.
Action of • Displays engine oil pressure monitor red on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Engine oil pressure sensor signal is input to engine controller and then transmitted to
machine monitor through CAN communication system.
Related • Engine oil pressure can be checked by using monitoring function.
information (Code: 37200)
• Method of reproducing failure code: Start engine.
Low engine oil pressure
1 (when system works Engine oil pressure may be low. Check it and remove cause if it is low.
properly)
If no failure is found by checks on cause 1, engine oil pressure sensor circuit
Defective engine oil
2 may be defective. Perform troubleshooting for failure codes [CA135] and
pressure sensor circuit
[CA141].
40-126 PC88MR-10
40 Troubleshooting
Failure code [B@BCNS] Eng Water Overheat (PC400-BaBCNS-400-A-Z0-A)
Action level Failure code Engine Water Overheat

Failure
L02 B@BCNS (Engine controller system)
Detail of • While engine is running, voltage from engine coolant temperature sensor drops, so engine
failure controller determines that engine coolant is overheated.
Action of • Displays engine coolant temperature monitor red on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function
information (Code: 04107 Engine coolant temperature)
Overheating of engine
1 coolant 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
2 sensor system may be defective. Carry out troubleshooting for failure
temperature sensor system
codes [CA144] and [CA145].
PC88MR-10 40-127
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error (PC88MR-CA115-400-A-Z0-A)
Action level Failure code Engine Ne and Bkup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Detail of • Both signals from engine Ne speed sensor and engine Bkup speed sensor are unusual.
failure
Action of • None in particular.
controller
Problem on • Engine stops.
machine • Engine does not start.
Related • Method of reproducing failure code: Start engine.
information
Poor connection of sensor Connectors of engine Ne speed sensor and Bkup sensor may be poorly
1 (incorrectly) connected. Check their connection.
connector
Defective Ne speed sensor
2 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
system
If no failure is found by above checks, engine controller is defective.
4 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)
40-128 PC88MR-10
40 Troubleshooting
Failure code [CA122] Charge Air Pressure Sensor High Error (PC88MR-CA122-400-
A-Z0-A)
Action level Failure code Charge Air Pressure Sensor High Error
Failure
Detail of • High voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
Action of • Closes EGR valve and opens variable flow turbocharger fully.
controller • Limits engine output and runs engine.
Problem on • Acceleration performance of engine drops.
machine • Engine output lowers.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked with
monitoring function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
monitoring function. (Code: 36500 (kPa))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
• If sensor connector is disconnected, failure code [CA123] for "Low Error" is displayed
even in normal condition.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "Related information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
2. Disconnect connector TMAP.
If failure code changes from [CA122] to [CA123], charge (boost) pressure
sensor is defective.
a Other failure code [CA153] for temperature sensor is also displayed.
Defective charge Ignore this code since this is displayed due to disconnection of sensor
3 (boost) pressure sensor connector.
• Reference
Sensor
Voltage Between J1 (15) and (59) 0.3 to 4.7 V
output
1. Turn starting switch to OFF position, then perform troubleshooting.
Short circuit in wiring 2. Disconnect connectors J1 and TMAP, and connect T-adapter to female
4
harness side of connector J1.
Resistance Between J1 (female) (15) and (60) Min. 1 Mz
Hot short circuit in 2. Disconnect connector TMAP, and insert T-adapter into connector J1.
5 wiring harness 3. Turn starting switch ON (with connector TMAP disconnected).
Voltage Between J1 (15) and (59) Max. 1 V
PC88MR-10 40-129
40 Troubleshooting

Open circuit in wiring
harness If no failure is found by above checks, wiring harness probably has open
6 (wire breakage or circuit. (*)
defective contact of a To check open circuit in GND line
connector)
Defective engine If no failure is found by above checks, engine controller is defective.
7
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".
Circuit diagram related to charge pressure sensor
40-130 PC88MR-10
40 Troubleshooting
Failure code [CA123] Charge Air Pressure Sensor Low Error (PC88MR-CA123-400-A-
Z0-A)
Action level Failure code Charge Air Pressure Sensor Low Error
Failure
Detail of • Low voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
Problem on • Acceleration performance of engine drops.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked with
monitoring function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
monitoring function. (Code: 36500 (kPa))
• This failure code appears if sensor connector is disconnected.
harness connector
Defective power supply
system of charge If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 pressure sensor (boost for it first.
pressure sensor)
Short circuit in wiring 2. Disconnect connectors J1 and TMAP, and connect T-adapter to female
3
harness side of connector J1.
Resistance Between J1 (female) (15) and (59) Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position, then perform troubleshooting.
harness 2. Disconnect connectors J1 and TMAP, and connect T-adapter to female
4
(contact with ground side of connector J1.
circuit) Resistance Between J1 (female) (15) and ground Min. 1 Mz
harness
If no failure is found by above checks, wiring harness probably has open
5 (wire breakage or circuit. (*)
defective contact of
connector)
a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective charge 1. Turn starting switch to OFF position.
6 (boost) pressure sensor 2. Insert T-adapter into connector J1.
Sensor
output
7
*: Refer to "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
PC88MR-10 40-131
40 Troubleshooting
Circuit diagram related to charge pressure sensor
40-132 PC88MR-10
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error (PC88MR-CA131-400-A-Z0-A)
Action level Failure code Throttle Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of fuel dial sensor.
failure
Action of • Runs engine with signal voltage of fuel dial as fixed value (as if fuel dial is at the half
controller position)
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
Related (Code: 03000 "Fuel Dial Sensor Volt")
equipment" in "Checks before troubleshooting" of "Related
information on troubleshooting", and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code is not displayed, wiring harness connector is
defective.
Defective throttle sensor If failure code [CA2185] is also displayed, perform troubleshooting for it
2 power supply system first.
2. Disconnect connector P20, and connect T-adapter to male side.
Defective throttle sensor (fuel
3 Between P20 (male) (1) and (3) 4.0 to 6.0 kz
dial) Resis- Between P20 (male) (2) and (3)
3 to 7 kz
tance
Between P20 (male) (1) and (2) 3 to 7 kz
Open or short circuit in wiring 2. Disconnect connector CE03, and connect T-adapter to female side.
4
harness Resis- Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
tance Between CE03 (female) (51) and (42) 3 to 7 kz
5 Short circuit in wiring harness 2. Disconnect connectors CE03 and P20, and connect T-adapter to
either female side.
Resis- Between CE03 (female) (51) and (42), or
Min. 1 Mz
tance between P20 (female) (1) and (2)
Hot short circuit in wiring 2. Disconnect connector P20 and connect T-adapter to female side.
harness
Voltage Between P20 (female) (2) and ground Max 1 V
• Reference
2. Insert T-adapter into connector CE03.
7 Defective engine controller 3. Turn starting switch to ON position.
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
40 Troubleshooting
Circuit diagram related to throttle sensor
40-134 PC88MR-10
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error (PC88MR-CA132-400-A-Z0-A)
Action level Failure code Throttle Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of fuel dial sensor.
failure
Action of • Runs engine with signal voltage of fuel dial as fixed value (as if fuel dial is at the half
controller position)
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
Related (Code: 03000 "Fuel Dial Sensor Volt")
1
defective.
Defective throttle sensor If failure code [CA2186] is also displayed, perform troubleshooting for it
2 power supply system first.
Defective throttle sensor (fuel
3 Between P20 (male) (1) and (3) 4.0 to 6.0 kz
dial)
Resistance Between P20 (male) (2) and (3) 3 to 7 kz
Between P20 (male) (1) and (2) 3 to 7 kz
Open or short circuit in wiring 2. Disconnect connector CE03, and connect T-adapter to female side.
4
harness Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
Resistance
Between CE03 (female) (41) and (51) 3 to 7 kz
2. Disconnect connector CE03 and P20, and connect T-adapter to
Open circuit in wiring harness each female side.
5 (wire breakage or defective Between CE03 (female) (42) and P20
(female) (1) Max. 1 z
Between CE03 (female) (51) and P20
Resistance (female) (2) Max. 1 z
Between CE03 (female) (41) and P20
(female) (3) Max. 1 z

6 Short circuit in wiring harness 2. Disconnect connectors CE03 and P20, and connect T-adapter to
either female side.
Between CE03 (female) (51) and (41), or
Resistance between P20 (female) (2) and (3) Min. 1 Mz

Ground fault in wiring harness 2. Disconnect connectors CE03 and P20, and connect T-adapter to
7 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
40 Troubleshooting

• Reference
8 Defective engine controller 2. Insert T-adapter into connector CE03.
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
40-136 PC88MR-10
40 Troubleshooting
Failure code [CA144] Coolant Temperature Sensor High Error (PC88MR-CA144-400-

A-Z0-A)
Action level Failure code Coolant Temperature Sensor High Error

Failure
Detail of • High voltage occurs in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed value (90°C) and runs engine.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function. (Code: 04105 (V))
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to ON position.
Related
• Since female connector alone is provided for "socket" used for troubleshooting of this
information
k Drain approximately 10l l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
Defective wiring harness information on troubleshooting", and check it.
connector
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700
z to 37 kz when coolant temperature is min. 0°C.
Defective coolant
2 temperature sensor 0°C 30 to 37 kz
Between TWTR (male) (A) and (B) 25°C 9.3 to 10.7 kz
Resis-
50°C 3.2 to 3.8 kz
tance a Coolant temperature-
Resistance characteristics 80°C 1.0 to 1.3 kz
95°C 700 to 800 z
2. Disconnect connector J1 and connect T-adapter to female side.
Open or short circuit in Between J1 (female) (14) and (13) (Coolant
3 wiring harness temperature: Min. 0°C)
Resis- 700 z to 37
tance a Use Coolant temperature-Resistance kz
characteristics table for check on cause 2
as resistance criteria.
PC88MR-10 40-137
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-138 PC88MR-10
40 Troubleshooting
Failure code [CA145] Coolant Temperature Sensor Low Error (PC88MR-CA145-400-

A-Z0-A)
Action level Failure code Coolant Temperature Sensor Low Error

Failure
Detail of • Low voltage occurs in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed value (90°C) and runs engine.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
Related
• If temperature sensor connector is disconnected, failure code [CA144] for high error is
information
displayed in place of this failure code.
k Drain approximately 10l l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
equipment" in "Checks before troubleshooting" of "Related information
Defective wiring harness on troubleshooting", and check it.
connector
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700 z
to 37 kz when coolant temperature is min. 0°C.
0°C 30 to 37 kz
Between TWTR (male) (A) and (B) 25°C 9.3 to 10.7 kz
Defective coolant
2 a Coolant temperature-Resistance 50°C 3.2 to 3.8 kz
temperature sensor
characteristics 80°C 1.0 to 1.3 kz
Resis- 95°C 700 to 800 z
tance Whole
coolant
Between TWTR (male) (B) and
tempera- Min. 1 Mz
ground
ture
range
Between J1 (female) (14) and (13) (Coolant
Short circuit in wiring
3 temperature: Min. 0°C)
harness Resis-
700 z to 37 kz
tance a Use Coolant temperature-Resistance
characteristics table for check on cause 2
as resistance criteria.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and TWTR, and connect T-adapter to female
4 side of connector J1.
(contact with ground
circuit) Resis- Between J1 (female) (14) and ground Min. 1 Mz
tance
PC88MR-10 40-139
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-140 PC88MR-10
40 Troubleshooting
Failure code [CA153] Charge Air Temperature Sensor High Error (PC88MR-
CA153-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor High Error
Failure
Detail of • High voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Takes charge temperature (boost temperature) to be fixed value (46°C), and runs engine.
Problem on • Engine starting performance is deteriorated at low temperatures.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))
harness connector
2. Disconnect connector TMAP and connect socket to male side.
a Regard charge temperature sensor as normal if its resistance is 80 z to 48
kz (-40°C to -130°C).
-40°C 41 to 48 kz
-20°C 14 to 16 kz
Defective charge 5.4 to 6.1
2 temperature sensor 0°C
kz
Between TMAP (male) (3) and (4) 1.6 to 1.8
Resistance a Charge temperature-Resistance 30°C
kz
characteristics 560 to 600
60°C
z
230 to 250
90°C
z
130°C 80 to 90 z
Open or short circuit in Between J1 (female) (5) and (59)
3 wiring harness 80 z to 48
Resistance a Use Charge temperature-Resistance
characteristics table for check on cause 2 as kz
resistance criteria.
4
PC88MR-10 40-141
40 Troubleshooting
Circuit diagram related to charge (boost) temperature sensor
40-142 PC88MR-10
40 Troubleshooting
Failure code [CA154] Charge Air Temperature Sensor Low Error (PC88MR-
CA154-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor Low Error
Failure
Detail of • Low voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Takes charge temperature (boost temperature) to be fixed value (46°C), and runs engine.
Problem on • Engine starting performance is deteriorated at low temperatures.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
Related checked with monitoring function. (Code: 18500 (°C))
• If temperature sensor connector is disconnected, failure code [CA153] for "High error" is
displayed in place of this failure code.
harness connector
2. Disconnect connector TMAP and connect socket to male side.
a If charge temperature sensor has resistance of 80 z to 43 kz (-40°C to
-130°C), regard charge temperature sensor as normal.
-40°C 41 to 48 kz
-20°C 14 to 16 kz
5.4 to 6.1
Defective charge 0°C
kz
2 temperature sensor Between TMAP (male) (3) and (4) 1.6 to 1.8
30°C
a Charge temperature-Resistance kz
Resistance characteristics 560 to 600
60°C
z
230 to 250
90°C
z
130°C 80 to 90 z
Whole
Between TMAP (male) (3) and ground Min. 1 Mz
range
Short circuit in wiring Between J1 (female) (5) and (59)
3
harness 80 z to 43
Resistance a Use Charge temperature-Resistance
characteristics table for check on cause 2 as kz
resistance criteria.
harness 2. Disconnect connectors J1 and TMAP, and connect T-adapter to female
4
(contact with ground side of connector J1.
5
PC88MR-10 40-143
40 Troubleshooting
Circuit diagram related to charge (boost) temperature sensor
40-144 PC88MR-10
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Voltage Low Error (PC88MR-CA187-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage Low Error

Failure
Detail of • Low voltage occurs in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from engine oil pressure sensor, sets engine oil pressure to fixed value
(250 kPa {2.5 kg/cm2}), and runs engine.
• Ignores signals from ambient pressure sensor, sets ambient pressure to fixed value
Action of (52.44 kPa {0.53 kg/cm2}), and runs engine.
controller • Ignores signals from charge (boost) pressure sensor, sets boost pressure to fixed value
(400 kPa {4.1 kg/cm2}), and runs engine.
• Ignores signals from crankcase pressure sensor, sets crankcase pressure to fixed value
(0 kPa), and runs engine.
• Closes EGR valve and opens variable flow turbocharger fully.
• Limits engine output and runs engine.
Problem on • Engine output lowers.
machine
information
harness connector
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine wiring
harness is defective.
Defective sensor or a Other failure codes (many codes) are also displayed. They are generated
2 wiring harness because of disconnection of connector. Ignore failure codes other than
[CA187].
Bkup speed sensor CAM
Charge (Boost) pressure sensor TMAP
Connector Ambient pressure sensor PAMB
Crankcase pressure sensor CCV
Engine harness J1
Defective relevant
3 If other failure codes are also displayed, perform troubleshooting for them.
system
2. Disconnect connector J1 and connect T-adapter to male side.
Defective engine
4 3. Turn starting switch to ON position with connector J1 disconnected.
controller
Voltage Between ECM J1 (male) (60) and (59) 4.75 to 5.25
V
PC88MR-10 40-145
40 Troubleshooting
Circuit diagram related to sensor power supply 2 circuit
40-146 PC88MR-10
40 Troubleshooting
Failure code [CA221] Ambient Pressure Sensor High Error (PC88MR-CA221-400-A-Z0-

A)
Action level Failure code Ambient Pressure Sensor High Error

Failure
Detail of • High voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
harness connector
Defective ambient
2 pressure sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
supply system for it first.

2. Disconnect connector PAMB.
If failure code changes from [CA221] to [CA222], sensor is defective.
Defective ambient • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1 or PAMB.
Between J1 (16) and (59), or between Sensor
Voltage 0.3 to 4.7 V
PAMB (3) and (2) output
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and PAMB, and connect T-adapters to each
4 (wire breakage or female side.
connector) Resistance Between J1 (female) (59) and PAMB (female) (2) Max. 1 z
2. Disconnect connectors J1 and PAMB, and connect T-adapter to either
5 female side.
harness
Between J1 (female) (60) and (16), or between
Resistance PAMB (female) (1) and (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector PAMB, and connect T-adapter to female side.
6 wiring harness 3. Turn starting switch to ON position.
Voltage Between PAMB (female) (3) and (2) Max. 1 V
7
PC88MR-10 40-147
40 Troubleshooting
Circuit diagram related to ambient pressure sensor
40-148 PC88MR-10
40 Troubleshooting
Failure code [CA222] Ambient Pressure Sensor Low Error (PC88MR-CA222-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (not designed as T-adapter).
harness connector
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective ambient 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector PAMB, and connect T-adapter to female side.
supply system 3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between PAMB (female) (1) and (2)
supply input V
2. Disconnect connectors PAMB and J1, and connect T-adapter to either
3 female side.
harness
Resistance PAMB (female) (3) and (2) Min. 1 Mz

harness 2. Disconnect connectors PAMB and J1, and connect T-adapter to either
4 female side.
Between ground and J1 (female) (16) or PAMB
circuit) Resistance (female) (3) Min. 1 Mz

2. Disconnect connectors PAMB and J1, and connect T-adapter to female
Open circuit in wiring side of connector J1.
5 Between J1 (female) (16) and PAMB (female) (3) Max. 1 z
harness
Resistance Between J1 (female) (59) and PAMB (female) (2) Max. 1 z
Between J1 (female) (60) and PAMB (female) (1) Max. 1 z
PC88MR-10 40-149
40 Troubleshooting

a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective ambient 1. Turn starting switch to OFF position.
6 pressure sensor 2. Insert T-adapters into connector J1 or PAMB.
Between J1 (16) and (59), or between Sensor
PAMB (3) and (2) output
7
Circuit diagram related to ambient pressure sensor
40-150 PC88MR-10
40 Troubleshooting
Failure code [CA227] Sensor 2 Supply Voltage High Error (PC88MR-CA227-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage High Error

Failure
Detail of • High voltage occurs in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor, sets ambient pressure to fixed value
(52.44 kPa {0.53 kg/cm2}), and runs engine.
Action of • Ignores signals from charge (boost) pressure sensor, sets boost pressure to fixed value
controller (400 kPa {4.1 kg/cm2}), and runs engine.
• Ignores signals from crankcase pressure sensor, sets crankcase pressure to fixed value
(0 kPa), and runs engine.
machine
information
Defective sensor power
supply 2 circuit
PC88MR-10 40-151
40 Troubleshooting
Failure code [CA234] Engine Overspeed (PC88MR-CA234-400-A-Z0-A)
Action level Failure code Engine Overspeed

Failure
Detail of • Engine speed is above operating range.
failure
Action of • Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem on • Engine speed fluctuates.
machine
Related • Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
information • Method of reproducing failure code: Run engine at high idle.
1 Use of improper fuel Fuel used may be improper. Check it.
2 Defect in related system If another failure code is displayed, perform troubleshooting for it.
Improper use Usage of machine may be improper. Instruct operator on proper use of
3
machine.
If no problem is found by checks on causes 1 and 2, engine controller is
4 Defective engine controller defective.
40-152 PC88MR-10
40 Troubleshooting
Failure code [CA238] NE Speed Sensor Supply Voltage Error (PC88MR-CA238-400-A-

Z0-A)
Action level Failure code NE Speed Sensor Supply Voltage Error

Failure
Detail of • Ne speed sensor power supply (5 V) circuit is defective.
failure
Action of • Controls engine by using signals of Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also abnormal).
machine • Stopped engine cannot be started (when Bkup(G) speed sensor is also abnormal).
information
equipment" in "Checks before troubleshooting" of "General information on
harness connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
position each time.
3. After each troubleshooting, turn starting switch to OFF position.
Defective sensor or If this failure code is not displayed when a sensor is disconnected, sensor or
2 wiring harness engine wiring harness is defective.
a Other failure codes are displayed, too. This is because connector is
disconnected. Ignore failure codes other than [CA238].
Ne speed sensor NE
Connector
Engine wiring harness J1
Defective engine 3. Turn starting switch to ON position with engine wiring harness
3
controller disconnected.
Voltage Between J1 (male) (36) and (37) 4.75 to 5.25
V
Circuit diagram related to Ne speed sensor
PC88MR-10 40-153
40 Troubleshooting
Failure code [CA239] NE Speed Sensor Supply Voltage High Error (PC88MR-
CA239-400-A-Z0-A)
Action level Failure code NE Speed Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also defective).
machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).
information
equipment" in "Checks before troubleshooting" of "General
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
2. Disconnect connector NE.
2 Defective Ne speed sensor
harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than [CA239].
2. Disconnect connector J1.
3 Defective wiring harness If this failure code disappears, wiring harness is defective.
codes other than [CA239].
2. Disconnect connector J1 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
V
Circuit diagram related to Ne speed sensor
40-154 PC88MR-10
40 Troubleshooting
Failure code [CA271] PCV1 Short Circuit Error (PC88MR-CA271-400-A-Z0-A)
Action level Failure code PCV1 Short Circuit Error

Failure
Detail of • Short circuit is detected in supply pump control valve (SCV) circuit.
failure
Action of
controller
machine
Related • Under normal conditions, pulse voltage of approx. 24 V is applied to SCV while engine is
information running. However, it cannot be measured by using multimeter since it is pulse voltage.
harness connector
Defective supply pump 2. Disconnect connector SCV and connect socket to male side.
2 SCV 3. Turn starting switch to ON position.
(internal short circuit) Resistance Between SCV (male) (1) and (2) 1 to 5 z
Resistance Between SCV (male) (2) and ground Min. 1 Mz
Short circuit in wiring 2. Disconnect connector J1 and connect T-adapter to female side.
3
harness Between J1 (female) (30) and (40) (SCV
Resistance resistance) 1 to 5 z
harness 2. Disconnect connectors J1 and SCV, and connect T-adapter to female side
4
(contact with ground of connector J1.
Defective engine If no abnormality is found by above diagnosis, engine controller is defective.
5
Circuit diagram related to SCV
PC88MR-10 40-155
40 Troubleshooting
Failure code [CA272] PCV1 Open Circuit Error (PC88MR-CA272-400-A-Z0-A)
Action level Failure code PCV1 Open Circuit Error

Failure
Detail of • Open circuit occurs in supply pump control valve (SCV) circuit.
failure
Action of
controller
machine
• Under normal conditions, pulse voltage of approx. 24 V is applied to SCV while engine is
Related running. However, it cannot be measured by using multimeter since it is pulse voltage.
harness connector
Defective supply pump 1. Turn starting switch to OFF position.
2 SCV 2. Disconnect connector SCV and connect socket to male side.
(internal open circuit) Resistance Between SCV (male) (1) and (2) 1 to 5 z
Open or short circuit in 2. Disconnect connector J1 and connect T-adapter to female side.
3 wiring harness Between J1 (female) (30) and (40) (SCV
Resistance resistance) 1 to 5 z
harness 2. Disconnect connectors J1 and SCV.
4 3. Connect T-adapter to female side of connector J1.
5
Circuit diagram related to SCV
40-156 PC88MR-10
40 Troubleshooting
Failure code [CA322] Injector #1 (L#1) Open or Short Circuit (PC88MR-CA322-400-A-

Z0-A)
Action level Failure code Injector #1 (L#1) Open or Short Circuit

Failure
Detail of • Open circuit or short circuit is detected in injector #1 circuit.
failure
Action of
controller
machine • Engine speed does not stabilize.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
1
defective.
2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1 Resis- Between CN1 (male) (3) and (4)
0.4 to 1.1 z
tance
Resis- Between CN1 (male) (3) and ground
Min. 1 Mz
tance
Open circuit or ground fault in Resis-
3 wiring harness Between J1 (female) (48) and (58) 0.4 to 1.1 z
tance
Resis- Between J1 (female) (48) and ground
Min. 1 Mz
tance
Open circuit in wiring harness 2. Disconnect connectors J1 and CN1, and connect T-adapters to each
4 (wire breakage or defective female side.
contact of connector) Resis- Between J1 (female) (48) and CN1 (female) (3)
Max. 1 z
tance
Resis- Between J1 (female) (58) and CN1 (female) (4)
Max. 1 z
tance
5 harness 2. Disconnect connectors J1 and CN1, and connect T-adapters to
(contact with ground circuit) either female side.
Resis- Between J1 (female) (48) or CN1 (female) (3)
Min. 1 Mz
tance and ground
2. Disconnect connectors J1 and CN1, and connect T-adapters to
female side of connector J1.
6 Short circuit in wiring harness a Check by using multimeter in continuity mode.

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
40 Troubleshooting

Defective other cylinder If failure codes of other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them first.
Circuit diagram related to injector #1
40-158 PC88MR-10
40 Troubleshooting

Z0-A)

Failure
failure
Action of
controller
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to injector
information (positive) side. But it is pulse voltage and cannot be measured by using multimeter.
harness connector
2 Defective injector #3
Between CN2 (male) (3) and (4) 0.4 to 1.1 z
Resistance
Between CN2 (male) (3) and ground Min. 1 Mz
Open circuit or ground 2. Disconnect connector J1 and connect T-adapter to female side.
3 fault in wiring harness Between J1 (female) (44) and (54) 0.4 to 1.1 z
Resistance
Between J1 (female) (44) and ground Min. 1 Mz
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors J1 and CN2, and connect T-adapter to each
connector) Between J1 (female) (44) and CN2 (female) (3) Max. 1 z
Resistance
Between J1 (female) (54) and CN2 (female) (4) Max. 1 z
harness
5 2. Disconnect connectors J1 and CN2, and connect T-adapter to either
circuit) Between J1 (female) (44) or CN2 (female) (1) and
Resistance ground Min. 1 Mz

2. Disconnect connectors J1 and CN2, and connect T-adapter to the female
side of connector J1.
Short circuit in wiring a Check by using multimeter in continuity mode.
6
harness Between J1 (female) (44) and each No continuity (no sound
pin other than pin (44) is heard)
Continuity
Between J1 (female) (54) and each No continuity (no sound
Defective other cylinder
If failure codes of other injectors are displayed, perform troubleshooting for
7 injectors or wiring
them first.
harness
8
PC88MR-10 40-159
40 Troubleshooting
40-160 PC88MR-10
40 Troubleshooting

Z0-A)

Failure
failure
Action of
controller
harness connector
Resistance
Resistance
4 (wire breakage or 2. Disconnect connectors J1 and CN1, and connect T-adapters to each
Resistance
harness
5 2. Disconnect connectors J1 and CN1, and connect T-adapters to either

2. Disconnect connectors J1 and CN1, and connect T-adapters to female
6
Continuity
them first.
harness
8
PC88MR-10 40-161
40 Troubleshooting
40-162 PC88MR-10
40 Troubleshooting

Z0-A)

Failure
failure
Action of
controller
harness connector
Resistance
Resistance
4 (wire breakage or 2. Disconnect connectors J1 and CN2, and connect T-adapter to each
Resistance
harness
5 2. Disconnect connectors J1 and CN2, and connect T-adapter to either

2. Disconnect connectors J1 and CN2, and connect T-adapter to the female
6
Continuity
them first.
harness
8
PC88MR-10 40-163
40 Troubleshooting
40-164 PC88MR-10
40 Troubleshooting
Failure code [CA343] Engine Controller Internal Failure (PC88MR-CA343-400-A-Z0-A)
Action level Failure code Engine Controller Internal Failure

Failure
Detail of • Engine controller has internal defect.
failure
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine start if it is stopped.
• Power supply voltage of engine controller can be checked with monitoring function.
information • Method of reproducing failure code: Turn starting switch to ON position
Defective engine
controller system
PC88MR-10 40-165
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error (PC400-CA351-400-A-Z0-A)
Action level Failure code Injectors Drive Circuit Error

Failure
Detail of • Injector drive circuit is defective.
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
machine
information
Check failure code (injector system failure code) that is displayed at the
1 Defect in related system
same time. If another code is displayed, perform troubleshooting for it.
Defective engine controller
system
40-166 PC88MR-10
40 Troubleshooting
Failure code [CA352] Sensor1 Supply Voltage Low Error (PC88MR-CA352-400-A-Z0-A)
Action level Failure code Sensor1 Supply Voltage Low Error

Failure
Detail of • Low voltage occurs in sensor power supply 1 (5 V) circuit.
failure
Action of • Signals from EGR valve sensor and variable flow turbocharger sensor are ignored.
machine
information
harness connector
position each time.
Defective sensor or harness is defective.
2 wiring harness a Other failure codes (many codes) are also displayed. They are generated
because of disconnection of connector. Ignore failure codes other than
[CA352].
EGR valve EGR V
Connector Variable flow turbocharger VFT
Engine harness J2
Defective relevant
system
Defective engine
4 3. Turn starting switch to ON position with connector J2 disconnected.
controller
V
PC88MR-10 40-167
40 Troubleshooting
Circuit diagram related to sensor power supply 1 (5 V)
40-168 PC88MR-10
40 Troubleshooting
Failure code [CA356] MAF Sensor High Error (PC88MR-CA356-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor High Error
Failure
Detail of • High frequency occurs in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) and runs engine.
• Stops KDPF regeneration control.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
Related • Mass air flow sensor and intake air temperature sensor are integrated.
harness connector
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P55.
(internal defect)
If this failure code changes to [CA357], mass air flow sensor is defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connector P55, and connect T-adapter to female side.
supply system
Power Approx. 12
Voltage Between P55 (female) (2) and (3)
supply V
2. Disconnect connectors J1 and 55, and connect T-adapters to each female
5 (wire breakage or side.
connector) a To check open circuit in GND line
Resistance Between J1 (female) (22) and P55 (female) (3) Max. 1 z
2. Disconnect connectors J1 and P55 and connect T-adapter to female side
Short circuit in wiring of connector J1.
6
harness a Check by using multimeter in continuity mode.
Between J1 (female) (23) and each pin other than
Resistance pin (23) Min. 1 Mz

7
PC88MR-10 40-169
40 Troubleshooting
Circuit diagram related to mass air flow sensor
40-170 PC88MR-10
40 Troubleshooting
Failure code [CA357] MAF Sensor Low Error (PC88MR-CA357-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Low Error
Failure
Detail of • Low frequency occurs in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) and runs engine.
• Stops KDPF regeneration control.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, both this failure code and failure code [CA691] are
information displayed.
harness connector
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 1. Turn starting switch to OFF position.
sensor 2. Replace mass air flow sensor.
(internal defect)
If this failure code does not appear, original mass air flow sensor is defective.
supply system
Power Approx. 12
supply V
2. Disconnect connectors J1 and 55, and connect T-adapters to each female
side.
harness a If no failure is found by check on cause 4, this
check is not required. Max. 1 z
5 (wire breakage or Between J1 (female) (21) and P55 (female) (2)
connector) Resistance
a If no failure is found by check on cause 4, this
Between J1 (female) (22) and P55 (female) (3)
Between J1 (female) (23) and P55 (female) (1) Max. 1 z
harness 2. Disconnect connectors J1 and P55, and connect T-adapter to either
6 female side.
Between ground and J1 (female) (23) or P55

7
PC88MR-10 40-171
40 Troubleshooting

Hot short circuit in 3. Turn starting switch to ON position.
8 wiring harness
a Ignore displayed failure codes.
Voltage Between P55 (female) (1) and (3) Max. 1 V
9
40-172 PC88MR-10
40 Troubleshooting
Failure code [CA386] Sensor1 Supply Voltage High Error (PC88MR-CA386-400-A-Z0-A)
Action level Failure code Sensor1 Supply Voltage High Error

Failure
Detail of • High voltage occurs in sensor power supply 1 circuit.
failure
Action of • Signals from EGR valve sensor and variable flow turbocharger sensor are ignored.
machine
information
Abnormally high sensor
supply voltage
PC88MR-10 40-173
40 Troubleshooting
Failure code [CA435] Engine Oil Pressure SW Error (PC88MR-CA435-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Switch Error

Failure
Detail of • Failure occurs in engine oil pressure switch signal circuit.

failure

controller
Problem on • Protection function based on engine oil pressure does not work.
machine • Engine oil pressure monitor is not displayed normally.
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is
stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running).
• To generate this failure code, engine controller checks whether engine oil pressure switch
is in CLOSED (ON) only when engine is stopped, that is, whether signal voltage is zero or
Related not.
information • Failure of engine oil pressure switch with engine running is shown by failure code
[B@BAZG].
k When performing checking and replacement of engine oil pressure switch, open oil
filler port, and check that engine oil temperature cools down enough not to get
scalded.
harness connector
Defective engine oil
2 2. Disconnect connector POIL, and connect T-adapter to male side.
pressure switch
Resistance Between POIL (male) (1) and ground Max. 1 z
Open or short circuit in
3 2. Disconnect connector J1 and connect T-adapter to female side.
wiring harness
Resistance Between J1 (female) (31) and ground Max. 1 z
4
Circuit diagram related to engine oil pressure switch
40-174 PC88MR-10
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error (PC88MR-CA441-400-A-Z0-A)
Action level Failure code Battery Voltage Low Error

Failure
Detail of • Low voltage occurs in engine controller power circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and runs engine.
controller
Problem on • Engine stops (if engine is running).
machine • Engine startability is poor (if engine is stopped).
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03204(V))
Loose or corroded
1 Battery terminal may be loose or corroded. Check it directly.
battery terminal
Loose terminal or partial 1. Turn starting switch to OFF position.
2 open circuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
Defective wiring See descriptions of wiring harness and connectors in "c: Electrical equipment"
3 harness connector in "Checks before troubleshooting" of "Related information on
troubleshooting", and check it.
Improper battery 2. Perform troubleshooting with starting switch at OFF position and when
4 voltage starting engine.
Voltage Between battery terminals (+) and (-). 20 to 30 V
2. Insert T-adapter into connector E12.
5 Defective alternator 3. Start engine. (Engine speed: Middle or faster)
Between ground and E12 (1) or alternator R 27.5 to 29.5
Voltage
Terminal (16) V
• Reference
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
Defective engine 3. Turn battery disconnect switch to ON position.
6
controller 4. Measure voltage with starting switch at OFF position and when starting
engine.
Between CE03 (1) and (21) 20 to 30 V
Voltage
PC88MR-10 40-175
40 Troubleshooting
Circuit diagram related to battery voltage system
40-176 PC88MR-10
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error (PC88MR-CA442-400-A-Z0-A)
Action level Failure code Battery Voltage High Error

Failure
Detail of • High voltage (approximately 36 V or higher) appears in controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and runs engine.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
Related • Power supply voltage of engine controller can be checked with monitoring function.
system of engine controller
PC88MR-10 40-177
40 Troubleshooting
Failure code [CA449] Common Rail Pressure High Error 2 (PC88MR-CA449-400-A-Z0-A)
Action level Failure code Common Rail Pressure High Error 2

Failure
Detail of • High voltage (exceeding the preset limit) occurs in common rail pressure sensor circuit.
failure
Action of • Limits engine output and runs engine(limits common rail pressure).
controller
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
Defective common rail
pressure sensor system
40-178 PC88MR-10
40 Troubleshooting
Failure code [CA451] Common Rail Pressure Sensor High Error (PC88MR-CA451-
400-A-Z0-A)
Action level Failure code Common Rail Pressure Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of common rail pressure sensor.
failure
controller
machine
• This failure code appears if common rail pressure sensor connector is disconnected.
a If failure code [CA515] or [CA516] is also displayed, perform
troubleshooting for it first.
Defective common rail 2. Disconnect connector PFUEL, and connect T-adapter to female side
2 pressure sensor power supply of connector.
system 3. Turn starting switch to ON position.
Power
Between PFUEL (female) (1) and
Voltage supply 4.75 to 5.25
(3) V
input
2. Disconnect connectors PFUEL and J2, and connect T-adapters to
each female side of connectors.
a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Open circuit in wiring harness Between J2 (female) (31) and PFUEL
3 (wire breakage or defective (female) (1)
Resistance a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Between J2 (female) (21) and PFUEL
(female) (3)
(female) (2) (sensor output) Max. 1 z

2. Disconnect connectors PFUEL and J2.
4 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
40 Troubleshooting

2. Disconnect connector PFUEL and J2.
3. Connect T-adapter to either female side.
4. Turn starting switch to ON position (with connector PFUEL
Hot short circuit in wiring disconnected).
5
harness
a Pin (55) of connector J2 is connected to 5 V circuit via resistor inside
engine controller.
Between PFUEL (2) and (3), or J2 (55) and
Voltage Approx. 5 V
(21)
a If no failure is found by checks on causes 1 to 5 and if failure is
Defective common rail found by check on cause 6, sensor is defective.
pressure sensor 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connector PFUEL and J2.
(improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Between PFUEL (2) and (3), or J2 Sensor
Voltage
(55) and (21) output 0.2 to 4.6 V
Circuit diagram related to common rail pressure sensor
40-180 PC88MR-10
40 Troubleshooting
Failure code [CA452] Common Rail Pressure Sensor Low Error (PC88MR-CA452-
400-A-Z0-A)
Action level Failure code Common Rail Pressure Sensor Low Error
Failure
Detail of • Low voltage occurs in signal circuit of common rail pressure sensor.
failure
controller
machine
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400 (MPa))
• If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
1
defective.
a If failure code [CA515] or [CA516] is also displayed, perform
troubleshooting for it first.
Defective common rail 2. Disconnect connector PFUEL, and connect T-adapter to female side
2 pressure sensor power supply of connector.
system 3. Turn starting switch to ON position.
Power
Between PFUEL (female) (1)
Voltage supply 4.75 to 5.25 V
and (3)
input
2. Disconnect connector PFUEL.
If failure code [CA452] changes to [CA451], sensor is defective.
Defective common rail • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PFUEL or J2.
Between PFUEL (2) and (3), or Sensor
between J2 (55) and (21) output
2. Disconnect connectors J2 and PFUEL, and connect T-adapters to
Open circuit in wiring harness each female side of connectors.
4 (wire breakage or defective
contact of connector) a Open circuit of 5 V circuit
Resistance (female) (1) Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
Between ground and PFUEL (female) (2) or Min. 1 Mz
Resistance J2 (female) (55)
PC88MR-10 40-181
40 Troubleshooting

2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
6 Short circuit in wiring harness either female side.
Between PFUEL (female) (2) and (3) or
Resistance between J2 (female) (55) and (21) Min. 1 Mz
40-182 PC88MR-10
40 Troubleshooting
Failure code [CA466] KVGT Motor Driver Position Error (D37-CA466-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Position Error

Failure
Detail of • KVGT (turbocharger) position error has occurred.
failure
Action of • Closes EGR valve and opens turbocharger fully.
Problem on • Engine output reduces.
machine
Related a "KVGT" in the title of this failure code refers to "variable flow turbocharger" on this
information machine.
Defective sensor power If failure code [CA352] or [CA386] is displayed, perform troubleshooting for
1 supply system failure code [CA352] or [CA386] first.
2. Disconnect connectors J3 and VFT, and connect T-adapters to each
female side.
Open circuit in wiring Between J2 (female) (30) and VFT (female) (1) Max. 1 z
2 Between J2 (female) (47) and VFT (female) (5) Max. 1 z
harness
Resistance Between J2 (female) (53) and VFT (female) (2) Max. 1 z
Between J2 (female) (43) and VFT (female) (3) Max. 1 z
2. Disconnect connectors J2 and VFT, and connect T-adapter to either
Ground fault in wiring female side.
harness Between ground and J2 (female) (53) or VFT
(female) (2) Min. 1 Mz
3
Between ground and J2 (female) (43) or VFT

2. Disconnect connectors J2 and VFT, and connect T-adapter to either
Short circuit in wiring female side.
harness Between J2 (female) (43) and (53), or between VFT
(female) (2) and (3) Min. 1 Mz
4
(Short circuit between
Between J2 (female) (53) and (52), or between VFT
wiring harnesses) Resistance (female) (2) and (4) Min. 1 Mz
Between J2 (female) (43) and (52), or between VFT
Since this is an internal sensor failure of the turbocharger, troubleshooting
Turbocharger Position cannot be performed.
5
Sensor Error
Defective engine If no failure is found by above checks, engine controller may be defective.
6
PC88MR-10 40-183
40 Troubleshooting
Circuit diagram related to turbocharger
40-184 PC88MR-10
40 Troubleshooting
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error (PC88MR-CA515-
400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage High Error
Failure
Detail of • High voltage occurs in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and runs engine.
controller • Limits the common rail pressure.
machine
information
1
defective.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
codes other than this code.
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
Hot short circuit in wiring 2. Disconnect connector PFUEL, and connect T-adapter to female side
4 of connector.
harness
Voltage Between PFUEL (female) (1) and (3) 4.75 to 5.25
V
Voltage Between J2 (male) (31) and (21) 4.7 to 5.25 V
PC88MR-10 40-185
40 Troubleshooting
40-186 PC88MR-10
40 Troubleshooting
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error (PC88MR-CA516-
400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
controller • Limits the common rail pressure.
machine
information
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
Ground fault in wiring harness
4 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
(contact with ground circuit) female side of either connector.
Resis- Between ground and J2 (female) (31) or
PFUEL (female) (1) Min. 1 Mz
tance
5 Short circuit in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
female side of either connector.
Resis- Between J2 (female) (21) and (31), or
between PFUEL (female) (1) and (2) Min. 1 Mz
tance
2. Disconnect connector J2, and connect T-adapter to male side.
6 Defective engine controller 3. Turn starting switch to ON position.
V
PC88MR-10 40-187
40 Troubleshooting
40-188 PC88MR-10
40 Troubleshooting
Failure code [CA553] Common Rail Pressure High Error 1 (PC88MR-CA553-400-A-Z0-A)
Action level Failure code Common Rail Pressure High Error 1

Failure
Detail of • High voltage (above the limit) appears and continued 15 or more seconds in signal circuit
failure of common rail pressure sensor.
controller
machine
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
1
them.
2 Improper fuel Fuel used may be improper. Check it (the viscosity is high).
Defective electric system of Electrical system of common rail pressure sensor may be defective.
3 common rail pressure sensor Perform troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system
4 of common rail pressure Common rail pressure sensor may have mechanical failure. Check it.
sensor
The overflow valve may has a damaged spring, worn seat, or ball
5 Defective overflow valve clogging trouble. Check it.
6 Clogging of overflow piping Check overflow piping for clogging.
7 Defective pressure limiter The pressure limiter may have a mechanical failure. Check it.
PC88MR-10 40-189
40 Troubleshooting
Failure code [CA555] Crankcase Pressure High Error 1 (PC88MR-CA555-400-A-Z0-A)
Action level Failure code Crankcase Pressure High Error 1

Failure
Detail of • High pressure error of crankcase pressure is detected.
failure
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
1 Clogged KCCV filter Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
Blocked KCCV gas piping emulsion is found inside KCCV, KCCV blowby gas piping may be
2
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Crankcase pressure sensor Crankcase pressure sensor system may be defective. Perform
3 troubleshooting for failure codes [CA1843] and [CA1844].
defective
40-190 PC88MR-10
40 Troubleshooting
Failure code [CA556] Crankcase Pressure High Error 2 (PC88MR-CA556-400-A-Z0-A)
Action level Failure code Crankcase Pressure High Error 2

Failure
Detail of • Crankcase pressure high error (level 2) occurs.
failure
controller
machine
(Code: 48401 (V))
information (Code: 48400 (kPa))
• Method of reproducing failure code: Starting switch ON
1 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
2 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
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,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
PC88MR-10 40-191
40 Troubleshooting
Failure code [CA559] Common Rail Pressure Low Error 1 (PC88MR-CA559-400-A-Z0-A)
Action level Failure code Common Rail Pressure Low Error 1

Failure
Detail of • Supply pump pressure is very low (level 1).
failure
Action of • Limits the common rail pressure.
controller
machine
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400 (MPa))
information • Method of reproducing failure code: Start engine.
Defective relevant
1 If another failure code is displayed, perform troubleshooting for it first.
system
2 Improper fuel Improper fuel may be used, so check fuel.
3 Clogging of fuel filter a If fuel filter is clogged, replace it.
a For details of troubleshooting, see Note 1.
a For check of fuel pressure in low-pressure circuit, see Testing and
Defective low-pressure adjusting, "Testing fuel pressure".
4
circuit devices Fuel pressure in low-pressure circuit
-49 to 0 MPa
(with engine running at high idle or
{-0.5 to 0 kg/cm2}
under load equivalent to rated load)
Defective electrical Electrical problem with supply pump SCV is estimated, so perform
5 system of supply pump troubleshooting for following codes: CA271 and CA272.
SCV
Defective common rail Common rail pressure sensor may be defective. Check wiring harness for
6 pressure sensor damage.
a For check of leakage from pressure limiter, see Testing and adjusting,
"Testing fuel return rate and leakage".
Defective pressure Leakage from pressure limiter
7
limiter (Engine operation equivalent to rated Max. 20 cc/min (*)
operation (with load by torque
converter stall))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
"Testing fuel return rate and leakage".
Speed at rated operation Injector
(at stall) Limit return (spill) rate
8 Defective injector 1,600 rpm 190 cc/min
1,700 rpm 200 cc/min
Defective supply pump If no failure is found by checks on causes 1 to 8, supply pump may be
9
defective.
* Although upper limit is 20 cc/min, note that standard value is 0 cc/min (no leakage) in normal condition.
<How to use check sheet>
Perform above troubleshooting and fill in check results on attached "Check sheet for fuel pressure low error".
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
40 Troubleshooting
5. Clogging of fuel filter

6. Replace fuel filter when problem is not removed even if no clogging is found.
Check sheet for fuel pressure low error
Model Work No.
Machine serial No. # Date of check / /
Engine SAA4D95LE-6 Service meter h
Engine serial No. # Worker's name
No good
Good
A. Visual check
1 Fuel leakage to outside

2 Clogging of fuel tank breather
No good
Good
B. Inspection with machine monitor (02 = Abnormality record; 01 = Monitoring; 09 = Cylinder
cutout mode operation)
3 Check of failure code / / / /

Check of monitoring information
No good
Standard value
Good
Item displayed Testing conditions (Reference Measured
Code ISO unit
value) value
Minimums speed r/min 1,100 ± 50

01002 Engine speed Minimum speed r/min 2,100 ± 60
Rated speed r/min 2,050
Low idle % 0
31701 Throttle opening
High idle % 100
Last fuel injection
quantity
18600 command (relief) mg/st - - -
4
(in weight)
Last common rail
36200 pressure (arm in relief) MPa -
command
Common rail
36400 pressure (arm in relief) MPa -
Low idle CA - - -
Last injection
36300 timing command High idle CA - - -
(arm in relief) CA - - -
36500 Charge pressure (arm in relief) kPa - - ―
Engine coolant
04107 temperature Low idle °C - - -
14200 Fuel temperature Low idle °C - - -
PC88MR-10 40-193
40 Troubleshooting
Check result of cylinder cutout mode operation (engine speed)
No good
Standard value
Good
Cutout Measured
Function Testing conditions ISO unit (Reference
cylinder value
value)
No. 1
Low idle r/min - - -
5 cylinder
Set No. 2
cylinder to cylinder
be cut out No. 3
by cylinder. cylinder Low idle r/min - - -
No. 4
cylinder
No good
Standard value
Good
C. Check of fuel circuit Measured
Testing conditions Unit (Reference
pressure value
value)
High idle or under load
Fuel pressure in low- equivalent to rated MPa 0.15 to 0.3
6 pressure circuit operation (at arm in {kg/cm2} {1.5 to 3.0}
relieved)
No good
Good
D. Check of strainers and filters
7 Visual check of fuel filter
No good
Standard value
Good
E. Check of leakage and Testing conditions (Reference Measured
Unit
return rate value) value
Engine operation
Leakage from pressure equivalent to rated
8 cc/min Max. 20 (*)
limiter operation (with load by
torque converter stall)
Arm in hydraulic relief
1,600 rpm cc/min Max. 190
cc/min Max. 200 Speed:
1,700 rpm
9 Return rate from injector 1,800 rpm cc/min Max. 210
Arm in hydraulic relief Return
rate:
* Although upper limit is 20 cc/min, note that standard value is 0 cc/min (no leakage) in normal condition.
40-194 PC88MR-10
40 Troubleshooting
Failure code [CA689] Engine NE Speed Sensor Error (PC88MR-CA689-400-A-Z0-A)
Action level Failure code Engine NE Speed Sensor Error

Failure
Detail of • Engine Ne speed sensor signal is abnormal.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Bkup speed sensor is also defective).
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
be used to determine whether sensor is normal or not.
Related • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
information for measurement.
• Wheel (W) is mounted inside of crankshaft vibration damper and has holes for speed
sensing. Ne speed sensor detects rotating holes, and both engine speed and phase are
calculated by the engine controller.
harness connector
Defective Ne speed
2 sensor power supply If failure code [CA238] is also displayed, perform troubleshooting for it first.
system
Breakage or improper
installation (loosened) Engine Ne speed sensor may be broken or improperly installed (loose).
3
of engine Ne speed Check it.
sensor
Damage or poor (loose)
mounting of wheel for Check wheel (W) for speed sensing directly as it may be damaged or loosely
4
speed sensing mounted.

Defective Ne speed 2. Disconnect connector NE, and connect T-adapter to female side.
5 sensor power supply 3. Turn starting switch to ON position.
input Power 4.75 to 5.25
Voltage Between NE (female) (1) and (2)
supply input V
2. Disconnect connectors J1 and NE, and connect T-adapters to each female
side.
Open circuit in wiring If no failure is found by check on cause 4, this
harness check is not required. Max. 1 z
6 (wire breakage or Between J1 (female) (36) and NE (female) (1)
connector) Resistance If no failure is found by check on cause 4, this
Between J1 (female) (37) and NE (female) (2)
Between J1 (female) (26) and NE (female) (3) Max. 1 z
2. Disconnect connectors J1 and NE and connect T-adapter to either female
side.
7 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
PC88MR-10 40-195
40 Troubleshooting

harness 2. Disconnect connectors J1 and NE and connect T-adapter to either female
8 side.
Between ground and J1 (female) (26) or NE

Hot short circuit in 2. Disconnect connector NE, and connect T-adapter to female side.
Voltage Between NE (female) (3) and ground Max. 1 V
If no failure is found by above checks, engine Ne speed sensor may be
Defective engine Ne
10 speed sensor defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
11
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
40 Troubleshooting
Failure code [CA691] Intake Air Temperature Sensor High Error (PC88MR-CA691-
400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor High Error
Failure
Detail of • High voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of • Sets intake air temperature to fixed value (25°C) and runs engine.
controller
Problem on
machine
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, this failure code is displayed together with failure
information code [CA357].
harness connector
-30°C 25 to 28 kz
5.5 to 6.1
Defective intake air 0°C
kz
2 temperature sensor Between P55 (male) (3) and (4) 1.9 to 2.1
(internal defect) Resistance a Intake air temperature-Resistance 25°C
kz
characteristics 1.1 to 1.2
40°C
kz
180 to 185
100°C
z
wiring harness
180 z to 28
3 (short circuit, wire Resistance Between J1 (female) (6) and (22)
kz
breakage or defective
contact of connector) a Use Intake air temperature-Resistance characteristics table for check on
cause 2 as resistance criteria.
2. Disconnect connector P55.
Hot short circuit in 3. Insert T-adapter into connector J1, or connect T-adapter to female side of
4 wiring harness connector P55.
Between J1 (6) and (22) or between P55 (female)
Voltage Max. 5.25 V
(4) and (3)
5

6
PC88MR-10 40-197
40 Troubleshooting
Circuit diagram related to intake air temperature sensor
40-198 PC88MR-10
40 Troubleshooting
Failure code [CA692] Intake Air Temperature Sensor Low Error (PC88MR-CA692-
400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor Low Error
Failure
Detail of • Low voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of • Sets intake air temperature to fixed value (25°C) and runs engine.
controller
Problem on
machine
Related • Mass air flow sensor and intake air temperature sensor are integrated.
harness connector
If this failure code changes to failure code [CA691], intake air temperature
• Reference
Defective intake air -30°C 25 to 28 kz
2 temperature sensor
5.5 to 6.1
(internal defect) 0°C
kz
Between P55 (male) (3) and (4) 1.9 to 2.1
25°C
a Intake air temperature-Resistance kz
Resistance characteristics 1.1 to 1.2
40°C
kz
180 to 185
100°C
z
Between P55 (male) (4) and ground Whole
(sensor body) range Min. 1 Mz

wiring harness
180 z to 28
3 (short circuit, wire Resistance Between J1 (female) (6) and (22)
kz
breakage or defective
contact of connector) a Use Intake air temperature-Resistance characteristics table for check on
cause 2 as resistance criteria.
harness 2. Disconnect connectors J1 and P55, and connect T-adapter to either
4 female side.
Between ground and J1 (female) (6) or P55
PC88MR-10 40-199
40 Troubleshooting

5

6
Circuit diagram related to intake air temperature sensor
40-200 PC88MR-10
40 Troubleshooting
Failure code [CA697] Engine Con Internal Temp Sens High Error (PC88MR-
CA697-400-A-Z0-A)
Action level Failure code Engine controller Internal Temperature Sensor High Error
Failure
Detail of • High voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by
Related using monitoring function (Code: 18900(°C)).
1 Improper usage of controller Check if the controller has been used in high temperature environments.
PC88MR-10 40-201
40 Troubleshooting
Failure code [CA698] Engine Con Internal Temp Sens Low Error (PC88MR-CA698-
400-A-Z0-A)
Action level Failure code Engine controller Internal Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by

Related using monitoring function (Code: 18900(°C)).

1 Improper usage of controller Check if the controller has been used in low temperature environments.
40-202 PC88MR-10
40 Troubleshooting
Failure code [CA731] Engine Backup Speed Sensor Phase Error (PC88MR-
CA731-400-A-Z0-A)
Action level Failure code Engine Backup Speed Sensor Phase Error
Failure
Detail of • Phase error occurs between signals of engine Ne speed sensor and engine Bkup speed
failure sensor.
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
• Engine can not start or engine is hard to start.
Problem on • Idle speed is unstable.
machine • Exhaust gas color becomes black.
information
Damaged engine Ne
1 Engine Ne speed sensor may be damaged. Check it.
speed sensor
Damaged engine Bkup
2 Engine Bkup speed sensor may be damaged. Check it.
speed sensor
Improper installation or
damage of speed Wheel (W) on crankshaft side for speed sensing may be mounted incorrectly
3 or damaged. Check it by reading failure code [CA689].
sensing wheel on
crankshaft side
Speed detection ring on camshaft side may be installed improperly or
damaged. Check it according to following procedure.
Improper installation or 1. Rotate crankshaft clockwise when viewed from front to align wide notch
damage of speed (a) of wheel for speed sensing (W) with "1.4 TOP" (b) on cover.
4 2. Remove Bkup speed sensor.
sensing ring on
camshaft side 3. If you can see two slots on camshaft speed sensing ring (B) through
sensor mounting hole (H), ring for speed sensing is mounted correctly .
(Note that the two slots are visible only once in two turns, when #1 piston
comes to the top.)
Defective timing
adjustment of Timings of crankshaft and camshaft may not be matched each other. Check
5
crankshaft and them.
camshaft
Ground terminal may be poorly connected. Check following terminals:
Defective connection of • Ground terminal of machine ((-) terminal of battery)
6 ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
PC88MR-10 40-203
40 Troubleshooting
40-204 PC88MR-10
40 Troubleshooting
Failure code [CA778] Engine Backup Speed Sensor Error (PC88MR-CA778-400-A-Z0-A)
Action level Failure code Engine Backup Speed Sensor Error

Failure
Detail of • Engine Bkup speed (CAM) sensor signal is abnormal.
failure
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
Problem on • Engine startability is poor
machine • Engine output loweres.
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• This speed sensor detects groove in speed sensing ring, which is installed to camshaft, to
measure camshaft speed.
harness connector
2 supply 2 circuit for it first.
Breakage or improper
installation (loosened) Engine Bkup speed (CAM) sensor may be broken or installed improperly
3 of engine Bkup speed (loosened). Check it.
(CAM) sensor
2. Disconnect connector CAM, and connect T-adapter to female side.
Improper power supply 3. Turn starting switch to ON position.
4 input to engine Bkup Power 4.75 to 5.25
speed sensor Between CAM (female) (1) and (2)
supply V
Voltage Between CAM (female) (1) and (2) 4.75 to 5.25
V
harness 2. Disconnect connectors J1 and CAM, and connect T-adapters to each
female side.
5 (wire breakage or Between J1 (female) (60) and CAM (female) (1) Max. 1 z
connector) Resistance Between J1 (female) (59) and CAM (female) (2) Max. 1 z
Between J1 (female) (9) and CAM (female) (3) Max. 1 z
2. Disconnect connectors J1 and CAM, and connect T-adapter to either
female side.
6 Between J1 (female) (9) and (60), or between CAM
harness Min. 1 Mz
(female) (1) and (3)
Resistance
Between J1 (female) (9) and (59), or between CAM

harness 2. Disconnect connectors J1 and CAM, and connect T-adapter to either
7 female side.
Between ground and J1 (female) (9) or CAM Min. 1 Mz
circuit) Resistance (female) (3)
PC88MR-10 40-205
40 Troubleshooting

Hot short circuit in 2. Disconnect connector CAM, and connect T-adapter to female side.
Voltage Between CAM (female) (3) and ground Max. 1 V
Loosened camshaft Remove engine Bkup speed (CAM) sensor, and check ring through hole (H).
9 speed sensing ring a If speed sensing ring (B) is loosened, see "Reference".
If no failure is found by above checks, engine Bkup speed (CAM) sensor is
Defective engine Bkup defective.
10 speed (CAM) sensor
11
Circuit diagram related to engine Bkup speed sensor
• Reference
Check of camshaft ring for looseness
Remove front cover and check camshaft ring for looseness.
a 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
40 Troubleshooting
2. Remove crankshaft pulley (1).

(DP): Dowel pin
3. Remove front cover (2).

4. Remove front seal (3).
5. Check that mounting bolt (4) of camshaft ring (5) is not loosened.
3 Mounting bolt (4):
10 ± 2 Nm {0.98 ± 0.2 kgm}
(DP): Dowel pin
Installation
a See figures shown in removal procedure section.
1. Install front cover (2).
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
40 Troubleshooting
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
40 Troubleshooting
Failure code [CA1117] Engine Controller Partial Data Lost Error (PC88MR-CA1117-
400-A-Z0-A)
Action level Failure code Engine Controller Partial Data Lost Error
Failure
Detail of
• Internal defect occurred in controller.
failure
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on start if it is stopped.
machine • Engine controller cannot store internal data correctly.
Related • This error code is displayed when power supply is disconnected by battery disconnect
information switch, etc. before engine controller is normally exited.
Defective power supply Since the power supply circuit may be defective, carry out troubleshooting for
1 failure code [CA441].
circuit
Improper operation of
2 battery disconnect Battery disconnect switch may have been operated improperly.
switch
Defective engine If no failure is found by above checks, engine controller is defective. (Since
3 this is an internal defect, troubleshooting cannot be performed.)
controller
PC88MR-10 40-209
40 Troubleshooting
Failure code [CA1695] Sensor 5 Supply Voltage High Error (PC88MR-CA1695-400-A-Z0-

A)
Action level Failure code Sensor 5 Supply Voltage High Error

Failure
E03 CA1695 (Engine controller system)
Detail of • High voltage error occurs in sensor power supply 5 (5V) circuit.
failure
controller
Problem on
machine
information
Cause Procedure, measuring location, criteria, and remarks
Perform troubleshooting for failure code [CA1696].
40-210 PC88MR-10
40 Troubleshooting
Failure code [CA1696] Sensor 5 Supply Voltage Low Error (PC88MR-CA1696-400-A-Z0-

A)
Action level Failure code Sensor 5 Supply Voltage Low Error

Failure
Detail of • Low voltage error occurs in sensor power supply 5 (5 V) circuit.
failure
controller
machine
Related • Sensor power supply 5 (pin 52 of connector CE03) is not used.
Defective engine
controller
Voltage Between CE03 (male) (52) and (43) 4.75 to 5.25
V
Circuit diagram related to sensor power supply 5 circuit
PC88MR-10 40-211
40 Troubleshooting
Failure code [CA1843] Crankcase Pressure Sensor High Error (PC88MR-CA1843-

400-A-Z0-A)
Action level Failure code Crankcase Pressure Sensor High Error

Failure
Detail of • High voltage occurs in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approximately 0 kPa) and runs engine.
controller
Problem on
machine
(Code: 48401 (V))
harness connector
2 supply system for [CA187] or [CA227] first.
Defective crankcase 2. Disconnect connector CCV.
3 pressure sensor 3. Turn starting switch to ON position.
(internal defect) If failure code changes from [CA1843] to [CA1842], crankcase pressure
harness 2. Disconnect connectors J1 and CCV, and connect T-adapters to each
connector)
Resistance Between J1 (female) (59) and CCV (female) (2) Max. 1 z
2. Disconnect connectors J1 and CCV, and connect T-adapter to either
5 female side.
harness
Between J1 (female) (3) and (60), or between CCV
Resistance (female) (1) and (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector CCV and connect T-adapter to female side.
Voltage Between CCV (female) (3) and (2) Max 1 V
• Reference
Defective engine 1. Turn starting switch to OFF position.
7
controller 2. Insert T-adapter into connector J1.
Sensor
output
40-212 PC88MR-10
40 Troubleshooting
Circuit diagram related to crankcase pressure sensor
PC88MR-10 40-213
40 Troubleshooting
Failure code [CA1844] Crankcase Pressure Sensor Low Error (PC88MR-CA1844-

400-A-Z0-A)
Action level Failure code Crankcase Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approximately 0 kPa) and runs engine.
controller
Problem on
machine
(Code: 48401(V))
harness connector
for [CA187] or [CA227] first.
Defective sensor power 1. Turn starting switch to OFF position.

2 supply system 2. Disconnect connector CCV and connect T-adapter to female side.
Power 4.75 to 5.25
Voltage Between CCV (female) (1) and (2)
supply V
2. Disconnect connectors J1 and CCV, and connect T-adapters to each
female side.
Open circuit in wiring a If no failure is found by check on cause 2, this
harness Resistance check is not required. Max. 1 z
3 (wire breakage or Between J1 (female) (60) and CCV (female) (1)
connector) a If no failure is found by check on cause 2, this
Resistance check is not required. Max. 1 z
Between J1 (female) (59) and CCV (female) (2)
Resistance Between J1 (female) (3) and CCV (female) (3) Max. 1 z
harness 2. Disconnect connectors J1 and CCV, and connect T-adapter to either
4 female side.
Between ground and J1 (female) (3) or CCV

2. Disconnect connectors J1 and CCV, and connect T-adapter to either
5 female side.
harness
Between J1 (female) (3) and (59), or between CCV
Resistance (female) (2) and (3) Min. 1 Mz

Defective crankcase 2. Insert T-adapter into connector CCV.
6 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
40 Troubleshooting

• Reference
7
controller 2. Insert T-adapter into connector J1.
Sensor
output
Circuit diagram related to crankcase pressure sensor
PC88MR-10 40-215
40 Troubleshooting
Failure code [CA1896] EGR Valve Stuck Error (D37-CA1896-400-A-Z0-A)
Action level Failure code EGR Valve Stuck Error

Failure
Detail of • EGR valve stuck error has occurred (failed to learn zero point)
failure
machine
Related
information
Defective EGR
1 EGR may have mechanical failure. Check it.
mechanical system
Defective engine If no problem is found by above checks, engine controller is defective. (Since
controller
40-216 PC88MR-10
40 Troubleshooting
Failure code [CA1942] Crankcase Pressure Sensor In Range Error (PC88MR-

CA1942-400-A-Z0-A)
Action level Failure code Crankcase Pressure Sensor In Range Error

Failure
Detail of • Output value from crankcase pressure sensor is out of normal range.
failure
controller
Problem on
machine
(Code: 48401 (V))
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
2 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
3 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
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,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
PC88MR-10 40-217
40 Troubleshooting
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error (D37-1961CA-400-A-

Z0-A)
Action level Failure code EGR Motor Driver IC Over Temperature Error
Failure
Detail of • EGR motor driver IC over temperature error occurs in engine controller.
failure
machine
Related
information
Improper use
1 environment of Check whether controller is used in high temperature environment.
controller
Defective engine If no problem is found by above checks, engine controller is defective. (Since
controller
40-218 PC88MR-10
40 Troubleshooting
Failure code [CA2185] Throttle Sensor Supply Voltage High Error (PC88MR-
CA2185-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in throttle sensor power supply (5 V) circuit.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected
Action of with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "General information
connector
If this failure code disappears, wiring harness connector is defective.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2185].
2. Disconnect connectors CE03 and P20, and connect T-adapter to
3 female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than pin CE03 (female) (42)
Hot short circuit in wiring 1. Turn starting switch to OFF position.
4 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between P20 (female) (1) and ground 4.75 to 5.25 V
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
PC88MR-10 40-219
40 Troubleshooting
40-220 PC88MR-10
40 Troubleshooting
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error (PC88MR-
CA2186-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in throttle sensor power supply (5 V) circuit.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected
Action of with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "General information
connector
If this failure code disappears, wiring harness connector is defective.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2186].
Ground fault in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapter to either
3 harness female side.
(contact with ground circuit) Resis- Between ground and CE03 (female) (42) or P20
Min. 1 Mz
tance (female) (1)
2. Disconnect connectors CE03 and P20, and connect T-adapter to
Short circuit in wiring female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than pin CE03 (female) (42)
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
PC88MR-10 40-221
40 Troubleshooting
40-222 PC88MR-10
40 Troubleshooting
Failure code [CA2249] Common Rail Pressure Low Error 2 (PC88MR-CA2249-400-A-Z0-

A)
Action level Failure code Common Rail Pressure Low Error 2

Failure
Detail of • Supply pump does not feed fuel (level 2).
failure
Action of • Limits engine output (limits common rail pressure) and runs engine.
controller
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
Supply pump pressure low Perform troubleshooting for failure code [CA559].
1
error
PC88MR-10 40-223
40 Troubleshooting
Failure code [CA2272] EGR Valve Position Sensor Low Error (PC88MR-CA2272-400-
A-Z0-A)
Action level Failure code EGR Valve Position Sensor Low Error
Failure
Detail of • EGR position error has occurred.
failure
controller • Closes EGR valve and opens variable flow turbocharger fully.
machine
information
harness connector
for it first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector EGR V and connect T-adapter to female side.
Power 4.75 to 5.25
Voltage Between EGR V (female) (1) and (5)
supply V
2. Disconnect connectors EGR V and J2, and connect T-adapters to each
female side.
a If power supply voltage in check on cause 2 is
normal, this check is not required.
Open circuit in wiring Max. 1 z
Between J2 (female) (30) and EGR V (female)
harness (1)
3 (wire breakage or
defective contact of a If power supply voltage in check on cause 2 is
connector) Resistance normal, this check is not required.
Max. 1 z
Between J2 (female) (47) and EGR V (female)
(5)
Between J2 (female) (42) and EGR V (female) (2) Max. 1 z
2. Disconnect connectors J2 and EGR V and connect T-adapter to either
female side.
Between ground and J2 (female) (30) or EGR V
Ground fault in wiring Min. 1 Mz
(female) (1)
harness
4 Between ground and J2 (female) (42) or EGR V
(contact with ground (female) (2) Min. 1 Mz
circuit) Resistance
Between ground and J2 (female) (51) or EGR V Min. 1 Mz
(female) (4)
40-224 PC88MR-10
40 Troubleshooting

female side.
Short circuit in wiring EGR V (female) (2) and (3) Min. 1 Mz
5
harness
Resistance EGR V (female) (2) and (4) Min. 1 Mz
EGR V (female) (3) and (4) Min. 1 Mz
Defective EGR position Sensor inside EGR may be defective.

6
sensor (Since this is an internal defect, troubleshooting cannot be performed.)
7
Circuit diagram related to EGR valve
PC88MR-10 40-225
40 Troubleshooting
Failure code [CA2311] IMV Solenoid Error (D65-CA2311-400-A-Z0-A)
Action level Failure code Defective IMV solenoid

Failure
Detail of • Resistance value of supply pump actuator circuit is unusually high or low. Or rail pressure
failure error.
controller
machine
information
1 Defective IMV solenoid Perform troubleshooting for failure codes [CA271] and [CA272].
2 Rail pressure error Perform troubleshooting for failure code [CA449].
40-226 PC88MR-10
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error (PC88MR-CA2349-
400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Open Circuit Error
Failure
Detail of • Open circuit occurs in EGR valve motor circuit.
failure
machine
information
harness connector
2. Disconnect connector EGR V and connect T-adapter to male side.
Defective EGR valve Between EGR V (male) (6) and (7)
2 1 to 5 z
motor
Resistance Between EGR V (male) (7) and (8) 1 to 5 z
3 Between J2 (female) (3) and (4) 1 to 5 z
wiring harness
Resistance Between J2 (female) (4) and (5) 1 to 5 z
Between J2 (female) (5) and (3) 1 to 5 z
harness 2. Disconnect connectors J2 and EGR V, and connect T-adapters to each
defective contact of Between J2 (female) (3) and EGR V (female) (6) Max. 1 z
connector) Resistance Between J2 (female) (4) and EGR V (female) (7) Max. 1 z
5
PC88MR-10 40-227
40 Troubleshooting
40-228 PC88MR-10
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error (PC88MR-CA2353-
400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Short Circuit Error
Failure
Detail of
• Short circuit occurs in EGR valve motor circuit.
failure
machine
information
harness connector
Defective EGR valve 2. Disconnect connector EGR V and connect T-adapter to male side.
2 motor Between EGR V (male) (6) and (7) 1 to 5 z
(internal open circuit) Resistance Between EGR V (male) (7) and (8) 1 to 5 z
wiring harness
Ground fault in wiring female side.
harness Between ground and J2 (female) (3) or EGR V
4

2. Disconnect connector EGR V.
Hot short circuit in 4. Turn starting switch to OFF position.
5 wiring harness
Between J2 (3) and (47) or ground Max 5.5 V
Voltage Between J2 (4) and (47) or ground Max 5.5 V
6
PC88MR-10 40-229
40 Troubleshooting
40-230 PC88MR-10
40 Troubleshooting
Failure code [CA2357] EGR Valve Servo Error (D37-CA2357-400-A-Z0-A)
Action level Failure code EGR Valve Servo Error

Failure
Detail of • EGR valve servo error occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
Action of • Does not supply current to EGR valve (closes EGR valve).
controller • Fully open variable flow turbocharger.
machine
information
Defective relevant
system
Defective EGR valve
system
3 Defective EGR valve EGR valve may have mechanical trouble. Check it.
Defective engine If no failure is found by checks on causes 1 to 3, engine controller is defective.
4
PC88MR-10 40-231
40 Troubleshooting
Failure code [CA2765] Injector Trim Data Mismatch (PC88MR-CA2765-400-A-Z0-A)
Action level Failure code Injector Trim Data Mismatch

Failure
Detail of • Injector trim data input to to the engine controller is not correct.
failure
Action of
controller
Problem on • Since the engine controller can not know the production variance of each injector, the
machine exhaust gas purification will be degraded.
information
1 Injector trim data mismatch a When replacing injectors, see chapter 30 Testing and adjusting,
"Injector trim".
40-232 PC88MR-10
40 Troubleshooting
Failure code [CA3419] MAF Sensor Supply Voltage High Error (PC88MR-CA3419-
400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage High Error
Failure
Detail of • High voltage occurs in power supply (12 V) circuit of mass air flow sensor.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes same as [CA356] and [CA357].
Action of
controller • Sets mass air flow to fixed value (10 kg/min) and runs engine.
machine
information
1
defective.
Defective mass air flow sensor
2 If this failure code does not appear, MAF sensor is defective.
(internal defect)
3 Defective wiring harness If this failure code does not appear, wiring harness is defective.
4 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
PC88MR-10 40-233
40 Troubleshooting
40-234 PC88MR-10
40 Troubleshooting
Failure code [CA3421] MAF Sensor Supply Voltage Low Error (PC88MR-CA3421-
400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage Low Error
Failure
Detail of • High voltage occurs in power supply (12 V) circuit of mass air flow sensor.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes same as [CA356] and [CA357].
Action of
controller • Sets mass air flow to fixed value (10 kg/min) and runs engine.
machine
information
1
defective.
Defective mass air flow sensor
2 If this failure code does not appear, MAF sensor is defective.
(internal defect)
Defective wiring harness or
3 If this failure code does not appear, wiring harness is defective.
connector
Ground fault in wiring harness 2. Disconnect connectors J1 and P55, and connect T-adapter to either
4 female side.
Resis- Between ground and J1 (female) (21) or P55
tance
2. Disconnect connectors J1 and P55, and connect T-adapter to either
5 Short circuit in wiring harness female side.
Resis- Between J1 (female) (21) and (22), or between
P55 (female) (2) and (3) Min. 1 Mz
tance
6 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
PC88MR-10 40-235
40 Troubleshooting
40-236 PC88MR-10
40 Troubleshooting
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error (D37-CA3724-
400-A-Z0-A)
Action level Failure code EGR/KVGT Motor Driver Power Low Error
Failure
Detail of • Low voltage error occurs in EGR/KVGT (turbocharger) drive power in engine controller.
failure
machine
a "KVGT" in the title of this failure code refers to "variable flow turbocharger" on this
Related machine.
information • Power for GR valve and variable flow turbocharger motor driver are supplied from pin 30
of connector J2.
1
defective.
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
If this failure code is not displayed, disconnected motor or engine wiring
Defective motor or wiring harness is defective.
2
harness a Other failure codes (many codes) are also displayed. They are
codes other than this code [CA3724].
EGR valve motor driver EGR V
Connec- KVGT (turbocharger) motor driver
VFT
tor
Engine harness J2
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
40 Troubleshooting
Circuit diagram related to EGR V and turbocharger motor driver power (5 V)
40-238 PC88MR-10
40 Troubleshooting
Failure code [CA3918] KVGT Stuck Error (D37-CA3918-400-A-Z0-A)
Action level Failure code KVGT Stuck Error

Failure
Detail of • KVGT (urbocharger) stuck error has occurred.
failure (Failed to learn zero point of KVGT (turbocharger).)
machine
Defective KVGT
1 KVGT may have mechanical failure. Check it.
mechanical system
2
PC88MR-10 40-239
40 Troubleshooting
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error (D37-CA3919-400-A-
Z0-A)
Action level Failure code KVGT Motor Driver IC Over Temperature Error
Failure
Detail of • High KVGT (variable flow turbocharger) motor driver IC temperature error occurs in
failure engine controller.
machine
Improper use
1 environment of Check whether controller is used in high temperature environment.
controller
2
40-240 PC88MR-10
40 Troubleshooting
Failure code [CA3921] KVGT Servo Error 2 (D37-CA3921-400-A-Z0-A)
Action level Failure code KVGT Servo Error 2

Failure
Detail of • KVGT (turbocharger) servo error has occurred.
failure (KVGT (turbocharger) does not follow the command value for the KVGT (turbocharger))
machine
Improper use
Perform checks on causes 1 to 4 in troubleshooting for failure code [CA3922]
1 environment of
first.
controller
2 Defective Turbocharger Turbocharger may have mechanical failure. Check it.
3
PC88MR-10 40-241
40 Troubleshooting
Failure code [CA3922] KVGT Motor Driver Open Error (D37-CA3922-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Open Error

Failure
Detail of • Open circuit occurs in KVGT (turbocharger) motor driver.
failure
machine
harness connector
2. Disconnect connector VFT and connect T-adapter to male side.
Defective turbocharger Between VFT (male) (6) and (7)
2 8 to 15 z
motor
Resistance Between VFT (male) (7) and (8) 8 to 15 z
wiring harness

harness 2. Disconnect connectors J2 and VFT, and connect T-adapters to each
female side.
4 (wire breakage or Between J2 (female) (11) and VFT (female) (6) Max. 1 z
connector) Resistance Between J2 (female) (1) and VFT (female) (7) Max. 1 z
5
40-242 PC88MR-10
40 Troubleshooting
PC88MR-10 40-243
40 Troubleshooting
Failure code [CA3923] KVGT Motor Driver Short Error (D37-CA3923-400-A-Z0-A)
Action level Failure code KVGT Motor Driver Short Error

Failure
Detail of • Short circuit occurs in KVGT (turbocharger) motor driver.
failure
machine
harness connector
Defective turbocharger 2. Disconnect connector VFT and connect T-adapter to male side.
2 motor Between VFT (male) (6) and (7) 8 to 15 z
(internal open circuit) Resistance Between VFT (male) (7) and (8) 8 to 15 z
wiring harness
2. Disconnect connectors J2 and VFT.
Ground fault in wiring Between ground and J2 (female) (11) or VFT
harness (female) (6) Min. 1 Mz
4
(contact with ground Between ground and J2 (female) (1) or VFT

2. Disconnect connector VFT.
5 wiring harness
Voltage Between J2 (1) and (47) or ground Max 5.5 V
6
40-244 PC88MR-10
40 Troubleshooting
PC88MR-10 40-245
40 Troubleshooting
Failure code [D110KB] Battery Relay Output Short Circuit (PC88MR-D110KB-400-A-Z0-A)
Action level Failure code Battery Relay Output Short Circuit

Failure
L01 D110KB (Pump controller system)
Detail of • Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
failure
• Stops 24 V output to battery relay primary circuit (coil side).
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Each controller may fail in writing of data into its ROM (non-volatile memory).
machine
• As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
Related be measured at pump controller connector.
information • Method of reproducing failure code: Turn starting switch to ON position, then turn it to
OFF position.
Defective battery relay 1. Turn starting switch to OFF position.
1
(Internal short circuit) Continuity Between terminals R01 and R02 Continuity
2. Turn battery disconnect switch to OFF position (to prevent short
circuit during work).
Ground fault in wiring harness 3. Disconnect terminals R01 and R02, and disconnect connectors D01,
2 H15, and CP02.
(Contact with ground circuit)
Between terminal R02 (BR) and ground Min. 1 Mz
Resis- Between ground and terminal CP02 (female)
tance (108), R02 (harness side), D01 (female) (1) or Min. 1 Mz
(2)
If no failure is found by above checks, pump controller is defective.
• Reference
2. Insert T-adapters into connector D01.
3 Pump controller is defective.
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
40 Troubleshooting
Circuit diagram related to battery relay
PC88MR-10 40-247
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Open or Short (PC88MR-D19JKZ-400-A-Z0-

A)
Action level Failure code Personal Code Relay Open or Short

Failure
L03 D19JKZ (Machine monitor system)
Detail of • Open error or short circuit occurs in primary (coil) circuit of personal code relay.
failure
• None in particular (when open error occurred)
• Stops driving personal code relay (when short circuit occurred).
Action of • If cause of failure disappears, machine becomes normal by itself (when open error
machine occurred).
monitor • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when short circuit occurred).
Problem on
machine
• This failure code is displayed only when engine lock function is enabled.
• Method of reproducing failure code: Turn starting switch to ON position (when open circuit
Related occurred). Failure code cannot be reproduced on the machine (when short circuit
information occurred).
• Troubleshooting for this failure code covers circuits from fuse No. 3 in fuse box F01
through primary (coil) circuit of personal code relay R07 to machine monitor.
Blown No. 3 fuse of If fuse is blown, circuit may have ground fault.
1
fuse box F01
2. Disconnect relay R07, and connect T-adapter to male side.
200 to 600
Resistance Between R07 (male) (1) and (2)
Defective personal z
2 code relay R07 1. Turn starting switch to OFF position.
2. Replace relay R07 with light relay R05.
If this failure code disappears, original personal code relay R07 is defective.
2. Remove fuse No. 3 in fuse box F01.
Open circuit, short 3. Disconnect connectors CM01 and S14, and connect T-adapter to female
3 circuit, or ground fault in side of CM01.
wiring harness 200 to 600
Between F01-3 and CM01 (female) (6)
Resistance z
Between F01-3 or CM01 (female) (6) and ground Min. 1 Mz
Open circuit in wiring 3. Disconnect connector CM01 and relay R07, and connect T-adapters to
4
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
40 Troubleshooting

1.Turn starting switch to OFF position.
2.Remove fuse No. 3 in fuse box F01.
Ground fault in wiring 3.Disconnect connector CM01 and relay R07, and connect T-adapter to
5
harness either female side.
Between F01-3 or R07 (female) (1) and ground Min. 1 Mz
Resistance Between R07 (female) (2) and ground, or between
CM01 (female) (6) and ground Min. 1 Mz

3. Disconnect connectors CM01 and relay R07, and connect T-adapter to
female side of connector CM01.
6 a Check by using multimeter in continuity mode.
harness
No
Between CM01 (female) (6) and each pin other continuity
Continuity
than (6) (No sound
is heard.)
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
PC88MR-10 40-249
40 Troubleshooting
Circuit diagram related to personal code relay
40-250 PC88MR-10
40 Troubleshooting
Failure code [D811MC] KOMTRAX Malfunction (PC88MR-D811MC-400-A-Z0-A)
Action level Failure code KOMTRAX Malfunction

Failure
– D811MC (KOMTRAX system)
Detail of
• KOMTRAX malfunctions.
failure
Action of
controller
Problem on • KOMTRAX system does not operate properly.
machine
information
KOMTRAX is defective.
1 Malfunction of KOMTRAX
PC88MR-10 40-251
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit (PC88MR-D862KA-400-A-Z0-A)
Action level Failure code GPS Antenna Open Circuit

Failure
– D862KA (KOMTRAX system)
Detail of • Open circuit is detected in GPS antenna circuit.
failure
monitor
Problem on • GPS positioning cannot work.
machine
information
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
1
antenna cable (GPS).
Structural illustration
40-252 PC88MR-10
40 Troubleshooting
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) (PC88MR-

D8ALKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (KOMTRAX)

Failure
– D8ALKA (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which KOMTRAX outputs no current to
system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
• Although KOMTRAX is not able to light up system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
Defective fuse No. 16 in a If room lamp lights up, this check is not required.
1
fuse box F01 If fuse is blown, circuit probably has ground fault.
harness 2. Remove fuse No. 16 in fuse box F01.
2 (wire breakage or 3. Disconnect connector CK01 and connect T-adapter to female side.
connector) Resistance Between CK01 (15) and fuse F01-16 Max. 1 z
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective.
3
terminal (Since this is an internal defect, troubleshooting cannot be performed.)
PC88MR-10 40-253
40 Troubleshooting
Circuit diagram related to system operating lamp
40-254 PC88MR-10
40 Troubleshooting
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) (PC88MR-

D8ALKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (KOMTRAX)

Failure
- D8ALKB (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become low level while KOMTRAX outputs current to system
failure operating lamp.
controller
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
Related • Although KOMTRAX is not able to light up system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
Short circuit in wiring 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19. Connect T-
1
harness adapter to female side of connector L19.
Resistance Between L19 (female) (1) and (2) Min. 1 Mz
2
PC88MR-10 40-255
40 Troubleshooting
Failure code [D8AQKR] CAN 2 Defective Communication

(KOMTRAX) (PC88MR-D8AQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (KOMTRAX)
Failure
― D8AQKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize KOMTRAX over CAN communication-2 line
failure (KOMNET/c).
Action of
machine • None
monitor
Problem on
• None
machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• 4 different failure codes, [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR], are used for
defective CAN communication by CAN2, which are detected by machine monitor. When
all of these 4 failure codes are displayed, there may be a ground fault, short circuit, or hot
short in wiring harness (CAN communication circuit). In this case, check whether air
conditioner is operated (ON/OFF and air flow adjustment) from air conditioner operation
Related
screen since air conditioner is also controlled over CAN communication line.
information
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
Defective fusible link 2. Disconnect fusible link F03 and connect T-adapter to female side.
1 Resistance Between F03 (female) (1) and (2) Max. 1 z
F03
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in
2 2. Remove fuse No. 17 in fuse box F01.
fuse box F01
If fuse is blown, circuit probably has ground fault.
Defective power supply Perform troubleshooting for "E-54" of E mode.
3
to KOMTRAX terminal
Defective CAN
Perform checks on causes 4 to 9 in troubleshooting for failure code
4 communication 2
[DB2QKR].
system
5
6
40-256 PC88MR-10
40 Troubleshooting
Circuit diagram related to KOMTRAX
PC88MR-10 40-257
40 Troubleshooting
Failure code [DA20MC] Pump Controller Malfunction (PC400-DA20MC-400-A-Z0-A)
Action level Failure code Pump controller malfunction

Failure
– DA20MC (Pump controller system)
Detail of • Pump controller malfunctions.
failure
Action of
controller
Problem on • Pump controller does not function normally
machine
information
Malfunction of pump Pump controller is defective.
1
40-258 PC88MR-10
40 Troubleshooting
Failure code [DA22KK] Pump Con Solenoid Power Volt Low Error (PC88MR-
DA22KK-400-A-Z0-A)
Action level Failure code Pump Controller Solenoid Power Voltage Low Error
Failure
L03 DA22KK (Pump controller system)
Detail of • Power supply supply voltage of controller for driving solenoids is below 20 V.
failure
• Stops detection of failures (open circuit and short circuit) in all solenoid systems while this
Action of failure code is active.
controller • If cause of failure disappears, machine becomes normal by itself.
• No solenoid valve is energized properly, so machine does not work properly.
Problem on (Work equipment, swing, and travel systems do not work.)
machine • Hydraulic fan does not rotate in reverse direction.
• If failure code [D110KB] is displayed, perform troubleshooting for it first.
Related • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
information be measured at pump controller connector.
Defective fusible link If fusible link F02 is blown, circuit probably has ground fault (see Cause 6).
1
F02
Defective fuse No. 2 in If fuse is blown, circuit probably has ground fault (see Cause 7).
2
fuse box F01
Improper battery
3 2. After measuring voltage, measure it again when starting engine.
voltage
Voltage Between battery (+) and ground 20 to 30 V
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector CP02 and connect T-adapter to female side.
Defective wiring 4. Turn battery disconnect switch to ON position.
4
harness 5. Turn starting switch to ON position.
Between ground and each of CP02 (female) (116),
Voltage 20 to 30 V
(118) and (121)
a fusible link or fuse is blown, replace it in advance.
Open circuit in wiring Between R03 and each of CP02 (female) (116),
5 Resistance (118) and (121) Max. 1 z
harness
a If no failure is found by above checks, this check is not required.
1. Disconnect connector F02 and connect T-adapter to male side
furthermore.
Between F02 (male) (2) and each of CP02 (female)
Max. 1 z
Resistance (116), (118), and (121)
Between F04 (male) (1) and terminal R03 (M) Max. 1 z
PC88MR-10 40-259
40 Troubleshooting

Ground fault in wiring 3. Remove wire from terminal R03.
harness 4. Disconnect connectors F02 and CP02, and connect T-adapters to female
6
(Contact with ground side of CP02 and male side of F02.
circuit) Between ground and CP02 (female)(116), (118),
(121), or F04 (male) (2) Min. 1 Mz
Resistance
Between ground and F02 (male) (1) or terminal
R03 (M) Min. 1 Mz
Pump controller is If no failure is found by above checks, pump controller is defective.

7
defective. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to solenoid power supply
40-260 PC88MR-10
40 Troubleshooting
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error (PC88MR-DA25KP-400-

A-Z0-A)
Action level Failure code 5 V Sensor Power Supply Output 1 Voltage Low
Failure
― DA25KP (Pump controller system)
Detail of • Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
failure
• Stops output of power from 5 V sensor power supply output 1.
• Signal of pressure sensor is not input properly.
• The error code for the pressure sensor is displayed as well.
Problem on • Travel and work equipment speeds are slow.
machine • Automatic travel speed selector function does not work (pump pressure sensor system).
• Auto-decelerator function remains activated or fine control performance of work
equipment is poor.
information
2. Disconnect connectors of the following sensors one by one and turn
starting switch ON each time.
a If this failure code goes out, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear. Ignore all
of displayed failure codes other than this one.
Sensor Connector
Boom LOWER pressure sensor P06
Defective pressure Boom RAISE pressure sensor P03
1 sensor Arm IN pressure sensor P05
(Internal short circuit) Arm OUT pressure sensor P02
Bucket CURL pressure sensor P04
Bucket DUMP pressure sensor P01
Boom swing (right) pressure sensor P07
Boom swing (left) pressure sensor P08
Swing (right) pressure sensor P10
Swing (left) pressure sensor P11
Travel pressure sensor P26
Pump pressure sensor P25
Service pressure sensor (dummy) P49
a To measure voltage before controller stops output of power.
Hot short circuit in 2. Disconnect connectors P01 to 08, P10, P11, P25, P26 and P49.
2 wiring harness 3. Connect T-adapter to female side of connector P04.
4. Turn starting switch ON (with connector disconnected).
Voltage Between P09 (female) (3) and ground 4.5 to 5.5 V
harness 2. Disconnect connectors CP01, P01 to P08, P10, P11, P25, P26 and P49.
3 3. Connect T-adapter to female side of connector CP01.
circuit) Resistance Between CP01 (female) (6) and ground Min. 1 Mz
4
PC88MR-10 40-261
40 Troubleshooting
Circuit diagram related to 5 V sensor power supply 1
40-262 PC88MR-10
40 Troubleshooting
Failure code [DA29KQ] Model Selection Sig Mismatch (Pump Con) (PC88MR-
DA29KQ-400-A-Z0-A)
Action level Failure code Model Selection Signal Mismatch (Pump Controller)
Failure
L01 DA29KQ (Pump controller system)
Detail of • Model code signal for model which is not registered in controller is input.
failure
• Controls machine as default model (PC88MR standard specification machine).
Problem on • No problem appears if machine is PC88MR standard specification machine.
machine
• Pat number of pump controller assembly can be checked with monitoring function.
(Code: 20229)
• Signal status (ON/OFF) of model selection signal can be checked by using monitoring
function.
(Code: 02201)
a Blade specification
Related
information Model selection signal 1: OFF
Model selection signal 2: OFF
Model selection signal 5: ON
2. Disconnect connectors CP01, and connect T-adapter to female side of
CP01.
a Check by using multimeter in continuity mode.
Between CP01 (female) (21) and No continuity
Short circuit in wiring each pin other than (21) (No sound is heard.)
1
harness Between CP01 (female) (40) and No continuity
each pin other than (40) (No sound is heard.)
Continuity
Open circuit in wiring 2. Disconnect connectors CP01, and connect T-adapter to female side of
2
harness 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
3 wrong part number whether it is identical to that listed in Parts book.
PC88MR-10 40-263
40 Troubleshooting
Circuit diagram related to model selection abnormality
40-264 PC88MR-10
40 Troubleshooting
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) (PC88MR-
DA2LKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Pump Controller)
Failure
– DA2LKA (Pump controller system)
• Pump controller determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately (approx.)5 V or below for approximately (approx.)3
failure seconds after starting switch is turned to ON position, during which pump controller
outputs no current to system operating lamp.
controller
Problem on position. If the battery disconnect switch is turned OFF, the data stored in the pump
machine controller memory may be destructed.
• Although work equipment controller is not able to light up system operating lamp, no
Related trouble will result unless battery disconnect switch is turned to OFF position.
1
fuse box F01 If fuse is blown, circuit probably has ground fault.
2 (Wire breakage or 3. Disconnect connector CP02 and connect T-adapter to female side.
connector) Resistance Between CP02 (female) (100) and F01-16 Max. 1 z

3 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19. Connect T-
(Contact with ground adapter to female side of connector CP02.
circuit)
Resistance Between CP02 (female) (100) and ground Min. 1 Mz
4
PC88MR-10 40-265
40 Troubleshooting
40-266 PC88MR-10
40 Troubleshooting
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) (PC88MR-
DA2LKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Pump Controller)
Failure
― DA2LKB (Pump controller system)
• Pump controller determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become Low level while pump controller outputs current to system
controller
Problem on position. If the battery disconnect switch is turned OFF, the data stored in the pump
machine controller memory may be destructed.
Related • Although work equipment controller is not able to light up system operating lamp, no
information trouble will result unless battery disconnect switch is turned to OFF position.
1
harness adapter to female side of connector L19.
2
PC88MR-10 40-267
40 Troubleshooting
Failure code [DA2QKR] CAN 2 Defective Communication (Pump

Con) (PC88MR-DA2QKR-400-A-Z0-A)
Action level Failure code CAN2 Defective Communication (Pump Controller)
Failure
L03 DA2QKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication 2 line
failure (KOMNET/c).
Action of
• Retains information at time of occurrence of failure.
controller
• Information to be obtained from pump controller is not displayed and special functions that
Problem on need information do not work. Or update of received data is stopped (such as failure
machine codes and monitoring codes sent from the pump controller).
switch is received.
conditioner is operated (ON/OFF and air flow adjustment) from air conditioner operation
Related screen since air conditioner is also controlled over CAN communication line.
information • This can be activated even when power supply to pump controller is OFF.
using multimeter.
Defective fusible link 2. Disconnect fusible link F03 and connect T-adapter to female side.
1 Resistance Between F03 (female) (1) and (2) Max. 1 z
F03
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in
fuse box F01
If fuse is blown, circuit probably has ground fault.
Improper power supply 2. Disconnect connector CP01 and connect T-adapter to female side.
3 to pump controller 3. Turn starting switch to ON position.
Voltage
Open circuit in wiring OFF position.
3. Disconnect connectors F03 and CP01, and connect T-adapters to each
Between terminal R04 and F03 (female) (1) Max. 1 z
connector)
Between F03 (female) (2) and F01-16D 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
5 communication 2
[DB2QKR].
system
40-268 PC88MR-10
40 Troubleshooting

6
7
Circuit diagram related to pump controller power supply
PC88MR-10 40-269
40 Troubleshooting
Failure code [DA2RKR] CAN 1 Defective Communication (Pump

Con) (PC88MR-DA2RKR-400-A-Z0-A)
Action level Failure code CAN 1 Defective Communication (Pump Controller)
Failure
L04 DA2RKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication line 1
failure (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains current setting (Hi/Lo) of travel speed.
• Information to be obtained from pump controller is not displayed and special functions that
need information do not work. Or update of received data is stopped.
• Pump control is disabled.
Problem on • Hydraulic oil temperature gauge pointer disappears on machine monitor screen.
machine • Wiper operation is disabled.
• Washer operation is disabled.
• Flow rate of attachment oil pressure line cannot be controlled.
switch is received.
• When the machine monitor detects a CAN communication error in CAN1, failure code
[DB2RKR] becomes active. When failure code [DB2RKR] is displayed simultaneously on
screen, there may be a ground fault, short circuit, or hot short circuit in wiring harness
(CAN communication line).
Related • Terminal resistor of CAN1 on cab side is inside machine monitor, and that on engine side
information is led from J2 while no connector is used. (It is not in CAN communication-1 circuit
(KOMNET/r)).
using multimeter.
• This may occur even when power is not supplied to pump controller.
Defective pump
1 controller power supply
[DA2QKR].
system
Defective CAN
2 communication 1
[DB2RKR].
system
3
4
40-270 PC88MR-10
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality (PC400-DAF0MB-400-A-Z0-A)
Action level Failure code Monitor ROM Abnormality

Failure
– DAF0MB (Machine monitor system)
Detail of • Program of machine monitor is rewritten (program error).
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
1 Defective machine monitor
PC88MR-10 40-271
40 Troubleshooting
Failure code [DAF0MC] Monitor Malfunction (PC88MR-DAF0MC-400-A-Z0-A)
Action level Failure code Monitor Malfunction

Failure
– DAF0MC (Machine monitor system)
Detail of
• Machine monitor malfunctions.
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
40-272 PC88MR-10
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit (PC88MR-DAF8KB-400-A-

Z0-A)
Action level Failure code Camera Power Supply Short Circuit

Failure
L03 DAF8KB (Machine monitor system)
Detail of • Output power supply voltage from machine monitor to camera (rated voltage is 8 V) drops
failure to 6.0 V or less or increases to 10 V or more.
Action of • Stops driving power supply voltage to camera (rated voltage is 8 V).
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • Camera image is not displayed on monitor screen.
machine
information
Defective camera 2. Disconnect camera connector A45, and turn starting switch to ON
1 position.
(internal short circuit)
After disconnecting camera connector and performing failure code
reproducing procedure, if failure code disappears, camera has internal defect.
2. Disconnect connector CM04.
Defective machine 3. Connect T-adapter to male side of connector CM04.
2
monitor 4. Turn starting switch to ON position.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
harness 2. Disconnect connector CM04 and camera connector A45.
3 3. Connect T-adapter to female side of connector CM04.
circuit) Resistance Between CM04 (female) (1) and ground Min. 1 Mz
Hot short circuit in 2. Disconnect camera connector A45.
wiring harness 3. Insert T-adapter into connector CM04.
(contact with 24 V
circuit) (Disconnect camera and check that camera is not defective in advance.)
Voltage Between CM04 (1) and (5) Max. 10 V
Circuit diagram related to camera power supply
PC88MR-10 40-273
40 Troubleshooting
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor) (PC88MR-

DAF9KQ-400-A-Z0-A)
Action level Failure code Model Selection Signal Mismatch (Monitor)

Failure
L03 DAF9KQ (Machine monitor system)
Detail of • Machine model registered in machine monitor and pump controller differs.
failure (Machine monitor or pump controller of wrong part number is installed for replacement.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Signal status (ON/OFF) of model selection signal can be checked by using monitoring
function (Code: 02201).
Related Model selection signal 3: OFF
information Model selection signal 4: OFF
Model selection signal 5: ON
• Assembly part No. of pump controller program can be checked with monitoring function.
(Code: 20229)
• Assembly part No. of machine monitor program can be checked with monitoring function.
(Code: 20227)
1. Use monitoring function to display assembly part number and check
Defective machine whether it is identical to that listed in Parts book.
monitor
(Wrong machine model is programmed.)
1. Use monitoring function to display assembly part number and check
Pump controller is whether it is identical to that listed in Parts book.
2 Pump controller is defective.
defective.
(Wrong machine model is programmed.)
40-274 PC88MR-10
40 Troubleshooting
Failure code [DAFGMC] GPS Module Malfunction (PC88MR-DAFGMC-400-A-Z0-A)
Action level Failure code GPS Module Malfunction

Failure
– DAFGMC (KOMTRAX system in machine monitor)
Detail of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX
failure communication modem in 50 seconds after KOMTRAX started.
monitor
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (wait at least 50
information seconds after starting switch is turned to ON position).
GPS module in machine monitor may be defective.
PC88MR-10 40-275
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) (PC88MR-DAFLKA-

400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Monitor)

Failure
― DAFLKA (Machine monitor system)
• Machine monitor determines that system operating lamp circuit is open because voltage
Detail of of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which machine monitor outputs no current
to system operating lamp.
controller
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine machine monitor terminal memory.
• Although machine monitor is not able to light system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
1
fuse box F01. If fuse is blown, circuit probably has ground fault.
2 (wire breakage or 3. Disconnect connector CM01, and connect T-adapter to female side.
connector) Resistance Between CM01 (female) (8) and F01-16 Max. 1 z
3
40-276 PC88MR-10
40 Troubleshooting
PC88MR-10 40-277
40 Troubleshooting
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) (PC88MR-

DAFLKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Monitor)

Failure
― DAFLKB (Machine monitor system)
• Machine monitor determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become low level while machine monitor outputs current to system
controller
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine machine monitor terminal memory.
Related • Although machine monitor is not able to light system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
1
harness adapters to female side of connector L19.
2
40-278 PC88MR-10
40 Troubleshooting
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) (PC88MR-

DAFQKR-400-A-Z0-A)
Action code Failure code CAN 2 Defective Communication (Monitor)

Failure
- DAFQKR (KOMTRAX system)
Detail of • KOMTRAX terminal does not recognize machine monitor through CAN communication 2
failure line.
Action of
controller
Problem on • System may not function normally.
machine
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
Related not displayed on machine monitor and it can be observed only through KOMTRAX
information system.
using multimeter.
Defective power supply Perform troubleshooting for "E-4" in E mode troubleshooting.
1
to machine monitor
Defective CAN Perform checks on causes 4 and after in troubleshooting for failure code
2 [DB2QKR]
communication
PC88MR-10 40-279
40 Troubleshooting
Failure code [DAZ9KQ] Model Selection Sig Mismatch (A/C) (PC88MR-DAZ9KQ-400-A-

Z0-A)
Action level Failure code Model Selection Signal Mismatch (Aircon)

Failure
― DAZ9KQ (Machine monitor system)
• Machine model in machine monitor program differs from that in air conditioner controller
Detail of program.
failure (Replaced machine monitor or air conditioner controller has wrong part No.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Signal states (ON/OFF) of model selection signal can be checked by using monitoring
function (Code: 02201).
Related Model selection signal 4: OFF
information Model selection signal 5: ON
• Model code specified by air conditioner controller program cannot be checked with
monitoring function.
• Air conditioner control data of machine monitor (machine model and series) can be
checked with monitoring function. (Code: 55200)
• Air conditioner control data (machine model and product series) stored in air conditioner
controller can be checked with monitoring function. (Code: 55201) (It is normal if control
data is "01" (which means PC).)
Defective machine Defective machine monitor
1
monitor (Wrong machine model is programmed.)
Defective air conditioner Defective air conditioner controller
2
controller (Wrong machine model is programmed.)
40-280 PC88MR-10
40 Troubleshooting
Failure code [DAZQKR] CAN2 Defective Communication (A/C ECU) (PC88MR-

DAZQKR-400-A-Z0-A)
Action level Failure code CAN2 Defective Communication (Air Conditioner ECU)
Failure
L01 DAZQKR (Detected by machine monitor) (Machine monitor system)
Detail of • In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air
failure conditioner controller.
Action of
controller
• Function to collect information from engine controller does not work.
Problem on (Failure codes and monitoring codes that are sent by engine controller)
machine • Air conditioner cannot be operated (air does not blow out).
• Display of air conditioner operation screen of machine monitor is not correct.
switch is received.
• Four different failure codes, [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR], are used
for defective CAN communication by CAN2, which are detected by machine monitor.
Related When all of these four failure codes are displayed, there may be a ground fault, short
information circuit, or hot short in wiring harness (CAN communication circuit).
using multimeter.
1 to air conditioner a Perform troubleshooting shown in Chapter 80 "Troubleshooting of power
controller supply system".
Defective CAN 1. Turn starting switch to OFF position.

terminating resistor 2. Disconnect connectors CM02 and K02, and connect T-adapters to each
2 male side.
(internal open or short Between K02 (male) (A) and (B) 120 ± 12 z
circuit) Resistance
Between CM02 (male) (7) and (9) 120 ± 12 z
• CAN communication line
a CAN terminating resistor of 120 z is also located in machine monitor. That
is, 2 CAN terminating resistors of 120 z are connected in parallel. When
circuit resistance is measured at connector of controller other than
machine monitor, if combined resistance is 60 z, wiring harness does not
have open circuit.
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Disconnect related connectors and connect T-adapters to connectors to
be measured.
a If short circuit is found (resistance between 2 terminals is 1 z or below),
disconnect all CAN communication connectors of every controller and
Open or short circuit in check whether short circuit occurs between wiring harnesses or inside
3 wiring harness controller.
Between CM02 (female) (8) and (9) Approx. 120
z
Between CE03 (female) (17) and (18) Approx. 60
z
Between CP01 (female) (45) and (64) Approx. 60
z
Resistance Between AC01 (female) (9) and (10) Approx. 60
z
Between CK01 (female) (10) and (11) Approx. 60
z
Approx. 120
Between K02 (female) (A) and (B) z
PC88MR-10 40-281
40 Troubleshooting

• ACC signal of starting switch (start of CAN communication is not
recognized)
OFF position.
2. Disconnect connectors to be measured and insert T-adapters into them.
3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Between CM01 (10) and (3) 20 to 30 V
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
OFF position.
Open circuit in wiring 2. Disconnect related connectors and connect T-adapters to female side of
harness connectors to be measured.
4 (wire breakage or Between CM02 (female) (8) and CP01 (female)
(45) Max. 1 z
connector) Between CM02 (female) (9) and CP01 (female)
(64) Max. 1 z
Between CM02 (female) (8) and CE03 (female)
(17) Max. 1 z
Between CM02 (female) (9) and CE03 (female)
(18) Max. 1 z
Resistance Between CM02 (female) (8) and AC01 (female) (9) Max. 1 z
Between CM02 (female) (9) and AC01 (female)
(10) Max. 1 z
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
Between CE03 (female) (18) and K02 (female) (B) Max. 1 z
a If no failure (open circuit) is found by check on cause 3, measure
resistance at any one place in each case.
Ground fault in wiring OFF position.
harness 2. Disconnect related connectors and connect T-adapters to female side of
5
(contact with ground connectors to be measured.
circuit) Between ground and any point in CP01 (female)
(45), CM02 (female) (7), (8) or CE03 (female) (17) Min. 1 Mz
Resistance
Between ground and any point in CP01 (female)
(64), CM02 (female) (9) or CE03 (female) (18) Min. 1 Mz
a If no failure (open circuit) is found by check on cause 3, measure voltage

at any one place in each case.
OFF position.
Open circuit or hot short 2. Insert T-adapters into connectors to be measured.
circuit in wiring harness 3. Turn battery disconnect switch to ON position.
(contact with 24 V
circuit) a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
so regard wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and either of CM02 (8), CP01
(45), CK01 (10), AC01 (2) and CE03 (17). 1 to 4 V
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
40 Troubleshooting

• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR]
are displayed.
a To identify defective controller, repeat following steps 1. to 3. to disconnect
controllers one by one from CAN communication line.
Defective engine 1. Turn starting switch to OFF position, and set battery disconnect switch to
controller, pump OFF position.
7 controller, air 2. Disconnect CAN communication connector of engine controller (connector
conditioner unit, or CE03), pump controller (connector CP01), air conditioner unit (connector
KOMTRAX terminal AC01), and KOMTRAX terminal (connector CK01) one by one in turn.
3. Turn battery disconnect switch to ON position, turn starting switch to ON
position, then perform troubleshooting.
4. Return to step 1 to check next connector.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
Defective air conditioner If no failure is found by above checks, air conditioner controller is defective.
8
9
10
PC88MR-10 40-283
40 Troubleshooting
Circuit diagram related to CAN communication line 2
40-284 PC88MR-10
40 Troubleshooting
Failure code [DB2QKR] CAN2 Defective Communication (Engine

Con) (PC88MR-DB2QKR-400-A-Z0-A)
Action level Failure code CAN2 Defective Communication (Engine Controller)
Failure
L03 DB2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor cannot recognize engine controller over CAN communication-2 line
failure (KOMNET/c).
Action of
controller
• Information to be obtained from engine controller is not displayed and special functions
Problem on that need information do not work. Or update of received data is stopped.
machine (Failure codes and monitoring codes that are sent by engine controller)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
Related conditioner is operated (ON/OFF and air flow adjustment) from air conditioner operation
information screen since air conditioner is also controlled over CAN communication line.
using multimeter.
Defective fuse No. 15 or 1. Turn starting switch to OFF position.

1 2. Remove fuses No. 15 and No. 18 from fuse box F01.
No. 18 in fuse box F01
• When fuse is blown, engine controller may have internal short circuit.
a If fuse is not blown, this check is not required.
2 2. Disconnect connector CE03 and connect T-adapter to male side.
controller
Between CE03 (male) (1) and (21) Min. 10 z
Resistance
Between CE03 (male) (11) and (31) Min. 10 z
2. Disconnect connector CE03, and connect T-adapter to female side.
Defective power supply 3. Turn starting switch to ON position.
3 to engine controller
a If any trouble is found, perform troubleshooting for failure code [CA441].
Voltage
Defective CAN 2. Disconnect connectors CM02 and K02, and connect T-adapters to each
terminating resistor male side.
4
(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
40 Troubleshooting

have open circuit.
OFF position.
2. Disconnect related connectors and connect T-adapters to connectors to be
measured.
Open or short circuit in disconnect all CAN communication connectors of every controller and
5 wiring harness check whether short circuit occurs between wiring harnesses or inside
controller.
z
Between CE03 (female) (17) and (18) Approx. 60
z
Between CP01 (female) (45) and (64) Approx. 60
z
Resistance
Between AC01 (female) (9) and (10) Approx. 60
z
Between CK01 (female) (10) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx. 120
z
recognized)
OFF position.
2. Disconnect connectors to be measured and insert T-adapters into them.
ON position.
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
harness 1. Turn starting switch to OFF position, and set battery disconnect switch to
6 (wire breakage or OFF position.
defective contact of 2. Disconnect related connectors and connect T-adapters to female side of
connector) connectors to be measured.
Between CM02 (female) (8) and CP01 (female) (45) Max. 1 z
Between CM02 (female) (8) and CE03 (female) (17) Max. 1 z
Between CM02 (female) (9) and CE03 (female) (18) Max. 1 z
Between CM02 (female) (8) and AC01 (female) (9) Max. 1 z
Resistance Between CM02 (female) (9) and AC01 (female) (10) Max. 1 z
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
Between CE03 (female) (18) and K02 (female) (B) Max. 1 z
40-286 PC88MR-10
40 Troubleshooting

a If no failure (open circuit) is found by check on cause 5, measure
resistance at any one place in each case.
Ground fault in wiring OFF position.
harness 2. Disconnect related connectors and connect T-adapters to female side of
7
(contact with ground connectors to be measured.
circuit) Between ground and any of CP01 (female) (45),
CM02 (female) (7), (8) and CE03 (female) (17) Min. 1 Mz
Resistance
Between ground and any of CP01 (female) (64),
CM02 (female) (9) and CE03 (female) (18) Min. 1 Mz
a If no failure (open circuit) is found by check on cause 5, measure voltage at

any one place in each case.
OFF position.
Open circuit or hot short 2. Insert T-adapters into connectors to be measured.
circuit in wiring harness 3. Turn battery disconnect switch to ON position.
(contact with 24 V
circuit) a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
Between ground and any of CM02 (8), CP01 (45),
CK01 (10), AC01 (2) and CE03 (17) 1 to 4 V
Voltage
Between ground and any of CM02 (9), CP01 (64),
CK01 (11), AC01 (1) and CE03 (18) 1 to 4 V
• If all 4 failure codes [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR] are
displayed
a To identify defective controller, repeat following steps 1. to 3. to disconnect
controllers one by one from CAN communication line .
Defective engine 1. Turn starting switch to OFF position, and set battery disconnect switch to
controller, pump OFF position.
9 controller, air 2. Disconnect CAN communication connector of engine controller (connector
conditioner unit, or CE03), pump controller (connector CP01), air conditioner unit (connector
KOMTRAX terminal AC01), and KOMTRAX terminal (connector CK01) one by one in turn.
3. Turn battery disconnect switch to ON position, turn starting switch to ON
position, then perform troubleshooting.
4. Return to step 1 to check next connector.
Has the number of displayed failure codes If YES, disconnected
decreased from 4? controller is defective.
10
11
PC88MR-10 40-287
40 Troubleshooting
40-288 PC88MR-10
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Failure code [DB2RKR] CAN1 Defective Communication (Engine

Con) (PC88MR-DB2RKR-400-A-Z0-A)
Action level Failure code CAN1 Defective Communication (Engine Controller)
Failure
L04 DB2RKR (Detected by machine monitor.) (Machine monitor system)
Detail of • Machine monitor does not recognize engine controller over CAN communication-1 line
failure (KOMNET/r).
• Retains current working mode.
Action of
• Retains current selection of auto-deceleration.
controller
• Information to be obtained from engine controller is not displayed and special functions
that need information do not work. Or update of received data is stopped.
Problem on • Engine cannot be controlled.
machine • Engine speed and coolant temperature cannot be detected.
• Engine coolant and hydraulic oil temperature gauge pointers disappear on machine
monitor screen.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller is probably defective (cause
1).
• Machine monitor uses failure code [DA2RKR] to indicate failure in CAN communication
over CAN 1 line. When failure code [DA2RKR] is displayed simultaneously on screen,
Related there may be a ground fault, short circuit, or hot short circuit in wiring harness (CAN
information communication line).
• Terminating resistor of CAN1 on cab side is inside machine monitor, and that on engine
side is led from J2 while no connector is used (not in CAN communication-1 line
(KOMNET/r)).
using multimeter.
Defective engine Perform checks on causes 1 to 3 in troubleshooting for failure code
1 controller system [DB2QKR].
Defective CAN 1. Turn starting switch to OFF position.

terminating resistor 2. Disconnect connectors CM02 and J2, and connect T-adapters to male side
2 of CM02 and female side of J2.
(internal open or short Between J2 (female) (24) and (25) 120 ± 12 z
circuit) Resistance
Between CM02 (male) (10) and (12) 120 ± 12 z
have open circuit.
OFF position.
2. Disconnect connectors CM02, CP01, J1, and J2 one by one, and connect
Open or short circuit in T-adapters to female side of each connector.
3 wiring harness
disconnect all CAN communication connectors of every controller and
check whether short circuit occurs between wiring harnesses or inside
controller.
z
Approx. 60
Resistance Between CP01 (female) (7) and (26)
z
Between J1 (female) (8) and (18) Approx. 120
z
PC88MR-10 40-289
40 Troubleshooting

recognized)
OFF position.
2. Disconnect connectors CM01, CP01, CE03 and insert T-adapters.
ON position.
Open circuit in wiring Voltage Between CE03 (3) and (21) 20 to 30 V
harness Between CP01 (2) and each of (24), (43), and (80) 20 to 30 V
4 (wire breakage or
defective contact of a If no failure is found by check on cause 3, this check is not required.
connector) 1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors CM02, CP01, J1 and J2, and connect T-adapters
to each female side.
Between CM02 (female) (12) and CP01 (female)
Max. 1 z
Resistance (26)
Between CM02 (female) (11) and J1 (female) (8) Max. 1 z
Between CM02 (female) (12) and J1 (female) (18) Max. 1 z
OFF position.
2. Disconnect connectors CM02, CP01, J1 and J2, and connect T-adapter to
Ground fault in wiring female side of any one.
harness Between ground and any one of CP01 (female) (7),
5 CM02 (female) (10), (11), or J1 (female) (8) Min. 1 Mz
circuit) Between J2 (female) (24) and ground Min. 1 Mz
Resistance
Between ground and any one of CP01 (female)
(26), CM02 (female) (12), or J1 (female) (18) Min. 1 Mz
a If no failure (open circuit) is found by check on cause 3, measure voltage at
any one place in each case.
OFF position.
2. Disconnect either of connectors CM02 and CP01, and connect T-adapter
to female side of connector disconnected.
Open circuit or hot short 3. Turn battery disconnect switch to ON position.
circuit in wiring harness 4. Turn starting switch to ON position.
6
(contact with 24 V
circuit) a Do not take measurements at J1 or J2.
a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
Between ground and any one of CP01 (female) (7),
CM02 (female) (10), (11) 1 to 4 V
Voltage
Between ground and either of CP01 (female) (26)
and CM02 (female) (12) 1 to 4 V
• If failure code [DA2RKR] is also displayed.
a Disconnect pump controller and engine controller one by one from CAN
communication line to determine which controller is defective.
Pump controller is OFF position.
7
defective. 2. Disconnect pump controller (connector CP01).
ON position.
Does either or both of failure codes [DA2RKR] and If YES, pump controller is
[DB2RKR] disappear? defective.
40-290 PC88MR-10
40 Troubleshooting

• If failure code [DA2RKR] is also displayed.
a Disconnect pump controller and engine controller one by one from CAN
communication line to determine which controller is defective.
Defective engine OFF position.
8
controller 2. Disconnect engine controller (connector J1).
ON position.
Does either or both of failure codes [DA2RKR] and If YES, engine controller
[DB2RKR] disappear? is defective.
9
10
PC88MR-10 40-291
40 Troubleshooting
40-292 PC88MR-10
40 Troubleshooting
Failure code [DDNRKA] WE Lever Lock SW Open Circuit (PC88MR-DDNRKA-400-A-Z0-A)
Action level Failure code Work Equipment Lever Lock Switch Open Circuit
Failure
L03 DDNRKA (Pump controller system)
• No current flows on the PPC lock lever relay side when the PPC lock lever is in RELEASE
Details of position, so the open circuit is detected.
failure • No current flows on the controller side when the PPC lock lever is in LOCK position, so
the open circuit is detected.
Action of • None in particular (Lock lever automatic lock control may operate wrongly.)
Problem on • Starting motor does not start.
machine • All work equipment, swing, and travel are not operated.
• Condition of lock lever can be checked with monitoring function.
information • Method of reproducing failure code: Turn starting switch to ON position and operate work
equipment lock lever or release it.
Defective fuse No. 3 in If fuse No.3 in fuse box F01 is blown, circuit probably has ground fault.
1
fuse box F01
Defective work 1. Turn starting switch to OFF position.
equipment control lever 2. Disconnect connector S14 and connect T-adapter to female side.
2 lock switch LOCK Min 1 Mz
(Internal open circuit) Resistance Between S14 (female) (1) and (2)
FREE Max. 1 z
3. Disconnect connectors CP01 and S14, and connect T-adapters to female
Open circuit in wiring side of CP01 and male side of S14.
3
harness Between S14 (male) (79) and F01–3 Max. 1 z
Resistance Between CP01 (female) (79) and S14 (male) (3) Max. 1 z
Between CP01 (female) (78) and S14 (male) (2) Max. 1 z
4
PC88MR-10 40-293
40 Troubleshooting
Circuit diagram related to work equipment lever lock switch
40-294 PC88MR-10
40 Troubleshooting
Failure code [DDNRKY] WE Lever Lock SW Short Circuit (PC88MR-DDNRKY-400-A-Z0-A)
Action level Failure code Work Equipment Lever Lock Switch Short Circuit
Failure
L03 DDNRKY (Pump controller system)
• Signal voltage of circuit on controller side is 5.2 V or higher when PPC lock lever is in
Details of RELEASE position.
failure • Signal voltage of circuit on PPC lock lever relay side is 5.2 V or higher when PPC lock
lever is in LOCK position.
Action of • Stops PPC lock relay output.
Problem on • All work equipment, swing, and travel are not operated.
machine
• Condition of lock lever can be checked with monitoring function.
information • Method of reproducing failure code: Turn starting switch to ON position and operate work
equipment lock lever or release it.
Defective work 1. Turn starting switch to OFF position.
equipment lock lever 2. Disconnect connector S14 and connect T-adapter to female side.
1 switch LOCK Min 1 Mz
(internal short circuit) Resistance Between S14 (female) (1) and (2)
FREE Max. 1 z
2. Disconnect connector S14, and connect T-adapter to male side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness
Between S14 (male) (2) and ground Max. 1 V
Voltage
Between S14 (male) (3) and ground Max. 1 V
3
PC88MR-10 40-295
40 Troubleshooting
40-296 PC88MR-10
40 Troubleshooting
Failure code [DDNS00] Lock Lever Auto Lock Release SW On (PC88MR-DDNS00-

400-A-Z0-A)
Action level Failure code Lock Lever Automatic Lock Release Switch On
Failure
— DDNS00 (Pump controller system)
Details of • Lock lever automatic lock release switch operation is detected when lock lever is
failure released.
controller • Lock lever automatic lock does not operate.
Problem on • Lock lever automatic lock function does not operate.
machine • Automatic lock release switch monitor is displayed in red on machine monitor.
Related • Method of reproducing failure code: Turn starting switch to ON position and set PPC lock
information lever to FREE position.
Lock lever automatic If lock lever automatic lock function operates normally, turn lock lever
1
lock cancel switch ON automatic lock release switch OFF.
Hot short circuit in 2. Disconnect connector S25, and connect T-adapter to female side.
Voltage Between S25 (female) (7) and ground Max. 1 V
3
PC88MR-10 40-297
40 Troubleshooting
40-298 PC88MR-10
40 Troubleshooting
Failure code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault (PC88MR-
DGH2KB-400-A-Z0-A)
Action level Failure code Hydraulic Oil Temperature Sensor Ground Fault
Failure
L01 DGH2KB (Pump controller system)
Detail of • Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so pump controller
failure determines that circuit shorts.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • Hydraulic oil temperature gauge indicates 50°C.
machine
• Signal voltage from hydraulic oil temperature sensor can be checked with monitoring
function.
(Code: 04402)
Related
information k Loosen the oil filler cap of the hydraulic tank to release the pressure in the
hydraulic tank. For details, see Testing and adjusting "Releasing remaining
pressure in hydraulic circuit" when checking and replacing hydraulic oil
temperature sensor. With monitoring function (Code: 04401), check that hydraulic
oil temperature is 40°C or lower and cool enough not to burn.
Approx. 90
10°C
Defective hydraulic oil kz
temperature sensor Between P22 (male) (1) and (2) Approx. 35
1 30°C
(Internal open or short a Temperature-resistance kz
circuit) Resistance characteristics of oil temperature Approx. 6.5
80°C
sensor kz
Approx. 3.7
100°C
kz
Between P22 (male) (2) and ground Min. 1 Mz
2. Disconnect connector P22 and connect T-adapter to female side.
Open circuit, short
a If voltage is 0 V, wiring harness has open circuit, ground fault, or short
2 circuit, or ground fault in
circuit, and if voltage is 24 V, wiring harness has hot short circuit.
wiring harness
a Voltage of approx. 5 V is applied to temperature sensor signal circuits
through resistance in pump controller.
Voltage Between P22 (female) (1) and (2) Approx. 5 V
a Use Temperature-Resistance characteristics table for troubleshooting on
Short circuit or ground cause 1 as resistance criteria.
3 fault in wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Between CP01 (female) (28) and (46) 3.5 to 90 kz
Resistance
Between CP01 (female) (28) and ground Min. 1 Mz
harness
4 2. Disconnect connectors CP01 and P22, and connect T-adapter to either
(Contact with ground female side.
circuit) Between ground and CP01 (female) (28) or P22
Resistance (female) (2) Min. 1 Mz
Pump controller is If cause is not found by above checks, pump controller is defective.
5
PC88MR-10 40-299
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-300 PC88MR-10
40 Troubleshooting
Failure code [DHPAMA] Front Pump Press Sens Defective

Function (PC88MR-DHPAMA-400-A-Z0-A)
Action level Failure code Front Pump Pressure Sensor Defective Function
Failure
L01 DHPAMA (Pump controller system)
Detail of • Signal voltage of pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls pump taking pump pressure to be 0 MPa {0 kg/cm2}.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely,
pressure sensor will break. Accordingly, take extreme care when checking.
be measured at pump controller connector.
• Pump pressure can be checked by using monitoring function.
information • Method of reproducing failure code: Turn starting switch to ON position or start engine.
k Loosen the oil filler cap of the hydraulic tank to release the pressure in the
hydraulic tank. For details, see Testing and adjusting "Releasing remaining
pressure in hydraulic circuit" when checking and replacing oil pressure sensor.
With monitoring function (Code: 04401), check that hydraulic oil temperature is 40°
C or lower and cool enough not to burn.
If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
Defective 5 V sensor 3. Turn starting switch to ON position.
1 power supply 1 system
a If power supply voltage is abnormal, proceed to check on cause 3.
Power
Voltage Between P25 (female) (3) and (1) 4.5 to 5.5 V
supply
Sensor
Voltage Between P25 (2) and (1) 0.5 to 4.5 V
output
a If power supply voltage is normal and sensor output voltage is abnormal, it
is difficult to judge whether cause of failure is defective sensor, ground
Defective pump fault or hot short circuit in wiring harness. Check as below.
2 pressure sensor
(internal defect) 1. Turn starting switch to OFF position.
2. Replace connector P25 with connector P49 of other service pressure
sensor.
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
a After finishing test, restore connectors.
PC88MR-10 40-301
40 Troubleshooting

2. Disconnect connectors CP01 and P25, and connect T-adapters to each
female side.
harness a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
3 (Wire breakage or Between CP01 (female) (18) and P25 (female) (1)
connector) Resistance Between CP01 (female) (11) and P25 (female) (2) Max. 1 z
a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
Between CP01 (female) (6) and P25 (female) (3)
harness 2. Disconnect connectors C01 and P25, and connect T-adapter to either
4 female side.
(Contact with ground
Between ground and CP01 (female) (11) or P25

Hot short circuit in
5 3. Connect T-adapter to female side of connector P25.
wiring harness
Voltage Between P25 (female) (2) and ground Max. 1 V
6
Circuit diagram related to pump pressure sensor
40-302 PC88MR-10
40 Troubleshooting
Failure code [DHS3MA] Arm IN PPC Press Sensor Def Function (PC88MR-
DHS3MA-400-A-Z0-A)
Action level Failure code Arm IN PPC Pressure Sensor Defective Function
Failure
L01 DHS3MA (Pump controller system)
Detail of • Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Sets arm IN PPC pressure to 0 MPa {0 kg/cm2 }.
Problem on • Automatic deceleration does not cancel.
machine • Controllability of arm IN deteriorates.
pressure sensor will be broken. Accordingly, take extreme care when checking.
• Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
If failure code [DA25KP] is also displayed, perform troubleshooting for it
first.
Defective 5V sensor power 2. Disconnect connector P05 and connect T-adapters to female side.
1 supply 1 system 3. Turn starting switch to ON position.
Power 4.5 to 5.5
supply V
2. Insert T-adapters into connector P05.
Sensor 0.5 to 4.5
Voltage Between P05 (2) and (1)
output V
a If power supply voltage is normal and sensor output voltage is
abnormal, it is difficult to judge whether cause of failure is defective
Defective arm IN PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor (internal below.
defect)
2. Replace connector P05 with connector of other PPC pressure
sensor.
4. If E mark is not displayed again for this failure code, arm IN PPC
pressure sensor is defective.
PC88MR-10 40-303
40 Troubleshooting

2. Disconnect connectors CP01 and P05, and connect T-adapters to
each female side.
a If power supply voltage measured in check
on cause 1 is normal, this check is not
required. Max. 1 z
Open circuit in wiring harness Between CP01 (female) (18) and P05 (female)
3 (wire breakage or defective (1)
contact of connector) Resis- Between CP01 (female) (14) and P05 (female)
(2) Max. 1 z
tance
required. Max. 1 z
Between CP01 (female) (6) and P05 (female)
(3)
Ground fault in wiring harness 2. Disconnect connectors CP01 and P05, and connect T-adapter to
Resis- Between ground and CP01 (female) (14) or
P05 (female) (2) Min. 1 Mz
tance
Hot short circuit in wiring 2. Disconnect connector P05.
5 harness 3. Connect T-adapters to female side of connector P05.
(contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
6 Defective pump controller
Circuit diagram related to arm IN PPC pressure sensor
40-304 PC88MR-10
40 Troubleshooting
Failure code [DHS4MA] Bucket CURL PPC Press Sens Def

Function (PC88MR-DHS4MA-400-A-Z0-A)
Action level Failure code Bucket CURL PPC Pressure Sensor Defective Function
Failure
Detail of • Signal voltage of Bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5
failure V.
Action of • Sets Bucket CURL PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of Bucket CURL deteriorates.
• Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective Bucket CURL PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, Bucket CURL
PPC pressure sensor is defective.
PC88MR-10 40-305
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Circuit diagram related to Bucket CURL PPC pressure sensor
40-306 PC88MR-10
40 Troubleshooting
Failure code [DHS5MA] Travel PPC Sensor Abnormality (PC88MR-DHS5MA-400-A-Z0-A)
Action level Failure code Travel PPC Sensor Abnormality

Failure
Detail of • Signal voltage of Travel PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Sets Travel PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of Travel deteriorates.
• Travel PPC pressure can be checked with monitoring function.
(Code: 07102 Travel PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective Travel PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, Travel PPC
PC88MR-10 40-307
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
Circuit diagram related to Travel PPC pressure sensor
40-308 PC88MR-10
40 Troubleshooting
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function (PC88MR-
DHS8MA-400-A-Z0-A)
Action level Failure code Boom Raise PPC Pressure Sensor Defective Function
Failure
Detail of • Signal voltage of Boom Raise PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Sets Boom Raise PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of Boom Raise deteriorates.
• Boom Raise PPC pressure can be checked with monitoring function.
(Code: 07400 Boom Raise PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective Boom Raise PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, Boom Raise
PC88MR-10 40-309
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
Circuit diagram related to Boom Raise PPC pressure sensor
40-310 PC88MR-10
40 Troubleshooting
Failure code [DHS9MA] Boom Lower PPC Press Sens Def

Function (PC88MR-DHS9MA-400-A-Z0-A)
Action level Failure code Boom Lower PPC Pressure Sensor Defective Function
Failure
Detail of • Signal voltage of Boom Lower PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Sets Boom Lower PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of Boom Lower deteriorates.
• Boom Lower PPC pressure can be checked with monitoring function.
(Code: 07500 Boom Lower PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective Boom Lower PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, Boom Lower
PC88MR-10 40-311
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
Circuit diagram related to Boom Lower PPC pressure sensor
40-312 PC88MR-10
40 Troubleshooting
Failure code [DHSAMA] Swing Right PPC Press Sens Def Function (PC88MR-
DHSAMA-400-A-Z0-A)
Action level Failure code Swing Right PPC Pressure Sensor Defective Function
Failure
L01 DHSAMA (Pump controller system)
Detail of • Signal voltage of Swing Right PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Sets Swing Right PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of Swing Right deteriorates.
• Swing Right PPC pressure can be checked with monitoring function.
(Code: 09002 Swing Right PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective Swing Right PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, Swing Right
PC88MR-10 40-313
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
Circuit diagram related to Swing Right PPC pressure sensor
40-314 PC88MR-10
40 Troubleshooting
Failure code [DHSBMA] Swing Left PPC Press Sensor Def

Function (PC88MR-DHSBMA-400-A-Z0-A)
Action level Failure code Swing Left PPC Pressure Sensor Defective Function
Failure
L01 DHSBMA (Pump controller system)
Detail of • Signal voltage of Swing Left PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Sets Swing Left PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of Swing Left deteriorates.
• Swing Left PPC pressure can be checked with monitoring function.
(Code: 09001 Swing Left PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective Swing Left PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, Swing Left PPC
PC88MR-10 40-315
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Resis- Between ground and CP01 (female) (31) or P11
tance
Circuit diagram related to Swing Left PPC pressure sensor
40-316 PC88MR-10
40 Troubleshooting
Failure code [DHSCMA] Arm OUT PPC Press Sens Def Function (PC88MR-
DHSCMA-400-A-Z0-A)
Action level Failure code Arm OUT PPC Pressure Sensor Defective Function
Failure
L01 DHSCMA (Pump controller system)
Detail of • Signal voltage of arm OUT PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Sets arm OUT PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of arm OUT deteriorates.
• Arm OUT PPC pressure can be checked with monitoring function.
(Code: 07600 Arm OUT PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective Arm OUT PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, Arm OUT PPC
PC88MR-10 40-317
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
Circuit diagram related to arm OUT PPC pressure sensor
40-318 PC88MR-10
40 Troubleshooting
Failure code [DHSDMA] Bucket DUMP PPC Press Sens Def

Function (PC88MR-DHSDMA-400-A-Z0-A)
Action level Failure code Bucket DUMP PPC Pressure Sensor Defective Function
Failure
L01 DHSDMA (Pump controller system)
Detail of • Signal voltage of bucket DUMP PPC pressure sensor circuit is below 0.3 V or above 4.5
failure V.
Action of • Sets bucket DUMP PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of bucket DUMP deteriorates.
• Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective bucket DUMP PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, bucket DUMP
PC88MR-10 40-319
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
Circuit diagram related to bucket DUMP PPC pressure sensor
40-320 PC88MR-10
40 Troubleshooting
Failure code [DHSPMA] Boom Swing LH PPC Press Sensor

Abnormality (PC88MR-DHSPMA-400-A-Z0-A)
Action level Failure code Boom Swing LH PPC Pressure Sensor Abnormality
Failure
L01 DHSPMA (Pump controller system)
Detail of • Signal voltage of boom swing LH PPC pressure sensor circuit is below 0.3 V or above 4.5
failure V.
Action of • Sets boom swing LH PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of boom swing LH deteriorates.
• Boom Swing LH PPC pressure can be checked with monitoring function.
(Code: 07900 Boom Swing LH PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective boom swing LH sensor, ground fault or hot short circuit in wiring harness. Check as
2 PPC pressure sensor below.
(internal defect)
sensor.
4. If E mark is not displayed again for this failure code, boom swing LH
PC88MR-10 40-321
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
Circuit diagram related to boom swing LH PPC pressure sensor
40-322 PC88MR-10
40 Troubleshooting
Failure code [DHSQMA] Boom Swing RH PPC Press Sensor

Abnormality (PC88MR-DHSQMA-400-A-Z0-A)
Action level Failure code Boom Swing RH PPC Pressure Sensor Abnormality
Failure
L01 DHSQMA (Pump controller system)
Detail of • Signal voltage of boom swing RH PPC pressure sensor circuit is below 0.3 V or above 4.5
failure V.
Action of • Sets boom swing RH PPC pressure to 0 MPa {0 kg/cm2 }.
machine • Controllability of boom swing RH deteriorates.
• Boom Swing RH PPC pressure can be checked with monitoring function.
(Code: 07901 Boom Swing RH PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective boom swing RH sensor, ground fault or hot short circuit in wiring harness. Check as
2 PPC pressure sensor below.
(internal defect)
sensor.
4. If E mark is not displayed again for this failure code, boom swing RH
PC88MR-10 40-323
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
Circuit diagram related to boom swing RH PPC pressure sensor
40-324 PC88MR-10
40 Troubleshooting
Failure code [DKULKA] PPC Lock Relay Open Circuit (PC88MR-DKULKA-400-A-Z0-A)
Action level Failure code PPC Lock Relay Open Circuit

Failure
L03 DKULKA (Pump controller system)
Details of • Open circuit is detected in the circuit when output to PPC lock relay (coil side) is stopped
failure (during lock lever automatic lock control operation).
Action of • None in particular (Since no current flows, relay is not operated.)
Problem on • All work equipment, swing, and travel are not operated even when lock lever is in FREE
machine position.
Related • Method of reproducing failure code: Turn starting switch ON and release the lock lever
information while performing boom RAISE.
300 to 600
Defective PPC lock Resistance Between R12 (male) (1) and (2)
z
1 relay 1. Turn starting switch to OFF position.
2. Replace relay R12 with another one.
If this failure code disappears, original PPC lock relay is defective.
2. Disconnect connector CP02 and relay R12, and connect T-adapter to
Open circuit in wiring female side.
2
harness Between CP02 (female) (99) and R12 (female) (1) Max. 1 z
Resistance
Between R12 (female) (2) and ground Max. 1 z
3
PC88MR-10 40-325
40 Troubleshooting
Circuit diagram related to PPC lock solenoid
40-326 PC88MR-10
40 Troubleshooting
Failure code [DKULKB] PPC Lock Relay Short Circuit (PC88MR-DKULKB-400-A-Z0-A)
Action level Failure code PPC Lock Relay Short Circuit

Failure
L03 DKULKB (Pump controller system)
Details of • Short circuit is detected when output to PPC lock relay (coil side) is ON.
failure
• Stops output to PPC lock relay.
Problem on • All work equipment, swing, and travel are not operated even when lock lever is in FREE
machine position.
information
300 to 600
Defective PPC lock Resistance Between R12 (male) (1) and (2)
z
1 relay 1. Turn starting switch to OFF position.
2. Replace relay R12 with another one.
If this failure code disappears, original PPC lock relay is defective.
2. Disconnect connector CP02 and relay R12, and connect T-adapter to
2 female side.
harness
Between ground and CP02 (female) (99) or R12
Resistance (female) (1) Min 1 Mz

3
PC88MR-10 40-327
40 Troubleshooting
40-328 PC88MR-10
40 Troubleshooting
Failure code [DKULKY] PPC Lock Relay Hot Short Circuit (PC88MR-DKULKY-400-A-Z0-A)
Action level Failure code PPC Lock Relay Hot Short Circuit
Failure
L03 DKULKY (Pump controller system)
Details of • Hot short circuit is detected in the circuit when output to PPC lock relay (coil side) is
failure stopped (during lock lever automatic lock control operation).
Action of • None in particular (Since no current flows, relay is not operated.)
Problem on • Lock lever automatic lock control does not operate.
machine
Hot short circuit in 2. Disconnect relay R12, and connect T-adapter to female side.
Voltage Between R12 (female) (1) and ground Max 4.5 V
Defective pump If no failure is found by above checks, pump controller is defective.
2
PC88MR-10 40-329
40 Troubleshooting
40-330 PC88MR-10
40 Troubleshooting
Failure code [DV20KB] Travel Alarm Short Circuit (PC88MR-DV20KB-400-A-Z0-A)
Action level Failure code Travel Alarm Short Circuit

Failure
L01 DV20KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives travel alarm circuit.
failure
• Stops driving travel alarm circuit.
controller is set to OFF position.
Problem on
• Travel alarm does not sound.
machine
information • (2 persons are required for this check.)
2. Disconnect connector M14, and connect T-adapter to female side.
4. Perform troubleshooting by operating the travel lever.
k Never enter under the machine when operating travel lever.
a If voltage is normal but travel alarm does not sound, travel alarm is
Defective travel alarm defective.
1 Travel
(Internal defect)
control
lever: Max. 1 V
At
Voltage Between M14 (female) (1) and (2) NEUTRAL
Travel
control
lever: 20 to 30 V
Depressed
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
2 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz

2. Insert T-adapter into connector M14.
4. Perform troubleshooting by operating the travel lever.
k Never enter under the machine when operating travel lever.
Travel
Pump controller is control
3
defective. lever: Max. 1 V
At
Voltage Between M14 (1) and (2) NEUTRAL
Travel
control
lever: 20 to 30 V
Depressed
PC88MR-10 40-331
40 Troubleshooting
Circuit diagram related to travel alarm
40-332 PC88MR-10
40 Troubleshooting
Failure code [DW43KA] Travel Speed Solenoid Open Circuit (PC88MR-DW43KA-400-A-

Z0-A)
Action level Failure code Travel Speed Solenoid Open Circuit

Failure
L01 DW43KA (Pump controller system)
• Controller output voltage to solenoid is above standard value when pump controller does
Detail of not drive travel speed selector solenoid, so pump controller determines that open circuit
failure exists in travel speed selector solenoid circuit.
Action of • None in particular (Since no current flows, solenoid is not energized.)
Problem on • "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is "ON", sensor status
Related displayed on monitoring screen is "ON" even if solenoid is not energized due to short
information circuit.)
(Code: 02300)
Defective travel speed 1. Turn starting switch to OFF position.
1 selector solenoid 2. Disconnect connector V02, and connect T-adapter to male side.
(Internal open circuit) Resistance Between V02 (male) (1) and (2) 20 to 60 z
Open circuit, short 2. Disconnect connector V02 and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a 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.
Voltage Between V02 (female) (1) and (2) 1 to 4.5 V
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector CP02 and connect T-adapter to female side.
Between CP02 (female) (93) and each of (115),
Resistance (117), and (120) 20 to 60 z

harness 2. Disconnect connectors CP02 and V02, and connect T-adapters to each
4 (Wire breakage or female side.
defective contact of Between CP02 (female) (93) and V02 (female) (1) Max. 1 z
connector) Resistance Between V02 (female) (2) and each of CP02
(female) (115), (117), and (120) Max. 1 z

5
PC88MR-10 40-333
40 Troubleshooting
Circuit diagram related to travel speed solenoid
40-334 PC88MR-10
40 Troubleshooting
Failure code [DW43KB] Travel Speed Solenoid Short Circuit (PC88MR-DW43KB-400-

A-Z0-A)
Action level Failure code Travel Speed Solenoid Short Circuit

Failure
L01 DW43KB (Pump controller system)
• Abnormal current flows when pump controller drives travel speed selector solenoid, so
Detail of
pump controller determines that short circuit exists in travel speed selector solenoid
failure
circuit.
• Stops driving travel speed selector solenoid.
Problem on • "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel
machine speed is still "Lo".)
Related displayed on monitoring screen is "ON" even if solenoid is not energized due to short
(Code: 02300)
Defective travel speed 1. Turn starting switch to OFF position.
selector solenoid 2. Disconnect connector V02, and connect T-adapter to male side.
1
(Internal short circuit or Between V02 (male) (1) and (2) 20 to 60 z
ground fault) Resistance
Short circuit or ground
2 fault in wiring harness Between CP02 (female) (93) and each of (115),
20 to 60 z
Resistance (117), and (120)
a If no abnormality is found in check on cause 2, this check is not required.
harness
3 2. Disconnect connectors C02 and V02, and connect T-adapter to either
circuit) Between ground and CP02 (female) (93) or V02

4
PC88MR-10 40-335
40 Troubleshooting
40-336 PC88MR-10
40 Troubleshooting
Failure code [DW43KY] Travel Speed Sol Hot Short Circuit (PC88MR-DW43KY-400-A-Z0-
A)
Action level Failure code Travel Speed Solenoid Hot Short Circuit
Failure
L01 DW43KY (Pump controller system)
Detail of • When controller does not drive travel speed selector solenoid, output terminal voltage of
failure controller is higher than specified value, and hot short circuit is detected.
Problem on • Machine travels fast in "Lo" travel speed setting. (Although "Lo" is displayed on machine
machine monitor, actual travel speed is still "Hi".)
monitoring function. (As long as controller's command to solenoid is "OFF", sensor status
Related displayed on monitoring screen is "OFF" even if solenoid is not energized due to short
(Code: 02300)
Hot short circuit in 2. Disconnect connector V02 and connect T-adapter to female side.
Voltage Between V02 (female) (1) and ground Max. 4.5 V
2
PC88MR-10 40-337
40 Troubleshooting
Failure code [DW45KA] Swing Parking Brake Solenoid Open

Circuit (PC88MR-DW45KA-400-A-Z0-A)
Action level Failure code Swing Parking Brake Solenoid Open Circuit
Failure
L03 DW45KA (Pump controller system)
Detail of not drive swing holding brake solenoid, so pump controller determines that open circuit
failure exists in swing holding brake solenoid circuit.
• None in particular (Since no current flows, solenoid is not energized.) Swing holding brake
Action of will be applied.)
Problem on • Upper structure does not swing (swing holding brake is not released).
machine
• When solenoid and wiring harness are normal, swing operation is possible if swing
parking brake cancel switch is set to RELEASE position. (Note that swing holding brake is
applied when starting switch is in OFF position.)
• Keep swing parking brake cancel switch in release position during troubleshooting. When
starting switch is turned to ON position in this condition, normally current can flow in swing
holding brake solenoid circuit and the swing holding brake will be released.
Related • Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
circuit.)
(Code: 02300)
• Power for swing holding brake solenoid circuit is supplied from pin (101) of pump
controller connector C02 or fuse No.1 in fuse box F01.
Blown No. 1 fuse in fuse If fuse is blown, see failure code [DW45KB].
1
box F01
Defective swing parking 2. Disconnect connector V03, and connect T-adapters to male side.
2
brake solenoid
Resistance Between V03 (male) (1) and (2) 20 to 60 z
2. Remove diode arrays D01 and D03, and connect T-adapters to each male
side.
a Measure it with diode range of multimeter.
Defective diode array No
3 Between D01 (male) (3) (+) and (7) (-)
D01 or D03 continuity
Continuity
No
continuity
2. Swing lock switch OFF position
40-338 PC88MR-10
40 Troubleshooting

2. Remove diode D01.
Open or short circuit in 3. Disconnect connector CP02, and connect T-adapter to each female side.
5 wiring harness
a Swing lock switch OFF position
Between CP02 (female) (101) and D01 (female) (7) Max. 1 z
Resistance
Between D01 (female) (3) and CP02 (female) (115) 20 to 60 z
harness 2. Disconnect connectors D01, CP02, and V03, and connect T-adapters to
6 (Wire breakage or each female side.
defective contact of Between D01 (female) (3) and V03 (female) (1) Max. 1 z
connector) Resistance Between each of CP02 (female) (115), (117), (120)
and V03 (female) (2) Max. 1 z

7
PC88MR-10 40-339
40 Troubleshooting
Circuit diagram related to swing holding brake solenoid
40-340 PC88MR-10
40 Troubleshooting
Failure code [DW45KB] Swing Parking Brake Solenoid Short

Circuit (PC88MR-DW45KB-400-A-Z0-A)
Action level Failure code Swing Parking Brake Solenoid Short Circuit
Failure
L03 DW45KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives swing holding brake solenoid, so
failure pump controller determines that short circuit exists in swing holding brake solenoid circuit.
• Stops driving swing holding brake solenoid.
Problem on • Upper structure does not swing (swing holding brake is not released).
machine
• Keep the swing lock switch in the OFF position and the swing parking brake cancel switch
in the RELEASE position during troubleshooting. When starting switch is turned to ON
position in this condition, normally current can flow in swing holding brake solenoid circuit
and the swing holding brake will be released.
Related
• Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information
displayed on monitoring screen is "ON" even if solenoid is not energized due to short
circuit.)
(Code: 02300)
Blown No. 1 fuse in fuse Even if fuse is blown, perform troubleshooting according to following steps to
1 identify cause.
box F01
Defective swing parking 2. Disconnect connector V03, and connect T-adapter to male side.
2
brake solenoid Between V03 (male) (1) and (2) 20 to 60 z
Resistance
2. Remove diode arrays D01 and D03, and connect T-adapter to each male
side.
a Measure it with diode range of multimeter.
Defective diode array No
3 Between D01 (male) (3) (+) and (7) (-)
D01 or D03 continuity
Continuity
No
continuity
Ground fault in wiring 2.Remove fuse No.1 in fuse box F01 and diode D01.
harness 3.Disconnect connectors CP02, D01, and V03.
4 4.Connect T-adapters to female side of connectors CP02 and D01.
circuit) Between CP02 (female) (101) and ground Min. 1 Mz
Resistance
Between D01 (female) (3) and ground Min. 1 Mz
2. Remove fuse No.1 in fuse box F01 and diode D01.
Short circuit in wiring 3. Disconnect connector CP02.
5
harness 4. Connect T-adapters to female side of connectors D01 and CP02.
Between D01 (female) (3) and CP02 (female)
Resistance (115), (117), or (120) 20 to 60 z

6
PC88MR-10 40-341
40 Troubleshooting
40-342 PC88MR-10
40 Troubleshooting
Failure code [DW45KY] Swing Brake Sol Hot Short Circuit (PC88MR-DW45KY-400-A-Z0-
A)
Action level Failure code Swing Brake Solenoid Hot Short Circuit
Failure
L03 DW45KY (Pump controller system)
Detail of • When controller does not drive swing brake solenoid, output terminal voltage of controller
failure is higher than specified value, and hot short circuit is detected.
Problem on • Swing parking brake solenoid does not work.
machine
• Keep the swing lock switch in the OFF position and the swing parking brake cancel switch
in the RELEASE position during troubleshooting. When starting switch is turned to ON
position in this condition, normally current can flow in swing holding brake solenoid circuit
and the swing holding brake will be released.
Related
• Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information
circuit.)
(Code: 02300)
Hot short circuit in 2. Remove diode D01and connect T-adapter to female side.
Voltage Between D01 (female) (7) and ground Max. 4.5 V
2
PC88MR-10 40-343
40 Troubleshooting
40-344 PC88MR-10
40 Troubleshooting
Failure code [DW4CKY] PPC lock Sol Hot Short Circuit (PC88MR-DW4CKY-400-A-Z0-A)
Action level Failure code PPC Lock Solenoid System Hot Short Circuit
Failure
L03 DW4CKY (Pump controller system)
Details of • Hot short circuit is detected since the voltage of PPC lock solenoid circuit is 5.2 V or
failure higher during lock lever automatic lock.
Problem on • Lock cannot be engaged by using lock lever.
machine
Voltage Between V01 (female) (1) and ground Max 4.5 V
Pump controller is If no failure is found by preceding checks, pump controller is defective.
2
PC88MR-10 40-345
40 Troubleshooting
40-346 PC88MR-10
40 Troubleshooting
Failure code [DWJ0KA] Merge-divider Sol Open Circuit (PC88MR-DWJ0KA-400-A-Z0-A)
Action level Failure code Pump Merge-divider Solenoid Open Circuit

Failure
L01 DWJ0KA (Pump controller system)
Detail of not drive pump merge-divider solenoid, so pump controller determines that open circuit
failure exists in pump merge-divider solenoid circuit.
Problem on • Machine does not turn during travel.
machine
• Controller's command (ON/OFF) to pump merge-divider solenoid can be checked with
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
Related circuit.)
• pump merge-divider circuit is made when solenoid is de-energized.
Defective pump merge- 1. Turn starting switch to OFF position.
1 divider solenoid 2. Disconnect connector V04, and connect T-adapter to male side.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector CP02 and connect T-adapter to female side.

harness 2. Disconnect connectors CP02 and V04, and connect T-adapter to each
defective contact of Between CP02 (female) (85) and V04 (female) (1) Max. 1 z
connector) Resistance Between V04 (female) (2) and each of CP02
(female) (115), (117), and (120) Max. 1 z

5
PC88MR-10 40-347
40 Troubleshooting
Circuit diagram related to pump merge-divider solenoid
40-348 PC88MR-10
40 Troubleshooting
Failure code [DWJ0KB] Merge-divider Sol Short Circuit (PC88MR-DWJ0KB-400-A-Z0-A)
Action level Failure code Pump Merge-divider Solenoid Short Circuit

Failure
L01 DWJ0KB (Pump controller system)
• Abnormal current flows when pump controller drives pump merge-divider solenoid, so
pump controller determines that short circuit exists in pump merge-divider solenoid circuit.
Detail of • Controller output voltage to solenoid is above standard value when pump controller does
failure not drive pump merge-divider solenoid, so pump controller determines that open circuit
exists in pump merge-divider solenoid circuit.
• Stops driving pump merge-divider solenoid.
machine
Related circuit.)
• Pump merge-divider circuit is made when solenoid is de-energized.
Defective pump merge- 1. Turn starting switch to OFF position.
divider solenoid 2. Disconnect connector V04, and connect T-adapter to male side.
1
Short circuit or ground
20 to 60 z
harness
3 2. Disconnect connectors CP02 and V04, and connect T-adapter to either
circuit) Between ground and CP02 (female) (85) or V04

4
PC88MR-10 40-349
40 Troubleshooting
Circuit diagram related to pump merge-divider valve solenoid
40-350 PC88MR-10
40 Troubleshooting
Failure code [DWJ0KY] Merge-divider Sol Short Circuit (PC88MR-DWJ0KY-400-A-Z0-A)
Action level Failure code Pump Merge-divider Solenoid Short Circuit

Failure
L01 DWJ0KY (Pump controller system)
Detail of • When controller does not drive merge-divider solenoid, output terminal voltage of
failure controller is higher than specified value, and hot short circuit is detected.
machine
monitoring function. (As long as controller's command to solenoid is "OFF", sensor status
displayed on monitoring screen is "OFF" even if solenoid is not energized due to short
Related circuit.)
• Pump merge-divider circuit is made when solenoid is de-energized.
2
Circuit diagram related to Pump merge-divider valve solenoid
PC88MR-10 40-351
40 Troubleshooting
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit (PC88MR-
DXA8KA-400-A-Z0-A)
Action level Failure code Front Pump PC-EPC Solenoid Open Circuit
Failure
L03 DXA8KA (Pump controller system)
Detail of • No current flows when pump controller drives PC-EPC solenoid, so pump controller
failure determines that open circuit exists in PC-EPC solenoid circuit.
Problem on • If pump load increases, engine speed decreases largely and engine may stall.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stalling by
setting pump secondary drive switch to ON position.
Related • Drive current of PC–EPC solenoid can be checked by using monitoring function.
Incorrect operation of
1 pump secondary drive Set pump secondary drive switch at its normal position (lower side).
switch
Defective PC-EPC 1. Turn starting switch to OFF position.
2 solenoid 2. Disconnect connector V11, and connect T-adapter to male side.
2. Disconnect connector S25 and connect T-adapter to male side.
Defective pump Switch position: Normal Max. 1 z
Between S25 (male) (3)
secondary drive and (2) Switch position:
3 Min. 1 Mz
Emergency
(Internal open circuit) Resistance
Switch position: Normal Max. 1 z
and (5) Switch position:
Emergency Min. 1 Mz

Open circuit, short 2. Disconnect connector V11, and connect T-adapter to female side.
Voltage Between V11 (male) (1) and (2) Min. 20 V
Open or short circuit in 2. Disconnect connector CP02 and connect T-adapter to female side.
5 wiring harness
a Check that pump secondary drive switch is at normal position (lower side).

Open circuit in wiring 2. Disconnect connectors CP02, S25 and V11, and connect T-adapters to
harness each female side.
6 (Wire breakage or Between CP02 (female) (96) and S25 (female) (3) Max. 1 z
defective contact of Between S25 (female) (2) and V11 (female) (1) Max. 1 z
connector) Resistance Between S25 (female) (6) and each of CP02
(female) (115), (117), (120) Max. 1 z
Between S25 (female) (5) and V11 (female) (2) Max. 1 z
7
40-352 PC88MR-10
40 Troubleshooting
Circuit diagram related to PC-EPC solenoid
PC88MR-10 40-353
40 Troubleshooting
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit (PC88MR-
DXA8KB-400-A-Z0-A)
Action level Failure code Front Pump PC-EPC Solenoid Short Circuit
Failure
L03 DXA8KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives PC-EPC solenoid, so pump
failure controller determines that short circuit exists in PC-EPC solenoid circuit.
• Stops driving PC–EPC solenoid.
Problem on • If pump load increases, engine speed decreases largely and engine may stall.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stalling by
setting pump secondary drive switch to ON position.
Related • Drive current of PC–EPC solenoid can be checked by using monitoring function.
Defective PC-EPC 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V11, and connect T-adapter to male side.
1
Defective pump 2. Disconnect connector S25 and connect T-adapter to male side.
secondary drive switch Between S25 (male) (5) and each of
2 (internal short circuit or Switch Min. 1 Mz
(2) and (3)
ground fault) Resistance position:
Between ground and each of S25
Normal Min. 1 Mz
(male) (2) and (3)
Short circuit or ground a Check that pump secondary drive switch is at normal position (lower side).
3 to 14 z
Ground fault in wiring 2. Disconnect connectors CP02, S25 and V11, and connect T-adapter to any
harness female side.
4
(Contact with ground Between ground and CP02 (female) (96) or S25
circuit) (female) (3) Min. 1 Mz
Resistance
Between ground and S25 (female) (5) or V11

5
40-354 PC88MR-10
40 Troubleshooting
Circuit diagram related to PC-EPC solenoid
PC88MR-10 40-355
40 Troubleshooting
Failure code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid

Open Circuit (PC88MR-DXE7KA-400-A-Z0-A)
Action level Failure code Attachment Flow Regulating EPC 2 Solenoid Open Circuit
Failure
— DXE7KA (Pump controller system)
• When attachment flow rate adjustment EPC2 solenoid is driven, no current flows in the
Details of circuit, so the open circuit is detected.
failure
a Attachment flow rate adjustment EPC2 is ATT flow rate adjustment EPC2.
• Stops driving attachment flow rate adjustment EPC2 solenoid.
Action of • Also sets output command to attachment flow rate adjustment EPC5 solenoid to 0 mA.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with
information • Method of reproducing failure code: Turn starting switch ON and set machine in
attachment mode (ATT).
Defective attachment 1. Turn starting switch to OFF position.
flow rate adjustment 2. Disconnect connector V92, and connect T-adapter to male side.
1 EPC2

female side.
2 (Wire breakage or Between CP02 (female) (110) and V92 (female) (1) Max. 1 z

3
40-356 PC88MR-10
40 Troubleshooting
Circuit diagram related to ATT flow rate adjustment EPC2
PC88MR-10 40-357
40 Troubleshooting
Failure code [DXE7KB] Att Flow Regulating EPC 2 Short Circuit (PC88MR-
DXE7KB-400-A-Z0-A)
Action level Failure code Attachment Flow Regulating EPC 2 Short Circuit
Failure
— DXE7KB (Pump controller system)
• Abnormal current flows when pump controller drives attachment flow rate (service current)
Details of EPC2 solenoid, so pump controller determines that short circuit exists in attachment flow
failure rate adjustment (service current) EPC2 solenoid circuit.
Action of • Also sets output command to attachment flow rate adjustment EPC5 solenoid to 0mA.
Problem on
machine
1 EPC2
(Internal short circuit or Resistance
ground fault) Between V92 (male) (1) and ground Min 1 Mz

2 female side.
Between ground and CP02 (female) (110) or V92
circuit) Resistance (female) (1) Min 1 Mz
Defective pump If no failure is found by above checks, pump controller is defective.

3
40-358 PC88MR-10
40 Troubleshooting
PC88MR-10 40-359
40 Troubleshooting
Failure code [DXE7KY] Attachment Flow Regulating EPC 2 Solenoid Hot

Short Circuit (PC88MR-DXE7KY-400-A-Z0-A)
Action level Failure code Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit
Failure
— DXE7KY (Pump controller system)
Problem on
machine
1 EPC2
Hot short circuit in 2. Disconnect connector V92, and connect T-adapter to female side of V92.
3
40-360 PC88MR-10
40 Troubleshooting
PC88MR-10 40-361
40 Troubleshooting
Failure code [DXEAKA] Att Flow Regulating EPC 5 Open Circuit (PC88MR-
DXEAKA-400-A-Z0-A)
Action level Failure code Attachment Flow Regulating EPC 5 Open Circuit
Failure
— DXEAKA (Pump controller system)
• When attachment flow rate adjustment EPC5 solenoid is driven, no current flows in the
Details of circuit, so the open circuit is detected.
failure
a Attachment flow rate adjustment EPC5 is ATT flow rate attachment EPC5.
Problem on
machine
• Drive current of attachment flow rate adjustment (service current) EPC5 solenoid can be
checked with monitoring function.
1 EPC5

female side.
2 (Wire breakage or Between CP02 (female) (102) and V91 (female) (1) Max. 1 z

3
40-362 PC88MR-10
40 Troubleshooting
PC88MR-10 40-363
40 Troubleshooting
Failure code [DXEAKB] Att Flow Regulating EPC 5 Short Circuit (PC88MR-
DXEAKB-400-A-Z0-A)
Action level Failure code Attachment Flow Regulating EPC 5 Short Circuit
Failure
— DXEAKB (Pump controller system)
Problem on
machine
1 EPC5

2 female side.
Between ground and CP02 (female) (102) or V91
circuit) Resistance (female) (1) Min 1 Mz

3
40-364 PC88MR-10
40 Troubleshooting
PC88MR-10 40-365
40 Troubleshooting
Failure code [DXEAKY] Service Current EPC5 Hot Short Circuit (PC88MR-
DXEAKY-400-A-Z0-A)
Action level Failure code Service Current EPC5 Hot Short Circuit
Failure
— DXEAKY (Pump controller system)
Problem on
machine
1 EPC5
Hot short circuit in 2. Disconnect connector V91, and connect T-adapter to female side of V91.
3
40-366 PC88MR-10
40 Troubleshooting
PC88MR-10 40-367
40 Troubleshooting
Failure code [DY20KA] Wiper Motor Open Circuit (PC88MR-DY20KA-400-A-Z0-A)
Action level Failure code Wiper Motor Open Circuit

Failure
― DY20KA (Pump controller system)
Detail of • When windshield wiper works, W signal that indicates that wiper motor reaches working
failure area upper end position is not input.
Action of • Stops working output to wiper motor.
Problem on • Wiper motor does not work.
machine
• Signal input (ON/OFF) of W contact signal that indicates wiper working area end can be
checked by using monitoring function.
(Code: 02204)
• Method of reproducing failure code: Turn starting switch to ON position and set wiper switch
to INT or ON position.
2. Disconnect connector M05 and connect T-adapter to female side.
Wiper position:
Defective wiper Working area upper Max. 1 z
end
1 motor Between M05 (female) (6) and (5)
Resis- Wiper position: Other
(Internal open circuit)
tance than working area Min. 1 Mz
upper end
Wiper position: Whole
Between M05 (female) (1) and (3) Max. 20 z
range
2. Disconnect connectors CP01 and CP02, and connect T-adapters to each
female side.
Wiper position:
Working area upper Max. 1 z
Open or short circuit
2 in wiring harness Between CP01 (female) (56) and end
Resis- ground Wiper position: Other
tance than working area Min. 1 Mz
upper end
Between CP02 (female) (114) and Wiper position: Whole
(119) range Max. 20 z

Open circuit in wiring 2. Disconnect connectors CP01, CP02, and M05.
harness 3. Connect T-adapters to female side of connectors CP01 and CP02 and male
3 (Wire breakage or side of M05.
defective contact of Between CP01 (female) (56) and M05 (male) (6) Max. 1 z
connector) Resis- Between M05 (male) (5) and ground (T01) Max. 1 z
tance Between CP02 (female) (114) and M05 (male) (1) Max. 1 z
Between CP02 (female) (119) and M05 (male) (3) Max. 1 z
4
40-368 PC88MR-10
40 Troubleshooting
Circuit diagram related to wiper
PC88MR-10 40-369
40 Troubleshooting
Failure code [DY20MA] Wiper Motor Defective Function (PC88MR-DY20MA-400-A-Z0-A)
Action level Failure code Wiper Motor Defective Function

Failure
― DY20MA (Pump controller system)
Detail of • When windshield wiper rests, P signal that indicates that wiper motor is at rest area position
failure is not input.
Action of • Stops output for resting to wiper motor.
Problem on • Wiper does not rest.
machine
• Condition of P contact signal of wiper resting area can be checked by using monitoring
function.
(Code: 02204)
• Method of reproducing failure code: Turn starting switch to ON position and set wiper switch
to INT/ONoOFF position.
Defective wiper Wiper position: Rest
Max. 1 z
area
1 motor Between M05 (female) (4) and (5)
Resis- Wiper position:
(Internal open circuit) Min. 1 Mz
tance Working area
Wiper position: Whole
range
2. Disconnect connectors CP01 and CP02, and connect T-adapter to each
female side.
Wiper position: Rest
Open or short circuit Max. 1 z
2 in wiring harness Between CP01 (female) (75) and area
Resis- ground Wiper position:
Min. 1 Mz
tance Working area
Between CP02 (female) (114) and Wiper position: Whole
(119) range Max. 20 z

Open circuit in wiring 2. Disconnect connectors CP01, CP02, and M05.
harness 3. Connect T-adapters to female side of connectors CP01 and CP02 and male
3 (Wire breakage or side of M05.
defective contact of Between CP01 (female) (75) and M05 (male) (4) Max. 1 z
connector) Resis- Between M05 (male) (5) and ground (T01) Max. 1 z
tance Between CP02 (female) (114) and M05 (male) (1) Max. 1 z
Between CP02 (female) (119) and M05 (male) (3) Max. 1 z
4
40-370 PC88MR-10
40 Troubleshooting
PC88MR-10 40-371
40 Troubleshooting
Failure code [DY2CKB] Washer Motor Short Circuit (PC88MR-DY2CKB-400-A-Z0-A)
Action level Failure code Washer Drive Short Circuit

Failure
― DY2CKB (Pump controller system)
Detail of • When outputting current to window washer motor, abnormal current flows and short circuit
failure is detected.
• Stops driving washer motor.
Problem on • Window washer does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position and turn washer
information switch to ON position.
Defective fuse No. 4 in If the fuse is blown out, the circuit probably has a ground fault, etc.
1
fuse box F01
Defective washer motor 2. Disconnect connector M06 .
Between M06 (male) (1) and (2) Approx. 10
2 (Internal open circuit or
z
ground fault) Resistance Between M06 (male) (1) and ground, or between
M06 (male) (2) and ground Min. 1 Mz

2. Disconnect connector D02 and connect T-adapter to male side.
Defective assembled-
3 type diode D02 a Measure it with diode range of multimeter.
(Internal short circuit) Between D02 (male) (6) (+) and (2) (-) Continuity
Continuity No
continuity
Open or short circuit in 3. Turn starting switch to ON position.
4 wiring harness
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground 20 to 30 V
a If no failure is found in checks on cause 4, this check is not required.
Ground fault in wiring 2.Disconnect fuse No. 4 of fuse box F01.
harness 3.Disconnect connectors CP01, and D02, and connect T-adapter to any one
5
(Contact with ground of female sides.
circuit) Between F01-4 or D02 (female) (2) and ground Min. 1 Mz
Resistance Between ground and any one of CP01 (female) (3)
or D02 (female) (6) Min. 1 Mz

2. Disconnect connectors CP01 and M06, and connect T-adapter to female
side of CP01.
Hot short circuit in 3. Disconnect fuse No. 4 of fuse box F01.
a Ignore failure codes displayed on machine monitor.
Voltage Between D02 (female) (6) and ground Max. 4.5 V
7
40-372 PC88MR-10
40 Troubleshooting
Circuit diagram related to window washer motor
PC88MR-10 40-373
40 Troubleshooting
Failure code [DY2DKB] Wiper Motor (Normal) Short Circuit (PC88MR-DY2DKB-400-A-

Z0-A)
Action level Failure code Wiper Motor (Normal) Short Circuit

Failure
― DY2DKB (Pump controller system)
Detail of • When power to normal rotation side of wiper motor drive is supplied, short circuit was
failure detected because of abnormal current flown to the circuit.
• Stops driving wiper motor drive normal rotation side.
Problem on • Windshield wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
switch to INT or ON position.
Defective wiper motor 1. Turn starting switch to OFF position.

1 (Internal short circuit or
Between M05 (female) (3) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to either
2 harness side.
harness
Between CP02 (female) (119) and (114), or
Resistance between M05 (male) (1) and (3) Min. 1 Mz

harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to either
3 harness side.
Between CP02 (female) (119) and ground, or
circuit) Resistance between M05 (male) (3) and ground Min. 1 Mz
• Reference
Pump controller is 2. Insert T-adapter into connector M05.
defective.
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper
Max. 3 V
Voltage Between M05 (3) and (5) switch: OFF
Wiper Pulse below 3 V io
switch: ON above 20 V
40-374 PC88MR-10
40 Troubleshooting
PC88MR-10 40-375
40 Troubleshooting
Failure code [DY2EKB] Wiper Motor (Reverse) Short Circuit (PC88MR-DY2EKB-400-A-

Z0-A)
Action level Failure code Wiper Drive (Reverse) Short Circuit

Failure
― DY2EKB (Pump controller system)
Detail of • When driving reverse side of wiper motor drive circuit, short circuit was detected because
failure of abnormal current flown to the circuit.
• Stops driving wiper motor drive reverse side.
Problem on • Windshield wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
switch to INT or ON position.

1 (Internal short circuit or
Between M05 (female) (1) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to either
2 harness side.
harness
Between CP02 (female) (119) and (114), or
Resistance between M05 (male) (1) and (3) Min. 1 Mz

harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to either
3 harness side.
Between CP02 (female) (114) and ground, or
circuit) Resistance between M05 (male) (1) and ground Min. 1 Mz
• Reference
Pump controller is 2. Insert T-adapter into connector M05.
defective.
4. Turn wiper switch ON and OFF, and troubleshoot.
Wiper
Max. 3 V
Voltage Between M05 (1) and (5) switch: OFF
Wiper Pulse below 3 V io
switch: ON above 20 V
40-376 PC88MR-10
40 Troubleshooting
PC88MR-10 40-377
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode) (ALL-3840-001-A-01-A)
E-1 Engine does not start (Engine does not crank) (PC88MR-A21-400-A-Z0-A)
Failure • Engine does not start (engine does not crank).

• Engine starting circuit has following 2 start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by lock lever position
Related • If failure symptom "Battery relay operation sound is not heard" appears when starting
information switch is turned to ON position, perform troubleshooting for E-1 as well.
• If failure symptom is "Machine monitor displays nothing" when starting switch is turned to
ON position, main electric power supply system may be defective. So, perform
troubleshooting for E-4 (lines connecting to fusible link F03 and fuse No. 17).
Loose terminal or open
1 Check terminals of starting motor, alternator, battery relay, and ground
circuit at terminal
terminals T09, T08, T12, etc.
Poor contact Between battery relay terminal R01 and ground
2 (grounding) between a Use machine frame as grounding point for
battery relay and frame Resistance Max. 1 z
measurement.
a Loosened or rusted terminal T08
a Be ready with starting switch at OFF position, then perform
Insufficient battery troubleshooting without turning starting switch to ON position.
3 capacity Battery voltage (2 batteries) Min. 24 V
Specific gravity of electrolyte (each
battery) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated with
Defective engine
4 failure codes [DB2QKR] and [DB2RKR]. If these codes appear, perform
controller system
troubleshooting for Causes 1 to 3 of [DB2QKR] first.
Defective fuse No. 3 in If fuse is burnt out, circuit probably has ground fault. (See Cause 21.)
5
fuse box F01
1. Turn starting switch to ON position (to connect ACC).
Defective battery relay
6 system a If battery relay operation sound is not heard, go to checks on Causes 19
and after.
1. Turn starting switch to OFF position, and remove fuse No. 3 in fuse box
F01.
Defective fusible link 2. Turn starting switch to ON position (to connect ACC).
7 F02, defective wiring Between input terminal (1A) of fuse box F01-3 and
harness Voltage 20 to 30 V
ground
a If voltage is abnormal, go to check on Cause 10.
Defective starting 2. Remove fuse No. 18 (30 A) of fuse box F01. (To prevent engine from
switch, lock lever starting during troubleshooting)
switch, starting motor 3. Insert T-adapter into connector E12.
8 cut-off relay R06, 4. Turn starting switch to START position and hold it (two persons required
personal code relay for this check).
R07, battery relay, or Voltage Between E12 (1) and ground 20 to 30 V
wiring harness
a If voltage is abnormal, go to check on Cause 12 and after.
40-378 PC88MR-10
40 Troubleshooting

a If no failure is found by check on Cause 7, this check is not required.
If fusible link is burnt out, circuit may have ground fault. In this case,
perform troubleshooting for Cause 11 first.
Defective fusible link
9 • Fuses No. 1 to 13 are connected to fusible link F02.
F02
a Connected circuit is large in scale. Accordingly, if no failure is found by
check on Cause 11, reproduce trouble and find out ground fault position by
sound and burning smell.
Open circuit 1 in wiring 1. Turn starting switch to OFF position, and turn battery disconnect switch to
harness OFF position.
10 (Wire breakage or (To prevent short circuit during troubleshooting)
defective contact of 2. Disconnect fusible link F02 and fuse No. 3 of fuse box F01.
connector) 3. Connect T-adapter to male side of connector F02.
Between battery relay (R03) and F02 (male) (1) Max. 1 z
Resistance
Between F02 (male) (2) and F01-1A Max. 1 z
Ground fault 1 in wiring OFF position.
harness 2. Disconnect fusible link F02, fuse No. 3 of fuse box F01, and battery relay
11 R03 (M terminal).
circuit) 3. Connect T-adapter to male side of connector F02.
Between ground and battery relay R03 (harness
Min. 1 Mz
Resistance side) or F02 (male) (1)
Between ground and F02 (male) (2) or F01-1A Min. 1 Mz
2.Disconnect connector H15 and connect T-adapter to male side.
3.After troubleshooting, turn starting switch to ON and START positions to
perform troubleshooting again.
Turn starting switch to
OFF position. Min. 1 Mz
Between H15 (male) (1)
Defective starting and (2) Turn starting switch to
12 switch ON position. Max. 1 z
(Internal open circuit) Turn starting switch to
Resistance and (5)
ON position. Max. 1 z
and (4) Turn starting switch to
START position. Max. 1 z

Defective lock lever 1. Turn starting switch to OFF position.
13 switch 2. Disconnect connector S14 and connect T-adapter to female side.
(Internal open circuit) Between S14 (female) Lock lever: FREE Min. 1 Mz
Resistance (1) and (3)
Lock lever: LOCK Max. 1 z
a Before performing troubleshooting, check that the head lamp lights up.
Defective starting motor
14 cut-off relay 1. Turn starting switch to OFF position.
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
40 Troubleshooting

a Before performing troubleshooting, check that the head lamp lights up.
Defective personal
15 code relay 1. Turn starting switch to OFF position.
2. Interchange personal code relay (R07) with light relay (R05).
3. Start engine.
If engine starts, original personal lock relay is defective.
Defective alternator 2. Turn starting switch to ON position.
16 Input from
(internal short circuit) Between alternator R terminal and
Voltage alternator Max. 1 V
ground
generation
2. Turn starting switch to START position and perform troubleshooting.
Between starting motor terminal B Power
(SB) and ground supply 20 to 30 V
Defective starting motor
17 Voltage Starting
(Internal defect) Between starting motor terminal C input to
(SC) and ground 20 to 30 V
starting
motor
If power supply and starting input to starting motor are normal but starting
motor does not rotate, starting motor is defective.
2. Disconnect connector D01 and connect T-adapter to diode.
Defective diode D01 a Measure it with diode range of multimeter.

18 (Internal open or short Between D01 (male) (1) (+) and (5) (-) No continuity
circuit) Between D01 (male) (5) (+) and (1) (-) Continuity
Between D01 (male) (2) (+) and (6) (-) No continuity
40-380 PC88MR-10
40 Troubleshooting

• Battery relay
Between terminal R02 and D01 (female) (1) Max. 1 z
Resistance
Between D01 (female) (5) and H15 (female) (2) Max. 1 z
• Battery relay
a Check where 24 V power is reached to, and locate open section.
Between terminals R04 and R01 20 to 30 V
Voltage
Between terminal R01 and ground Max. 1 V
• Alternator and starting motor
3. Insert T-adapters into connectors H15, S14, R07, and E12.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to START position to perform troubleshooting.
a Check where 24 V power is reached to, and locate open section.
Between H15 (4) and ground 20 to 30 V
Between S14 (1) and ground 20 to 30 V
Open circuit in wiring Between S14 (3) and ground 20 to 30 V
harness
Voltage Between R07 (4) and ground 20 to 30 V
19 (Wire breakage or
Between E12 (1) and ground 20 to 30 V
connector) Between alternator terminal B and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
• If fuse or fusible link is burnt out, replace it with new one.
2. Disconnect connectors H15, S14, R06, R07, and CM01.
3. Connect T-adapters to female sides of H15, R06, R07, CM01 and to male
side of S14.
4. Remove fuse F01-3.
Between H15 (female) (4) and R06 (female) (3) Max. 1 z
Between R06 (female) (5) and R07 (female) (3) Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Max. 1 z
Between R07 (female) (2) and CM01 (female) (6) Max. 1 z
Between R07 (female) (4) and starting motor safety
relay terminal S Max. 1 z
Between alternator terminal B and starting motor
Resistance terminal B Max. 1 z
Between alternator terminal R and starting motor
safety relay terminal R Max. 1 z
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
Between R06 (female) (2) and ground (T05) Max. 1 z
PC88MR-10 40-381
40 Troubleshooting

Defective battery relay If voltage of terminal R03 only is unusual in battery relay checks on Cause 19,
20 battery relay is defective.
(Does not turn ON.)
2. Disconnect connectors H15, S14, R06, R07, and R17.
3. Connect T-adapters to female sides of H15, R06 and R07, and to male
side of S14.
4. Remove fuse No. 3 of fuse box F01.
Ground fault in wiring Between ground and H15 (female) (4) or R06
harness
21 Between ground and R06 (female) (5) or R07
(Contact with ground Min. 1 Mz
circuit) (female) (3)
Resistance Between ground and R07 (female) (4) or R17
Between ground and F01-3 or S14 (male) (1) Min. 1 Mz
Between ground and S14 (male) (3) or R06
wiring harness 2. Insert T-adapter into connector R17 or CM01.
(Contact with 24 V
circuit) Voltage Between ground and R17 (2) or CM01 (16) Max. 1 V
40-382 PC88MR-10
40 Troubleshooting
Circuit diagram related to engine starting circuit
PC88MR-10 40-383
40 Troubleshooting
E-2 Manual preheating system does not work (PC88MR-FEM-400-A-Z0-A)
Failure Manual preheating system does not work.

a This troubleshooting describes procedures to be followed when manual preheating does
not function to heat electrical intake air heater (ribbon heater) mounting portion.
• When only engine preheating monitor does not light up, perform troubleshooting for E-3
"While preheating is working, preheating monitor does not light up".
Related • If failure symptom "Machine monitor displays nothing" or "Battery relay does not make
information operating sound" appears when starting switch is turned to ON position, main electric
power supply system may be defective. In these cases, perform troubleshooting for E-4
and E-1 respectively.
• If fuse No. 17 in fuse box F01 is burnt out, perform troubleshooting for "Machine monitor
displays nothing".
• Before performing troubleshooting, check that no related failure code is displayed.
Defective fusible link
1 If fusible link is burnt out, circuit probably has ground fault. (See Cause 8.)
F06 (120 A)
Loose terminal or open
2 Check terminals of heater relay, battery relay, electrical intake air heater
circuit at terminal
(ribbon heater), etc.
2. Disconnect connectors CM01 and H15, and connect T-adapter to female
side of H15.
Between H15 (female) (3) and ground (coil Approx. 20
Resistance resistance of heater relay)
z
• Secondary side
Between R16B (input terminal on contact side of
Voltage 20 to 30 V
heater relay) and ground
Open and short circuit • Primary side
3 in wiring harness 1. Turn starting switch to OFF position.
a To prevent current from flowing through heater when starting switch is
3. Turn starting switch to the HEAT position (connect R1).
Voltage Between heater relay terminal R15 and ground 20 to 30 V
Between R16A (wiring harness side)
Continuity Continuity
and ground
a If no failure is found in primary side by check on Cause 3, this check is not
required.
Defective diode D02 1. Turn starting switch to OFF position.
2. Disconnect connector D02 and connect T-adapter to diode.
4 (Internal open or short
circuit) a Measure it with diode range of multimeter.
Continuity Between D02 (male) (1) (+) and (5) (-) No continuity
Continuity Between D02 (male) (5) (+) and (1) (-) Continuity
40-384 PC88MR-10
40 Troubleshooting

a If no failure is found in primary side by check on Cause 3, this check is not
required.
Defective starting 2. Turn battery disconnect switch to OFF position.
5 3. Disconnect connector H15 and connect T-adapter to male side.
switch
4. Turn starting switch to OFF and the HEAT positions to perform
troubleshooting.
OFF Min. 1 Mz
Resistance Between H15 (male) (1) and (3)
HEAT Max. 1 z
Defective electrical 1. Turn starting switch to OFF position.
intake air heater (ribbon 2. Disconnect terminal E01.
6 heater)
Continuity Between E01 terminal and ground Continuity
Defective heater relay
If no failure is found by check on Cause 3 and heater relay operation sound is
7 (Does not turn ON) not heard, heater relay is defective.
(terminal R16A)
2. Disconnect connectors H15, CM01, D02, terminals R15, E01, and F06
Ground fault in wiring terminal of fuse.
harness Between heater relay terminal R15 (wiring harness
8 Min. 1 Mz
(Contact with ground side) and ground
circuit) Between heater relay R16B (contact side input
Resistance terminal) and ground Min. 1 Mz
Between heater terminal E01 (wiring harness side)
and ground Min. 1 Mz
PC88MR-10 40-385
40 Troubleshooting
Circuit diagram related to engine preheating system
40-386 PC88MR-10
40 Troubleshooting
E-3 While preheating is working, preheating monitor does not light

up (PC88MR-FE2-400-A-Z0-A)
Failure While preheating is working, preheating monitor does not light up.
Related • Check whether manual preheating function works first.
information
harness 2. Disconnect connectors CM01 and HDT, and connect T-adapters to each
connector) Resistance Between HIS (female) (3) and CM01 (female) (12) Max. 1 z
If no failure is found by preceding checks, machine monitor is defective.
• Reference
Defective machine 3. Disconnect heater relay terminal R16A.
2
monitor
a To prevent current from flowing through heater when starting switch is
4. Turn starting switch to HEAT.
Resistance Between CM01 (12) and (3) 20 to 30 V
PC88MR-10 40-387
40 Troubleshooting
Circuit diagram related to engine preheating system
40-388 PC88MR-10
40 Troubleshooting
E-4 When starting switch is turned to ON position, machine monitor

displays nothing (PC88MR-FEG-400-A-Z0-A)
Failure When starting switch is turned to ON position, machine monitor displays nothing.
• 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.
information • Depending on ambient temperature and condition of battery, battery voltage may lower
suddenly and machine monitor displays nothing temporarily when engine is started. But
this phenomenon does not mean that machine monitor is defective.
Battery disconnect
Turn starting switch to OFF position and check that battery disconnect switch
1 switch left in OFF
is in ON position.
position
a Be ready with starting switch at OFF position, then perform
Insufficient battery troubleshooting without turning starting switch to ON position.
2 capacity Battery voltage (2 batteries) Min. 24 V
Specific gravity of electrolyte (each Min. 1.26
battery)
Defective fusible link If fusible link is burnt out, circuit probably has ground fault. (See Cause 9.)
3
F03
4 Defective fuse F01-15 If fuse is burnt out, circuit probably has ground fault. (See Cause 10.)
5 Defective fuse F01-17 If fuse is burnt out, circuit probably has ground fault. (See Cause 10.)
Loose terminal or open 1. Turn starting switch to OFF position.
6
circuit at terminal Check terminals of battery relay, etc.
Defective wiring 4. Turn battery disconnect switch to ON position.
7 harness, starting switch, 5. Turn starting switch to ON position (to connect ACC).
or machine monitor Between CM01 (1) and (3) 20 to 30 V
2. Disconnect connector H15 and connect T-adapter to male side.
Defective starting 3. Turn starting switch to ON position and perform troubleshooting again.
8 switch Between H15 (male) (1) Turn starting switch to
(Internal open circuit) and (5) OFF position. Min. 1 Mz
Resistance
Between H15 (male) (1) Turn starting switch to
and (5) ON position. Max. 1 z
If no failure is found by check on Cause 7, this check is not required.
3. Disconnect fusible link F03, No. 15 and 17 fuses of fusebox F01, and
connectors H15 and CM01.
4. Connect T-adapters to male side of connector F03 and female side of H15
and CM01.
Open circuit in wiring Between battery (-) terminal and ground Max. 1 z
9 harness Between battery (+) and F03 (male) (1) Max. 1 z
(Internal open circuit) Between F03 (male) (2) and F01-16F Max. 1 z
Between F01-17 and CM01 (female) (1), (2) Max. 1 z
Resistance Between ground (T09) and each of CM01 (female)
(3) and (4) Max. 1 z
Between F01-17 and H15 (female) (1) Max. 1 z
Between H15 (female) (5) and F01-15E Max. 1 z
Between F01-15 and CM01 (female) (10) Max. 1 z
PC88MR-10 40-389
40 Troubleshooting

If no failure is found by checks on causes 3 to 5 and 7, this check is not
required.
OFF position.
2. Disconnect fusible link F03, No. 15 and No. 17 terminals of fusebox F01,
Ground fault in wiring and connectors H15, CM01, and CP01.
harness 3. Connect T-adapters to male side of connector F03 and female side of H15
10 and CM01.
circuit) Between ground and battery (+) or F03 (male) (1) Min. 1 Mz
Between ground and F03 (male) (2) or F01-16F Min. 1 Mz
Between ground and F01-17, CM01 (female) (1),
Resistance Min. 1 Mz
(2), or H15 (female) (1)
Between ground and H15 (female) (5) or CM01
Defective machine If no failure is found by preceding checks, machine monitor is defective.

11
40-390 PC88MR-10
40 Troubleshooting
Circuit diagram related to machine monitor power supply
PC88MR-10 40-391
40 Troubleshooting
E-5 Engine coolant temperature monitor lights up in white while engine

is running (PC88MR-FES-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in white while engine is running.
• Signal voltage of coolant temperature sensor is input to engine controller and then the
Related data is transmitted to machine monitor through CAN communication system.
information • Coolant temperature can be checked with monitoring function.
(Code: 04107)
Insufficient warm-up of If monitor lights up in white, coolant temperature may be low (below
machine approximately 30°C). Warm up engine.
1
(When system works • Being lit in white: Coolant temperature is low.
properly) • Being lit in blue: Coolant temperature is proper.
If no failure is found by preceding checks, engine coolant temperature gauge
system may be defective. Perform following troubleshooting.
Defective engine
coolant temperature • E-14 Engine coolant temperature gauge display does not move from
2
gauge system minimum or maximum
• E-15 Engine coolant temperature gauge indicates incorrect temperature
(indicates neither minimum nor maximum)
40-392 PC88MR-10
40 Troubleshooting
E-6 Hydraulic oil temperature monitor lights up in white while engine is

running (PC88MR-FEU-400-A-Z0-A)
Failure Hydraulic oil temperature monitor lights up in white while engine is running.
• Signal of hydraulic oil temperature sensor is input to pump controller and then data is
Related transmitted to machine monitor through CAN communication system.
information • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401)
Insufficient warm-up of If monitor lights up in white, hydraulic oil temperature may be low (below
machine approximately 20°C). Warm up engine.
1
(when system works • Being lit in white: Hydraulic oil temperature is low.
properly) • Being lit in blue: Hydraulic oil temperature is proper.
If no failure is found by preceding checks, hydraulic oil temperature gauge
Defective oil
temperature gauge • E-16 Hydraulic oil temperature gauge does not move from minimum or
2
system maximum
• E-17 Hydraulic oil temperature gauge indicates incorrect temperature
PC88MR-10 40-393
40 Troubleshooting
E-7 Charge level monitor lights up while engine is running (PC88MR-FEP-400-A-Z0-A)
Failure Charge level monitor lights up in red while engine is running.

Related • Power-generation signal from alternator can be checked with monitoring function.
Defective alternator
1 Perform troubleshooting for failure code [AB00KE].
system
40-394 PC88MR-10
40 Troubleshooting
E-8 Fuel level monitor lights up in red while engine is running (PC88MR-FEQ-400-A-
Z0-A)
Failure Fuel level monitor lights up in red while engine is running.

Related • Signal voltage of fuel sensor can be checked with monitoring function.
Low fuel level
1 (When system works Fuel level may be low. Check it and add fuel if necessary.
properly)
If no failure is found by preceding checks, fuel gauge system may be
defective. Perform following troubleshooting.
Defective fuel gauge
2 system • E-12 Fuel gauge display does not move from minimum or maximum
• E-13 Fuel gauge indicates incorrect amount (indicates neither full nor
empty)
PC88MR-10 40-395
40 Troubleshooting
E-9 Engine coolant temperature monitor lights up in red while engine is

running (PC88MR-FEV-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in red while engine is running.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
(Code: 04107)
If monitor lights up in red, coolant temperature may be high (above
Overheating of engine approximately 102°C). Cool down coolant. (Run engine at low idle.)
coolant • Being lit in red: Coolant temperature is high (overheating).
1 • Being lit in blue: Coolant temperature is proper.
(When system works
properly) Perform troubleshooting for "S-17 Coolant temperature rises too high
(overheating)".
If no failure is found by preceding checks, engine coolant temperature gauge
Defective engine
coolant temperature • E-14 Engine coolant temperature gauge display does not move from
2
gauge system minimum or maximum
40-396 PC88MR-10
40 Troubleshooting
E-10 Hydraulic oil temperature monitor lights up in red while engine is

running (PC88MR-FEW-400-A-Z0-A)
Failure Hydraulic oil temperature monitor lights up in red while engine is running.
• Signal from hydraulic oil temperature sensor is input to pump controller and then data is
(Code: 04401)
If monitor lights up in red, hydraulic oil temperature may be high (above
Overheating of
approximately 102°C). Cool down hydraulic oil. (Run engine at low idle or stop
hydraulic oil
1 engine.)
(When system works
• Being lit in red: Hydraulic oil temperature is high (overheating).
properly)
• Being lit in blue: Hydraulic oil temperature is proper.
If no failure is found by preceding checks, hydraulic oil temperature gauge
Defective oil
temperature gauge • E-16 Hydraulic oil temperature gauge does not move from minimum or
2
system maximum
• E-17 Hydraulic oil temperature gauge indicates incorrect temperature
PC88MR-10 40-397
40 Troubleshooting
E-11 Engine oil pressure monitor lights up in red while engine is

running (PC88MR-FEX-400-A-Z0-A)
Failure Engine oil pressure monitor lights up in red while engine is running.
• Signal of engine oil pressure sensor is input to engine controller and then the data is
information • Engine oil pressure can be checked with monitoring function.
• (Code: 37200)
Lowered engine oil
pressure Engine oil pressure may be lowered. Check engine oil pressure.
1
(When system works • Perform troubleshooting "S-14 (Oil pressure drops)".
properly)
Defective engine oil If no failure is found by check on Cause 1, engine oil pressure switch system
2 pressure system may be defective. 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.
3
monitor
40-398 PC88MR-10
40 Troubleshooting
E-12 Fuel gauge display does not move from minimum or

maximum (PC88MR-FGE-400-A-Z0-A)
1) While fuel is added, fuel gauge indicator does not rise from red range (E).
Failure
2) While fuel level is low, fuel gauge indicator does not lower from green range top (F)
Defective fuel level 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P21 and connect T-adapter to male side.
1 Approx. 10
(internal open or short Between P21 (male) (1) Fuel level: FULL
circuit) Resistance z
and ground
Fuel level: EMPTY 85 to 95 z
2. Disconnect connector CM01, and connect T-adapter to female side.
Open and short circuit
2 in wiring harness Approx. 10
Between CM01 (female) Fuel level: FULL
Resistance z
(15) and ground
Fuel level: EMPTY 85 to 95 z
Open circuit in wiring a If no failure is found by check on Cause 2, this check is not required.
harness
3 (wire breakage or 2. Disconnect connectors CM01 and P21 and connect T-adapters to each
connector) Resistance Between CM01 (female) (15) and P21 (female) (1) Max. 1 z
harness 2. Disconnect connectors CM01 and P21, and connect T-adapter to either
4 female side.
Between ground and CM01 (female) (15) or P21

Hot short circuit in 3. Insert T-adapter into connector CM01 or connect T-adapter to female side
5 wiring harness of connector P21.
Voltage Between ground and CM01 (15) or P21 (female) (1) Approx. 3.3
V
Defective machine If no failure is found by preceding checks, machine monitor is defective.
6 (Since this is an internal defect, troubleshooting cannot be performed.)
monitor
Circuit diagram related to fuel level sensor
PC88MR-10 40-399
40 Troubleshooting
E-13 Fuel gauge indicates incorrect amount (indicates neither full nor
empty) (PC88MR-FGF-400-A-Z0-A)
1) Indication of fuel gauge is different from actual fuel level.
Failure
2) Indication of fuel gauge does not accord with indication of fuel level monitor.
Defective fuel level Perform troubleshooting for "E-13 Cause 1".
1
sensor
a Turn starting switch to ON position or start engine to perform
troubleshooting.
Fuel level: 96 l Fuel gauge level: 6
Defective machine Fuel level: 78 l Fuel gauge level: 5
2 Color of
monitor Fuel level: 60 l Fuel gauge level: 4 Blue
monitor
light (a) Fuel level: 41 l Fuel gauge level: 3
Fuel level: 32 l Fuel gauge level: 2
Fuel level: 23 l Fuel gauge level: 1 Red
Fuel gauge and fuel level monitor
40-400 PC88MR-10
40 Troubleshooting
E-14 Engine coolant temperature gauge display does not move from
minimum or maximum (PC88MR-FGG-400-A-Z0-A)
1) While coolant temperature is rising normally, it does not rise from white range (C).
Failure
2) While coolant temperature is stabilized normally, it rises to red range (H).
• Signal voltage of coolant temperature sensor is input to engine controller and then the
Related data is transmitted to machine monitor through CAN communication system.
(Code: 04107)
Defective coolant
Coolant temperature sensor system may be defective. Perform
troubleshooting for failure codes [CA144] and [CA145].
system
Defective machine If no failure is found by check on Cause 1, machine monitor may be defective.
2
Engine coolant temperature gauge and coolant temperature monitor
PC88MR-10 40-401
40 Troubleshooting
E-15 Engine coolant temperature gauge indicates incorrect temperature

(indicates neither full nor empty) (PC88MR-FGH-400-A-Z0-A)
1) Coolant temperature is different from indication of engine coolant temperature gauge.
Failure 2) Indication of engine coolant temperature gauge is different from indication of coolant
temperature monitor.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
(Code: 04107)
Defective coolant
Coolant temperature sensor system may be defective. Perform
troubleshooting for failure codes [CA144] and [CA145].
system
troubleshooting.
Engine coolant
Coolant temperature
temperature gauge level:
105°C
6
Red
Engine coolant
Coolant temperature
102°C
5
Engine coolant
Defective machine Coolant temperature
2 Color of temperature gauge level:
monitor 100°C
monitor 4
light (a) Engine coolant
Coolant temperature 80°
temperature gauge level: Blue
C
3
Engine coolant
C
2
Engine coolant
temperature gauge level: White
C
1
Engine coolant temperature gauge and coolant temperature monitor
40-402 PC88MR-10
40 Troubleshooting
E-16 Hydraulic oil temperature gauge does not move from minimum or
maximum (PC88MR-FGJ-400-A-Z0-A)
1) While hydraulic oil temperature is rising normally, it does not rise from white range (C).
Failure
2) While hydraulic oil temperature is stabilized normally, it rises to red range (H).
(Code: 04401)
Approx. 90
10°C
Defective hydraulic oil kz
temperature sensor Between P22 (male) (1) and (2) Approx. 35
1 30°C
(Internal open or short kz
circuit) Resistance a Thermal characteristics of oil 80°C
Approx. 6.5
temperature sensor kz
Approx. 3.5
100°C
kz
Between P22 (male) (2) and ground Min. 1 Mz
Open and short circuit Between CP01 (female) (28) and (46)
2 in wiring harness 3.5 to 90 kz
Resistance a Resistance accords with thermal characteristics
table in Cause 1.
Open circuit in wiring a If no failure is found by check on Cause 2, this check is not required.
3 (Wire breakage or 2. Disconnect connectors CP01 and P22 and connect T-adapters to each
connector) Between CP01 (female) (28) and P22 (female) (2) Max. 1 z
Resistance
Between CP01 (female) (46) and P22 (female) (1) Max. 1 z
harness
4 2. Disconnect connectors CP01 and P22, and connect T-adapter to either
circuit) Between ground and CP01 (female) (28) or P22

Hot short circuit in 3. Insert T-adapter into connector CP01 or connect T-adapter to female side
5 wiring harness of connector P22.
Voltage Between ground and CP01 (28) or P22 (female) (2) Approx. 5 V
6
PC88MR-10 40-403
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-404 PC88MR-10
40 Troubleshooting
E-17 Hydraulic oil temperature gauge indicates incorrect temperature

(indicates neither full nor empty) (PC88MR-FGK-400-A-Z0-A)
1) Hydraulic oil temperature is different from indication of hydraulic oil temperature gauge.
Failure 2) Indication of hydraulic oil temperature gauge is different from indication of hydraulic oil
temperature monitor.
(Code: 04401)
Defective hydraulic oil
1 See previous page.
temperature sensor
troubleshooting.
Hydraulic oil Hydraulic oil temperature
temperature: 105°C gauge level: 6
Red
Defective machine Hydraulic oil Hydraulic oil temperature
2 Color of
monitor temperature: 100°C gauge level: 4
monitor
light (a) Hydraulic oil Hydraulic oil temperature
temperature: 80°C gauge level: 3 Blue
temperature: 20°C gauge level: 1 White
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
PC88MR-10 40-405
40 Troubleshooting
E-18 Some areas of machine monitor screen are not displayed (PC88MR-FFC-400-
A-Z0-A)
Failure Some areas of machine monitor screen are not displayed.

• Liquid crystal panels sometimes allow, as one of their properties, presence of black spots
Related (spots that are not lit up) and bright spots (spots that remain constantly lit) on panel. If the
information number of bright spots and black spots does not exceed 10, liquid crystal panel is not
faulty or defective.
Defective machine a Turn starting switch to ON position, then perform troubleshooting.

1 monitor If following switch operation lights up all pixel on liquid crystal panel (entire
(Liquid crystal panel) screen turns to white), liquid crystal panel is normal.
• 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.
2 monitor
(Monitor itself)
40-406 PC88MR-10
40 Troubleshooting
E-19 Function switch does not work (PC88MR-HBC-400-A-Z0-A)
Failure Function switch does not work.

Related • Signal of function switch can be checked with monitoring function.
Defective machine Machine monitor may be defective. (Since this is an internal defect,
1 troubleshooting cannot be performed.)
monitor
PC88MR-10 40-407
40 Troubleshooting
E-20 Automatic warm-up system does not operate (in cold season) (PC88MR-
FEN-400-A-Z0-A)
Failure Automatic warm-up system does not operate (in cold season).
• Automatic warm-up function increases engine speed to 1,300 rpm when coolant
temperature is below 30°C.
Related • With starting switch at ON position or after engine is started, if fuel control dial is kept at
information 70% or more of full open range for 3 seconds, automatic warm-up operation is canceled.
• If coolant temperature is below 10°C, turbocharger protection function works to keep
engine speed below 1,000 rpm for up to 20 seconds after engine is started.
troubleshooting.
a If level indication of engine coolant temperature gauge differs from actual
coolant temperature, perform following troubleshooting.
• E-15 Engine coolant temperature gauge display does not move from
minimum or maximum
Defective coolant Coolant temperature
1 temperature signal 6 (a: Red)
105°C
system Coolant temperature 5 (a: Red)
102°C
Coolant temperature 4 (a: Blue)
Coolant Monitoring code 04107 100°C
temperature
level (Coolant temperature) Coolant temperature 80° 3 (a: Blue)
C
Coolant temperature 60° 2 (a: Blue)
C
Coolant temperature 30° 1 (a: White)
C
Defective engine If no failure is found by checks on Cause 1, engine controller is defective.
2
Engine coolant temperature gauge and engine coolant temperature monitor
40-408 PC88MR-10
40 Troubleshooting
E-21 Auto-deceleration monitor does not light up, or does not go out,
while auto-deceleration switch is operated (PC88MR-FFD-400-A-Z0-A)
Auto-deceleration monitor does not light up or does not go out while auto-deceleration switch
Failure is operated.
Related • Condition of signal of auto-decelerator switch can be checked with monitoring function.
monitor
PC88MR-10 40-409
40 Troubleshooting
E-22 Auto-deceleration function does not operate or is not canceled

while lever is operated (PC88MR-FPM-400-A-Z0-A)
Failure Auto-deceleration function does not operate or is not canceled while lever is operated.
Related • Since set engine speed for auto-deceleration is 1,175 rpm, auto-deceleration is not
information actuated or canceled if engine speed set with fuel control dial is below this speed.
a Start engine and perform troubleshooting (with monitoring function).
a If display of monitor is incorrect, perform troubleshooting for "E-42 to 53
Monitoring function does not display *** properly".
When lever is operated:
ON
Swing
When lever is in neutral:
OFF
ON
Travel
OFF
ON
Boom LOWER
Monitoring When lever is in neutral:
code OFF
01900 ON
Boom RAISE
OFF
ON
Arm IN
OFF
Defective PPC oil ON
1 pressure signal Arm OUT
Monitoring OFF
display When lever is operated:
ON
Bucket CURL
OFF
ON
Bucket DUMP
code OFF
01901 ON
Blade RAISE
OFF
ON
Blade LOWER
OFF
ON
Boom swing left
code OFF
01902 ON
Boom swing right
OFF
40-410 PC88MR-10
40 Troubleshooting

Defective machine If no failure is found by preceding checks, machine monitor may be defective.
2
Pump controller is If no failure is found by preceding checks, pump controller may be defective.
3
Defective engine If no failure is found by preceding checks, engine controller may be defective.
4
PC88MR-10 40-411
40 Troubleshooting
E-23 Working mode selection screen is not displayed while working

mode selector switch is operated (PC88MR-FFE-400-A-Z0-A)
Working mode selection screen is not displayed while working mode selector switch is
Failure operated.
Related • Signal of working mode switch can be checked with monitoring function.
monitor
40-412 PC88MR-10
40 Troubleshooting
E-24 Setting of engine and hydraulic pump is not changed while working
mode is changed (PC88MR-FP9-400-A-Z0-A)
Failure Setting of engine and hydraulic pump is not changed while working mode is changed.
Related
information
monitor
Pump controller is Pump controller may be defective. (Since this is an internal defect,
defective.
PC88MR-10 40-413
40 Troubleshooting
E-25 Travel speed monitor does not change when travel speed switch is
operated (PC88MR-FFF-400-A-Z0-A)
Failure Travel speed monitor does not change while travel speed switch is operated.
Related • Condition of signal of travel speed switch can be checked with monitoring function.
monitor
40-414 PC88MR-10
40 Troubleshooting
E-26 Travel speed does not change while travel speed selection is
changed (PC88MR-BQ3-400-A-Z0-A)
Failure Travel speed does not change while travel speed selection is changed.
• If Cause 1 occurs, actual travel speed does not lower when travel speed selection is
Related changed to Lo.
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
2
If no failure is found by checks on Causes 1 and 2, pump controller may be
Pump controller is defective.
3
defective.
PC88MR-10 40-415
40 Troubleshooting
E-27 Alarm buzzer does not stop sounding (PC88MR-KB3-400-A-Z0-A)
Failure Alarm buzzer does not stop sounding.

• Condition of signal of alarm buzzer cancel switch can be checked with monitoring
Related function.
monitor
40-416 PC88MR-10
40 Troubleshooting
E-28 Service meter is not displayed, while starting switch is in OFF

position (PC88MR-FFL-400-A-Z0-A)
Failure Service meter is not displayed while starting switch is in OFF position.
• When following switches are operated while stating switch is in OFF position, service
Related meter appears at top center of screen.
information Operation of switches: [4] and [1] (press simultaneously)
When starting switch is turned to ON position, if machine monitor displays
nothing, backup power supply system may be defective. In this case, perform
Defective backup power the following troubleshooting.
1 supply system
• E-4 When starting switch is turned to ON position, machine monitor
displays nothing
2
PC88MR-10 40-417
40 Troubleshooting
E-29 Service mode cannot be selected (PC88MR-HB1-400-A-Z0-A)
Failure Service mode cannot be selected.

• Operate the following switch operations, then service mode is displayed.
Related Operation of switches: [4] + [1]o[2]o[3] (While pressing [4], press [1], [2] and [3] in this
information order.)
monitor
40-418 PC88MR-10
40 Troubleshooting
E-30 Any of work equipment, swing and travel does not work (PC88MR-FT5-400-A-
Z0-A)
Failure None of work equipment, swing or travel works.

Related
information
Defective fuse No. 3 of If fuse is burnt out, circuit may have ground fault, etc. (See check on Cause
1 8.)
F01
Defective PPC lock 1. Turn starting switch to OFF position.
lever relay 2. Replace PPC lock lever relay R12 with R08
2 3. Start engine.
(Internal open or short
4. Set the lock lever to FREE position.
circuit)
If work equipment moves, original PPC lock lever relay is defective.
Defective PPC lock 2. Disconnect connector S14 and connect T-adapter to female side.
3 switch 3. Operate lock lever and perform troubleshooting.
(Internal open circuit) FREE Max. 1 z
Resistance Between S14 (female) (1) and (2)
LOCK Min. 1 Mz
solenoid 2. Disconnect connector V01 and connect T-adapter to male side.
4
(Internal open, short Between V01 (male) (1) and (2) 20 to 60 z
circuit, or ground fault) Resistance
2. Disconnect connector D01 and connect T-adapter to male side.
Defective diode array
5 D01 a Measure it with diode range of multimeter.
(Internal ground fault) Continuity Between D01 (male) (8) (+) and (4) (-) Continuity
No
Continuity Between D01 (male) (4) (+) and (8) (-)
continuity
2. Remove fuse No. 3.
Open or short circuit in 3. Set PPC lock switch to FREE position.
6 wiring harness
Between fuse F01-3 outlet and ground
Resistance 20 to 60 z
a Resistance of PPC lock solenoid
2.Remove fuse No. 3.
3.Disconnect connectors S14, V01, R12, and CP02, and connect T-adapter
Open circuit in wiring to each female side.
7 Between V01 (female) (2) and ground
harness Max. 1 z
Between V01 (female) (1) and R12 (female) (5) Max. 1 z
Resistance Between R12 (female) (3) and S14 (male) (2) 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
40 Troubleshooting

2. Remove fuse No. 3.
Ground fault in wiring 3. Disconnect connectors S14, D01, V01, and R12, and then connect T-
harness adapter to male side of S14 or female side of V01.
8
(Contact with ground Between ground and V01 (female) (1) or R12
circuit) (female) (5) Min. 1 Mz
Resistance Between ground and R12 (female) (3) or S14
(male) (2) Min. 1 Mz
Between S14 (male) (1) and ground Min. 1 Mz
9
40-420 PC88MR-10
40 Troubleshooting
E-31 Any of work equipment, swing and travel cannot be locked (PC88MR-FT7-
400-A-Z0-A)
Failure Any of work equipment, swing, and travel cannot be locked.

Related
information
Defective lock lever 1. Turn starting switch to OFF position.

switch 2. Disconnect connector S14 and connect T-adapter to female side.
1
(internal short circuit) Between S14 (female) Lock lever: LOCK Min. 1 Mz
Resistance (1) and (2)
Lock lever: FREE Max. 1 z
lever relay 2. Replace PPC lock lever relay R12 with R08
2 3. Start engine.
4. Set the lock lever to FREE position.
circuit)
If work equipment moves, original PPC lock lever relay is defective.
2. Disconnect connector V01 and connect T-adapter to female side.
Hot short circuit in
wiring harness
4. Turn lock lever to LOCK position.
Voltage Between V01 (female) (2) and (1) Max. 1 V
PC88MR-10 40-421
40 Troubleshooting
40-422 PC88MR-10
40 Troubleshooting
E-32 Upper structure does not swing while swing parking brake cancel
switch is set to CANCEL position (PC88MR-FGM-400-A-Z0-A)
Upper structure does not swing while swing parking brake cancel switch is set to CANCEL
Failure position.
Related • Condition of swing lock switch signal can be checked with monitoring function.
information (Pump controller system code: 02200)
Defective fuse No. 1 in If fuse is burnt out, circuit probably has ground fault. In this case, perform
1
fuse box F01 check on Cause 5 first.
Defective swing parking 2. Disconnect connector S25 and connect T-adapter to male side.
2 brake cancel switch Swing parking brake
Between S25 (male) (13) cancel switch: Normal Min. 1 Mz
(internal short circuit) Resistance and (14)
Swing parking brake
Max. 1 z
cancel switch: FREE
2. Remove diode array and connect T-adapter to male side.
(Internal short circuit) Continuity Between D01 (male) (7) (+) and (3) (-) Continuity
No
continuity
(Internal short circuit) Continuity Between D03 (male) (5) (+) and (1) (-) Continuity
No
continuity
2. Disconnect connector V03 and connect T-adapter to female side.
Defective wiring a Swing lock switch OFF position
5
harness
Swing parking brake
Between V03 (female) 20 to 30 V
Voltage cancel switch: FREE
(1) and (2) Swing parking brake
Max. 1 V
cancel switch: Normal
harness 2. Disconnect connectors V03 and S25 and connect T-adapters to each
6 (Wire breakage or male side.
defective contact of a Swing lock switch OFF position
connector)
Between V03 (female) (1) and S25 (female) (8) Max. 1 z
Resistance
Between V03 (female) (2) and ground Max. 1 z
Ground fault in wiring a If no failure is found by check on Cause 5, this check is not required.
7 2. Disconnect connectors S25 and V03 and connect T-adapter to female side
circuit) of V03.
Resistance Between V03 (female) (1) and ground Min. 1 Mz
PC88MR-10 40-423
40 Troubleshooting
Circuit diagram related to swing parking brake
40-424 PC88MR-10
40 Troubleshooting
E-33 Swing brake does not operate while swing parking brake cancel
switch is set to NORMAL position (PC88MR-FGN-400-A-Z0-A)
Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
Failure position.
Related
information
Defective swing parking 2. Disconnect connector S25 and connect T-adapter to male side.
1 brake cancel switch Swing parking brake
Between S25 (male) (13) cancel switch: Normal Min. 1 Mz
(internal short circuit) Resistance and (14)
Swing parking brake
Max. 1 z
cancel switch: FREE
wiring harness 3. Turn starting switch to ON position.
2 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
40 Troubleshooting
Circuit diagram related to swing parking brake solenoid
40-426 PC88MR-10
40 Troubleshooting
E-34 Work equipment does not operate while lock lever automatic
release switch is in release position (PC88MR-K1V-400-A-Z0-A)
Work equipment does not operate while lock lever automatic release switch is in release
Failure position.
Related
information
Defective fuse No. 3 of If fuse is burnt out, circuit may have ground fault, etc. (See check on Cause
1 6.)
F01
2. Disconnect connector S25 and connect T-adapter to male side.
Lock lever automatic
2 Defective switch lock cancel switch: Min 1 Mz
Resistance and (7) Normal
Lock lever automatic
Max. 1 z
lock cancel switch: Error
2. Disconnect diode array D03 and connect T-adapters to male side.
(Internal ground fault) Between D03 (male) (7) (+) and (3) (-) Continuity
Continuity No
continuity
Open circuit in wiring 2. Disconnect connectors S25 and CP01 and connect T-adapters to each
4
harness female side.
Resistance Between CP01 (female) (22) and S25 (female) (8) Max. 1 z
Pump controller is If no failure is found by above checks, pump controller is defective. (Since this
5 is an internal defect, troubleshooting cannot be performed.)
defective.
2.Remove fuse No. 3.
Ground fault in wiring 3.Disconnect connectors S14, D03, V01, and S25, and then connect T-
harness adapter to male side of S14 or female side of V01.
6
(Contact with ground Between ground and V01 (female) (1) or S25
circuit) (female) (8) Min 1 Mz
Resistance Between ground and S14 (male) (1) or S25
(female) (7) Min 1 Mz
Between S14 (male) (1) and ground Min 1 Mz
PC88MR-10 40-427
40 Troubleshooting
40-428 PC88MR-10
40 Troubleshooting
E-35 Alarm does not sound during travel (PC88MR-KA4-400-A-Z0-A)
Failure Alarm does not sound during travel.

Related
information
a Be ready with starting switch OFF, then run engine to perform
troubleshooting.
a If monitoring data is not displayed normally, perform troubleshooting for "E-
49 Travel is not displayed correctly with monitoring function".
1 Defective travel signal
Monitoring code Item Correct display
When both levers
operated: ON
01900 Travel
OFF
Defective travel alarm 3. Start engine and operate travel lever.
2
(Internal defect) a If voltage is normal but travel alarm does not sound, travel alarm is
defective.
Voltage Between M14 (female) (1) and (2) 20 to 30 V
harness 2. Disconnect connectors M14 and CP02, and connect T-adapters to each
defective contact of Between CP02 (female) (107) and M14 (female) (1) Max. 1 z
Between M14 (female) (2) and ground Max. 1 z
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
4 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz
PC88MR-10 40-429
40 Troubleshooting
E-36 Alarm does not stop sounding while machine is stopped (PC88MR-KB5-400-A-
Z0-A)
Failure Alarm does not stop sounding while machine is stopped.

Related
information
Defective travel PPC oil
pressure sensor system Perform troubleshooting for “E-51 Travel is not displayed correctly with
1
(Internal open or short monitoring function”.
circuit)
Hot short circuit in 2. Disconnect connector M14 and connect T-adapter to female side.
Voltage Between M14 (female) (1) and ground Max. 1 V
40-430 PC88MR-10
40 Troubleshooting
E-37 Horn does not sound (PC88MR-KA2-400-A-Z0-A)
Failure Horn does not sound.

Related
information
Defective fuses F01-5 If fuses F01-5 and F01-8 are blown out, the circuit probably has ground fault.
1 In this case, perform check on cause 8 first.
and F01-8
Defective horn relay 2. Replace horn relay (connector: R08) with another relay.
2 (Internal open or short 3. Turn starting switch to ON position.
circuit) 4. Press horn switch.
If horn sounds, original horn relay is defective.
3 D03 a Measure it in diode range.
(Internal short circuit) Between D03 (male) (8) (+) and (4) (-) Continuity
Continuity No
continuity
Defective horn switch 1. Turn starting switch to OFF position.

2. Disconnect connector M22 and connect T-adapter to male side.
circuit) Between M22 (male) (1) Switch: OFF Min. 1 Mz
Resistance and (2)
Switch: ON Max. 1 z
Defective horn (M07) 1. Turn starting switch to OFF position.
5 (Internal open or short 2. Disconnect connector M07 and connect T-adapter to male side.
circuit) Continuity Between M07 (male) (1) and (2) Continuity
Defective wiring
harness
4. Press R.H. knob switch.
Voltage Between M07 (female) (1) and (2) 20 to 30 V
2. Disconnect connector R08, and connect T-adapter to female side.
Continuity Between R08 (female) (5) and ground Continuity
a If no failure is found by check on cause 6 or preceding check, this check is
Open circuit in wiring not required.
harness
7 (Wire breakage or 2. Remove fuse F01-5 and F01-8
defective contact of 3. Disconnect connectors R08 and M22, and connect T-adapters to each
connector) female side.
Between F01-8 and M22 (female) (1) Max. 1 z
Between M22 (female) (2) and R08 (female) (1) Max. 1 z
Resistance
Between R08 (female) (2) and ground Max. 1 z
Between R08 (female) (3) and F01-5 Max. 1 z
a If fuse is not burnt out, this check is not required.
Ground fault in wiring 2.Remove fuse F01-5 and F01-8
harness 3.Disconnect connector R08, M07, M08, and connect T-adapter to female
8
(Contact with ground side.
circuit) Between R08 (female) (1) and ground Min. 1 Mz
Resistance Between R08 (female) (3) and ground Min. 1 Mz
Between R08 (female) (5) and ground Min. 1 Mz
Defective horn
9 If no failure is found by preceding checks, horn may be defective.
(Internal defect)
PC88MR-10 40-431
40 Troubleshooting
Circuit diagram related to horn
40-432 PC88MR-10
40 Troubleshooting
E-38 Horn does not stop sounding (PC88MR-KB2-400-A-Z0-A)
Failure Horn does not stop sounding.

Related
information
Defective horn switch 1. Turn starting switch to OFF position.

2. Disconnect connector M22 and connect T-adapter to male side.
Between M22 (male) (1) Switch: OFF Min. 1 Mz
circuit) Resistance and (2)
Switch: ON Max. 1 z
Defective horn relay 2. Replace horn relay (connector: R08) with another relay.
2 (Internal open or short 3. Turn starting switch to ON position.
circuit) 4. Press horn switch.
If horn sounds, original horn relay is defective.
Hot short circuit in 2. Disconnect connector M07, and connect T-adapter to female side.
Voltage Between M07 (female) (1) and (2) Max. 1 V
Circuit diagram related to horn
PC88MR-10 40-433
40 Troubleshooting
E-39 Wiper monitor does not light up, or does not go out, while wiper
switch is operated (PC138-FG4-400-A-Z0-A)
Failure 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)
monitor
40-434 PC88MR-10
40 Troubleshooting
E-40 Wiper does not operate while wiper switch is operated (PC88MR-FG0-400-A-Z0-A)
Failure Wiper does not operate while wiper switch is operated.

• Condition of window rear limit switch signal can be checked with monitoring function.
information • Wiper motor is troubleshooted for failure codes [DY20KA], [DY20MA], [DY2DKB], and
[DY2EKB].
Defective rear limit 2. Disconnect connector W03.
1 switch for window Front window: When
Min. 1 Mz
(internal short circuit) Between W03 (male) (1) closed
Resistance and (2) Front window: When
pulled up Max. 1 z

2 2. Disconnect connector M05 and connect T-adapter to female side.
Continuity Between M05 (female) (1) and (3) Continuity
a Wiper motor system
Open circuit in wiring See troubleshooting for [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].
harness
a Rear limit switch system
3 (Wire breakage or
defective contact of 1. Turn starting switch to OFF position.
connector) 2. Disconnect connector CP01 and connect T-adapter to female side.
3. Front window: When pulled up
Resistance Between CP01 (female) (76) and ground Max. 1 z
harness 2. Disconnect connector CP01 and connect T-adapter to female side.
4
(Contact with ground 3. Front window: When closed
circuit) Resistance Between CP01 (female) (76) and ground Min. 1 Mz
5
PC88MR-10 40-435
40 Troubleshooting
Circuit diagram related to wiper motor
40-436 PC88MR-10
40 Troubleshooting
E-41 Window washer does not operate while window washer switch is
operated (PC138-FH0-400-A-Z0-A)
Failure Window washer does not operate while window washer switch is operated.
• Condition of window washer switch signal can be checked with monitoring function.
information • Failure in window washer is expressed by failure code [DY2CKB].
monitor
PC88MR-10 40-437
40 Troubleshooting
E-42 Boom LOWER is not displayed correctly with monitoring

function (PC88MR-FFR-400-A-Z0-A)
Failure "Boom LOWER" is not displayed correctly with monitoring function.
Related • Monitoring code: 01900 Pressure Switch 1
information
Defective boom
LOWER PPC oil
1 pressure sensor system Perform troubleshooting for failure codes [DHS9MA].
(internal open or short
circuit)
40-438 PC88MR-10
40 Troubleshooting
E-43 Arm OUT is not displayed correctly with monitoring function (PC88MR-
FFS-400-A-Z0-A)
Failure "Arm OUT" is not displayed correctly with monitoring function.

information
Defective Arm OUT
PPC oil pressure
1 Perform troubleshooting for failure codes [DHSCMA].
sensor system (internal
open or short circuit)
PC88MR-10 40-439
40 Troubleshooting
E-44 Arm IN is not displayed correctly with monitoring function (PC88MR-FFN-

400-A-Z0-A)
Failure "Arm IN" is not displayed correctly with monitoring function.

information
Defective arm IN PPC
oil pressure sensor
1 Perform troubleshooting for failure codes [DHS3MA].
system (internal open or
short circuit)
40-440 PC88MR-10
40 Troubleshooting
E-45 Boom RAISE is not displayed correctly with monitoring

function (PC88MR-FFM-400-A-Z0-A)
Failure "Boom RAISE" is not displayed correctly with monitoring function.
information
Defective boom RAISE
PPC oil pressure
PC88MR-10 40-441
40 Troubleshooting
E-46 Bucket CURL is not displayed correctly with monitoring

function (PC88MR-FFP-400-A-Z0-A)
Failure "Bucket CURL" is not displayed correctly with monitoring function.
information
Defective bucket CURL
PPC oil pressure
40-442 PC88MR-10
40 Troubleshooting
E-47 Bucket DUMP is not displayed correctly with monitoring

function (PC88MR-FFQ-400-A-Z0-A)
Failure "Bucket DUMP" is not displayed correctly with monitoring function.
information
Defective bucket DUMP
PPC oil pressure
1 Perform troubleshooting for failure codes [DHSDMA].
PC88MR-10 40-443
40 Troubleshooting
E-48 Boom swing left is not displayed correctly with monitoring

function (PC88MR-K1W-400-A-Z0-A)
Failure "Boom swing left" is not displayed correctly with monitoring function.
information
Defective Boom swing
left PPC oil pressure
1 Perform troubleshooting for failure codes [DHSPMA].
40-444 PC88MR-10
40 Troubleshooting
E-49 Boom swing right is not displayed correctly with monitoring

function (PC88MR-K1X-400-A-Z0-A)
Failure "Boom swing right" is not displayed correctly with monitoring function.
information
Defective Boom swing
right PPC oil pressure
1 Perform troubleshooting for failure codes [DHSQMA].
PC88MR-10 40-445
40 Troubleshooting
E-50 Swing is not displayed correctly with monitoring function (PC88MR-FFT-400-

A-Z0-A)
Failure "Swing" is not displayed correctly with monitoring function.

information
Defective swing PPC oil
1 Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA].
(internal open or short
circuit)
40-446 PC88MR-10
40 Troubleshooting
E-51 Travel is not displayed correctly with monitoring function (PC88MR-FFU-400-

A-Z0-A)
Failure "Travel" is not displayed correctly with monitoring function.

information
Defective travel PPC oil
circuit)
PC88MR-10 40-447
40 Troubleshooting
E-52 Blade RAISE ON is not displayed correctly with monitoring

function (PC88MR-HBS-400-A-Z0-A)
Failure Blade RAISE is not displayed correctly with monitoring function.
• Monitoring code: 01901 Pressure Switch 2
Related • Use "short socket adapter": 799-601-7230 for 2-pin X connector in test for cause 6.
information • As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot
Defective blade raise 3. Start engine.
PPC oil pressure switch 4. Operate blade control lever and perform troubleshooting.
1 (internal open or short Blade control lever:
circuit) Between P12 (male) (1) NEUTRAL Min. 1 Mz
Resistance and (2)
Blade control lever:
Max. 1 z
Blade RAISE
3. Start engine.
Defective harness or 4. Operate blade control lever and perform troubleshooting.
2 pump controller Blade control lever: Approxi-
NEUTRAL mately 7 V
Max. 1 V
Blade RAISE
harness (wire breakage 2. Disconnect connectors CP01 and P12 and connect T-adapters to each
3 or defective contact of female side.
Resistance
Between P12 (female) (1) and ground (T11) Max. 1 z
4 harness (contact with 2. Disconnect connectors CP01 and P12, and connect T-adapter to either
ground circuit) female side.

Hot short circuit in 2. Disconnect connector P12, and connect T-adapter to female side.
Approxi-
Voltage Between P12 (female) (2) and ground
mately 7 V
3. Connect "short socket adapter" to female side of T-adapter.
Pump controller is 4. Turn starting switch to ON position.
6
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
40 Troubleshooting
Circuit diagram related to blade RAISE oil pressure switch
PC88MR-10 40-449
40 Troubleshooting
E-53 Blade LOWER ON is not displayed correctly with monitoring

function (PC88MR-HBT-400-A-Z0-A)
Failure Blade LOWER is not displayed correctly with monitoring function.
• Monitoring code: 01901 Pressure Switch 2
Related • Use "short socket adapter": 799-601-7230 for 2-pin X connector in test for cause 6.
information • As pump controller connector uses "socket-type box" T-adapter, operating voltage cannot
Defective blade lower 3. Start engine.
PPC oil pressure switch 4. Operate blade control lever and perform troubleshooting.
1 (internal open or short Blade control lever:
circuit) Between B13 (male) (1) NEUTRAL Min. 1 Mz
Resistance and (2)
Max. 1 z
Blade LOWER
3. Start engine.
Defective harness or 4. Operate blade control lever and perform troubleshooting.
2 pump controller Blade control lever: Approxi-
NEUTRAL mately 7 V
Max. 1 V
Blade LOWER
harness (wire breakage 2. Disconnect connectors CP01 and P13 and connect T-adapters to each
3 or defective contact of female side.
Resistance
Between P13 (female) (1) and ground (T11) Max. 1 z
4 harness (contact with 2. Disconnect connectors CP01 and P13, and connect T-adapter to either
ground circuit) female side.
Resistance (female) (2) Max. 1 Mz

Hot short circuit in 2. Disconnect connector P13, and connect T-adapter to female side.
Approxi-
Voltage Between P13 (female) (2) and ground
mately 7 V
3. Connect "short socket adapter" to female side of T-adapter.
Pump controller is 4. Turn starting switch to ON position.
6
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
40 Troubleshooting
Circuit diagram related to blade LOWER oil pressure switch
PC88MR-10 40-451
40 Troubleshooting
E-54 KOMTRAX system does not operate normally (PC88MR-F50-400-A-Z0-A)
Failure KOMTRAX system does not operate normally.

• Perform following troubleshooting if administrator of KOMTRAX system requests to check
Related whether failure occurs in system on machine.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Check all results of troubleshooting on service menu display of machine monitor.
Defective 2. Display "Terminal status" screen.
1
communication 1 Monitoring
Check item: Station set-up check Complete
display
2. Display "GPS & Communication Status" screen.
N ###.##.## (Latitude)
Defective positioning by Monitoring
2 Check item: Positioning E ###.##.## (Longitude)
GPS display
Positioning in Progress
If latitude and longitude are not displayed within 5 minutes under the open
sky, contact KOMTRAX support center.
2. Display "GPS & Communication Status" screen.
Defective Monitoring Satellite in View or No
3 communication display Check item: Communication
Satellite in View
environment If Communication Status does not display "Satellite in view" within 15 minutes
under the open sky, check whether the connector of TC330 or the antenna on
top of cab is properly connected.
Defective 2. Display "GPS & Communication Status" screen.
4
communication 2 Monitoring Check item: Number of message(s)
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
40 Troubleshooting
PC88MR-10 40-453
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting of hydraulic and mechanical system (H-mode) (ALL-

3840-001-A-02-A)
Information described in troubleshooting table (H-mode) (ALL-5170-010-A-00-A)
(Rev. 2011/03)
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5
40-454 PC88MR-10
40 Troubleshooting
mode)
System chart of hydraulic and mechanical systems (PC88MR-C000-054-K-00-A)
PC88MR-10 40-455
40 Troubleshooting
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
40 Troubleshooting
mode)
Failure mode and cause table (PC88MR-5340-40D-A-Z0-A)

Component causing failure Hydraulic pump
Tank
Troubleshooting code
Check valve, shuttle valve
Engine system
PC-EPC valve
Hydraulic oil
Servo piston
Piston pump
PC valve
LS valve
Strainer
Damper
Cap
Failure mode
All work equipment, and swing and travel system operate slowly or lack
q q q q q q q q H-1
power
Engine speed lowers extremely or engine stalls q q q q q q H-2
Whole work equipment
Any of work equipment, travel and swing does not work q q q H-3
Swing, travel
Unusual noise is heard from around hydraulic pump q q q q H-4
Fine control performance or response is poor q q H-5
Boom speed or power is low H-6
Arm speed or power is low H-7
Bucket speed or power is low H-8
Boom swing speed or power is low H-9
Blade speed or power is low H-10

Work equipment
Work equipment does not move in single operation H-11
Boom H-12
Arm H-13
Hydraulic drift of work equipment is large
Bucket H-14
Blade H-15
Time lag of work equipment is large H-16

In combined operation of work equipment, equipment having heavier load
H-17
moves slower
Swing +
Boom
In combined operations of swing and boom RAISE, boom rising speed is

H-18
low
Work equipment or Swing＋
Travel
In combined operation of work equipment or swing and travel, travel

H-19
speed drops largely
Machine does not travel straight q H-20
Travel speed is slow H-21

Travel
Machine is hard to steer or travel power is low q H-22
Travel speed does not change, or travel speed is too slow or fast H-23
PC88MR-10 40-457
40 Troubleshooting
mode)
Component causing failure Hydraulic pump

Tank
Check valve, shuttle valve
Engine system
PC-EPC valve
Hydraulic oil
Servo piston
Piston pump
PC valve
LS valve
Strainer
Damper
Cap
Failure mode
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
In both directions (right and
H-27
Swing acceleration or swing speed is low left)
In only one direction H-28
Swing
Upper structure overruns excessively when (Both right and left) H-29
it stops swinging (Either right or left) H-30
Shock is large when upper structure stops swinging H-31
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
Attachment
Oil flow in attachment circuit cannot be controlled H-35
40-458 PC88MR-10
40 Troubleshooting
mode)
Component causing failure

Control valve
Pressure compensation valve
Self-pressure reducing valve
Boom regeneration valve
Arm regeneration valve
Boom rise assist valve
Travel junction valve
Merge-divider valve
Main relief valve
Boom lock valve

LS line orifice
Suction valve
Unload valve
Safety valve
Spool
Failure mode
All work equipment, and swing and travel system operate slowly or
q q q H-1
lack power
Engine speed lowers extremely or engine stalls H-2
Any of work equipment, travel and swing does not work q H-3
Swing, travel
Unusual noise is heard from around hydraulic pump H-4
Fine control performance or response is poor q H-5
Boom speed or power is low q q q q q H-6
Arm speed or power is low q q q q H-7
Bucket speed or power is low q q q H-8
Boom swing speed or power is low q q q H-9
Blade speed or power is low q q q H-10

Work equipment
Work equipment does not move in single operation q q H-11
Boom q q q H-12
Arm q q q H-13
Bucket q q q q H-14
Blade q q H-15
Time lag of work equipment is large q q H-16

In combined operation of work equipment, equipment having heavier
q H-17
load moves slower
Swing +
In combined operations of swing and boom RAISE, boom rising

Boom
q H-18
speed is low
Travel

q q q H-19
speed drops largely
Machine does not travel straight q q q q q H-20
Travel speed is slow q q q q q q H-21

Travel
Machine is hard to steer or travel power is low q q q q q H-22
Travel speed does not change, or travel speed is too slow or fast H-23
One of tracks does not run q q H-24
PC88MR-10 40-459
40 Troubleshooting
mode)

Control valve
Pressure compensation valve
Self-pressure reducing valve
Boom regeneration valve
Arm regeneration valve
Boom rise assist valve
Travel junction valve
Merge-divider valve
Main relief valve
Boom lock valve

LS line orifice
Suction valve
Unload valve
Safety valve
Spool
Failure mode
Upper structure does
not swing to the right or q H-25
Machine does not swing left
Upper structure swing
q H-26
only to the right or left
In both directions (right
q H-27
Swing acceleration or swing speed is low and left)
In only one direction q H-28
Swing
Upper structure overruns excessively when it (Both right and left) H-29
stops swinging (Either right or left) q H-30
Large unusual noise is heard when upper structure stops swinging H-32
When parking brake
H-33
works
When parking brake is
q H-34
OFF
Attachment
40-460 PC88MR-10
40 Troubleshooting
mode)
Component causing failure Swing motor

Solenoid valve
Travel speed selector solenoid

Swing PPC slow return valve
Work equipment lock solenoid
Swing holding brake solenoid

Pump merge-divider solenoid
PPC valve (travel lever)
PPC valve (right lever)
ATT control EPC valve

PPC valve (left lever)
PPC valve (service)

PPC valve (swing)
PPC valve (blade)
Shock-less valve
Parking brake
Suction valve
Piston motor
Safety valve
Check valve
Failure mode
H-1
power
Engine speed lowers extremely or engine stalls q H-2
Any of work equipment, travel and swing does not work H-3
Swing, travel
Fine control performance or response is poor H-5
Boom speed or power is low q H-6
Arm speed or power is low q H-7
Bucket speed or power is low q H-8
Boom swing speed or power is low q H-9
Blade speed or power is low q H-10

Work equipment
Work equipment does not move in single operation q q H-11
Boom H-12
Arm H-13
Bucket H-14
Blade H-15

H-17
moves slower
Swing +
Boom

H-18
low
Travel

H-19
speed drops largely
Machine does not travel straight q q H-20
Travel speed is slow q q H-21

Travel
Machine is hard to steer or travel power is low q q H-22
Travel speed does not change, or travel speed is too slow or fast q H-23
PC88MR-10 40-461
40 Troubleshooting
mode)
Component causing failure Swing motor

Solenoid valve
Travel speed selector solenoid

Swing PPC slow return valve
Work equipment lock solenoid
Swing holding brake solenoid

Pump merge-divider solenoid
PPC valve (travel lever)
PPC valve (right lever)
ATT control EPC valve

PPC valve (left lever)
PPC valve (service)

PPC valve (swing)
PPC valve (blade)
Shock-less valve
Parking brake
Suction valve
Piston motor
Safety valve
Check valve
Failure mode
One of tracks does not run H-24
q q q q H-25
q q q q H-26
q q q H-27
In only one direction q q q q q H-28
Swing
Upper structure overruns excessively when it (Both right and left) q q H-29
stops swinging (Either right or left) q q q q q q H-30
Shock is large when upper structure stops swinging q q q q H-31
Large unusual noise is heard when upper structure stops swinging q q H-32

When parking brake is OFF q q q q q q H-34
Attachment
Oil flow in attachment circuit cannot be controlled q q H-35
40-462 PC88MR-10
40 Troubleshooting
mode)

Travel motor
Counterbalance valve
Center swivel joint
Hydraulic cylinder
Swing machinery
Parking brake
Piston motor
Safety valve
Check valve
Final drive
Failure mode
H-1
power
Engine speed lowers extremely or engine stalls H-2
Any of work equipment, travel and swing does not work H-3
Swing, travel
Fine control performance or response is poor H-5
Boom speed or power is low q H-6
Arm speed or power is low q H-7
Bucket speed or power is low q H-8
Boom swing speed or power is low q H-9
Blade speed or power is low q H-10

Work equipment
Work equipment does not move in single operation H-11
Boom q H-12
Arm q H-13
Bucket q H-14
Blade q H-15

H-17
moves slower
Swing +
Boom

H-18
low
Travel

H-19
speed drops largely
Machine does not travel straight q q q q q H-20
Travel speed is slow q q H-21

Travel
Machine is hard to steer or travel power is low q q q q H-22
Travel speed does not change, or travel speed is too slow or fast q H-23
One of tracks does not run q q q q q q H-24

q H-25
Swing

H-26
PC88MR-10 40-463
40 Troubleshooting
mode)

Travel motor
Counterbalance valve
Center swivel joint
Hydraulic cylinder
Swing machinery
Parking brake
Piston motor
Safety valve
Check valve
Final drive
Failure mode
q H-27
In only one direction H-28
Upper structure overruns excessively when it (Both right and left) H-29
stops swinging (Either right or left) H-30
Large unusual noise is heard when upper structure stops swinging q H-32

When parking brake is OFF H-34
Attachment
40-464 PC88MR-10
40 Troubleshooting
mode)
H-1 All of work equipments, swing and travel operations lack speed or
power (PC88MR-A8A-400-A-Z0-A)
Failure • All of work equipment, swing and travel operation lacks speed or power.
• Perform all troubleshooting with working mode set in power (P) mode.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information (DXA8KA or DXA8KB)
• Pump pressure can be checked with monitoring function. (monitoring code: 01100)
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of unload high idle.
1
valve 3.4 ± 1.0 MPa
Unload pressure All levers in NEUTRAL
{35 ± 10 kg/cm2}
Defective adjustment of high idle.
2
main relief valve 26.5 ± 1.5 MPa
Main relief pressure Arm IN hydraulic relief
{270 ± 15kg/cm2}
Malfunction of main When pressure cannot be adjusted to normal level, check main relief valve for
3 malfunction (fatigue of spring) and internal defect (defective valve seat).
relief valve
high idle.
Malfunction of self- Control circuit 3.2 ± 0.5 MPa
4 pressure reducing valve source pressure All levers in NEUTRAL
{33 ± 5 kg/cm2}
a Since relief valve of self-pressure reducing valve is not adjustable, replace
self-pressure reducing valve assembly if normal pressure is not obtained.
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and at high idle.
Engine at low idle and all levers in 1.72 to 0.5 MPa
Malfunction of PC-EPC
5 PC-EPC valve NEUTRAL {17.5 to 26.5 kg/cm2}
valve
output pressure Engine at high idle and all levers 0.69 to 1.42 MPa
in NEUTRAL {7.0 to14.5 kg/cm2}
Replace PC-EPC valve if any failure is found.
high idle.
Oil pressure to be Oil pressure ratio
Measurement condition
measured
Defective adjustment of Pump discharge
6 Arm IN hydraulic relief 1
PC valve pressure
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
40 Troubleshooting
mode)

high idle.
Lever position and oil pressure LS differential
Oil pressure to be ratio pressure
Defective adjustment of measured
7 All levers in NEUTRAL Bucket CURL relief
LS valve
Pump discharge Almost same as LS valve output
pressure pressure Approx. 2.11 MPa
LS valve output Almost same as pump discharge {21.5 kg/cm2}
pressure pressure
If normal oil pressure is not obtained after adjustment, check LS valve for
8 Malfunction of LS valve malfunction (fatigue of spring) and internal failure (stuck or seized LS spool).
Malfunction of servo
9 piston or PC valve (*) Servo piston may malfunction. Check it.
If no failure is found by above checks, piston pump may have degraded
Malfunction of piston performance, malfunction, or have internal failure.
10 pump
Check hydraulic tank strainer and return filter element for metal particles.
40-466 PC88MR-10
40 Troubleshooting
mode)
H-2 Engine speed drops significantly or engine stalls (PC88MR-FPN-400-A-Z0-A)
Failure • Engine speed drops significantly or engine stalls.

Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information (DXA8KA or DXA8KB)
Malfunction of main high idle.
1
relief valve 26.5 ± 1.5 MPa
Main relief pressure Arm IN hydraulic relief
{270 ± 15 kg/cm2}
Malfunction of main When pressure cannot be adjusted to normal level, check main relief valve for
2 malfunction (fatigue of spring) and internal defect (defective valve seat).
relief valve
running at low idle and at high idle.
3
Malfunction of PC-EPC Engine at low idle and all levers in 1.72 to 2.60 MPa
valve PC-EPC valve NEUTRAL {17.5 to 26.5 kg/cm2}
output pressure Engine at high idle and all levers 0.69 to 1.42 MPa
in NEUTRAL {7.0 to 14.5 kg/cm2}
high idle.
Oil pressure to be Oil pressure ratio
Defective adjustment of Measurement condition
4 measured
PC valve Pump discharge
Arm IN hydraulic relief 1
pressure
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
5 Malfunction of PC valve malfunction (fatigue of spring) or internal defect (stuck or seized PC spool).

high idle.
measured
Defective adjustment of All levers in NEUTRAL Bucket CURL relief
6 Pump discharge pressure is
LS valve Pump discharge
almost same as LS valve
pressure
pressure. Approx. 2.11 MPa
Pump discharge pressure is {21.5 kg/cm2}
LS valve output
almost same as LS valve
pressure
pressure.
If normal oil pressure is not obtained after adjustment, check LS valve for
7 Malfunction of LS valve malfunction (fatigue of spring) and internal failure (stuck or seized LS spool).
Clogging of orifice or Check orifices and filters in pump servo devices for clogging.
8
filter in serve device
If no failure is found by above checks, piston pump may malfunction or have
Malfunction of servo internal defect.
9 piston
Check hydraulic tank strainer and return filter element for metal particles.
PC88MR-10 40-467
40 Troubleshooting
mode)
H-3 Any of work equipment, swing and travel does not work (PC88MR-FT5-400-A-Z1-
A)
Failure • Any of work equipment, swing and travel does not work.
Related • Perform all troubleshooting with working mode set in power (P) mode.
information
high idle.
Malfunction of work 0 MPa
1 equipment lock When locked
solenoid valve Solenoid output {0 kg/cm2}
pressure When torque converter lockup 3.14 ± 0.5 MPa
clutch is disengaged {32 ± 5 kg/cm2 }
high idle.
2 pressure reducing valve source pressure All control levers in NEUTRAL
{33 ± 5 kg/cm2}
Piston pump may malfunction or has internal defect. Check it by following
method.
3 Defective piston pump
• Crank the engine with main oil pressure pickup port plug removed. o If
any oil flows out, piston pump is normal.
4 Defective damper Pump shaft may not rotate due to some internal defect of damper.
40-468 PC88MR-10
40 Troubleshooting
mode)
H-4 Unusual sound is heard from around hydraulic pump (PC400-BAA-400-A-Z0-A)
Failure • Unusual sound is heard from around hydraulic pump

Related information —
Check hydraulic oil level directly.
1 Lowering of hydraulic oil level (Reference) If the hydraulic oil level is low while no hydraulic oil leaks to
the outside, it is assumed that hydraulic oil may flow in the flywheel
chamber due to a pump shaft seal damage.
2 Defective hydraulic oil Air may mix in hydraulic oil. Check it for bubbles or milky state.
Cap of the hydraulic tank cap may be clogged, causing negative
3 Clogging of hydraulic tank cap
pressure inside the tank. Check the cap.
Clogging of hydraulic tank Strainer in the hydraulic tank may be clogged, causing negative
4 pressure in the suction circuit. Check the strainer.
strainer
Clogging of hydraulic tank Check the return filter in the hydraulic tank may be clogged, especially
5 by metallic materials. Check the return filter.
return filter
If any metallic materials are detected in Cause 4 and 5 above, piston
6 Defective piston pump
pump may have internal defect.
PC88MR-10 40-469
40 Troubleshooting
mode)
H-5 Fine control performance or response is poor (PC88MR-FTB-400-A-Z0-A)
Failure • Fine control performance or response is poor.

information
Clogged orifice in LS Orifice may be clogged. Check it.
1
circuit
high idle.
Defective adjustment of measured
2 All levers in NEUTRAL Bucket CURL relief
LS valve
pressure pressure Approx. 2.11 MPa
LS valve output Almost same as pump discharge {21.5 kg/cm2 }
pressure pressure
When pressure cannot be adjusted to normal level, check LS valve for
3 Malfunction of LS valve malfunction (fatigue of spring) or internal defect (stuck or seized LS spool).
Malfunction of servo
4 Check orifices and filters in pump servo devices for clogging.
piston
40-470 PC88MR-10
40 Troubleshooting
mode)
H-6 Boom speed or power is low (PC88MR-A8B-400-A-Z0-A)
Failure Boom speed or power is low.

information • Pump pressure can be checked with monitoring function. (monitoring code: 01100)
high idle.
Malfunction of R.H. R.H. work
1 PPC valve (boom equipment NEUTRAL 0 MPa {0 kg/cm2}
circuit) PPC valve output control lever
pressure R.H. work
Boom RAISE or 2.65 MPa {27 kg/
equipment cm2} Min
LOWER
control lever
high idle.
Malfunction of merge- Work equipment control lever is in 0 MPa
2
divider solenoid valve Output pressure of neutral {0 kg/cm2}
solenoid valve Bucket CURL and Arm IN 3.14 ± 0.5 MPa
hydraulic relief {32 ± 5 kg/cm2}
a Release remaining pressure from hydraulic tank and piping, and then
perform troubleshooting with engine stopped.
Malfunction of merge- • Check for stuck or seized main spool in merge-divider valve body.
3 divider main spool (Spool must move smoothly and must not be caught.)
• Remove main spool from valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing spool.
Malfunction of merge- • Check for stuck or seized LS spool in merge-divider valve body.
4 divider LS spool (Spool must move smoothly and must not be caught.)
• Remove LS spool from valve body and check it for defects and dirt.
Malfunction of boom • Check for stuck or seized boom spool in control valve body.
5 control valve (spool) (Spool must move smoothly and must not be caught.)
• Remove boom spool from valve body and check it for defects and dirt.
high idle.
26.5 ± 1.5 MPa
Boom relief pressure Boom RAISE hydraulic relief
{270 ± 15 kg/cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Hydraulic oil temperature within
Malfunction of boom operating range, bucket with rated If visible hydraulic
control valve (pressure Hydraulic drift drift is observed, it is
load, boom horizontal, arm
6 compensation valve) abnormal.
cylinder fully retracted
(boom RAISE side)
a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, it is abnormal.)
a 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
40 Troubleshooting
mode)

high idle.
26.5 ± 1.5 MPa
Boom relief pressure Boom LOWER hydraulic relief
{270 ± 15 kg/cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Hydraulic oil temperature: Within
Malfunction of boom operating range, arm cylinder fully If visible hydraulic
control valve (pressure Hydraulic drift drift is observed, it is
extended, machine raised off
ground
(boom LOWER side)
a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, it is abnormal.)
compensation valves on RAISE and LOWER sides, and check whether
(Pressure compensation valves have different area ratio, so be sure to
return them to their original positions after test.)
high idle.
Boom relief pressure Boom RAISE hydraulic relief, arm 26.5 ± 1.5 MPa
and arm relief IN hydraulic relief, or arm OUT
pressure hydraulic relief {270 ± 15 kg/cm2}
Malfunction of boom
8 control valve (safety
valve for lock valve) a Among above relief pressures, if arm IN relief pressure and boom RAISE
relief pressure are low, safety valve may be defective. Check safety valve
for damaged sealing material.
a When disassembling the safety valve, replace the safety valve assembly
with a new one since its relief pressure cannot be adjusted on the
machine.
• Check that pilot piston and poppet are seated on body in position (they are
not stuck halfway).
• Check for stuck or seized pilot piston and poppet in lock valve body (pilot
Malfunction of boom
piston and poppet must move smoothly).
9 control valve (lock
• Remove pilot piston and poppet from valve body and check them for
valve)
defects and dirt.
• Check poppet spring for fatigue and deformation.
high idle.
26.5 ± 1.5 MPa
Boom relief pressure Boom RAISE hydraulic relief
{270 ± 15 kg/cm2}
Malfunction of boom
control valve (suction a Among above relief pressures, if only boom RAISE relief pressure is low,
10 valve) (boom RAISE
suction valve may be defective. Check it.
side)
• Check that check valve is seated on valve body in position (it is not stuck
halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for fatigue and deformation.
Malfunction of boom high idle.
control valve (suction- 26.5 ± 1.5 MPa
11 safety valve) (boom Boom relief pressure Boom LOWER hydraulic relief
{270 ± 15 kg/cm2}
LOWER side)
a If boom LOWER relief pressure is low, suction-safety valve may be
defective.
40-472 PC88MR-10
40 Troubleshooting
mode)

halfway).
machine.
12 Defective boom cylinder high idle.
Leakage from boom
Boom RAISE hydraulic relief Max. 7.5 cc/min
cylinder
PC88MR-10 40-473
40 Troubleshooting
mode)
H-7 Arm speed or power is low (PC88MR-A8C-400-A-Z0-A)
Failure • Arm speed or power is low.

high idle.
L.H. work
Malfunction of left PPC 0 MPa {0 kg/cm2}
1 equipment NEUTRAL
valve (arm circuit) PPC valve output control lever
pressure L.H. work Arm IN or OUT 2.65 MPa {27 kg/
equipment operation cm2} Min
control lever
high idle.
Malfunction of pump 0 MPa
2 merge-divider solenoid Work equipment control lever is in
valve Output pressure of neutral {0 kg/cm2}
Malfunction of merge- • Check for stuck or seized LS spool in merge-divider valve body.
4 divider LS spool (Spool must move smoothly and must not be caught.)
• Remove LS spool from valve body and check it for defects and dirt.
Malfunction of arm • Check for stuck or seized arm spool in control valve body.
• Remove arm spool from valve body and check it for defects and dirt.
high idle.
26.5 ± 1.5 MPa
Arm relief pressure Arm IN hydraulic relief
{270 ± 15 kg/cm2}
a Check hydraulic drift of arm cylinder with engine stopped.
Malfunction of arm Hydraulic oil temperature: Within If visible hydraulic
control valve (pressure Hydraulic drift operating range, bucket with rated drift is observed, it is
6 compensation valve) load, arm cylinder fully extended abnormal.
(arm IN side) a Check whether arm cylinder moves slowly when performing hydraulic
relief of other work equipment. (If arm cylinder moves, it is abnormal.)
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
40 Troubleshooting
mode)

high idle.
26.5 ± 1.5 MPa
Arm relief pressure Arm OUT hydraulic relief
{270 ± 15 kg/cm2}
a Check hydraulic drift of arm cylinder with engine stopped.
Malfunction of arm Hydraulic oil temperature: Within If visible hydraulic
control valve (pressure Hydraulic drift operating range, bucket with rated drift is observed, it is
7 compensation valve) load, arm cylinder fully retracted abnormal.
(arm OUT side) a Check whether arm cylinder moves slowly when performing hydraulic
relief of other work equipment. (If arm cylinder moves, it is abnormal.)
symptom.)
high idle.
26.5 ± 1.5 MPa
Arm relief pressure Arm OUT hydraulic relief
{270 ± 15 kg/cm2}
Malfunction of arm
8 control valve (suction a If arm OUT relief pressure is low, suction valve (check valve) may be
valve) (arm OUT side) defective. Check it.
halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for setting and deformation.
high idle.
26.5 ± 1.5 MPa
{270 ± 15 kg/cm2}
Malfunction of arm
control valve (suction- a If arm IN relief pressure is low, suction-safety valve may be defective.
9 safety valve) (arm IN Check it.
side) • Check that check valve of suction-safety valve is seated on valve body in
position (it is not stuck halfway).
a Since relief pressure cannot be adjusted with safety valve installed on
machine, replace safety valve assembly if safety valve is found to be
defective.
10 Defective arm cylinder high idle.
Leakage from arm
Arm IN hydraulic relief Max. 7.5 cc/min
cylinder
PC88MR-10 40-475
40 Troubleshooting
mode)
H-8 Bucket speed or power is low (PC88MR-A8D-400-A-Z0-A)
Failure • Bucket speed or power is low.

high idle.
Malfunction of R.H. R.H. work
1 PPC valve (bucket equipment NEUTRAL 0 MPa {0 kg/cm2}
circuit) PPC valve output control lever
pressure R.H. work 2.65 MPa {27 kg/
equipment Arm IN or OUT cm2} Min
control lever
high idle.
Malfunction of bucket • Check for stuck or seized bucket spool in control valve body.
• Remove bucket spool from valve body and check it for defects and dirt.
high idle.
Bucket relief 26.5 ± 1.5 MPa
pressure Bucket CURL relief
{270 ± 15 kg/cm2}
a Check hydraulic drift of bucket cylinder with engine stopped.
operating range,
If visible hydraulic
Malfunction of bucket Hydraulic drift bucket with rated load, arm drift is observed, it is
control valve (pressure cylinder fully retracted, bucket abnormal.
5 compensation valve) cylinder fully extended, boom top
(bucket CURL side) face horizontal
a Check whether bucket cylinder moves slowly when performing hydraulic
relief of other work equipment. (If bucket cylinder moves, it is abnormal.)
symptom.)
40-476 PC88MR-10
40 Troubleshooting
mode)

high idle.
Bucket DUMP hydraulic relief
pressure {270 ± 15 kg/cm2}
a Check hydraulic drift of bucket cylinder with engine stopped.
operating range,
Malfunction of bucket If visible hydraulic
Hydraulic drift bucket empty, arm cylinder fully drift is observed, it is
control valve (pressure retracted, bucket cylinder fully
retracted, boom top face
(bucket DUMP side) horizontal
a Check whether bucket cylinder moves slowly when performing hydraulic
relief of other work equipment. (If bucket cylinder moves, it is abnormal.)
symptom.)
high idle.
pressure Bucket CURL relief
Malfunction of bucket {270 ± 15 kg/cm2}
control valve (suction- • If bucket CURL relief pressure is low, suction valve may be defective.
7 safety valve) (bucket Check it.
CURL side) • Check that check valve of suction-safety valve is seated on valve body in
defective.
high idle.
Bucket DUMP hydraulic relief
Malfunction of bucket pressure {270 ± 15 kg/cm2}
control valve (suction- • If bucket DUMP relief pressure is low, suction valve may be defective.
8 safety valve) (bucket Check it.
DUMP side) • Check that check valve of suction-safety valve is seated on valve body in
defective.
Defective bucket high idle.
9 cylinder Leakage from
bucket cylinder Bucket CURL relief Max. 7.5 cc/min
PC88MR-10 40-477
40 Troubleshooting
mode)
H-9 Boom swing speed or power is low (PC88MR-K1Y-400-A-Z0-A)
Failure • Boom swing speed or power is low.

Related • Perform all troubleshooting with working mode set in power mode (P).
Malfunction of boom high idle.
1 swing PPC valve (boom Boom swing
NEUTRAL 0 MPa {0 kg/cm2}
swing circuit) PPC valve output control pedal
pressure Boom swing R.H. or L.H 2.65 MPa {27 kg/
control pedal control cm2} Min
high idle.
2 merge-divider solenoid Work equipment lever is in neutral
valve Output pressure of {0 kg/cm2}
3 divider main spool (It must be moved smoothly and must not be caught.)
• Be careful to prevent foreign matter from entering into it when re-installing
spool.
Malfunction of boom • Check for stuck or seized bucket spool in control valve body.
4 swing control valve (It must be moved smoothly and must not be caught.)
(spool) • Remove bucket spool from valve body and check it for defects and dirt.
spool.
high idle.
Boom swing relief 26.5 ± 1.5 MPa
Boom swing right relief
Malfunction of boom
a Check whether boom swing cylinder moves slowly when performing
swing control valve
hydraulic relief of other work equipment. (If boom cylinder moves, it is
5 (pressure
abnormal.)
compensation valve)
(right swing side) a If any failure is found in either of above check items, interchange pressure
compensation valves on right and left swing sides, and check whether
symptom.)
40-478 PC88MR-10
40 Troubleshooting
mode)

high idle.
Boom swing left relief
Malfunction of boom
swing control valve a Check whether boom swing cylinder moves slowly when performing
6 (pressure hydraulic relief of other work equipment. (If boom cylinder moves, it is
compensation valve) abnormal.)
(left swing side)
compensation valves on right and left swing sides, and check whether
symptom.)
high idle.
Boom swing right relief
Malfunction of boom pressure {270 ± 15 kg/cm2}
swing control valve • If boom swing right relief pressure is low, suction valve may be defective.
7 (suction-safety valve) Check it.
(right swing side) • Check that check valve of suction safety valve is seated on valve body in
defective.
high idle.
Boom swing left relief
Malfunction of boom pressure {270 ± 15 kg/cm2}
swing control valve • If boom swing left relief pressure is low, suction valve may be defective.
8 (suction-safety valve) Check it.
(left swing side) • Check that check valve of suction-safety valve is seated on valve body in
defective.
Defective boom swing high idle.
Boom swing right relief Max. 7.5 cc/min
bucket cylinder
PC88MR-10 40-479
40 Troubleshooting
mode)
H-10 Blade speed or power is low (PC88MR-K1Z-400-A-Z0-A)
Failure • Blade speed or power is low.

Malfunction of blade high idle.
1 PPC valve (blade Blade control 0 MPa {0 kg/cm2}
NEUTRAL
circuit) PPC valve output lever
pressure Blade control Blade RAISE or 2.65 MPa {27 kg/
lever LOWER control cm2} Min
high idle.
spool.
Malfunction of blade • Check for stuck or seized bucket spool in control valve body.
4 control valve (spool) (It must be moved smoothly and must not be caught.)
spool.
high idle.
21.1 ± 1.5 MPa
Blade relief pressure Blade LOWER relief
{215 ± 15 kg/cm2}
Malfunction of blade
5 control valve (LOWER a Check hydraulic drift of blade cylinder with engine stopped.
side) Hydraulic oil temperature: Within
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
40 Troubleshooting
mode)

high idle.
12.7 ± 1.5 MPa
Blade relief pressure Blade RAISE relief
{135 ± 15 kg/cm2}
Malfunction of blade
6 control valve (RAISE a Check hydraulic drift of bucket cylinder with engine stopped.
side) Hydraulic oil temperature: Within
the operating range, fully
retracted blade cylinder, fully If visible hydraulic
Hydraulic drift drift is observed, it is
retracted arm cylinder, fully
retracted bucket cylinder, and abnormal.
boom top face horizontal
high idle.
12.7 ± 1.5 MPa
Blade relief pressure Blade RAISE relief
{135 ± 15 kg/cm2}
Malfunction of boom • If blade RAISE relief pressure is low, suction valve may be defective.
7 RAISE (suction-safety Check it.
valve) • Check that check valve of suction safety valve is seated on valve body in
defective.
high idle.
21.1 ± 1.5 MPa
{215 ± 15 kg/cm2}
Malfunction of blade • If blade LOWER relief pressure is low, suction valve may be defective.
8 LOWER (suction-safety Check it.
valve) • Check that check valve of suction-safety valve is seated on valve body in
defective.
9 Defective blade cylinder high idle.
Leakage from
bucket cylinder Blade LOWER relief Max. 7.5 cc/min
Performance deterioration, malfunction, and internal defect of the gear pump
10 Defective gear pump may be occurred. Check it directly.
PC88MR-10 40-481
40 Troubleshooting
mode)
H-11 Work equipment does not move in single operation (PC88MR-FTC-400-A-Z0-A)
(1) Boom does not move in single operation.

Failure (2) Arm does not move in single operation.
(3) Bucket does not move in single operation.
information
at high idle.
1 Malfunction of PPC valve Work equipment 0 MPa {0 kg/cm2}
NEUTRAL
PPC valve output control lever
pressure Work equipment 2.65 MPa {27 kg/
Operation
control lever cm2} Min
Malfunction of boom • Check for stuck or seized boom spool in control valve body.
2 control valve (spool)
(Spool must move smoothly and must not be caught.)
• Remove boom spool from valve body and check it for defects and dirt.
Malfunction of arm control • Check for stuck or seized arm spool in control valve body.
3 valve (spool)
4 control valve (spool)
(Reference) While work equipment is moved in single operation, if pump pressure remains at approximately 4
MPa {approximately 40 kg/cm2}, control valve spool probably stays at NEUTRAL position. (All oil from pump
is drained to tank through unload valve.)
40-482 PC88MR-10
40 Troubleshooting
mode)
H-12 Hydraulic drift of boom is large (PC88MR-MS3-400-A-Z0-A)
Failure • Hydraulic drift of boom is large.

information
1 Defective boom cylinder high idle.
Leakage from boom
Boom RAISE hydraulic relief Max. 7.5 cc/min
cylinder
high idle.
Boom relief pressure Boom RAISE hydraulic relief or 26.5 MPa
and arm relief arm IN hydraulic relief or arm
pressure OUT hydraulic relief {270 ± 15 kg/cm2}
Malfunction of boom
2 control valve (safety
valve for lock valve) a Among above relief pressures, if arm OUT relief pressure and boom
RAISE relief pressure is low, safety valve may be defective. Check safety
valve for damaged sealing material.
machine.
• Check that pilot piston and poppet are seated on lock valve body in
position (they are not stuck halfway).
Malfunction of boom • Check for stuck or seized pilot piston and poppet in lock valve body (pilot
3 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
40 Troubleshooting
mode)
H-13 Hydraulic drift of arm is large (PC88MR-MS4-400-A-Z0-A)
Failure • Hydraulic drift of arm is large.

information
1 Defective arm cylinder high idle.
Leakage from arm
Arm IN hydraulic relief Max. 7.5 cc/min
cylinder
high idle.
26.5 MPa
{270 ± 15 kg/cm2}
Malfunction of arm
control valve (suction- a Among above relief pressures, if only arm IN relief pressure is low,
2 safety valve) (arm IN suction-safety valve may be defective.
side) • Check that check valve of suction-safety valve is seated on valve body in
defective.
Malfunction of arm perform troubleshooting with engine stopped.
3 control valve (spool) • Check for stuck or seized arm spool in control valve body.
40-484 PC88MR-10
40 Troubleshooting
mode)
H-14 Hydraulic drift of bucket is large (PC88MR-MS2-400-A-Z0-A)
Failure • Hydraulic drift of bucket is large.

information
Defective bucket high idle.
bucket cylinder Bucket CURL relief Max. 7.5 cc/min

high idle.
Malfunction of bucket Bucket relief Bucket CURL or DUMP hydraulic 26.5 ± 1.5 MPa
2 control valve (suction- pressure relief {270 ±15 kg/cm2}
safety valve)
a If relief pressure is low, suction-safety valve may be defective.
a You can replace suction-safety valve with other one and check whether
failure symptom changes for judgment.
PC88MR-10 40-485
40 Troubleshooting
mode)
H-15 Hydraulic drift of blade is large (PC88MR-K2A-400-A-Z0-A)
Failure • Hydraulic drift of blade is large.

information
1 Defective blade cylinder high idle.
Leakage from blade
cylinder Blade LOWER relief Max. 7.5 cc/min

high idle.
Malfunction of blade 21.1 ± 1.5 MPa

2 control valve (suction- {215 ± 15 kg/cm2}
safety valve)
a If relief pressure is low, suction-safety valve may be defective.
Malfunction of blade • Check for stuck or seized bucket spool in control valve body.
3 control valve (spool) (It must be moved smoothly and must not be caught.)
• Remove blade spool from valve body and check it for defects and dirt.
spool.
40-486 PC88MR-10
40 Troubleshooting
mode)
H-16 Time lag of work equipment is large (PC88MR-FTD-400-A-Z0-A)
Failure • Time lag of work equipment is large.

Malfunction of boom • Check for stuck or seized boom regeneration valve in control valve body.
1 control valve (Spool must move smoothly and must not be caught.)
(regeneration valve) • Check that regeneration valve (check valve ) is seated on control valve in
position (it is not stuck halfway), and then remove it from control valve
body and check it for defects and dirt.
• Check spring of check valve for fatigue and deformation.
Malfunction of arm • Check for stuck or seized arm regeneration valve in control valve body.
2 control valve (Spool must move smoothly and must not be caught.)
(regeneration valve) • Check that regeneration valve (check valve ) is seated on control valve in
position (it is not stuck halfway), and then remove it from control valve
body and check it for defects and dirt.
a Check relief pressure of each work equipment. If relief pressure only of
Malfunction of boom boom cylinder head end is unusual, suction-safety valve of boom control
3 control valve (suction- valve may malfunction.
safety valve)
Malfunction of arm arm cylinder bottom end is unusual, suction-safety valve of arm control
4 control valve (suction- valve may malfunction.
safety valve)
Malfunction of bucket bucket cylinder bottom end is unusual, suction-safety valve of bucket
5 control valve (suction- control valve may malfunction.
safety valve)
a Check whether boom cylinder moves slowly to RAISE side when
performing hydraulic relief of other work equipment. (If boom cylinder
Malfunction of boom moves, it is abnormal.)
control valve (pressure a If any failure is found in above check item, interchange pressure
6 compensation valve) compensation valves between both ports, and check whether failure
(boom RAISE side) symptom changes.
symptom.)
Malfunction of boom
control valve (pressure a Check whether boom cylinder moves slowly to LOWER side when
7 compensation valve) performing hydraulic relief of other work equipment. (If boom cylinder
(boom LOWER side) moves, it is abnormal.)
Malfunction of arm
control valve (pressure a Check whether arm cylinder moves slowly to arm IN side when performing
8 compensation valve) hydraulic relief of other work equipment. (If arm cylinder moves, it is
(arm IN side) abnormal.)
PC88MR-10 40-487
40 Troubleshooting
mode)

Malfunction of arm
control valve (pressure a Check whether arm cylinder moves slowly to arm OUT side when
9 compensation valve) performing hydraulic relief of other work equipment. (If arm cylinder moves,
(arm OUT side) it is abnormal.)
Malfunction of bucket
control valve (pressure a Check whether bucket cylinder moves slowly to bucket CURL side when
10 compensation valve) performing hydraulic relief of other work equipment. (If bucket cylinder
(bucket CURL side) moves, it is abnormal.)
control valve (pressure a Check whether bucket cylinder moves slowly to bucket DUMP side when
(bucket DUMP side) moves, it is abnormal.)
40-488 PC88MR-10
40 Troubleshooting
mode)
H-17 In combined operation of work equipment , equipment having

heavier load moves slower (PC88MR-D34-400-A-Z0-A)
Failure • In combined operation of work equipment, equipment having heavier load moves slower.
Related
information
Malfunction of control Operations
Heavier load side Smaller load side
valve on smaller load combined
side (pressure Boom RAISE and
1 Boom RAISE Arm IN
compensation valve) arm IN
(arm IN) Pressure compensation valve of control valve on smaller load side may
malfunction.
side (pressure Boom RAISE and
2 Arm OUT Boom RAISE
compensation valve) arm OUT
(boom RAISE) Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
combined
Boom RAISE and
Boom RAISE Bucket CURL
Malfunction of control bucket CURL
valve on smaller load Pressure compensation valve of control valve on smaller load side may
side (pressure malfunction.
3
compensation valve) Operations
(bucket CURL) combined
Arm OUT and bucket
Arm OUT Bucket CURL
CURL
Pressure compensation valve of control valve on smaller load side may
malfunction.
side (pressure Boom LOWER and
4 Arm OUT Boom LOWER
compensation valve) arm OUT
(boom LOWER) Pressure compensation valve of control valve on smaller load side may
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
40 Troubleshooting
mode)
H-18 In combined operation of swing and boom RAISE, boom rising

speed is low (PC88MR-D35-400-A-Z0-A)
Failure • In combined operations of swing and boom RAISE, boom rising speed is low.
Related • If boom raise single operation is also slow, troubleshoot the following first.
information • H-6 Boom speed or power is low
Malfunction of boom • Check for stuck or seized spool in control valve body.
1 (It must be moved smoothly and must not be caught.)
raise assist valve
• 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.
40-490 PC88MR-10
40 Troubleshooting
mode)
H-19 In combined operation of work equipment or swing and travel,

travel speed drops largely (PC88MR-D26-400-A-Z0-A)
Failure • In combined operation of work equipment or swing and travel, travel speed drops largely.
Related • Before performing troubleshooting, check that the hydraulic oil level tank is normal.
information • Hydraulic oil temperature: 45 to 55°C
Malfunction of pump high idle.
1 merge-divider solenoid Work equipment control lever is in 0 MPa {0 kg/cm2}
valve Main EPC output neutral
pressure 3.14 ± 0.5 MPa
Bucket CURL and Arm IN {32 ± 5 kg/cm2}
spool.
a Check whether boom cylinder moves slowly to RAISE side when
performing hydraulic relief of other work equipment. (If boom cylinder
Malfunction of boom moves, it is abnormal.)
control valve (pressure a If any failure is found in above check item, interchange pressure
3 compensation valve) compensation valves between both ports, and check whether failure
(boom RAISE side) symptom changes.
symptom.)
Malfunction of boom
control valve (pressure a Check whether boom cylinder moves slowly to LOWER side when
4 compensation valve) performing hydraulic relief of other work equipment. (If boom cylinder
(boom LOWER side) moves, it is abnormal.)
Malfunction of arm
control valve (pressure a Check whether arm cylinder moves slowly to arm IN side when performing
5 compensation valve) hydraulic relief of other work equipment. (If arm cylinder moves, it is
(arm IN side) abnormal.)
Malfunction of arm
control valve (pressure a Check whether arm cylinder moves slowly to arm OUT side when
6 compensation valve) performing hydraulic relief of other work equipment. (If arm cylinder moves,
(arm OUT side) it is abnormal.)
control valve (pressure a Check whether bucket cylinder moves slowly to bucket CURL side when
(bucket CURL side) moves, it is abnormal.)
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
8 compensation valve) moves, it is abnormal.)
(bucket DUMP side)
PC88MR-10 40-491
40 Troubleshooting
mode)

high idle.
3.48 (+2.0/-1.5) MPa
Travel relief R.H. travel FORWARD hydraulic
pressure relief {355 (+20/-15) kg/
Malfunction of travel cm2}
control valve (pressure
9 compensation valve) a If only 1 place of right, left, forward, and reverse is abnormal, pressure
(R.H. travel FORWARD compensation valve may malfunction.
side) Interchange pressure compensation valves on FORWARD and
REVERSE sides, and check whether failure symptom changes.
a If relief pressures of R.H. travel FORWARD and L.H. travel REVERSE are
the same and low, main relief valve of rear pump may malfunction. Check
arm relief pressure additionally.
Malfunction of travel high idle.
control valve (pressure Travel relief R.H travel REVERSE hydraulic 26.5 ± 1.5 MPa
10 compensation valve) pressure relief {270 ± 15 kg/cm2}
(R.H. travel REVERSE
side) If measured values in checks on causes (10) and (11) are the same and low,
main relief valve of rear pump may malfunction. Check arm relief pressure
additionally.
control valve (pressure Travel relief L.H. travel FORWARD hydraulic 26.5 ± 1.5 MPa
11 compensation valve) (L. pressure relief {270 ± 15 kg/cm2}
H. travel FORWARD
side) If relief pressures of L.H. travel FORWARD and L.H. travel REVERSE are
same and low, main relief valve of front pump may malfunction. Check bucket
relief pressure additionally.
control valve (pressure Travel relief L.H. travel REVESE hydraulic 26.5 ± 1.5 MPa
H. travel REVERSE
side) If measured values in checks on causes (12) and (13) are same and low,
main relief valve of front pump may malfunction. Check bucket relief pressure
additionally.
40-492 PC88MR-10
40 Troubleshooting
mode)
H-20 Machine does not travel straight (PC88MR-FTF-400-A-Z0-A)
Failure • Machine does not travel straight.

Related • If failure codes are displayed, perform troubleshooting for them first. (DW91KA, DW91KB)
information • Travel PPC pressure can be checked with monitoring function. (monitoring code: 07102,
07103, 07104, 07105)
high idle.
1 pressure reducing valve source pressure All levers in NEUTRAL
{33 ± 5 kg/cm2}
high idle.
Malfunction of R.H. R.H. travel lever FORWARD or Min. 2.65 MPa
2 R.H. travel PPC
travel PPC valve
valve output REVERSE {Min. 27 kg/cm2}
pressure Difference in output pressures Max. 0.4 MPa
between L.H. and R.H. PPC
{Max. 4 kg/cm2}
valves
high idle.
Malfunction of L.H. L.H. travel lever FORWARD or Min. 2.65 MPa
3 L.H. travel PPC
travel PPC valve
{Max. 4 kg/cm2}
valves
4 merge-divider solenoid All levers in NEUTRAL 0 MPa {0 kg/cm2}
valve Output pressure of 3.14 ± 0.5MPa
Travel lever is operated
solenoid valve
independently. {32 ± 5 kg/cm2}
high idle.
Lever position and oil pressure ratio
L.H. track: Running
Oil pressure to be idle off ground in Hi
Defective adjustment of measured All levers in NEUTRAL speed setting
5
LS valve Lever moved
halfway
pressure pressure 1
LS valve output Almost same as pump discharge Approx. 0.6 (Approx.
pressure pressure 3/5)
Malfunction of travel • Check for stuck or seized travel junction valve spool in merge-divider
6 junction valve (spool) valve body.
• Remove travel junction valve spool from valve body and check it for
defects and dirt.
PC88MR-10 40-493
40 Troubleshooting
mode)

Malfunction of unload high idle.
7
valve 3.4 ± 1.0 MPa
Unload pressure All control levers in NEUTRAL
{35 ± 10 kg/cm2}
Malfunction of R.H. perform troubleshooting with engine stopped.
8 travel control valve • 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.
Malfunction of L.H. perform troubleshooting with engine stopped.
Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
10 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
The travel motor may have a defect in it. Check it.
11 Defective travel motor (It may be checked whether or not the direction of travel deviation changes by
swapping right and left travel motor and final drive assemblies.)
12 Defective final drive a Check for unusual noise, unusual heat, and metallic powders in drained oil
to make judgment.
Defective adjustment of
Adjust travel deviation adjustment plug. For details, see Testing and adjusting,
13 travel deviation "Testing and adjusting travel deviation".
adjustment plug
40-494 PC88MR-10
40 Troubleshooting
mode)
H-21 Travel speed is slow (PC88MR-D20-400-A-Z0-A)
Failure • Travel speed is slow.

07103, 07104, 07105)
Malfunction of self- high idle.
1 pressure reducing valve Control circuit 3.2 ± 0.5 MPa
source pressure All control levers in NEUTRAL
{33 ± 5 kg/cm2}
high idle.
Malfunction of R.H. R.H. travel lever FORWARD or Min. 2.65 MPa
2 R.H. travel PPC
travel PPC valve
{Max. 4 kg/cm2}
valves
high idle.
Malfunction of L.H. L.H. travel lever FORWARD or Min. 2.65 MPa
3 L.H. travel PPC
travel PPC valve
pressure Difference in output pressure Max. 0.4 MPa
{Max. 4 kg/cm2}
valves
4 merge-divider solenoid All levers in NEUTRAL 0 MPa {0 kg/cm2}
valve Output pressure of 3.14 ± 0.5MPa
Travel lever is operated
solenoid valve
independently. {32 ± 5 kg/cm2}
• Check for stuck or seized travel junction valve spool in merge-divider
Malfunction of travel valve body.
5 junction valve (spool) (Spool must move smoothly and must not be caught.)
defects and dirt.
Malfunction of pump • Check for stuck or seized main spool in merge-divider valve body.
6 merge-divider valve (Spool must move smoothly and must not be caught.)
Malfunction of travel
7 • Check for stuck or seized travel spool in control valve body.
control valve (spool)
PC88MR-10 40-495
40 Troubleshooting
mode)

high idle.
Malfunction of travel Travel relief Right travel FORWARD hydraulic 26.5 ± 1.5 MPa
control valve (pressure pressure relief {270 ± 15 kg/cm2}
8 compensation valve)
(right travel FORWARD a If only one of right, left, forward, and reverse is abnormal, pressure
side) compensation valve may malfunction.
Interchange pressure compensation valves on FORWARD and
high idle.
(right travel REVERSE Travel relief Right travel REVERSE hydraulic 26.5 ± 1.5 MPa
side) pressure relief {270 ± 15 kg/cm2}
high idle.
(left travel FORWARD Travel relief Left travel FORWARD hydraulic 26.5 ± 1.5 MPa
high idle.
(left travel REVERSE Travel relief Left travel REVESE hydraulic 26.5 ± 1.5 MPa
Malfunction of travel If relief pressure of only 1 port is low after adjusting relief valve, suction valve
12 control valve (suction may malfunction.
valve) Check suction valve (check valve) for defects and fatigue of spring.
to make judgment.
40-496 PC88MR-10
40 Troubleshooting
mode)
H-22 Machine is hard to steer or travel power is low (PC88MR-L18-400-A-Z0-A)
Failure • Machine is hard to steer or travel power is low.

07103, 07104, 07105)
high idle.
Malfunction of R.H.
1 R.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
travel PPC valve
valve output R.H. travel lever FORWARD and Min. 2.65 MPa
pressure REVERSE {Min. 27 kg/cm2}
high idle.
Malfunction of L.H.
2 L.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
travel PPC valve
valve output L.H. travel lever FORWARD and Min. 2.65 MPa
pressure REVERSE {Min. 27 kg/cm2}
high idle.
3 merge-divider solenoid Travel lever in the neutral position
valve Output pressure of {0 kg/cm2}
solenoid valve Single operation of travel (either 3.14 ± 0.5 MPa
or both tracks) {32 ± 5 kg/cm2}
• Check for stuck or seized travel junction valve spool in merge-divider
Malfunction of travel valve body.
4 junction valve (spool) (Spool must move smoothly and must not be caught.)
defects and dirt.
Malfunction of hydraulic The check valve of the hydraulic pump may malfunction or its sealing may be
5 pump (check valve) defective. Check it.
Malfunction of hydraulic The shuttle valve of the hydraulic pump may malfunction or its sealing may be
6 pump (shuttle valve) defective. Check it.
Malfunction of R.H. perform troubleshooting with engine stopped.
Malfunction of L.H. perform troubleshooting with engine stopped.
PC88MR-10 40-497
40 Troubleshooting
mode)

high idle.
3.48 (+2.0/-1.5) MPa
Travel relief R.H. travel FORWARD hydraulic
pressure relief {355 (+20/-15) kg/
Malfunction of travel cm2}
10 compensation valve) a If only 1 place of right, left, forward, and reverse is abnormal, pressure
(R.H. travel FORWARD compensation valve may malfunction.
side) Interchange pressure compensation valves on FORWARD and
a If relief pressures of R.H. travel FORWARD and L.H. travel REVERSE are
the same and low, main relief valve of rear pump may malfunction. Check
arm relief pressure additionally.
control valve (pressure Travel relief R.H travel REVERSE hydraulic 26.5 ± 1.5 MPa
11 compensation valve) pressure relief {270 ± 15 kg/cm2}
(R.H. travel REVERSE
side) If measured values in checks on causes (10) and (11) are the same and low,
main relief valve of rear pump may malfunction. Check arm relief pressure
additionally.
control valve (pressure Travel relief L.H. travel FORWARD hydraulic 26.5 ± 1.5 MPa
H. travel FORWARD
side) If relief pressures of L.H. travel FORWARD and L.H. travel REVERSE are
same and low, main relief valve of front pump may malfunction. Check bucket
relief pressure additionally.
control valve (pressure Travel relief L.H. travel REVESE hydraulic 26.5 ± 1.5 MPa
H. travel REVERSE
side) If measured values in checks on causes (12) and (13) are same and low,
main relief valve of front pump may malfunction. Check bucket relief pressure
additionally.
Malfunction of travel If relief pressure of only 1 port is low after adjusting relief valve, suction valve
14 control valve (suction may malfunction.
valve) Check suction valve (check valve) for defects and fatigue of spring.
Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
15 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
If relief pressures of both R.H. travel FORWARD and REVERSE or those of
R.H. travel FORWARD and REVERSE are unusual in checks on causes (10)
Defective R.H. travel and (11) respectively, respective safety valves are probably defective.
16 motor (safety valve)
Interchange safety valves of L.H. and R.H. travel motors, and check whether
If relief pressures of both L.H. travel FORWARD and REVERSE are unusual
in checks on causes (12) and (13) respectively, respective safety valves may
Defective L.H. travel be defective.
If pressure compensation valves are found to be normal in checks on causes
Defective R.H. travel (10) and (11), check valves may malfunction.
18 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
40 Troubleshooting
mode)

If pressure compensation valves are found to be normal in checks on causes
Defective L.H. travel (12) and (13), check valves may malfunction.
The counterbalance valve and check valve of travel motor may have the
Malfunction of travel malfunction. Check them.
20 motor (counterbalance
valve and check valve) (It may be checked from how the symptom changes after switching between
forward and reverse travel by a motor or after swapping right and left motors.)
PC88MR-10 40-499
40 Troubleshooting
mode)
H-23 Travel speed does not change, or travel speed is too slow or
fast (PC88MR-BQ4-400-A-Z0-A)
Failure • Travel speed does not change, or travel speed is too slow or fast.
Related • If failure codes are displayed, perform troubleshooting for them first.(DW43KA, DW43KB)
information • Travel speed selector solenoid (ON/OFF) can be checked with monitoring function.
(monitoring code: 02300)
high idle.
Travel lever: Travel speed: 0 MPa {0 kg/cm2}
Malfunction of travel NEUTRAL Lo
1 speed solenoid valve
Output pressure of Approx. 3.14 ± 0.5
solenoid valve Travel lever: MPa
Travel speed: Hi
Fine operation {Approx. 32 ±5 kg/
cm2}
If no failure is found by checks on causes (1), speed switching part of travel
2 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
40 Troubleshooting
mode)
H-24 One of tracks does not run (PC88MR-BG1-400-A-Z0-A)
Failure • One of tracks does not run.

Related • Travel PPC pressure can be checked with monitoring function. (monitoring code: 07102,
information 07103, 07104, 07105)
high idle.
Malfunction of R.H.
1 R.H. travel lever NEUTRAL 0 MPa {0 kg/cm2}
travel PPC valve PPC valve output
FORWARD and Min. 2.65 MPa
pressure R.H. travel lever
REVERSE {Min. 27 kg/cm2}
high idle.
Malfunction of L.H.
2 L.H. travel lever NEUTRAL 0 MPa {0 kg/cm2}
travel PPC valve PPC valve output
FORWARD and Min. 2.65 MPa
pressure L.H. travel lever
REVERSE {Min. 27 kg/cm2}
Malfunction of R.H. If no failure is found by check on cause (1) and one track does not run when
3 travel control valve travel control lever is operated with pump pressure at approx. 4 MPa, check
(spool) whether spool is stuck near NEUTRAL position.
Malfunction of L.H. If no failure is found by check on cause (2) and one track does not run when
4 travel control valve travel control lever is operated with pump pressure at approx. 4 MPa, check
(spool) whether spool is stuck near NEUTRAL position.
Malfunction of R.H.
When R.H. travel lever is operated, if R.H. track does not run because of low
5 travel control valve
pump pressure, check suction valve.
(suction valve)
Malfunction of L.H.
When L.H. travel lever is operated, if L.H. track does not run because of low
6 travel control valve
pump pressure, check suction valve.
(suction valve)
high idle.
Travel relief R.H. travel FORWARD and 26.5 ± 1.5 MPa
Defective R.H. travel pressure hydraulic relief REVERSE {270 ± 15 kg/cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
high idle.
Travel relief L.H. travel FORWARD and 26.5 ± 1.5 MPa
Defective L.H. travel pressure hydraulic relief REVERSE {270 ± 15 kg/cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
If safety valve is found to be normal in checks on cause (7), sealing of check
Defective R.H. travel valve may be defective.
9 motor (check valve) Interchange check valves on FORWARD and REVERSE sides of same travel
If safety valve is found to be normal in checks on cause (8), sealing of check
Defective L.H. travel valve may be defective.
PC88MR-10 40-501
40 Troubleshooting
mode)

Defective R.H. travel When running R.H. track idle off ground, if R.H. track does not run with R.H.
11 motor (parking brake) travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
Defective L.H. travel When running L.H. track idle off ground, if L.H. track does not run with L.H.
12 motor (parking brake) travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
to make judgment.
40-502 PC88MR-10
40 Troubleshooting
mode)
H-25 Upper structure does not swing to the right or left (PC88MR-L41-400-A-Z0-A)
Failure • Upper structure does not swing to the right or left.

high idle.
Malfunction of swing Swing control
1 At NEUTRAL 0 MPa {0 kg/cm2}
PPC valve Swing PPC valve lever
output pressure Swing control Left swing and Min. 2.65 MPa
lever Right swing {Min. 27 kg/cm2}
high idle.
Malfunction of swing
2 holding brake solenoid Swing control 0 MPa {0 kg/cm2}
Swing holding brake NEUTRAL
valve lever
solenoid output 3.14 ± 0.5 MPa
Swing control Left swing and
pressure
lever Right swing {32 ± 5 kg/cm2}
When no failure is found by check on cause (1), if upper structure does not
Malfunction of swing swing with swing circuit pressure reaching relief pressure, swing holding
3 motor (swing holding brake may malfunction.
brake)
(Check pump pressure by using monitoring function to make judgment.)
If no failure is found by checks on causes (1) and (2) and upper structure does
4 not swing when swing control lever is operated with pump pressure at approx.
4 MPa, check whether spool is stuck near NEUTRAL position.
high idle.
After troubleshooting, restore the machine to its original state.
Defective swing motor Remove swing
5 (safety valve) Swing relief parking brake Swing hydraulic 20.5 ± 1.5 MPa
pressure solenoid valve relief {210 ± 15 kg/cm2}
connector.
If relief pressures of left swing and right swing are same and low, sealing of
safety valve may be defective.
high idle.
6 Defective swing motor
Remove swing
Leakage from swing parking brake Swing hydraulic
Max. 7 l/min
motor solenoid valve relief
connector.
Swing machinery may have internal failure.
Defective swing
7 machinery a Check for unusual noise, unusual heat, and metallic powders in drained oil
to make judgment.
PC88MR-10 40-503
40 Troubleshooting
mode)
H-26 Upper structure swing only to the right or left (PC88MR-L42-400-A-Z0-A)
Failure • Upper structure swing only to the right or left.

information
high idle.
PPC valve Swing PPC valve lever
output pressure Swing control Left swing and Min. 2.65 MPa
If no failure is found by check on cause (1) and upper structure does not
2 swing when swing control lever is operated with pump pressure at approx. 4
MPa, check whether spool is stuck near NEUTRAL position.
high idle.
Malfunction of swing After troubleshooting, restore the machine to its original state.
3 motor (safety valve) Swing relief Remove swing
parking brake Swing hydraulic 20.5 ± 1.5 MPa
pressure
solenoid valve relief {210 ± 15 kg/cm2}
(pump pressure) connector.
Defective seating of Interchange shuttle valves on left and right swing sides of swing motor, and
4 swing motor (shuttle check whether failure symptom changes to make judgment.
valve) When removing valve, check it for sticking and defects.
Defective seating of Interchange check valves on left and right swing sides of swing motor, and
5 swing motor (check check whether failure symptom changes to make judgment.
40-504 PC88MR-10
40 Troubleshooting
mode)
H-27 Swing acceleration or swing speed is low in both directions (right

and left) (PC88MR-L44-400-A-Z0-A)
Failure • Swing acceleration or swing speed is low in both directions (right and left).
Malfunction of swing Swing spool may malfunction.
1 control valve (spool) Check spool for getting stuck and defects.
high idle.
2 holding brake solenoid Swing control 0 MPa {0 kg/cm2}
Swing holding brake NEUTRAL
valve lever
pressure
lever right swing {32 ± 5 kg/cm2}
If no failure is found by check on cause (2), swing holding brake may
3 motor (swing holding
malfunction (dragging).
brake)
high idle.
connector.
If normal pressure is not obtained after adjustment, sealing of safety valve
may be defective.
high idle.
Remove swing
Max. 7 l/min
connector.
Defective swing
to make judgment.
PC88MR-10 40-505
40 Troubleshooting
mode)
H-28 Swing acceleration performance is poor or swing speed is slow in

only one direction (PC88MR-L45-400-A-Z0-A)
Failure • Swing acceleration performance is poor or swing speed is slow in only one direction.
information
high idle.
PPC valve PPC valve output lever
pressure Swing control Left swing and Min. 2.65 MPa
lever right swing {Min. 27 kg/cm2}
If no failure is found by check on cause (1) and upper structure does not
2 swing when swing control lever is operated with pump pressure at approx. 4
MPa, check whether spool is stuck near NEUTRAL position.
high idle.
pressure
solenoid valve relief {210 ± 15kg/cm2}
(pump pressure) connector.
Defective seating of Interchange suction valves on left and right swing sides of swing motor, and
4 swing motor (suction check whether failure symptom changes to make judgment.
40-506 PC88MR-10
40 Troubleshooting
mode)
H-29 Upper structure overruns excessively when it stops swinging (both

right and left) (PC88MR-L47-400-A-Z0-A)
Failure • Upper structure overruns excessively when it stops swinging (both right and left).
high idle.
connector.
may be defective.
high idle.
Remove swing
Max. 7 l/min
connector.
PC88MR-10 40-507
40 Troubleshooting
mode)
H-30 Upper structure overruns excessively when it stops swinging

(either right or left) (PC88MR-L48-400-A-Z0-A)
Failure • Upper structure overruns excessively when it stops swinging (either right or left).
information
high idle.
pressure Swing control Left swing and Min. 2.65 MPa
Slow return valve for right swing PPC may malfunction. Interchange slow
return valves for left and right swings, and check whether failure symptom
Clogged slow return changes to make judgment.
2 valve for right swing
When removing slow return valve, check slow return valve strainer for
clogging.
Slow return valve for left swing PPC may malfunction. Interchange slow return
valves for left and right swings, and check whether failure symptom changes
Clogged slow return to make judgment.
3 valve for left swing PPC
When removing slow return valve, check slow return valve strainer for
clogging.
Malfunction of swing Swing spool may malfunction.
4 control valve (spool) Check spool for getting stuck and defects.
high idle.
pressure
solenoid valve relief {210 ± 15 kg/cm2}
(Pump pressure) connector.
40-508 PC88MR-10
40 Troubleshooting
mode)
H-31 Shock is large when upper structure stops swinging (PC88MR-L49-400-A-Z0-A)
Failure • Shock is large when upper structure stops swinging.

information
high idle.
pressure Swing control Left swing and 2.65 MPa
lever Right swing {27 kg/cm2}
Malfunction of slow Slow return valve for right swing PPC may malfunction. Interchange slow
2 return valve for right return valves for left and right swings, and check whether failure symptom
swing PPC changes to make judgment.
Malfunction of slow Slow return valve for left swing PPC may malfunction. Interchange slow return
3 return valve for left valves for left and right swings, and check whether failure symptom changes
swing PPC to make judgment.
Malfunction of swing Reverse prevention valve of swing motor may malfunction.
4 motor (reverse
prevention valve) Check for stuck spool and fatigue of spring.
PC88MR-10 40-509
40 Troubleshooting
mode)
H-32 Large unusual noise is heard when upper structure stops

swinging (PC88MR-BAB-400-A-Z0-A)
Failure • Large unusual noise is heard when upper structure stops swinging.
information
Malfunction of back Back pressure valve of control valve may malfunction.
1 pressure valve Check for stuck valve, defects of valve, and fatigue of spring.
Safety valve of swing motor may malfunction.
2 motor (safety valve) If normal pressure is not obtained after adjustment, safety valve may have
internal failure.
Defective swing
to make judgment.
40-510 PC88MR-10
40 Troubleshooting
mode)
H-33 Swing drift on a slope is large while swing parking brake is

applied (PC88MR-MS6-400-A-Z0-A)
Failure • Swing drift on a slope is large while swing parking brake is applied.
• When swing lock switch is set to ON position or swing parking brake cancel switch is set
to NORMAL position, swing parking brake is applied and swing system is locked by disc
Related brake.
information • Perform all troubleshooting with working mode set in power (P) mode.
• If failure codes are displayed, perform troubleshooting for them first. (DW45KA, DW45KB)
high idle.
1 parking brake solenoid Swing control 0 MPa {0 kg/cm2}
swing parking brake At NEUTRAL
valve lever
pressure
lever Right swing {32 ± 5 kg/cm2}
motor (swing parking If no failure is found by check on cause (1), swing parking brake may
2
brake) malfunction.

high idle.
Remove swing
Max. 7 l/min
connector.
PC88MR-10 40-511
40 Troubleshooting
mode)
H-34 Swing drift on a slope is large while swing parking brake is

released (PC88MR-MS7-400-A-Z0-A)
Failure • Swing drift on a slope is large while swing parking brake is released.
Related • Perform all troubleshooting with working mode set in power mode (P).
1 Spool of swing control valve may malfunction. Check for stuck spool.
high idle.
connector.
may be defective.
Interchange suction valves on left and right swing sides of swing motor, and
Defective seal of swing check whether failure symptom changes to make judgment.
3 motor (suction valve)
When removing valve, check it for sticking and defects.
Defective sealing of Interchange check valves on left and right swing sides of swing motor, and
Malfunction of swing Reverse prevention valve of swing motor may malfunction.
5 motor (reverse
prevention valve) Check for stuck spool and fatigue of spring.
40-512 PC88MR-10
40 Troubleshooting
mode)
H-35 Oil flow in attachment circuit cannot be controlled (PC88MR-HBE-400-A-Z0-A)
Failure • Oil flow in attachment circuit cannot be controlled.

• For machines with provision for attachment, oil flow rate of attachment circuit varies
depending on selected working mode.
Related • Procedure for oil flow rate adjustment differs between working modes, ATT mode and B
information mode. For details, see Operation and Maintenance Manual.
• If failure codes are displayed, perform troubleshooting for them first. (DXE4KA, DXE4KB)
high idle.
ATT control
switch At NEUTRAL 0 MPa {0 kg/cm2}
ATT control EPC (full stroke)
valve output Pressure
pressure ATT control
Malfunction of ATT switch corresponding to
1 Depressed
control EPC valve selected oil flow
(full stroke) setting
a 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
40 Troubleshooting
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode) (ALL-3840-001-A-03-A)
Information mentioned in troubleshooting table (S mode) (ALL-5170-010-A-01-A)
(Rev. 2011/01)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
Related Information related to the detected failure or troubleshooting
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment
40-514 PC88MR-10
40 Troubleshooting
S-1 Engine does not crank when starting switch is turned to START
position (D65-A26-400-A-Z0-A)
Failure Engine does not crank when starting switch is turned to START position.
Related • See E mode (E-1) for troubleshooting of electrical system.
information • If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
Defective wiring harness in • When starting switch is turned to START Perform
1 starting circuit position, starting motor pinion is not pushed troubleshooting for E-1
out and take remedies.
• Grating noise is heard from starting motor
pinion.
(When starting switch is turned to START
position, starting motor pinion is pushed
out.)
• Starting motor pinion disengages during
operation.
position, starting motor pinion is pushed Perform
2 Defective starting motor troubleshooting for E-1
out.)
• Rattling noise is heard and starting motor and take remedies.
does not rotate.
position, starting motor pinion is pushed
out.)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
• If grating noise is heard from starting motor
3 Broken flywheel ring gear pinion and starting motor does not rotate, Replace if damaged
visually check flywheel ring gear.
• Remove EGR cooler outlet gas piping and
check whether coolant containing
Cracked EGR cooler COOLANT flows out. Replace EGR cooler
4 (Reference: coolant in and drain water from
exhaust gas) a Water in exhaust gas can be normally engine cylinders
condensed, so check that condensate is
coolant or not.
PC88MR-10 40-515
40 Troubleshooting
S-2 Engine cranks but no exhaust smoke comes out (D37-A27-400-A-Z0-A)
Failure Engine cranks but no exhaust smoke comes out.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
1 Insufficient fuel in tank • Fuel tank is empty. Add fuel.
Flush air breather hole
Clogged air breather hole in
2 • Air breather hole in fuel tank cap is clogged. in fuel tank cap and
fuel tank cap clean surrounding
area.
• Check used hours of fuel filter. If used
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
3
may be clogged. element.
Foreign material in fuel • Rust and water are found in fuel drained Replace fuel.
4
from fuel tank.
• Air is bled during air bleeding of fuel system. Perform air bleeding.
5 Air in fuel piping system (Reference: See Testing and adjusting, Repair or replace fuel
"Bleeding air from fuel system".) piping.
• Fuel leaks from fuel piping.
Leakage from fuel piping Repair or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts.
"Testing fuel circuit for leakage".)
• Injector return rate is excessive.
Fuel leakage from injector (Reference: See Testing and adjusting, Check or replace
7 "Testing fuel discharge, return and injector.
area
leakage".)
• See Testing and adjusting, "Testing fuel Replace supply pump
8 Defective supply pump
discharge, return and leakage". or pressure limiter.
• No resistance is felt or large effort is
9 Defective priming pump Replace priming pump.
required when operating priming pump.
• Monitored common rail pressure does not Loosen injection piping
Improper air bleeding of lower even after engine is stopped. (Code: and high-pressure pipe
10 common rail or injection 36400 Common rail pressure) mounting nuts on
piping (Pressure may not decrease if air still common rail and bleed
remains.) air.
40-516 PC88MR-10
40 Troubleshooting
S-3 Fuel is being injected but engine does not start (misfiring: engine
cranks but does not start) (D37-A28-400-A-Z0-A)
Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
Failure does not start).
information
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge battery.
area.
4
5
from fuel tank.
• Injector return rate is excessive.
Fuel leakage from injector (Reference: See Testing and adjusting, Check or replace
8 "Testing fuel discharge, return and injector.
area
leakage".)
• Air cleaner dust indicator indicates that dust Check and clean air
10 Clogged air cleaner element
is at caution level. cleaner element.
• When preheating works, intake air heater
mounting area does not become hot.
• When preheating works or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor does heater.
not indicate properly.
• Check valve clearance.
(Reference: See Testing and adjusting,
Worn valve or rocker arm, "Testing and adjusting valve clearance".) Replace valve or
12
etc. • When engine is cranked, unusual noise is rocker arm.
heard from around cylinder head.
• Testing compression pressure
Replace piston ring or
13 Defective piston ring (Reference: See Testing and adjusting,
piston.
"Testing compression pressure".)
• When engine is run in cylinder cutout mode
Defective injector with some cylinder cutout, engine speed
14 (clogged injector or defective does not change. Replace injector.
fuel spray) (Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
• Since this is an internal defect, Replace engine
15 Defective engine controller troubleshooting cannot be performed. controller.
PC88MR-10 40-517
40 Troubleshooting
S-4 Engine startability is poor (D37-A10-400-A-Z0-A)
Failure Engine startability is poor.

• If any failure code is displayed, perform troubleshooting for that code first.
• Common rail fuel injection system (CRI) controls fuel injection timing electrically.
Related
Therefore, in some cases, engine does not start before crankshaft makes 2 turns
information
maximum even if starting operation is performed. This does not indicate any abnormality,
however.
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge battery.
• Fuel other than specified one is used.
• Fuel used does not accord with ambient
temperature. Use proper fuel
(Reference: If engine can start in warm specified in Operation
3 Improper fuel used
weather but does not easily start in cold and Maintenance
weather) Manual.
• Deposited wax (milky) is found in clear bowl
of fuel prefilter.
area.
5
6
from fuel tank.
• Air cleaner dust indicator indicates that dust Check and clean air
10 Clogged air cleaner element
• When preheating works, intake air heater
mounting area does not become hot.
• When preheating works or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor does heater.
not indicate properly.
• Remove exhaust gas piping from EGR
cooler outlet and inlet, and check whether
Cracked EGR cooler Replace EGR cooler
coolant containing COOLANT flows out.
12 (Reference: Coolant enters and drain water from
exhaust gas piping.) a Water in exhaust gas can be normally engine cylinders
condensed, so check that condensate is
coolant or not.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
13 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
40-518 PC88MR-10
40 Troubleshooting

• Measure compression pressure (see
Standard value table).
(Reference: See Testing and adjusting, Correct contact
Defective contact between "Testing compression pressure".) between valve and
15
valve and valve seat • Check valve clearance. valve seat or replace
(Reference: See Testing and adjusting, them.
"Testing and adjusting valve clearance".)
• Check exhaust gas at KDOC muffler outlet.
"Testing exhaust gas color".)
• Measure compression pressure (see Replace piston ring or
16 Defective piston ring Standard value table). piston.
• Check piston ring and piston ring groove.
PC88MR-10 40-519
40 Troubleshooting
S-5 Engine does not pick up smoothly (D37-A30-400-A-Z0-A)
Failure Engine does not pick-up smoothly.

information
area.
3
4
from fuel tank.
• When crankcase pressure high error (failure
code: CA555) is still displayed even after
Abnormally high crankcase KCCV filter is replaced, blowby pressure is Perform following
8 pressure probably high (see Testing and adjusting, checks on causes 10
"Testing blowby pressure"). In this case, and after.
KVGT may be seized or damaged.
does not change.
• Unusual noise is heard from turbocharger.
Seized or broken • Check whether turbocharger shaft rotates.
10 turbocharger Replace KVGT.
(Move turbocharger vanes with hand in axial
and radial directions to make judgment.)
• When engine is cranked, unusual noise is
• Check valve clearance. Adjusting valve
11 Incorrect valve clearance
(Reference: See Testing and adjusting, clearance
40-520 PC88MR-10
40 Troubleshooting

13
PC88MR-10 40-521
40 Troubleshooting
S-6 Engine stops during operation (PC88MR-AF0-400-A-Z0-A)
Failure Engine stops during operation.

information
area.
3
4
from fuel tank.
Defective air intake hose
9
(between air cleaner and • Visually check air intake hose for breakage. Replace air intake
variable flow turbocharger hose.
inlet)
• Check air intake manifold for internal Replace air intake
10 Defective air intake manifold breakage. manifold.
Defective boost piping and
connections
Correct or replace
11 (between variable flow • Air leaks from boost piping.
boost piping.
turbocharger outlet and air
intake manifold)
Defective exhaust gas piping• Check exhaust gas piping for damage and
exhaust gas leakage. Replace exhaust gas
12 (from exhaust manifold to (Check soot on heat insulation cover and piping.
KDOC muffler inlet) heat insulation plate.)
• Check valve and rocker arm.
Replace valve or
13 Damaged valve or rocker arm (Unusual noise is heard and engine stops
suddenly.) rocker arm.
• Metal particles are found in oil drained from
oil pan.
• Remove oil pan and check piston and
Broken or seized piston Replace piston and
14 connecting rod connecting rod.
connecting rod.
(Reference: Unusual noise is heard and
engine stops suddenly, or stops due to
overheat.)
• Metal particles are found in oil drained from
Broken or seized crankshaft oil pan. Replace crankshaft
15 bearing • Remove oil pan and check crankshaft main main bearing.
bearing.
• Check wiring harness of engine controller
Defective wiring harness of Repair wiring harness
power supply.
16 engine controller power of engine controller
(Reference: See Troubleshooting, "Failure
supply power supply.
code [CA343]".)
40-522 PC88MR-10
40 Troubleshooting

Defective starting switch Perform
17 wiring • Check starting switch wiring harness. troubleshooting for E-1
and take remedies.
• See "H-2 Engine speed drops significantly Perform
18 Defective hydraulic system or engine stalls" in H mode. troubleshooting for H-2
and take remedies.
PC88MR-10 40-523
40 Troubleshooting
S-7 Engine runs rough or is unstable (D37-A40-400-A-Z0-A)
Failure Engine runs rough or is unstable.

information
area.
3
4
from fuel tank.
• Check boost system (between turbocharger Repair or replace
Fuel leakage from boost
7 outlet and aftercooler, aftercooler and air boost piping related
system
intake manifold) for fuel leakage. parts.
• Replace sensor and check whether
Defective mass air flow and symptom disappears. Replace mass air flow
8 temperature sensor (Failure code may not be generated if and temperature
sensor is covered with dust.) sensor.
40-524 PC88MR-10
40 Troubleshooting
S-8 Engine lacks power (D37-A60-400-A-Z0-A)
Failure Engine lacks power.

information
area.
3
4
from fuel tank.
Clogged air cleaner element • Air cleaner dust indicator indicates that dust Check and clean air
8
• Check air cleaner and rectifying wire net for Correct or replace air
9 Defective air cleaner
deformation. cleaner.
Defective air intake hose
10 (between air cleaner and • Visually check air intake hose for breakage. Replace air intake
hose.
turbocharger inlet)
• Check air intake manifold for internal Replace air intake
11 Defective air intake manifold breakage. manifold.
connections Correct or replace
12 • Air leaks from boost piping.
(between turbocharger outlet boost piping.
and air intake manifold)
Defective installation of • Air leaks from mounting part of charge Correct installation of
13 charge pressure sensor pressure sensor. charge pressure
sensor.
Defective exhaust gas piping• Check exhaust gas piping for damage and
15 Gas leakage from EGR piping • Gas leaks from EGR piping. Replace EGR piping.
16 turbocharger Replace turbocharger.
PC88MR-10 40-525
40 Troubleshooting

does not change.
20
• Open exhaust color inspection hole that is
just upstream of the KDOC muffler, and
check exhaust gas.
"Testing exhaust gas color".) Replace piston ring or
21 Defective piston ring • Measure compression pressure (see piston.
40-526 PC88MR-10
40 Troubleshooting
S-9 Exhaust smoke is black (D37-AH5-400-A-Z0-A)
Failure Exhaust smoke is black.

information
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
2
from fuel tank.
• Check air cleaner and rectifying wire net for Correct or replace air
3 Defective air cleaner
deformation. cleaner.
Defective exhaust gas piping • Check exhaust gas piping for damage and
Defective installation of Correct installation of
• Air leakage from installed position of charge
5 charge (boost) pressure charge (boost)
(boost) pressure sensor
sensor pressure sensor.
connections Correct or replace
6 • Air leaks from boost piping.
(between turbocharger outlet boost piping.
and air intake manifold)
• KDOC muffler is clogged. Check exhaust
Replace KDOC
7 Defective KDOC muffler pressure pressure at location just upstream
muffler.
of KDOC muffler.
8 Gas leakage from EGR piping • Gas leaks from EGR piping. Replace EGR piping.
9 Replace turbocharger.
turbocharger (Move turbocharger vanes with hand in axial
does not change.
• Measured fuel return rate is excessive.
Correct or replace fuel
11 Defective fuel return piping "Testing fuel discharge, return and
return piping.
leakage".)
• Check fuel return piping for clogging.
• Replace sensor and check whether
Defective mass air flow and symptom disappears. Replace mass air flow
12 temperature sensor (Failure code may not be generated if and temperature
sensor is covered with dust.) sensor.
PC88MR-10 40-527
40 Troubleshooting

14
40-528 PC88MR-10
40 Troubleshooting
S-10 Engine oil consumption is excessive (D37-B10-400-A-Z0-A)
Failure Engine oil consumption is excessive.

information
Dust sucked from air intake • When intake piping between air cleaner and Clean or replace intake
1 system engine is removed, dust is found inside. piping.
• Measured blowby pressure exceeds
standard value.
• Blowby pressure is still high after KCCV
filter element is replaced. Replace piston ring or
2 Broken or worn piston ring
• Measure compression pressure (see correct its installation.
Oil leakage from KCCV oil • Check oil leakage from KCCV oil return Correct installation of
3 return piping piping. oil piping or replace it.
4 Oil leakage outside engine • Check for oil leakage. Repair oil leaks.
Oil leakage from oil filter • Check oil filter for oil leakage. Reinstall or replace oil
5
filter.
Correct installation of
6 Oil leakage from oil piping • Check oil piping for oil leakage.
oil piping or replace it.
Retighten oil drain
7 Oil leakage from oil drain plug • Check oil drain plug for oil leakage.
plug.
8 Oil leakage from oil pan • Check oil pan for oil leakage.
oil pan or replace it.
Oil leakage from cylinder • Check cylinder head for oil leakage. cylinder head or
9
head replace it.
Worn or damaged rear oil • Oil in clutch chamber or damper chamber
10 rear oil seal or replace
seal on machine increases.
it.
• turbocharger blower inlet and outlet, and
turbine outlet are dirty with oil.
11 Oil leakage from turbocharger • Check whether turbocharger shaft rotates. Replace turbocharger.
• Oil is in coolant.
• Remove oil cooler and check for oil leakage
12 Oil leakage from oil cooler outside oil cooler. Replace oil cooler.
• Check oil cooler for oil leakage by applying
air pressure.
• Check valve guide and stem seal.
• Remove cylinder head, and check inside
Worn or damaged valve Replace valve guide or
13 guide or stem seal diameter of guide and stem seal for
damage. stem seal.
(Reference: See "Maintenance standards".)
PC88MR-10 40-529
40 Troubleshooting
S-11 Oil becomes contaminated quickly (D37-B20-400-A-Z0-A)
Failure Oil becomes contaminated quickly.

information
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
2
and Maintenance
Manual.
• Check exhaust gas color at KDOC muffler Perform
Black exhaust gas at KDOC outlet (see standard value table). troubleshooting for "S-
3 (Reference: See Testing and adjusting, 9 Exhaust smoke is
muffler outlet.
"Testing exhaust gas color".) black".
standard value. Perform following
4 Excessive blowby gas
• Blowby pressure is still high after KCCV checks.
filter element is replaced.
• Rotate turbocharger shaft and check for
Defective seal on play.
5 Replace turbocharger.
turbocharger turbine side (Move turbocharger vanes with hand in axial
• Check oil level for excessive refilling.
6 Excessive refilling of oil (If oil level is excessive, oil will reach high Refill with oil to correct
temperatures and early deteriorates.) oil level.
• Visually check oil cooler element for
contamination. Clean or replace oil
7 Dirty oil cooler element
(Contaminated oil cooler element can cooler element.
increased oil temperature.)
standard value.
• Blowby pressure is still high after KCCV
filter element is replaced. Replace piston ring or
8 Broken or worn piston ring
• Measure compression pressure (see correct its installation.
• Check valve guide and stem seal.
• Remove cylinder head, and check inside
Worn or damaged valve Replace valve guide
9 diameter of guide and stem seal for
guide or stem seal and stem seal.
damage.
(Reference: See "Maintenance standards".)
40-530 PC88MR-10
40 Troubleshooting
S-12 Fuel consumption is excessive (D37-B70-400-A-Z0-A)
Failure Fuel consumption is excessive.

information
Replace injector.
• Measure spill rate from injector.
Excessive spill of fuel from (Reference: See Testing and adjusting, Lots of dusts are is
1 injector "Testing fuel discharge, return and probably in fuel. Check
leakage".) storage management
of fuel.
• Check fuel return piping for clogging.
Correct or replace fuel
2 Clogged fuel return piping (Injection rate may be increased due to
return piping.
clogged fuel return piping.)
with some cylinder cutout, engine speed
does not change.
Fuel leakage from cylinder • Check for increased oil level. Repair defective parts.
4
head • Check for smell of diesel fuel.
• Check for increased engine oil level and
Fuel leakage from supply
5 smell of diesel fuel. Replace supply pump.
pump oil seal
• Check supply pump oil seal.
6 Fuel leakage outside engine • Check for fuel leakage outside engine. Repair defective parts.
PC88MR-10 40-531
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)
Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block
40-532 PC88MR-10
40 Troubleshooting
S-14 Oil pressure drops (D37_ICT-10D-400-A-Z0-A)
Failure Oil pressure drops

• If any failure code is displayed, carry out troubleshooting for it first.
Related information • Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
• Oil level in oil pan is low
1 Lack of oil in oil pan • Oil pressure monitor indicates low oil Add oil
pressure when operating on slopes
Defective oil pressure sensor, Replace oil pressure
• Check oil pressure sensor, wiring harness,
2 wiring harness sensor, wiring harness,
and connector
or connector
If oil is contaminated
with fuel, carry out
• Perform oil analysis and check for fuel in oil
3 Fuel in oil troubleshooting for "S-
• Engine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
• Perform oil analysis and check for water in with water, carry out
4 Water in oil oil troubleshooting for "S-
• Oil is milky 16 Water mixes into
engine oil (milky)"
• Check oil filter
(Reference: Oil filter has been used beyond
5 Clogged oil filter the specified period, oil heavily Replace oil filter
deteriorated, etc.)
• Water in oil can cause oil filter blockage
6 Clogged oil strainer • Check oil strainer Clean oil strainer
Crushed or clogged hydraulic Replace hydraulic
7 • Hydraulic piping is crushed or clogged
piping piping
• Check oil pump
8 Defective oil pump (worn or damaged gear) Replace oil pump
• Oil pump rotation is heavy or it has play
Defective regulator valve • Check valve spring for fatigue or damage Replace regulator
9
valve
• Valve and spring of oil pump relief valve is Replace oil pump relief
10 Defective oil pump relief valve fatigued, damaged. valve
Cracks in oil pump suction • Check around oil pump suction piping Replace oil pump
11 piping (cracked piping) suction piping
Defective seal between oil
12 pump and oil pump suction • Check seal Replace seal
piping
Defective boost oil pump relief • Check boost oil pump relief valve for fatigue Replace boost oil
13 or damage on valve and spring pump relief valve
valve
• Check main journal bearing
Replace main journal
14 Worn main journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
• Check pin journal bearing
Replace pin journal
15 Worn pin journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
Worn idler bushing, damaged Replace idler bushing
16 idler gear • Check idler bushing and idler gear
or idler gear
Breakage or falling off of Replace piston cooling
17 piston cooling nozzle • Check piston cooling nozzle
nozzle
PC88MR-10 40-533
40 Troubleshooting
S-15 Fuel mixes into engine oil (PC400-B31-400-A-Z0-A)
Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
1 Defective injector • When a certain cylinder is cut out, engine Replace Injector
speed does not change
"Handling of cylinder cut-out operation".)
Fuel leakage from injector or
2 • Check injector or O-ring Replace injector O-ring
O-ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced
40-534 PC88MR-10
40 Troubleshooting
S-16 Water mixes into engine oil (milky) (D65-B32-400-A-Z0-A)
Failure Water mixes into engine oil (milky).

• If oil mixes into coolant, perform troubleshooting for "S-13 Oil mixes into coolant".
When engine starting and stopping is frequently repeated in low ambient temperatures,
Related since KCCV is installed, condensed water vapor in blowby gas may mix into oil leading to
information milky oil or emulsified oil inside engine, but this is normal. This is not problem if coolant is
not leaking.
If coolant leakage is suspected from rapid drop of coolant level, perform following
troubleshooting procedures.
• Coolant containing COOLANT flows out
when gas piping are removed from EGR
cooler outlet.
(Check whether water contains COOLANT
or not. It can be condensed water.)
1 Cracks in EGR cooler (Reference: Note that cracks in EGR cooler Replace EGR cooler.
are caused by and preceded by drop of
coolant level of cooling system in some
cases. When replacing EGR cooler, check
cooling system piping and radiator for water
leakage.)
Damaged oil cooler element • Check oil cooler element and gasket Replace oil cooler
2 or gasket • Pressure test on oil cooler shows that water element or gasket.
leaks.
Replace cylinder head
Damaged cylinder head or • Disassemble engine to check cylinder head
3 or cylinder head
cylinder head gasket and cylinder head gasket.
gasket.
• Engine oil level increases and oil is milky.
Cracks or pitting in cylinder • Disassemble engine and check inside of Replace cylinder block.
4
block cylinder block for cracks or pitting.
PC88MR-10 40-535
40 Troubleshooting
S-17 Coolant temperature rises too high (overheating) (PC88MR-AL0-400-A-Z0-A)
Failure Coolant temperature rises too high (overheating).

information
Clogged radiator core • Check radiator core for clogging, and check
1 Clean radiator core.
fin for crush.
• Thermostat does not open at cracking
temperature.
a Thermostat cracking temperature
2 Malfunction of thermostat Replace thermostat.
Primary valve: 76ºC
Secondary valve: 83ºC
(Full open temperature: 95°C)
• Error related to coolant temperature is Replace coolant
Defective coolant temperature sensor,
3 displayed, but measured value of radiator
temperature gauge monitor or wiring
coolant temperature is normal.
harness.
Perform
Increased fuel injection rate • Fuel injection rate is high. troubleshooting for "S-
4
12 Fuel consumption is
excessive".
5 Low coolant level • Check coolant level for lowering Refill with coolant
6 Leakage of coolant • Check water leakage from coolant piping Replace coolant piping
• Visually check water pump
(Check shaft seal for water leakage,
7 Breakage of water pump Replace water pump.
impeller for damage, and shaft for
breakage.)
Overheating due to increased
EGR ratio (EGR amount Replace mass air flow
against fresh air amount) • Check mass air flow and temperature
8 and temperature
caused by defective mass air sensor.
sensor.
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount • Check air cleaner for deformation and Repair or replace air
9 against fresh air amount) presence. cleaner.
caused by air cleaner
deformation
Defective cylinder head or • Check radiator coolant for excessive Perform
10 cylinder head gasket bubbles and spurt back troubleshooting for "S-
13 Oil is in coolant".
• Open exhaust color inspection hole for the
KDOC muffler outlet, and check exhaust
gas.
"Testing exhaust gas color".) Replace piston ring or
11 Defective piston ring • Measure compression pressure (see piston.
40-536 PC88MR-10
40 Troubleshooting
S-18 Unusual noise is heard (D37-BA1-400-A-Z0-A)
Failure Unusual noise is heard.

• Check whether noise source is in or outside engine before starting troubleshooting.
• Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
Related • When engine accelerates, it switches into acceleration mode and its sound becomes
information slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
• Exhaust gas leaks from piping between
cylinder head and exhaust manifold,
between exhaust manifold and
Exhaust gas leakage from Repair or replace
1 turbocharger, or between turbocharger
piping defective parts.
outlet and KDOC muffler.
• Exhaust gas leaks from EGR piping or air
intake piping.
Vibration of exhaust piping or • Visually check for vibration. Check and retighten
2 piping brackets.
exhaust bellows
• Check whether turbocharger shaft rotates.
Seized or broken
3 turbocharger (Move turbocharger vanes with hand in axial Replace turbocharger.
Replace KDOC
4 Damage inside KDOC muffler • Check inside KDOC muffler.
muffler.
does not change.
• Check valve clearance.
6 Incorrect valve clearance (Reference: See Testing and adjusting, Adjusting valve
"Testing and adjusting valve clearance".) clearance
Seized pin bushing, front Repair or replace
7 bearing, or main bearing • Check for metal particles in oil pan.
damaged parts.
• If metal particles is found in oil pan or oil
filter, overhaul engine and check piston ring
and cylinder liner.
Worn piston ring or cylinder Replace piston ring or
8 • Measure compression pressure (see
liner cylinder liner.
• Overhaul engine and check valves and Replace valve or
9 Damaged valve or rocker arm rocker arm parts. rocker arm.
10 Damaged idler gear • Overhaul engine and check idler gear parts. Replace idler gear.
• Check fan and fan belt for damage and Repair or replace
11 Defective fan or fan belt damaged parts.
interference.
PC88MR-10 40-537
40 Troubleshooting
S-19 Vibration is excessive (D37-BC0-400-A-Z0-A)
Failure Vibration is excessive.

• If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-18
Related Unusual noise is heard", too.
information • If any failure code is displayed, perform troubleshooting for that code first.
• Visually check engine mounting bolts for
Loose engine mounting bolts Retighten bolts or
1 looseness and cushions for cracks and
or defective cushions replace cushions.
hardening.
Defective output shaft or • Check output shaft for damage and damper Replace defective
2 internal defect of damper parts.
for internal defect.
Misalignment and facial
• Measure misalignment and facial runout at
runout at connection between Replace defective
3 connection between engine and hydraulic
engine and hydraulic pump parts.
pump.
are out of standard range.
does not change.
Worn main bearing or • If metal particles are found in oil pan or oil Repair or replace
5 connecting rod bearing filter, overhaul engine. damaged parts.
• If metal particles are found in oil pan or oil Repair or replace
6 Stuck valve or rocker arm filter, open cylinder head cover and check damaged parts.
valves and rocker arms.
• If metal particles are found in oil pan or oil
Replace camshaft
7 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings.
bushings.
40-538 PC88MR-10
40 Troubleshooting
S-20 Air cannot be bled from fuel circuit (WA380_7-A29-400-A-Z0-A)
Failure Air cannot be bled from fuel circuit.

information
• Check drain valve of fuel pre-filter for
Loosened drain valve of fuel looseness.
2 pre-filter (Air enters fuel circuit from loosened drain Close drain valve.
valve.)
3
• Air is bled during air bleeding of fuel system.
Repair or replace fuel
4 Air in fuel piping system (Reference: See Testing and adjusting,
piping.
"Bleeding air from fuel system".)
"Checking fuel circuit for leakage".)
PC88MR-10 40-539
40 Troubleshooting
40-540 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
50 Disassembly and assembly

7 50 Disassembly and assembly
PC88MR-10 50-1
Table of contents

50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system ........................................................................................................ 50-17
Removal and installation of supply pump assembly............................................................... 50-17
Removal and installation of injector assembly....................................................................... 50-20
Removal and installation of cylinder head assembly.............................................................. 50-27
Removal and installation of radiator assembly ...................................................................... 50-39
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-43
Removal and installation of aftercooler assembly .................................................................. 50-46
Removal and installation of engine and main pump assembly ................................................ 50-49
Removal and installation of engine front oil seal .................................................................... 50-57
Removal and installation of engine rear oil seal..................................................................... 50-58
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
Removal and installation of air cleaner assembly .................................................................. 50-69
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly....................... 50-71
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly........................ 50-73
Removal and installation of fan belt...................................................................................... 50-74
Power train system ................................................................................................................... 50-76
Removal and installation of travel motor and final drive assembly ........................................... 50-76
Disassembly and assembly of travel motor and final drive assembly....................................... 50-78
Removal and installation of swing motor and swing machinery assembly ...............................50-111
Disassembly and assembly of swing machinery assembly................................................... 50-113
Removal and installation of swing circle assembly .............................................................. 50-121
Undercarriage and frame......................................................................................................... 50-122
Separation and connection of track.................................................................................... 50-122
Removal and installation of sprocket.................................................................................. 50-123
Removal and installation of idler and idler cushion assembly ............................................... 50-124
Disassembly and assembly of idler assembly ..................................................................... 50-125
Disassembly and assembly of idler cushion assembly......................................................... 50-128
Disassembly and assembly of track roller assembly ............................................................ 50-131
Removal and installation of revolving frame assembly ......................................................... 50-134
Removal and installation of counterweight assembly [For machines with additional
counterweight].................................................................................................... 50-136
Hydraulic system .................................................................................................................... 50-138
Removal and installation of center swivel joint assembly ..................................................... 50-138
Disassembly and assembly of center swivel joint assembly ................................................. 50-140
Removal and installation of hydraulic tank assembly ........................................................... 50-141
Removal and installation of main pump assembly ............................................................... 50-144
Removal and installation of control valve assembly ............................................................. 50-148
Disassembly and assembly of control valve assembly......................................................... 50-152
Disassembly and assembly of work equipment PPC valve assembly.................................... 50-155
Disassembly and assembly of travel PPC valve assembly ................................................... 50-157
Disassembly and assembly of work equipment cylinder assembly........................................ 50-158
Work equipment ..................................................................................................................... 50-162
Removal and installation of work equipment assembly ........................................................ 50-162
Removal and installation of boom swing bracket ................................................................. 50-165
Removal and installation of anti-drop valve for boom assembly ............................................ 50-166
Removal and installation of anti-drop valve for arm assembly............................................... 50-169
50-2 PC88MR-10
Table of contents
Disassembly and assembly of anti-drop valve assembly...................................................... 50-172

Removal and installation of blade assembly ....................................................................... 50-173
Removal and installation of operator's cab assembly........................................................... 50-175
Removal and installation of operator's cab door .................................................................. 50-179
Removal and installation of operator's cab glass (adhered glass) ......................................... 50-182
Removal and installation of front window assembly ............................................................. 50-193
Removal and installation of floor frame assembly................................................................ 50-194
Removal and installation of air conditioner unit assembly..................................................... 50-199
Removal and installation of air conditioner compressor assembly......................................... 50-204
Removal and installation of air conditioner condenser assembly .......................................... 50-206
Removal and installation of operator's seat......................................................................... 50-208
Removal and installation of seat belt .................................................................................. 50-209
Removal and installation of front wiper assembly ................................................................ 50-210
Removal and installation of starting motor assembly ........................................................... 50-217
Removal and installation of engine controller assembly ....................................................... 50-218
Removal and installation of pump controller assembly......................................................... 50-219
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
PC88MR-10 50-3
Related information on disassembly and assembly
Related information on disassembly and assembly (ALL-3851-001-A-00-A)
How to read this manual (ALL-0320-011-A-00-A)

(Rev.2013.05)
Removal and installation of TTTT assembly • The general tools required for "Installation" are
Special tools listed as [1], [2], ..., without description of part
• The special tools required for removal and number, part name, and quantity.
installation work are described in the list as • Marks used in "Installation" section are
symbols such as A1, ..., X1. Part number, part explained below.
name, necessity, and quantity are described. k: This mark shows safety-related precautions
• Mark used in the column of necessity are which must be followed when performing the
explained below. work.
t: Tools are not substituted, must always be
equipped (used). a : This mark gives knowledge or precautions
q: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tools. 4 : This mark shows the weight of the part
• For details and the sketches of the special tools, or equipment.
see "Special tool list" and "Sketches of special
tools." 2 : This mark shows a specific coating
agent to be used.
Removal
• In "Removal" section, the work procedures, 3 : This mark shows the specified
precautions and know-how to do the work, and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark shows the amount of oil or
• The general tools required for "Removal" are coolant to be added.
listed as [1], [2], ..., without description of part • For details of oil or coolant to be
number, part name, and quantity. added after installation, see
• Marks used in "Removal" section are explained Specification "Table of fuel, coolant
below. and lubricants".
k: This mark shows safety-related precautions Disassembly and assembly of TTTT assembly
which must be followed when performing the Special tools
work. • The special tools required for disassembly and
assembly work are described in the list as
a : This mark gives knowledge or precautions
symbols such as A1, ..., X1. Part number, part
when performing the work.
name, necessity, and quantity are described.
[*1]: This mark indicates that knowledge or • Mark used in the column of necessity are
precautions for the assembly installation work are explained below.
given in the "Installation" section. t: Tools are not substituted, must always be
equipped (used).
6 : This mark shows the amount of oil or q: Tools extremely useful if available or tools
coolant to be drained. that can be substituted with commercially
available tools.
4 : This mark shows the weight of the part • For details and the sketches of the special tools,
or equipment. see "Special tool list" and "Sketches of special
Installation tools."
• The work procedure of "Installation" is in the Disassembly
reversed order to removal unless otherwise • "Disassembly" describes the work procedure as
specified. well as the precautions, knowledge, and drain
• For knowledge and precautions required for amounts of oil and coolant required for the work.
"Installation", a [*1] mark is assigned to the • The general tools required for "Disassembly" are
"Removal" work procedure to indicate the work listed as [1], [2], ..., without description of part
item of the installation knowledge or precaution. number, part name, and quantity.
50-4 PC88MR-10
• Marks used in the section of "Disassembly" are

explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.

6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of the part

or equipment.
Assembly
• "Assembly" describes the work procedure as
well as the precautions, knowledge, and drain
amounts of oil and water required for the work.
• The general tools required for "Assembly" are
listed as [1], [2], ..., without description of part
number, part name, and quantity.
• Marks used in the section of "Assembly" are
explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.

4 : This mark shows the weight of the part

or equipment.
2 : This mark shows a specific coating
agent to be used.
3 : This mark shows the specified
tightening torque.
5 : This mark shows the amount of oil or

coolant to be added.
• For details of oil or coolant to be
added after installation, see
Specification "Table of fuel, coolant
and lubricants".
PC88MR-10 50-5
Coating materials list (ALL-3540-071-A-00-A)
(Rev.2012.11)
a The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly
are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20 g Polyethy- polypropylene, tetrafluoroethylene and
LT-1B 790-129-9050 (contained 2 lene vinyl chloride), rubber, metal, and non-
pieces) container metal parts which require immediate
and strong adhesion.
• Features: Resistance to heat and
Polyethy- chemicals
LT-2 790-129–9180 50 g lene • Use to prevent bolts and plugs from
container coming loose and as sealant.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 Set of adhesive Can plastics.
Hardener:
and hardener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene • Use to seal plugs for blank holes.
container
• Heat-resistant seal used to repair
Holts MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
Polyethy- • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 50 g lene • Use mainly to bond metals, rubbers,
container plastics, and woods.
• Instantaneous adhesive
2g Polyethy- • Quick-curing type (max. strength is
Aron Alpha 201 790-129-9130 (contained 5 lene obtained after 30 minutes)
pieces) container • Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 cc Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
Polyethy- • Features: Resistance to heat and
Loctite 648-50 79A-129-9110 50 cc lene chemicals
container • Use to bond high-temperature fit parts.
50-6 PC88MR-10
Liquid gasket
• Use to seal various threaded parts,
LG-5 Polyethy- pipe joints, and flanges.
790-129-9080 1 kg lene
ThreeBond 1110F • Use to seal taper plugs, elbows, and
container nipples for hydraulic piping.
• Features: Silicon-based heat and cold-
LG-6 resistant sealant.
790-129-9160 250 g Tube • Use to seal flange surface and
ThreeBond 1215 threaded parts.
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
LG-7 sealant
790-129-9170 150 g Tube • Use to seal flywheel housing, intake
ThreeBond 1207C manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
419-15-18131 100 g Tube and shock-resistant sealant.
ThreeBond 1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
790-129-9310 200 g Tube clamped by bolts, gaps in the weld
ThreeBond 1206D which must be caulked, etc.
• Can be coated with paint.
• Use as lubricant or sealant when the
LG-10
790-129-9320 200 g Tube radiator hoses are put on.
ThreeBond 1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission case
and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted
LM-P 09940-00040 200 g Tube parts, and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S 09995-00250 190 g Can metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.
PC88MR-10 50-7
Seizure prevention compound

• Feature: Seizure and galling prevention
compound with metallic super-fine-
LC-G grain, etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.
Grease
SYG2-400LI-A
G2-LI SYGA-16CNLI • Lithium grease with extreme pressure
G0-LI(*) SYG0-400LI-A Various Various lubrication performance, general
*: For cold districts (*) purpose type.
SYG0-16CNLI (*)
• Use for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows- • Do not use this grease for rolling
disulfide grease type bearings like swing circle bearings,
SYG2-400M-A 400 g x 20 container etc. and spline.
LM-G(G2-M) SYGA-16CNM 16 kg Can • Use this grease for work equipment
pins only when installing them, but
do not use it afterward.
Hyper white SYG2-400T • Higher seizure resistance, heat
grease Bellows-
SYG2-16CNT 400 g type resistance, and waterproof than
G2-T molybdenum disulfide grease
SYG0-400T(*) 16 kg container
G0-T(*) • Not conspicuous on machine since
SYG0-16CNT(*) Can color is white.
*: For cold districts
Biogrease
SYG2-400B
G2-B Bellows-
SYGA-16CNB • Since this grease is biodegradable in
G2-BT(*) 400 g type
SYG2-400BT(*) container short period, it has less impact on
*: For use at high 16 kg microorganisms, animals, and plants.
SYGA-16CNBT Can
temperature and
(*)
under high load
• Feature: Silicon-based grease with
wider operating temperature range and
G2-S superior thermal oxidative stability to
— 200 g Tube prevent deterioration of rubber and
ThreeBond 1855 plastic.
• Use for oil seals of the transmission,
etc.
• Feature: Urea (organic) grease with
heat resistance and long life, inclusion
type.
G2-U-S
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
ENS grease
damper.
Caution: Do not mix with lithium
grease.
50-8 PC88MR-10
Primer
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 ml
container instantaneous adhesive.
SUNSTAR Paint • Use as primer for cab side.
Glass (Effective period: 4 months after
Surface Primer 20 ml
container manufacture)
580 SUPER
417-926-3910
SUNSTAR Glass • Use as primer for glass side.
Glass (Effective period: 4 months after
Primer 580 20 ml
For adhered window glass

container manufacture)
SUPER
• Use as primer for painted cab sheet
SUNSTAR Paint metal surface.
Glass
Surface Primer 22M-54-27230 20 ml (Effective period: 4 months after
container
435-95 manufacture)
• Use as primer for black ceramic-
SUNSTAR coated glass surface and for hard
PRIMER 435-41 22M-54-27240 150 ml Steel can polycarbonate-coated surface.
for glass (Effective period: 4 months after
manufacture)
• Use as primer for sash (alumite
SUNSTAR sash Glass surface treatment).
primer GP-402 22M-54-27250 20 ml (Effective period: 4 months after
container
manufacture)
Adhesive
• Use "S" as adhesive for glass in
high temperature months (during

SUNSTAR Polyethy- summer) and "W" in low
Penguin Seal 580 417-926-3910 320 ml lene temperature months (during winter).
SUPER "S" or "W" container (Effective period: 4 months after
manufacture)
• Use as adhesive for glass.
Sika Japan Cartridge (Effective period: 6 months after
20Y-54-39850 310 ml
Sikaflex 256HV manufacture)
SUNSTAR Ecocart • Use as adhesive for glass.
Penguin Super 22M-54-27210 320 ml (special (Effective period: 6 months after
560 container) manufacture)
Caulking material
SUNSTAR • Use to seal glass-to-glass joint.
Penguin Seal 417-926-3920 330 ml Cartridge (Effective period: 4 months after

No.2505 manufacture)
• Use to seal front window.
SEKISUI Silicone Cartridge (Effective period: 6 months after
20Y-54-55130 333 ml
Sealant 83 manufacture)
• Translucent white seal used for joint

GE TOSHIBA seals between glasses
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL381 manufacture)
PC88MR-10 50-9
Special tools list (PC88MR-3530-061-A-00-A)
a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tools.
a New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
a Tools marked with Q in the sketch column have the sketches (See "Sketches of special tools").
New/Redesign
Necessity
Sketch
Sym- Details of work and
Q'ty
Work Part No. Part name
bol remarks
Removal and
Removal of supply
installation of supply 1 790-101-3000 Push puller t 1 N
pump gear
pump assembly
795T-221-1010 Push tool t 1 Q
Removal and 790-101-5201 Push tool kit t 1
Installation of engine
installation of engine 2 790-101-5271 • Plate 1
front seal
front oil seal 790-101-5221 • Grip 1
01010-51225 • Bolt 1
795T-221-1020 Plate t 1 Q
Removal and A 790-101-5401 Push tool kit t 1
Installation of engine
installation of engine 3 790-101-5431 • Plate 1
rear seal
rear oil seal 790-101-5421 • Grip 1
01010-51240 • Bolt 1
4 796–401–1300 Fixing jig t 1
5 796–401–1330 • Collar t 1
Removal and 6 796–401–1310 • Bracket t 1
Removal of fan belt
installation of fan belt 7 01583–13018 Nut t 1
Commercially t 1
8 Wrench
available
1 790-201-2750 Spacer t 1 Removal of split collar
Removal of shaft
2 790-201-2730 Spacer t 1
assembly
790-101-2501 Push puller kit q 1
790-101-2510 • Block 1
790-101-2550 • Leg 1
790-101-2560 • Nut 2
Disassembly and 3 790-101-2570 • Plate 4 Removal of bearing
assembly of swing F 790-101-2901 Bearing puller q 1
machinery assembly • Puller
790-101-4200 (294 kN {30 ton} q 1
790-101-1102 Hydraulic pump q 1
Press fit of bearing
790-101-5401 Push tool kit (C) q 1
outer race
4 790-101-5461 • Plate 1 For main bearing
790-101-5441 • Plate 1 For sub bearing
790-101-5421 Grip 1
50-10 PC88MR-10
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
01010-81240 Bolt 1
5 790-201-2850 Spacer t 1 Press fit of bearing
6 790-201-2750 Spacer t 1 inner race
796T-426-1140 Push tool t 1 Q
7 Press fit of oil seal
790-201-2680 Plate q 1
791-620-3000 Remover and installer t 1
791-635-3110 • Frame 1
791-635-3120 • Support 1
791-635-3130 • Nut 1
791-635-3140 • Screw 1
791-635-3150 • Hook 1
791-635-3160 • Extension 1
791-635-3170 • Nut 4
Separation and 791-635-3180 • Screw 2
791-635-3190 • Screw (for fixing) 1 Removal and press fit
connection of track R of master pin
shoe assembly 791-635-3210 • Pilot 1
791-630-3220 • Adapter 1
791-620-3260 • Pin pusher 1
796T-226–
Push tool t 1 Q
1120
Cylinder (980 kN {100
790-101-1300 ton})
or t 1
Cylinder (686 kN {70
790-101-1600 ton})
791-101-1102 Pump t 1
790-101-5001 Push tool kit q 1
Disassembly and
790-101-5041 • Plate 1
assembly of idler L 1 Press fit of bushing
assembly 790-101-5021 • Grip 1
01010-50816 • Bolt 1
790–101–5001 Push tool kit q 1
790-101–5111 • Plate 1
Disassembly and 3
790101–5021 • Grip 1 Compression of
assembly of track L
01010–50816 • Bolt 1 spring
roller assembly
796T-230–
4 Installer t 1
1210
791-600-2001 Compressor (A)
or t 1 Q
791-685-8006 Compressor (B)
791-635-3160 Push tool kit q 1 Compression of
Disassembly and 2 790–201–2770 • Spacer 1 spring
assembly of idler Cylinder
cushion assembly 790-101-1600 (686 kN {70 ton}) 1
790-101-1102 Pump 1
Press fit of pin dust
3 796T-230-1210 Installer t 1 Q seal
PC88MR-10 50-11
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
791-601-1000 Oil pump q 1
• Plate (outer diameter:

790-201-1590 74 mm) 1
• Plate (outer diameter:
790-201-1610 79 mm) 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
791-620-3000 Remover and installer 1
791-635-3110 • Frame 1
Removal and 791-635-3120 • Support 1
installation of 791-635-3130 • Nut 1
hydraulic oil cooler
assembly 791-635-3140 • Screw 1
Removal and
installation of engine 791-635-3150 • Hook 1
and main pump
assembly
791-635-3160 • Extension 1 Press-fit and
Removal and 791-635-3170 • Nut 4
D hollowing of master
installation of
791-635-3180 • Screw 2 pin
hydraulic tank
assembly • Screw (for
791-635-3190 installation) 1
Removal and
installation of main 796-635-3210 • Pilot 1
pump assembly 796-620-3220 • Adapter 1
Removal and 791-615-7161 Pusher pin t 1
installation of control 791-615-7170 Guide t 1
valve assembly Cylinder
790-101-1300 (480 kN {100 ton}) t 1
790-101-1102 Hydraulic pump t 1
790-101-2501 Push puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly and 790-101-2540 • Washer 1
assembly of center Disconnection of rotor
T 791-112-1180 • Nut 1
swivel joint assembly and shaft
790-101-2630 • Leg 2
790-101-2570 • Washer 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
50-12 PC88MR-10
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
790-502-1003 Repair stand t 1 Disassembly and

1 assembly of cylinder
790-102-3802 Wrench assembly t 1 Removal and
2 installation of piston
790-330-1100 Wrench assembly t 1
Socket
790-102-1320 (width across flats: 70 t 1
mm)
Socket
mm) Press fit of bucket
3 cylinder roll bushing
Socket
mm)
Socket
mm)
Installation of bucket
4 790-720-1000 Expander q 1 cylinder dust seal
Disassembly and 790-720-1650 Band q 1
assembly of work 07281-01029 Clamp q 1
equipment cylinder 796-720-1670 Band q 1 Expansion of piston
assembly 5 ring
07281-01154 Clamp q 1
796-720-1670 Band q 1
07281-01274 Clamp q 1
U 790-201-1702 Push tool kit q 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1791 • Push tool 1
Removal of bucket
790-101-5021 • Grip 1
6 cylinder and piston
ring
01010-50816 • Bolt 1
790-201-1781 • Push tool 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1771 • Push tool 1
790-201-1610 • Plate 1
790-201-5021 • Grip 1
Disassembly and 01010-50816 • Bolt 1
assembly of work 790-201-1500 Push tool kit q 1
equipment cylinder 7
790-201-1590 • Plate 1
assembly 790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1580 • Plate 1
PC88MR-10 50-13
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Removal and 1 793-498-1210 Lifter (suction cup) t 2 Holding glass
installation of
operator's cab glass X
(adhered window 2 22B-54-38320 Stopper rubber t 3 Fixing glass
glass)
50-14 PC88MR-10
Sketches of special tools (PC88MR-3531-066-A-00-A)
Note) Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A2 Push tool
A3: Plate
PC88MR-10 50-15
Note) Komatsu does not take any responsibility for special tools manufactured according to these sketches.
F7: Push tool
R: Guide
50-16 PC88MR-10
Removal and installation of supply pump assembly (PC88MR-AD70-924-K-00-A)
a Special tools 5. Disconnect connector (2) of oil pressure switch

and connector (3) of supply pump regulator
S-
Necessity
SCV.
y-
Q'ty
Part No. Part name 6. Remove clip (4).
7. Remove clamp (4b) of wiring (4b).
mbol
A-
790–101–3000 Push puller t 1
1
lower the work equipment to the ground in a
stable posture.
k Stop the engine, turn the battery disconnect

switch to OFF position, and remove the key.
(For details, see "Testing and adjusting",
"Handling battery disconnect switch".)
k Set the lock lever in LOCK position.

8. Remove clamp mounting bolts (5) (2 piece), and
Removal (PC88MR-AD70-520-K-00-A) disconnect crank rotation sensor NE connector
1. Open cover (1a), and turn valve (1b) to CLOSE (6).
position (S).
9. Remove mounting bolt (7), and remove plates

(8) and (9). [*1]
2. Remove the counterweight assembly. For

details, see "Removal and installation of 10.Remove bolts (10) (2 pieces), and disconnect
counterweight assembly". wiring (11).
3. Remove the fan belt. For details, see "Removal
and installation of fan belt".
4. Remove clamp mounting nut (1).
PC88MR-10 50-17
11.Remove mounting bolts (12) (2 pieces), and 18.Remove mounting bolts (25), and remove
remove clamp (13). supply pump assembly (26) together with the
gear. [*6]
12.Remove joint bolts (14) and (15), and

disconnect fuel tubes (16) and (17). [*2] 19.Loosen nut (27).
13.Remove joint bolt (18), and disconnect fuel hose
a Do not remove nut (27) from the shaft.
(19). [*3]
14.Remove fuel spray prevention caps (21) (2
pieces) of fuel high-pressure pipe (20). [*4]
15.Remove fuel high-pressure pipes (20). [*5]
a When removing the fuel high-pressure pipe,
be careful not to apply excessive force to the
tube.
16.Remove joint bolt (22), and disconnect tube
(23).
20.Install tool A1 in between the flange and gear

(31) of the supply pump.
17.Remove mounting bolts (24) (4 pieces).
50-18 PC88MR-10
3 Sleeve nut for fuel high-pressure pipe

(20):
39.0 to 44.0 Nm {4.0 to 4.5 kgm}
[*6]
• Perform positioning of supply pump gear
a Perform the positioning of top positions of
pistons #1 and #4.
a When installing the supply pump assembly to
the front cover, align straightly tapped hole (a) of
the gear and the tapped hole (b) of the front
cover viewing from the engine front.
21.Remove nut (29), washer (30) and gear (31)
from shaft (28). [*6]
a Install it with the stamp mark "C" (A) part of the

gear facing the idler pulley.
Installation (PC88MR-AD70-720-K-00-A)
• Perform installation in the reverse order to

removal.
[*1]
8.8 to 14.7 Nm {0.9 to 1.5 kgm}
[*2]
3 Joint bolts (14) and (15):
14.8 to 12.7 Nm {15 to 1.3 kgm}
[*3]
3 Joint bolt (18): 3 Gear mounting nut (27):
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 58.8 to 68.6 Nm {6.0 to 7.0 kgm}
[*4]
a Make the slit of the fuel spray prevention caps
installed to fuel high-pressure pipe (12) to face
down.
a The fuel spray prevention caps are installed so
that fuel will not spout over the hot part of the
engine when it leaks by any chance.
[*5]
1. Install fuel high-pressure pipe (20).
a When installing fuel high-pressure pipe (20),
tube.
PC88MR-10 50-19
Removal and installation of injector assembly (PC88MR-AE60-924-K-00-A)

stable posture.

a When disconnecting the wiring harness, check

the positions of each clamp.
3. Remove engine hood assembly. For details, see
Removal (PC88MR-AE60-520-K-00-A) "Removal and installation of engine hood
1. Open cover (1a), and turn valve (1b) at the assembly".
bottom of the main pump to CLOSE position (S). 4. Remove KCCV ventilator. For details, see
"Removal and installation of KCCV ventilator".
5. Remove KDOC muffler. For details, see
"Removal and installation of KDOC muffler".
6. Disconnect the air conditioner compressor
assembly, and move it to the machine side. For
details, see "Removal and installation of air
conditioner compressor assembly".
a Do not disconnect the air conditioner hose.
7. Remove clamp (1), and remove aftercooler
upper hose (2). [*1]
a Also remove the hose on the ribbon heater
side.
2. Open fuel drain cock (1c), and drain the fuel. 8. Remove clamp (3), and remove KCCV piping (4).
[*2]
6 When filled up with fuel:
125 l
a It is for fuel not to flow reverse from return
fuel piping into cylinder.
50-20 PC88MR-10
9. Remove mounting bolt (5) (1 piece). 14.Disconnect connectors CN1 (14) and CN2 (15)
10.Remove clamp (6), and remove engine oil filler on the intake side.
hose (7). [*3] 15.Remove fuel spray prevention cap (16) on the
injector side.
16.Disconnect ribbon heater wiring E01 (16a).
11.Remove mounting bolts (8) (2 pieces) of EGR

piping (13), and remove clamp (9).
12.Remove mounting bolts (10) (3 pieces), and
remove bracket (11).
13.Remove clamp (12), and remove EGR piping
(13) together with the hose. [*4]
17.Remove clamp (17).

pieces) on the common rail side.
19.Loosen the sleeve nuts on the injector side and
common rail side to remove fuel high-pressure
pipe (19).
a When removing fuel spray prevention cap
(19), be careful not to apply excessive force
to the tube.
PC88MR-10 50-21
a Record the cylinder number to which the

injector is installed and the character string
(M) listed on the QR code tab (Q) as a set,
and remove the injector.
a Read character string (M) in the order
indicated by the arrow in the figure.
20.Remove mounting bolts (20) (3 pieces) and

remove cylinder head cover (21).
21.Remove nuts (23) (8 pieces) of injector harness

(22) from the injector.
a Installing position of injector wiring harness
Color of injector wiring Cylinder No.
harness
White 1, 3 a Check the noted character string (M) is
Black 2, 4 correct.
a Do not remove QR code tab (Q) attached to
the injector head.
a Do not damage the QR code tab (Q) on the
injector head. (Reference: The QR code or
character string indicates the compensation
value for fuel injection of the injector, which is
specific to each injector.)

remove injector holders (25) (4 pieces).
a Use the new bolts (24) (4 pieces).
a Do not reuse the bolt and replace it with a
new one. If it is reused, the engine oil may
enter the fuel return circuit.
23.Remove injector assemblies (26) (4 pieces).
50-22 PC88MR-10
Installation (PC88MR-AE60-720-K-00-A)
1. Injector assembly
a When replacing the injector assembly or
engine controller assembly, write the
character string into the engine controller
according to the following procedure. For
details, see Testing and adjusting, "Writing
compensation values at replacement of
injector and engine controller".
• Note the number of cylinder to which a new
injector is installed and character string (M)
listed on the QR code tab at the top of the 1) Install gasket (27) to injector assembly (26).
injector as a set. 2) Install O-rings (28) and (29) to injector
assembly (26).
a Read character string (M) in the order
indicated by the arrow in the figure. a Do not put the O-ring in spill groove (e).
3) Apply engine oil to O-ring (28) and head side
inserting hole of injector assembly (26).
2 O-ring and head side inserting
hole:
Engine oil
4) Make the fuel inlet hole of injector assembly
(26) to face to the fuel inlet manifold side,
and insert it into the cylinder head while
inserting injector holder (25) into (f) part of
the injector.
a Be careful that gasket (27) at the tip of the
injector nozzle does not fall.
5) Tighten the mounting bolt (24) of injector
a Be sure to check that the recorded holder (25) lightly.
character string is correct.
• Write the recorded character string into the a Apply Loctite 204 to threaded part of
engine controller. mounting bolt (24).
a Be sure to write the noted character string 2 Threaded part:
into the cylinder number column of the Adhesive (Loctite No. 204 or
cylinder to which the injector is installed. equivalent)
a If the character strings are not written a Use the new bolts (24) (4 pieces).
correctly, the engine may not operate
normally. a Do not reuse the bolt and replace it with a
new one. If it is reused, the engine oil
(Reference: The QR code or character may enter the fuel return circuit.
string indicates the compensation value
for fuel injection of the injector, which is a Do not tighten the bolts excessively.
PC88MR-10 50-23
k Do not bend the fuel high-pressure pipe

to correct.
k Be sure to use the genuine fuel high-

pressure pipe clamp and strictly observe
the specified tightening torque.
k Check the following items and install the

fuel high-pressure pipe. If it has any
defect, replace the high-pressure pipe
with a new one since fuel may leak.
• Be sure that the taper seal part of the
2. Cylinder head assembly connection ((a) part: 2 mm area from the tip-
1) Tighten injector harness (22) with nut (23). end) is free from longitudinal slits (b) or pits
(c) with visual check.
3 Lock nut (23): Be sure that part (d) (2 mm from the tip-end)
2.0 to 2.4 Nm {0.20 to 0.24 kgm} is free from steps which can be felt by your
a Be careful that the injector harness is not fingernail, and from fatigue.
pinched by the tool and rocker housing.
a Installing position of injector wiring
harness
harness
White 1, 3
Black 2, 4
1) Temporarily tighten the injector side of fuel

high-pressure pipe (19) to inlet connectors
(30) (4 pieces) with sleeve nut (31).
a Also temporarily tighten the common rail
side of the fuel high-pressure pipes with
sleeve nut.
2) Tighten mounting bolt (24) of injector holder
2) Tighten cylinder head cover (21) with (25) to the specified torque.
mounting bolt (20). 3 Mounting bolt (24):
3 Mounting bolt (20): 39.0 to 49.0 Nm {4.0 to 5.0 kgm}
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
3. Fuel high-pressure pipe
50-24 PC88MR-10
3) Tighten the mounting sleeve nut of the fuel

high-pressure pipe on the injector side to the
specified torque.
3 Mounting sleeve nut:
39.0 to 44.0 Nm {4.0 to 4.5 kgm}
high-pressure pipe on the common rail side
to the specified torque.
3 Mounting sleeve nut:
39.0 to 44.0 Nm {4.0 to 4.5 kgm}
5) Install clamp (17) of fuel high-pressure pipe
(19).
6) Install fuel spray prevention cap (18) to each
sleeve nut of the fuel high-pressure pipes.
a Make the slit of the fuel spray prevention
cap to face down.
a The fuel spray prevention caps are
installed so that fuel will not spout over
the hot part of the engine when it leaks by
any chance.
[*2]
3 Clamp (3):
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
[*3]
3 Clamp (6):
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*4]
• Insertion position of EGR piping (13) and the
• Perform subsequent installation in the reverse clamp must be as shown in the following figure.
order to removal.
[*1] a Install the hose and tube to the position
marked when they were installed.
• Insertion positions of aftercooler upper hose (2)
and the clamp must be as shown in the following 3 Clamp (12):
figure. 8.8 ± 0.49 Nm {0.9 ± 0.05 kgm}
a Install the hose and tube to the position marked
when they were installed.
a Check mark (e) of the hose facing upward and
then install it.
a: 5 mm
b: 60 mm
c: 9 mm
d: 30 deg.
3 Clamp (1):
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
• Bleed air
PC88MR-10 50-25
Bleed air in the fuel system. For details, see

"Testing and adjusting", "Bleed air from fuel
system".
• Test fuel
Check for fuel leakage. For details, see "Testing
and adjusting", "Testing fuel circuit for leakage".
• Refill with oil
Check that the oil filler plug is closed before
refilling.
Refill it with oil to the specified level through the
oil filler port. Run the engine to circulate the oil
through the piping. Then check the oil level
again.
5 When it is filled up with fuel:

125 l (specified capacity: 100 l )
50-26 PC88MR-10
Removal and installation of cylinder head assembly (PC88MR-A100-924-K-00-A)

stable posture.

(For details, see Testing and adjusting,
Removal (PC88MR-A100-520-K-00-A)
a Record the disconnected position of the hose 3. Remove engine hood assembly. For details, see
and wiring connector to avoid misplacing. "Removal and installation of engine hood
1. Open cover (1a) and turn valve (1b) at the assembly".
bottom of the main pump to CLOSE position (S). 4. Remove KCCV ventilator. For details, see
"Removal and installation of KCCV ventilator".
a Disconnect the fuel hose. 5. Remove KDOC muffler. For details, see
"Removal and installation of KDOC muffler".
6. Open cover (1), loosen the coolant drain plug,
and drain the coolant.
6 Coolant:
13 l
7. Remove mounting bolts (2) (6 pieces), and

remove cover (3).
2. Disconnect hose (1c).

a It is for fuel not to flow reverse from return
fuel piping into cylinder.

remove cover (5).
PC88MR-10 50-27

remove bracket (7).
16.Disconnect connector VFT (16).

17.Disconnect clamp (17), and disconnect turbo
10.Disconnect the air conditioner compressor charger assembly (19) from tube (18) on the air
assembly, and reposition it out of the way for intake outlet side. [*5]
working. For details, see "Removal and
installation of air conditioner compressor
assembly".
a Do not disconnect the hose.
11.Remove clamp (7), and remove aftercooler
18.Remove KDOC assembly. For details, see

"Removal and installation of KDOC assembly".
remove turbo charger cover (21). [*6]
12.Remove clamp (9), and remove KCCV piping

(10). [*2]
13.Remove clamp (10a), and remove hoses (11)
and (12). [*3]
14.Remove clamp (13), and air cleaner hose (14).
[*4]
15.Remove lubricating oil drain tubes (15) and
(15a).
50-28 PC88MR-10
24.Disconnect connector TWTR (28), and

reposition wiring (29) out of the way.
25.Remove hose (30).
26.Remove bracket (31).
20.Remove mounting nuts (22) (4 pieces), and

remove turbo charger assembly (19).
27.Disconnect radiator upper hose (32) from the

radiator side. [*8]
21.Remove mounting bolt (23) (4 pieces), and

remove tube (24). [*7]
28.Remove the fan belt. For details, see "Removal

and installation of fan belt".
29.Remove mounting bolt (33), and loosen bolt (34)
to move alternator (35) to the machine side.
22.Remove tubes (25) and (26).
30.Remove clamp (36), and disconnect radiator

lower hose (37). [*9]
23.Disconnect clamp (27).
PC88MR-10 50-29
31.Remove mounting bolt (38). 38.Disconnect connectors CN1 (48) and CN2 (49)
32.Remove clamp (39), and remove engine oil filler on the intake side.
hose (40). [*10] 39.Remove fuel spray prevention cap (50) on the
injector side.
40.Disconnect ribbon heater wiring E01 (51).
33.Remove EGR piping (46) mounting bolts (41) (2

pieces), and remove clamp (42).
35.Remove clamp (45), and remove EGR piping
(46) and hose as a unit. [*11]
36.Remove joint bolt (46a), and remove hot water
tube (47) on the muffler side. [*12]
37.Remove cover (47a).
41.Remove clamp (52).

pieces) on the common rail side.
43.Loosen the sleeve nuts on the injector side and
common rail side to remove fuel high-pressure
pipe (54).
a When removing fuel high-pressure pipe (54),
tube.
44.Loosen clamp (55) and remove fuel tube (56).
[*13]
50-30 PC88MR-10
45.Remove mounting bolts (57) (6 pieces), and 49.Remove nut (72) of injector wiring harness (71)
remove fan (58) and fan pulley (59). from the injector.
a Installing position of injector wiring harness
harness
White 1, 3
Black 2, 4
a Remove injector harness connectors (73) (2

pieces) of the injector from the rocker
housing only when required.
remove rocker housing (75).

remove tube (61).
mounting bolt (63) (1 piece), and remove water
pump (64).
51.Loosen lock nuts (76) (8 pieces) and fully loosen

adjustment screws (77) (8 pieces).
52.Remove mounting bolts (78) (7 pieces) and stud
bolts (79) (3 pieces), and remove rocker arm
assembly (80).
48.Remove mounting bolt (65), and remove

cylinder head cover (66). [*14]
53.Remove push rods (81) (8 pieces).
PC88MR-10 50-31
54.Remove crosshead (82). a Read character string (M) in the order

a Note the mounting position and the shapes

of holes (a) and (b).
a Check that the noted character string (M) is
(For reinstallation in the same direction) correct.
a Do not remove QR code tab (Q) attached to
the injector head.
a Do not damage QR code tab (Q) attached to
the injector head.
(Reference: The QR code or character string
indicates the compensation value for fuel
injection of the injector, which is specific to
each injector.)

remove injector holders (84) (4 pieces).
a Use the new bolts (83) (4 pieces).
a Do not reuse the bolt and replace it with a
new one. If it is reused, the engine oil may
enter the fuel return circuit.
56.Remove injector assemblies (85) (4 pieces).
a Record the cylinder number to which the
injector is installed and the character string
(M) listed on the QR code tab (Q) as a set,
and remove the injector.
57.Remove mounting bolt (86), sling cylinder head

assembly (87) and remove it.
4 Cylinder head assembly (87):

60 kg
50-32 PC88MR-10
3) Apply molybdenum disulfide lubricant to the

threaded part of cylinder head mounting bolt
(86).
2 Threaded part of mounting bolt
(86):
Lubricant containing molybdenum
disulfide (LM-P)
a Tighten the mounting bolt (86) by 2 to 3
threads.
58.Place cylinder head assembly (87) onto the

block, and remove the intake and exhaust
manifold, heater, and connector.
a Remove the intake and exhaust manifold,
heater, and connector. For details, see
"General disassembly of engine" of Engine
Shop Manual.
Installation (PC88MR-A100-720-K-00-A)
1. Install the intake manifold, heater, and connector.

For details, see "General assembly of engine" of 4) Tighten mounting bolt (86) in the order of [1]
Engine Shop Manual. to [17] in the following figure and with the
2. Cylinder head assembly following procedures.
1) Check that the cylinder head and the cylinder F: Indicates the engine front.
block mounting face are free from dirt or A: Indicates the engine inlet side.
foreign matter and install cylinder head B: Indicates engine exhaust side.
gasket (88) to cylinder block assembly (89). 3 Cylinder head mounting bolt (86):
a Install it so that stamp mark "TOP" (a) on 1st time: 68.6 ± 9.8 Nm {7 ± 1 kgm}
the cylinder head gasket comes to upper 2nd time: 107.8 ± 4.9 Nm {11 ± 0.5
side. kgm}
a Check that pin (90) to prevent the wrong 3rd time: Put mark (c) on the bolt
installation of cylinder head gasket on the head and cylinder head, then turn
upper side of the cylinder block and the the bolt 90 deg. (+30 deg./ 0 deg.)
hole of cylinder head gasket are aligned. to tighten.
a After tightening, put a punch mark (d) on
each bolt head to indicate the number of
tightening.
a A bolt which already have 5 punch marks
(d) must be replaced without being
reused any more.
2) Sling cylinder head assembly (87) and install

it onto the cylinder block assembly.
4 Cylinder head assembly (87):

60 kg
PC88MR-10 50-33
3. Injector assembly 1) Install gasket (91) to injector assembly (85).

a When replacing the injector assembly or 2) Install O-rings (92) and (93) to injector
engine controller assembly, write the assembly (85).
character string into the engine controller a Do not put the O-ring in spill groove (e).
according to the following procedure. For 3) Apply engine oil to O-ring (92) and head side
details, see "Testing and adjusting", "Writing inserting hole of injector assembly (85).
compensation values at replacement of
injector and engine controller". 2 O-ring and head side inserting
hole:
• Note the number of cylinder to which a new
injector is installed and character string (M) Engine oil
listed on the QR code tab at the top of the 4) Face the fuel inlet hole of injector assembly
injector as a set. (85) to the fuel inlet manifold side, and insert
it into the cylinder head while inserting
a Read character string (M) in the order injector holder (84) into (f) part of the injector.
a Do not let the gasket at the tip of the
a Be sure to check that the noted character injector nozzle fall.
string is correct. 5) Tighten the mounting bolt (83) of injector
• Write the noted character string into the holder (84) lightly.
engine controller.
a Apply Loctite 204 to threaded part of
a Be sure to write the noted character string mounting bolt (83).
into the cylinder number column of the
cylinder to which the injector is installed. 2 Threaded part:
Adhesive (Loctite No. 204 or
a If the character strings are not written
equivalent)
correctly, the engine may not operate
normally. a Use the new bolts (83) (4 pieces).
(Reference: The QR code or character a Do not reuse the bolt and replace it with a
string indicates the compensation value new one. If it is reused, the engine oil
for fuel injection of the injector, which is may enter the fuel return circuit.
a Do not tighten the bolts excessively.
50-34 PC88MR-10

19.6 to 29.4 Nm {2.0 to 3.0 kgm}
a Loosen lock nut (76) and sufficiently
return adjustment screw (77).
4) Adjust the valve clearance.
a Adjust the valve clearance. For details,
see "Testing and adjusting", "Test and
adjust valve clearance".
5) Tighten lock nut (76) with adjustment screw
(77) fixed after adjustment of valve
clearance.
4. Push rod and crosshead 3 Lock nut (76):
1) Insert push rods (81) in the tappet guides. 39.2 to 49.0 Nm {4.0 to 5.0 kgm}
a The push rods for the intake and exhaust a Check the valve clearance again after
valves are the same. tightening the locknut.
a If the push rods are free from defects,
install them in the same positions as
before.
2) Install crosshead (82).
a Install the cross rod so that long hole (a)
faces the exhaust side and the short hole
(b) faces the inlet side.
6. Rocker housing assembly

1) Install rocker housing (75) with mounting bolt
(74) tightened in the order of [1] to [19] in the
following figure.
• Rocker housing tightening order
5. Rocker arm assembly

1) Install rocker arm assembly (80).
2) Check that the ball of adjustment screw (77)
is set in the push rod socket securely.
3) Tighten rocker arm assembly (80) with stud
bolt (79) and mounting bolt (78).
PC88MR-10 50-35
by your fingernail. (Namely, this part must

be free from fatigue.)
2) Tighten injector harness (71) with nut (72).

3 Lock nut (72):
2.0 to 2.4 Nm {0.20 to 0.24 kgm}
1) Temporarily tighten the injector side of fuel
a Be careful that the injector harness is not high-pressure pipe (54) to inlet connectors
pinched by the tool and rocker housing. (94) (4 pieces) with sleeve nut (95).
a Installing position of injector wiring a Also temporarily tighten the common rail
harness side of the fuel high-pressure pipes with
Color of injector wiring sleeve nut.
Cylinder No. 2) Tighten mounting bolt (83) of injector holder
harness
White 1, 3 (84) to the specified torque.
Black 2, 4 3 Mounting bolt (83):
39.0 to 49.0 Nm {4.0 to 5.0 kgm}
7. Fuel high-pressure pipe

k Do not bend the fuel high-pressure pipe high-pressure pipe on the injector side to the
to correct. specified torque.
k Be sure to use the genuine fuel high- 3 Mounting sleeve nut:

pressure pipe clamp and strictly observe 39.0 to 44.0 Nm {4.0 to 4.5 kgm}
the specified tightening torque. 4) Tighten the mounting sleeve nut of the fuel
high-pressure pipe on the common rail side
k Check the following items and install the to the specified torque.
fuel high-pressure pipe. If it has any 3 Mounting sleeve nut:
defect, replace the high-pressure pipe
with a new one since fuel may leak. 39.0 to 44.0 Nm {4.0 to 4.5 kgm}
5) Install clamp (52) of fuel high-pressure pipe
• Be sure that the taper seal part of the (54).
connection ((a) part: 2 mm area from the 6) Install fuel tube (56).
tip-end) is free from longitudinal slits (b) 7) Install clamp (55).
or pits (c) with visual check. 8) Install fuel spray prevention cap (53) to each
Be sure that part (d) (2 mm from the tip- sleeve nut of the fuel high-pressure pipes.
end) is free from steps which can be felt
50-36 PC88MR-10
a Make the slit of the fuel spray prevention

cap to face downward.
a The fuel spray prevention caps are
installed so that fuel will not spout over
the hot part of the engine when it leaks by
any chance.
[*2]
3 Clamp (9):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*3]
3 Tube (10a):
• Perform subsequent installation in the reverse 3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
order to removal. [*4]
[*1]
3 Clamp (13):
and the clamp are as shown in the following 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
figure. [*5]
a Install the hose and tube to the position marked 3 Clamp (17):
when they were installed. 5.9 ± 7.8 Nm {0.6 ± 0.8 kgm}
a Check mark (e) of the hose facing upward and [*6]
then install it.
a: 5 mm
8.8 to 10.8 Nm {0.9 to 1.1 kgm}
b: 60 mm
[*7]
c: 9 mm
Tighten tube (24) in the order of [1] to [4] in the
d: 30 deg. following figure.
3 Clamp (7): a Fit the gasket to the mounting faces of the both
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm} ends of tube.
1st time: 9.8 to 14.7 Nm {1 to 1.5 kgm}
2nd time: 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
3rd time: 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
PC88MR-10 50-37
2 Threaded part of mounting bolt (25): [*12]

Molybdenum dioxide lubricant (LM-P) 3 Joint bolt (46a):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
[*13]
3 Fuel tube (56) mounting nut:
39 to 40 Nm {4.0 to 0.45 kgm}
[*14]
3.6 to 4.4 Nm {0.37 to 0.45 kgm}
• Refill with coolant
Refill it with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
[*8], [*9]
check the coolant level again.
• Apply TB1206E (ThreeBond) to the area of
approximately 30 mm from the tip of the 5 Coolant:
insertion opening where the radiator hose is
13 l
installed, and then install the radiator hose.
• Refill with oil
• Check that the hose is normal without any crack,
and then install it.
refilling.
• Also check that inner surface of the hose
insertion part is not damaged.
3 Radiator upper hose (32) clamp: through the piping. Then check the oil level
10.5 ± 0.5 Nm {10.7 ± 0.05 kgm} again.
3 Clamp (36): 5 When it is filled up with fuel:

8.8 ± 0.5 Nm {0.9 ± 0.05 kgm} 125 l (specified capacity: 100 l )
[*10]
3 Clamp (38):
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*11]
• Insertion position of EGR piping (46) and the
clamp must be as shown in the following figure.
f: 15 mm
g: 45 mm
a Install the hose and tube to the position
marked when they were installed.
3 Clamp (45):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
50-38 PC88MR-10
Removal and installation of radiator assembly (PC88MR-B220-924-K-00-A)
k Place the machine on a level ground and installation of air conditioner condenser
lower the work equipment to the ground in a assembly".
stable posture. 4. Open cover (1), loosen coolant drain plug (1a),
and drain the coolant.
k Stop the engine, turn the battery disconnect 5. Remove clamp (2a), and disconnect drain hose
switch to OFF position, and remove the key. (2b).
"Handling battery disconnect switch".) 6 Coolant:
13 l
k Loosen the cap of the hydraulic tank slowly

to release the pressure in the hydraulic tank.
Removal (PC88MR-B220-520-K-00-A)
a Make a mark on the tube so that the insertion

amount can easily be checked when removing
the hose.
1. Remove the air cleaner assembly. For details,
see "Removal and installation of air cleaner
assembly".
2. Remove battery (1a) according to the following
procedure.
1) Remove rubber cover (2a).
2) Disconnect wiring (3a), (3b), and (3c).

3) Remove mounting bolts (4a) (4 pieces), and
remove brackets (5a) (2 pieces).
4) Remove batteries (1a) (2 pieces).
6. Disconnect aftercooler upper hose (2). [*1]

7. Disconnect radiator upper hose (3). [*2]
8. Disconnect radiator overflow hose (4), and
remove partition plate (5).
3. Remove the air conditioner condenser assembly

and reposition it. For details, see "Removal and
PC88MR-10 50-39
9. Remove mounting bolts (6) (3 pieces), and 14.Remove wing screws (15) (4 pieces), and
remove cover (7). remove nets (16) (3 pieces). [*5]
a (Net (16) is an optional specification.)

disconnect aftercooler lower tube (9).
15.Remove mounting bolts (17), and remove net
11.Disconnect radiator lower hose (10). [*3]
rail (18).
remove covers (12) and (13).

remove plate (20) and bracket (20a). [*6]
13.Remove mounting bolts (14) (2 pieces). [*4]
50-40 PC88MR-10
3 Aftercooler upper hose (2) clamp:

10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
17.Remove the aftercooler assembly. For details,

see "Removal and installation of aftercooler
assembly".
18.Sling and remove radiator assembly (21) after
moving it to the removed aftercooler side. [*6]
a Be careful not to catch the bottom of radiator
assembly (21) when slinging it.
[*2], [*3]
approximately 30 mm from the tip of the
Installation (PC88MR-B220-720-K-00-A) • Check that the hose is normal without any crack,
• Perform installation in the reverse order to and then install it.
removal. • Also check that inner surface of the hose
[*1] insertion part is not damaged.
• Insertion positions of aftercooler upper hose (2) 3 Radiator upper hose (3) clamp:
and the clamp are as shown in the following 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
figure.
3 Radiator lower hose (10) clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
then install it. 4 Mounting bolt (14):
a: 5 mm 44 ± 9.8 Nm {4.5 ± 1.0 kgm}
b: 60 mm [*5]
c: 9 mm
d: 30 deg. 4 Wing screw (15):
8.8 ± 14.7 Nm {8.8 ± 1.5 kgm}
[*6]
4 Radiator assembly (21):

10 kg
PC88MR-10 50-41

5 Coolant:
13 l
50-42 PC88MR-10
Removal and installation of hydraulic oil cooler assembly (PC88MR-B8P0-924-K-00-A)
a Special tools
Necessity
S-
y-
Q'ty
Part No. Part name
mbol
2796-460-1210 Oil stopper t 1
D
796T-460-1240 Lot ● 1

stable posture. 2) Disconnect wiring (3a), (3b), and (3c).
k Stop the engine, turn the battery disconnect remove brackets (5a) (2 pieces).
switch to OFF position, and remove the key. 4) Remove batteries (1a) (2 pieces).
k Remove the drain plug, and drain the

remaining hydraulic oil from the hydraulic oil
cooler.
k Loosen the cap of the hydraulic tank slowly,

and release the pressure in the hydraulic
tank.
Removal (PC88MR-B8P0-520-K-00-A)
remove cover (4e).
"Removal and installation of engine hood
assembly".
assembly".
3. Remove clamp (1), and remove air cleaner hose
(2). [*1]
6. Loosen drain plug (5b) of the hydraulic oil tank,

and drain the oil. [*2]
6 Hydraulic oil:
a When using tool D, remove the hydraulic
4. Remove battery (1a) according to the following tank strainer, install tool D and stop draining
procedure. the oil.
PC88MR-10 50-43
10.Remove mounting nuts (5) (2 pieces), and

disconnect hose (6).
7. Remove mounting bolts (6a) (3 pieces), and

remove cover (7a).
8. Remove drain plug (8a), and drain the remaining

hydraulic oil from the hydraulic oil cooler. 12.Disconnect the air conditioner condenser
assembly. For details, see "Removal and
installation of air conditioner condenser
assembly".
a Do not remove the hose when removing the
air conditioner condenser assembly.
13.Remove the fuel cooler assembly. For details,
see "Removal and installation of fuel cooler
assembly".
14.Remove the aftercooler. For details, see
"Removal and installation of aftercooler".
15.Remove rail (9).
9. Remove clamps (4) (2 pieces).
50-44 PC88MR-10

remove hydraulic oil cooler assembly (12) while
tilting it forward. [*3]
Installation (PC88MR-B8P0-720-K-00-A)

removal.
[*1]
3 Air cleaner hose (1) clamp:
8.8 ± 0.5 Nm {0.9± 0.05 kgm}
[*2]
3 Hydraulic oil drain plug (5b):
58.8 to 78.4 Nm {6 to 8 kgm}
[*3]
44 ± 9.8 Nm {4.5 ± 1.0 kgm}
PC88MR-10 50-45
Removal and installation of aftercooler assembly (PC88MR-A9A0-924-K-00-A)

stable posture.

Removal (PC88MR-A9A0-520-K-00-A)
1. Remove engine hood assembly. For details, see 8. Remove mounting bolts (7) (3 pieces), and
"Removal and installation of engine hood remove cover (8).
assembly".
assembly".
3. Disconnect aftercooler upper hose (1). [*1]
4. Remove partition plate (1a).

disconnect aftercooler lower tube (10).
remove cover (12).
5. Remove mounting bolts (2) (2 pieces). [*2}

6. Remove wing screws (3) (2 pieces), and remove
nets (4) (3 pieces). (Net (4) is an option.) [*3]
11.Remove aftercooler assembly (13). [*4]

remove net rail (6).
50-46 PC88MR-10
3 Aftercooler upper hose (1) clamp:

10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
Installation (PC88MR-A9A0-720-K-00-A)

removal.
[*1]
and the clamp are as shown in the following
figure.
then install it.
a: 5 mm
b: 60 mm
c: 9 mm [*2]
d: 30 deg. 3 Mounting bolt (2):
44 ± 9.8 Nm {4.5 ± 1.0 kgm}
[*3]
4 Wing screw (3):

8.8 ± 14.7 Nm {8.8 ± 1.5 kgm}
[*4]
• Align convex portions (a) and (b) at the
aftercooler bottom and concave parts (a) and (b)
on the machine side before installing.
PC88MR-10 50-47
50-48 PC88MR-10
Removal and installation of engine and main pump assembly (PC88MR-R400-924-K-

00-A)
a Special tools 2. Open fuel drain cock (1c), and drain the fuel.
Necessity
S-
y- 6 When filled up with fuel:
Q'ty
Part No. Part name 125 l
mbol a It is for fuel not to flow reverse from return
796-460-1210 Oil stopper t 1 fuel piping into cylinder.
D
796T-460-1240 Lot ● 1

stable posture.


k Release the remaining pressure in the remove cover (2).
hydraulic system. For details ,see "Testing
and adjusting", "Releasing remaining
pressure from hydraulic system".
Removal (PC88MR-R400-520-K-00-A)
1. Open cover (1a), and turn valve (1b) at the

bottom of the main pump to CLOSE position (S).
4. Open coolant drain cock (3), and drain the

coolant.
6 Coolant:
13 l

remove cover (5).
PC88MR-10 50-49
6. Loosen drain plug (6) of the hydraulic oil tank, 8. Loosen bolt (9), and drain the remaining
and drain the oil. [*1] hydraulic oil in the suction piping.
6 Hydraulic oil:
tank strainer, install tool D and stop draining
the oil.

assembly".
10.Remove the counterweight assembly. For
details, see "Removal and installation of
counterweight assembly".
11.Remove the air conditioner compressor
assembly, and move it to the machine body side.
For details, see "Removal and installation of air
a Do not disconnect the hose.
remove engine oil filter (13) together with the
bracket.
a Bind the removed oil filter on the engine.
7. Remove mounting bolt (7), and remove cover

(8).
50-50 PC88MR-10
14.Remove mounting bolts (16) (2 pieces). (23): PEPC source pressure input port hose
(24): Pd (drain) port hose
15.Rotate frame (17) as shown in the photo.

17.Disconnect clamps (25) and (26).
18.Remove clamp (28) and bracket (29) as a unit,
disconnect hydraulic oil temperature sensor
connector P22 (30) and PC-EPC valve
connector V11 (31) from bracket (33).
bracket (33) for easier operation.
16.Disconnect hoses (18) to (24) (7 pieces) from

the oil pressure pump.
(18): P3 port hose
(19): P2 port hose
(20): P1 port hose
(21): PLS port hose
(22): PPLS port hose
PC88MR-10 50-51
20.Remove mounting bolts (34) (4 pieces), and 24.Remove clamp (40), and disconnect aftercooler
disconnect suction piping (35) from the oil upper hose (41). [*3]
pressure pump. [*2] 25.Remove clamp (42), and disconnect radiator

disconnect suction piping (37).
26.Remove clamps (44) (2 pieces), and disconnect

22.Remove the air conditioner compressor hoses (45) (2 pieces). [*5]
assembly, and move it to the radiator side. For 27.Remove clamp (47), and disconnect KCCV
details, see "Removal and installation of air return piping (46).
remove fan pulley (39).
50-52 PC88MR-10
31.Disconnect fuel hoses (55) and (56).
28.Remove clamp (48), and disconnect radiator

lower hose (49). [*6]
32.Remove clamps (57) and (57a) of hoses (55)
and (56).
33.Disconnect engine ground wiring (57b).
29.Remove clip (50), and disconnect heater hose

(51).
34.Disconnect clamp (58), and disconnect starting
motor B terminal (59). [*7]
30.Remove CAN terminating resistor K02 (52) from

the clip, and disconnect ground wiring (53) and
connector CE03 (54) from the clamp.
35.Remove clamp (60), and disconnect starting
motor C terminal SC (61). [*8]
a For starting motor C terminal SC (61),
remove the cap and loosen the screw by
using a Phillips screwdriver.
PC88MR-10 50-53
36.Disconnect ribbon heater terminal E01 (62). 40.Remove mounting bolts (68) (6 pieces), and
remove cover (69).
37.Disconnect connector E24 (63).

41.Disconnect connector E12 (71) and B terminal
AB (72) of alternator (70).
38.Remove clamps (64) (3 pieces), and disconnect

harness (65).
42.Remove clamps (73) (2 pieces).

remove cover (67). 43.Remove clamps (74) (2 pieces).
50-54 PC88MR-10
44.Disconnect heater hose (75). Installation (PC88MR-R400-720-K-00-A)

removal.
[*1]
3 Hydraulic oil drain plug (6):
58.8 to 78.4 Nm {6 to 8 kgm}
[*2]
54 to 89 Nm {5.5 to 9 kgm}
[*3]
3 Clamp (40):
45.Remove mounting bolts (76) (4 pieces), sling
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
engine and pump assembly (77), and hold it. [*9]
[*4], [*6]
approximately 30 mm from the tip of the
• Check that the hose is normal without any crack,
• Also check that inner surface of the hose
insertion portion is not damaged.
3 Clamps (42) and (48):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
46.Sling engine pump assembly (77) at the position
3 Clamp (44):
as shown in the photo, and remove it.
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
a Be careful not to interfere with the
[*7]
turbocharger when slinging.
3 Starter B terminal (59):
4 Engine assembly (77): 17.7 to 24.5 Nm {1.8 to 2.5 kgm}
515 kg [*8]
3 Starter C terminal SC (61):
2.6 to 4.6 Nm {0.27 to 0.47 kgm}
[*9]
245 to 309 Nm {25.0 to 31.5 kgm}
PC88MR-10 50-55

5 Coolant:
13 l
• Refill with oil
refilling.
again.
5 Hydraulic oil:
a Drain plug
58.8 to 78.4 Nm{6.0 to 8.0 kgm}
• Adjusting air conditioner compressor belt
Adjust the air conditioner compressor belt. For
details, see "Testing and adjusting", "Test and
adjust air conditioner compressor belt tension".
• Adjust fan belt
details, see "Testing and adjusting", "Replace
fan belt".
• Bleed air (hydraulic system)
Bleed air from the hydraulic pump circuit. For
details, see "Testing and adjusting", "Bleed air
from hydraulic system".
50-56 PC88MR-10
Removal and installation of engine front oil seal (PC138-A350-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
795T-221-1010 Push tool t 1

790-101-5201 Push tool kit t 1
A 2 790-101-5271 • Plate 1
790-101-5221 • Grip 1
01010-51225 • Bolt 1
Removal (PC138-A350-520-K-00-A)
1. Remove the engine assembly. For details, see Installation (PC138-A350-720-K-00-A)

"Removal and installation of engine and main a Before installing the front oil seal, check that the
pump assembly". end corner and the lip sliding surface of the
2. Remove mounting bolt (1) to remove idler pulley crankshaft are free from a flaw, burr, fin, and
assembly (2). rust.
1. By using tool A2, install front oil seal (6).
2. After press fitting the front oil seal, fill the space
between oil seal lips with approximately 2 cc of
grease.
2 Front oil seal:
Grease (G2-LI)
3. Remove mounting bolt (3) to remove plate (4)

and crank pulley assembly (5). [*1]
• Perform subsequent installation in the

reverse order of removal.
[*1]
3 Crank pulley mounting bolt:
343 to 402 Nm {35 to 41 kgm}
4. Remove front oil seal (6).
PC88MR-10 50-57
Removal and installation of engine rear oil seal (PC138-A510-924-K-00-A)
a Special tools 1) Screw a slide hammer, etc. in the metal ring

of rear oil seal (5), and pull out the rear oil
Necessity
seal by using the the impact of the slide
Sym-
Q'ty
Part No. Part name hammer.
bol
a Before pulling out the seal, drive the seal
795T-221-1020 Plate t 1 inward a little to separate it from the housing
790-101-5401 Push tool kit t 1 for easy removal.
A 3 790-101-5431 • Plate 1 a Do not use a drill, etc. as metal chips may
790-101-5421 • Grip 1 enter the engine.
01010-51240 • Bolt 1
Removal (PC138-A510-520-K-00-A)
1. Remove main pump assembly. For details, see

"Removal and installation of main pump
assembly".
2. Removal of flywheel
1) Remove mounting bolts (1) (6 pieces), and
remove coupling (2). [*1]
Installation (PC138-A510-720-K-00-A)
a Before installing the rear oil seal, check that the

end corner and the lip sliding surface of the
crankshaft are free from a flaw, burr, fin, and
rust.
1. Install rear oil seal (5) by using tool A3.
2. After press-fitting the rear oil seal, fill the space
between oil seal lips with approximately 3 cc of
2) Sling flywheel (3). grease.
3) Remove flywheel (3) mounting bolts (5 2 Rear oil seal:
pieces) but leave the remaining one. [*2]
Grease (G2-LI)
4) Remove the remaining mounting bolt (4) (1
piece), sling flywheel (3), and remove it.
4 Flywheel:
40 kg
a Be careful not to remove the guide bolt.
3. Removal of rear oil seal
50-58 PC88MR-10
3. Rotate the flywheel 1 turn, and measure the

difference between the maximum and
minimum readings of the dial gauge pointer.
a When the flywheel rotated 1 turn, check
that the dial gauge indicates the same
value as it of the starting rotation.
• Perform subsequent installation in the reverse

order of removal.
[*1]
3 Coupling mounting bolt:
98 to 122.6 Nm {10 to 12.5 kgm}
[*2]
• Tighten the flywheel mounting bolts according to • Measurement of facial runout of flywheel
the following procedure. a Standard value: Max. 0.30 mm
1. Apply engine oil to the threaded portions of 1. Similarly to the measurement of radial runout,
mounting bolts. set dial gauge [2] so that its probe is at a right
2 Mounting bolt threads: angle with the end face (b) near the outer
circumference of the flywheel.
Engine oil
2. Tighten the mounting bolts twice in order a Perform the measurement with the
according to the following torque. crankshaft pulled to either the front or
rear side of the engine to prevent errors
3 Mounting bolt:
caused by backlash.
1st time: 58.8 to 117.7 Nm {6.0 to 2. Rotate the flywheel one turn, and measure
12.0 kgm} the difference between the maximum and
2nd time: 186.3 to 196.1 Nm {19.0 minimum readings of the dial gauge pointer.
to 20.0 kgm}
• The following figure shows the tightening order.
• Measurement of radial runout of flywheel

a Standard value: Max. 0.30 mm
1. Install dial gauge [1] to the flywheel housing.
2. Set the probe of the dial gauge at a right
angle to the spigot joint portion (a) or outside
of the flywheel.
PC88MR-10 50-59
Removal and installation of fuel cooler assembly (PC88MR-B7W0-924-K-00-A)
k Place the machine on a level ground and a Be sure to fix the elbow on the fuel cooler
lower the work equipment to the ground in a side by using another wrench, and
stable posture. disconnect it so that the force is not applied
to the cooler main unit.
a If the wrench is not used, the force may be
applied to the cooler main unit and the weld
portion may crack.
remove fuel cooler assembly (5) together with
the bracket.
Removal (PC88MR-B7W0-520-K-00-A)

assembly".
2. Remove battery (1a) according to the following
procedure.
Installation (PC88MR-B7W0-720-K-00-A)

removal.
[*1]
a When installing the hose, be sure to fix the
elbow on the fuel cooler side by using another
wrench, and tighten it so that the force is not
2) Disconnect wiring (3a), (3b), and (3c). applied to the cooler main unit.
remove brackets (5a) (2 pieces). a If the wrench is not used, the force may be
4) Remove batteries (1a) (2 pieces). applied to the cooler main unit and the weld part
may crack.
3. Disconnect clamp (1).

4. Disconnect hoses (2) and (3). [*1]
a Plug the disconnected hose to prevent oil
leakage and dirt entry.
50-60 PC88MR-10
Removal and installation of fuel tank assembly (PC88MR-AD10-924-K-00-A)

stable posture.

Removal (PC88MR-AD10-520-K-00-A)
1. Open cover (1), open fuel drain cock (2) and 5. Remove hose clamp mounting bolt (7), and
drain the fuel. remove hose (7a).
6 When filled up with fuel: remove cover (9).
125 l 7. Remove mounting bolts (10) (2 pieces), and
remove cover (11).
8. Disconnect fuel level sensor connector P21 (12).
2. Remove step (3).

3. Remove handrail (4).
4. Remove cover (5), and remove side cover (6).
9. Remove clamp (13), and disconnect fuel return
hose (14).
PC88MR-10 50-61
13.Remove fuel tank assembly (20).
4 Fuel tank assembly:

50 kg

remove cover (16).
Installation (PC88MR-AD10-720-K-00-A)

removal.
[*1]
2 Fuel tank mounting bolt (19):
Adhesive (LT-2)
11.Disconnect hoses (2 pieces) from the fuel tank.

(17): Hose between fuel prefilters
(18): Drain hose
12.Remove fuel tank mounting bolts (19) (4 pieces).

[*1]
50-62 PC88MR-10
Removal and installation of engine hood assembly (PC88MR-H540-924-K-00-A)

stable posture.

Removal (PC88MR-H540-520-K-00-A)
1. Open engine hood assembly (1), and fix it by 7. Remove mounting bolts (8) and (9) (2 pieces
using lock bar (2). each), sling engine hood assembly (1), and
a Securely fix it by using the lock bar. remove it. [*2]
2. Remove cover (2a).
4 Engine hood assembly (1):
25 kg
3. Remove clamp mounting bolt (3) (1 piece), and

disconnect rearview camera connector A40 (4).
(Rearview camera is available as an option.)
Installation (PC88MR-H540-720-K-00-A)

removal.
[*1]
59 to 74 Nm {6 to 7.5 kgm}
[*2]
• Adjust the hood catch. For details, see "Testing
and adjusting", "Test and adjust hood catch".
3 Mounting bolts (8) and (9):
59 to 74 Nm {6 to 7.5 kgm}
4. Pass the lifting tool through the hole where
preceding cover (2a) was removed, sling engine
hood assembly (1) and hold it.
remove hinge (6). [*1]
6. Remove gas spring (7).
PC88MR-10 50-63
Removal and installation of KDOC muffler (PC88MR-A9H2-924-K-00-A)
k Place the machine on a level ground and a Cover it with vinyl, etc. to prevent dust, etc.
lower the work equipment to the ground in a from entering.
stable posture.

Removal (PC88MR-A9H2-520-K-00-A)
1. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
3. Remove mounting bolt (1a), remove fuel prefilter
(1b) and remove the heat insulation plate.
a Do not remove the piping.
5. Loosen clamp mounting nuts (2) and (2a), and
remove exhaust pipe (3). [*1]

remove rubber sheet (11) from cover (13).
remove cover (13).
10.Remove bolt (14), and remove water drain pipe

(15).
11.Remove mounting nuts (16) (2 pieces) of U-bolt
(18). [*3]
12.Remove mounting bolts (17) (4 pieces) of U-
bolt.
6. Remove mounting bolts (4) (7 pieces), and 13.Remove U-bolts (18) (2 pieces).
remove plates (5) (3 pieces), cover (6) and plate
(7). [*2]
remove cover (9).
50-64 PC88MR-10
17.Remove V-clamp (25). [*4]

remove cover (20). 18.Remove KDOC muffler assembly (26).
15.Remove mounting bolts (21) (6 pieces), and 19.Remove mounting bolt (27), and remove
remove cover (22). bellows piping (28). [*5]

PC88MR-10 50-65
• Replace the gasket when installing the belows

Installation (PC88MR-A9H2-720-K-00-A)
piping.
a Always use a new gasket when replacing it.
removal.
[*1] 3 Mounting bolt (27):
a When tightening nut (2) and (2a) to the specified 58.8 to 73.5 Nm {6 to 7.5 kgm}
torque, if clearance (a) is 0, replace clamp (b) 2 Mounting bolt (27):
without reusing.
Molybdenum disulfide (LM-P)
3 Mounting nut (2):

41 to 46 Nm {4.2 to 4.7 kgm}
3 Mounting nut (2a):
59 to 74 Nm {6 to 7.5 kgm}
[*2]
• Installation procedure of cover (6) and plate (7)
1. Install side cover (6), connection plate (7),
and anti-runout plates (5) (3 pieces) without
installing them forcibly, and lightly tighten
them.
2. Tighten mounting bolts (4) (7 pieces) to the
specified torque in the order of 1 to 7.
[*3]
3 Mounting nut (18):
14 ± 1 Nm {1.43 ± 0.1 kgm}
[*4]
3 V-clamp (25):
5.9 to 8.8 Nm {0.7 to 0.9 kgm}
[*5]
50-66 PC88MR-10
Removal and installation of KCCV ventilator (PC88MR-A180-924-K-00-A)

stable posture.

1. Open cover (1), loosen coolant drain plug (1a), 3. Remove clamp (3), and disconnect hose (4). [*1]
and drain the coolant. 4. Remove clamp (5), and disconnect hose (6). [*2]
6 Coolant:
13 l
5. Remove clamp (7), and disconnect hose (8). [*3]
6. Remove clamp (9), and disconnect hose (10).

[*4]
2. Open engine hood assembly (2), and fix it by
using lock bar (2b).
a Securely fix it by using the lock bar.
PC88MR-10 50-67
7. Remove clamp (11), and disconnect hose (12).

remove KCCV ventilator (14) together with the
bracket.
remove KCCV ventilator (14).

removal.
[*1]
3 Clamp (3):
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
[*2]
3 Clamp (5):
3.0 to 3.5 Nm {0.30 to 0.35 kgm}
[*3]
3 Clamp (7):
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
[*4]
3 Clamp (9):
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
5 Coolant:
13 l
50-68 PC88MR-10
Removal and installation of air cleaner assembly (PC88MR-A910-924-K-00-A)

stable posture.

1. Open engine hood (1a), and fix it by using lock 5. Disconnect mounting bolts (6) (2 pieces), and
bar (1b). disconnect hose (7) together with the bracket.
a Securely fix it by using the lock bar. 6. Remove mounting bolt (2), and remove air
cleaner assembly (8) together with hose (7).
7. Remove air cleaner assembly (8), and then
immediately cover hose (7) and air cleaner
opening with clean vinyl.
a If dirt enters air intake piping, it may cause an
engine trouble.
2. Open side cover (1).
• When replacing air cleaner

Remove mass air flow and temperature sensor
(3), dust indicator (9) and hose (7) (together with
the bracket), and install them to the air cleaner to
be replaced.
3. Disconnect connector P55 of mass air flow and a Mass air flow and temperature sensor (3) is a
temperature sensor (3). precision part. Do not blow compressed air to
4. Remove clamp (4), and disconnect hose (5). [*1] it and spray the detergent liquid.
3 Mass air flow and temperature sensor
(3) screw:
0.98 ± 1.27 Nm {0.1 to ± 0.13 kgm}
a Apply liquid gasket to the threaded part of
dust indicator (9).
2 Dust indicator (9):
3 Dust indicator (9):
1.96 to 3.92 Nm {0.2 ± 0.4 kgm}
PC88MR-10 50-69
a Keep the opening of the air cleaner covered

with a plastic film, etc. until just before it is
installed to prevent entry of dirt.
Perform subsequent installation in the reverse

order to removal.
[*1]
3 Clamp (4):
8.3 to 8.8 Nm {0.85 to 0.9 kgm}
50-70 PC88MR-10
Removal and installation of EGR (Exhaust Gas Recirculation) cooler

assembly (PC88MR-A9L0-924-K-00-A)
stable posture.

Removal (PC88MR-A9L0-520-K-00-A)
1. Open cover (1), loosen the coolant drain plug, 4. Remove mounting bolts (6) (4 pieces), and
and drain the coolant. remove bracket (7).
6 Coolant:
13 l
5. Remove clamp (8).

disconnect tube (10).
remove cover (3).

remove tube (12). [*1]
remove cover (5).
PC88MR-10 50-71
8. Remove joint bolts (13) and (14), and then

disconnect tubes (15) and (16). [*2]
9. Remove clamps (17) and (18), and disconnect
tubes (19) and (20).
remove EGR cooler assembly (22).
Installation (PC88MR-A9L0-720-K-00-A)

removal.
[*1]
• Tighten mounting bolt (11) 3 times in the order of
[1] to [4] to install it.
1st time: 9.8 to 14.7 Nm {1 to 1.5 kgm}
2nd time: 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
3rd time: 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
2 Threaded part of mounting bolt (11):
Molybdenum dioxide lubricant (LM-P)
[*2]
3 Joint bolts (13) and (14):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
50-72 PC88MR-10
Removal and installation of EGR (Exhaust Gas Recirculation) valve

assembly (PC88MR-A9K1-924-K-00-A)
stable posture.

Removal (PC88MR-A9K1-520-K-00-A)
1. Open engine hood (1), and fix it by using lock 4. Disconnect wiring (7).
bar (2).
a Securely fix it by using the lock bar.
5. Remove mounting nut (8), and remove EGR

valve assembly (9).
remove bracket (4).
Installation (PC88MR-A9K1-720-K-00-A)
3. Remove mounting bolts (5) (3 pieces), and • Perform installation in the reverse order to
disconnect tube (6). removal.
PC88MR-10 50-73
Removal and installation of fan belt (PC88MR-B430-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
4 796–401–1300 Fixing jig t 1

5 796–401–1330 • Collar t 1
6 796–401–1310 • Bracket t 1
A
7 01583–13018 Nut t 1
Commercially
8 Wrench t 1
available
k Place the machine on a level ground and 4. Apply the wrench A8 to portion (C) (width across
lower the work equipment to the ground in a flats: 12.7 mm) of tensioner assembly (2), and
stable posture. turn it in the direction opposite to the tightening
k Make sure that it is securely inserted into
k Stop the engine, turn the battery disconnect part (C) of tensioner assembly (2) before
switch to OFF position, and remove the key. turning the wrench A8. (The spring of
Removal (PC88MR-B430-520-K-00-A) wrench is loosely inserted, the wrench A8
1. Remove cover (1). may accidentally come off while being
k After removing fan belt (4), return

tensioner assembly (2) to its original
position slowly and carefully.
k Be careful not to get your fingers caught

between the pulley and fan belt (4) during
work.
2. Install guide collar A5 to spacer (3) of auto-

tensioner (2).
3. Insert holding bracket A6 into collar A5 and
tighten it lightly with nut A7.
At this time, fit hollow part "a" of holding bracket
A6 to protruding part "b" of auto-tensioner (2).
5. Tighten nut A7 at the position where the belt

a Check that holding bracket A6 is inserted
collar A5 and that of nut A7 become flush at
this time.
k If holding bracket A6 is insufficiently

tighten nut A7.
50-74 PC88MR-10
6. Replace fan belt (4).

Installation (PC88MR-B430-720-K-00-A)
1. Install fan belt (4).

2. Apply the wrench to portion (C) (width across
direction.
a Make sure that it is securely inserted into part
(C) of tensioner assembly (2) before turning
the wrench. (The spring of tensioner
assembly (2) is strong. If the wrench is
loosely inserted, the wrench may
accidentally come off while being turned, and
it is extremely dangerous.)
3. Remove nut A7, and disconnect holding bracket
A6.
4. Replace collar A5.
a After removing fan belt (4), return tensioner
assembly (2) to its original position slowly
and carefully.
5. Check that the groove of the alternator belt (3)
fits in the each pulley groove (5) without any
displacement.
PC88MR-10 50-75
Power train system
Power train system (ALL-C100-001-K-50-A)
Removal and installation of travel motor and final drive assembly (PC88MR-
DF10-924-K-00-A)

stable posture.

k Lower the work equipment to the ground and

stop the engine. Then, loosen the cap of the
hydraulic tank to release the internal 5. Disconnect travel motor hoses (3) (4 pieces).
pressure in the tank.
Removal (PC88MR-DF10-520-K-01-A)
1. Separate the track. For details, see "Separation

and connection of track shoe assembly".
2. Swing the work equipment 90 deg. and raise the
machine off the ground by using the work
equipment to set block [1] between the track
frame and track shoe.
3. Keep slinging sprocket (1) and remove it. [*1]
4 Sprocket (1):
20 kg 6. Sling travel motor and final drive assembly (4),
and remove them. [*2]
a Take extreme care not to damage the nipple
seal of hose mounting portion.
4 Travel motor and final drive assembly

(4):
90 kg
4. Remove travel motor cover (2).
Installation (PC88MR-DF10-720-K-00-A)
• Perform installation in the reverse order of

removal.
[*1]
50-76 PC88MR-10
Power train system
2 Threaded part of sprocket (1) mounting

bolt:
Adhesive (LT-2)
3 Sprocket (1) mounting bolt:
186.3 to 225.6 Nm {19 to 23 kgm}
[*2]
2 Threaded part of travel motor and final
drive assembly (4) mounting bolt:
Adhesive (LT-2)
3 Travel motor and final drive assembly (4)
mounting bolt:
235 to 285 Nm {235 to 29.5 kgm}
• Bleed air from the travel motor. For details, see
"Testing and adjusting", "Bleed air from each
part".
• Refilling with oil
through the piping, and check the oil level again.
PC88MR-10 50-77
Power train system
Disassembly and assembly of travel motor and final drive

assembly (PC88MR-DF10-926-K-01-A)
Component parts figure
50-78 PC88MR-10
Power train system
Parts list
No. Part name
No. Part name
3 Carrier
1 Hub
4 Sun gear No.1
2 Spindle
PC88MR-10 50-79
Power train system
No. Part name No. Part name

5 Planetary gear No.2 167 Pivot
6 Sun gear No.2 171 Pin
7 Planetary gear No.1 190 Spring
9 Thrust collar No.2 301 Rear flange
10 Thrust washer No.2 321 Plug
11 Thrust washer No.1 323 Spool
12 Thrust washer 324 Plug
13 Cover 325 Spring retainer
22 Ring nut 327 Valve
24 Ball bearing 328 Spring
27 Needle bearing cage 330 Spring
28 Needle bearing cage 336 O-ring
29 Inner bearing 338 Ring
30 Inner bearing 342 Dowel pin
31 Floating seal 345 Hexagonal socket head bolt:
33 Plug with flange 352 Plug
35 O-ring 363 Valve
37 O-ring 364 Stopper
39 Plug 365 Ring
40 Bolt 366 Spring
41 Ball 368 Seal ball
42 Dowel pin 373 O-ring
43 O-ring 375 Plug
44 O-ring 379 Filter
45 Ring 380 Orifice
47 Hexagonal socket head bolt: 382 Plug
50 Snap ring 383 Flange plug
51 Bolt 399 Plate
102 Shaft
103 Swash plate
104 Cylinder block
105 Piston
106 Shoe
107 Retainer plate
108 Thrust ball
109 Timing plate
110 Washer
111 Washer
112 Piston
113 Spring
114 Spring
115 Disc
116 Plate
132 Oil seal
135 O-ring
139 O-ring
145 THS snap ring
149 Ball bearing
150 Ball bearing
151 Needle
161 Piston
162 Shoe
50-80 PC88MR-10
Power train system
Maintenance outline
Tool
• Standard tool
No. Part name Model, size Q'ty
3 (M6)
6 (M8, PF1/4)
1 Hexagonal wrench 1 each
8 (PF3/8)
10 (PF1/2, M12)
2 Socket wrench handle Potbelly shape 1
Dial shape: 12 N
Dial shape: 90 N
3 Torque wrench 1 each
Dial shape: 150 N
Dial shape: 600 N
Socket nominal: 13, 30
4 Torque wrench adapter 1 each
Shaft nominal: 3, 6, 8
5 Socket wrench Width across flats: 13, 17, 24, 36 mm 1
6 Extension bar 150 mm 1
7 Hammer Nominal: 12 1
8 Plastic hammer L: 300 mm 1
9 Flat-head screwdriver L: 50, 150 mm 1 each
10 Snap ring pliers For shaft and hole 1 each
11 Pliers 200 mm 2
Sling load: Min. 2,940 N {300 kg} 1 set
12 Lifting tool Eyebolt (PF3/8) 2
Wire with hook 1
13 Container General pad (W450 x D300 x H120 mm) 2
14 Leather gloves - 1 pair
• Bolts
No. Part name Model, size Q'ty
M6 (P1.0 x 50) 1
1 Hexagonal socket head bolt: M16 (P2.0 x 40) 2
M16 (P2.0 x 150) 3
• Equipment
Application, part Model, size Q'ty
Part name
number
Disassembly and
General work stand - 1
assembly
Parts cleaning Cleaning tank Simple cleaning, finishing of cleaning 1
104, 149 Press work stand Press performance: Min. 1,960 N {200 kg} 1
Heating performance: Min. 100ºC
149 Heating tank 1
Volume: Min. W500 x D500 x H500
Drying after parts Inflation pressure: 0.29 to 0.49 MPa {3 to 5
Compressed air -
cleaning kg/cm2}
• Manufacturing tools
Work stand [1]
• Fixing during disassembly and assembly of
travel motor
PC88MR-10 50-81
Power train system
Jig [2] Push tool [5]

• Fixing during connection of spindle (2) and • Press-fit of oil seal (132) to spindle (2)
hub (1)
Push tool [6]

No.1 holder [3] • Press-fit of ball bearing (24) to hub (1)
• Installation of spring (114), washer (110), and
snap ring (145) to cylinder block (104)
• Removal of spring (114) from cylinder block
(104)
Steel bar [7]

• Removal of ball bearing (45) from hub (1)
No.2 holder [4]

• Removal of ball bearing (149) from shaft
(102)
50-82 PC88MR-10
Power train system
Jig [8] Spatula [11]

• Removal and installation of ring nut (22) • Removal of timing plate (109) from rear
installed to spindle (2) during bearing preload flange (301)
adjustment
Pin punch [12]

Pin punch [9] • Removal of outer race from bearing cage
• Removal of ring (365) from inside of the pilot (24)
valve
Jig [13]
Eyebolt [10] • Removal of cover (13) from hub (1)
• Slinging of travel motor (1a), spindle (2), and
hub (1)
Application Dimension (A)
Hub M14
Spindle M16
Travel motor M16
PC88MR-10 50-83
Power train system
No.1 installation jig [14] Jig [17]

• Installation of floating seal (31) to hub (1) • Positioning of carrier (3) when fixing No.1
thrust washer (12)
a No.1 thrust washer (12) can be fixed without
this jig.
No.2 installation jig [15]

• Installation of floating seal (31) to hub (1) and
spindle (2)
Jig [18]
• Positioning of spindle (2) when fixing No.2
thrust washer (10)
a No.2 thrust washer (10) can be fixed without
this jig.
No.3 installation jig [16]

• Installation of floating seal (31) to spindle (2)
Tightening torque
Width
Part Nominal of parts across flats Q'ty Torque (Nm {kgm})
Part name
number (mm)
33 Plug with flange PF3/8 8 1 58.8 ± 9.81 {6.0 ± 1.0}
39 Plug PF3/8 8 2 58.8 ± 9.81 {6.0 ± 1.0}
40 Bolt M8 (P1.25) 13 3 33.3 ± 4.9 {3.4 ± 0.5}
50-84 PC88MR-10
Power train system
Width
Part Nominal of parts across flats Q'ty Torque (Nm {kgm})
Part name
number (mm)
Hexagonal socket head M8 (P1.25) 9.81 ± 1.60 {1.0 ± 0.2}
47 3 2
bolt:
51 Bolt M10 (P1.5) 17 4 57.9 ± 9.81 {5.9 ± 1.0}
321 Plug PF3/8 8 1 58.8 ± 9.81 {6.0 ± 1.0}
321 Plug M30 (P1.5) 36 2 353 ± 39.2 {36 ± 4.0}
Hexagonal socket head M12 (P1.75) 102 ± 15.7 {10.4 ± 1.6}
345 10 8
bolt:
Hexagonal socket head 98.1 ± 19.6 {10 ± 2.0}
382 PF1/2 10 3
bolt:
Weight table
Part Weight (kg)
Part name
number
- Travel motor assembly 85
1 Hub 25
2 Spindle 25
301, etc. Rear flange assembly 15
Disassembly (PC88MR-DF10-530-K-01-A)
Preparation items may occur. The parts may not be installed

1. Preparation before disassembly and the performance may be deteriorated.
4) If leaving the parts during disassembly and
1) Preparation of work stand
disassembled parts, the parts may be rusted
• Prepare the work stand for disassembly due to humidity or dust. Before leaving the
and assembly of the travel motor. parts, be sure to perform the rust-proofing or
• Prepare the robust work stand that can dust-proofing.
be used for disassembly and assembly of 5) When disassembling, make a match mark on
the travel motor internal parts and on the mating surfaces of the parts.
which the parts can be put. 6) To prevent from the parts being damaged or
• Spread a rubber or vinyl sheet on the lost during disassembly, order and store the
work stand. removed parts.
2) Prepare the above tools and equipment. 7) Do not reuse the disassembled or removed
2. General precautions for working seals. Replace them with new ones.
8) Illustration shown of this section is a typical
k Oil is applied to the internal parts during model. Therefore, disassembly procedure is
disassembly, and they are slippery. not changed even if the shown parts are
Handle the parts carefully to prevent the parts partially different from the actual machine.
from falling. Otherwise, personal injury may a For the part number that is not described in
occur and the parts may be damaged. the figure of this manual, see ""Component
parts figure"".
k Flammable material such as JIS No.1 1. Cleaning of travel motor assembly
kerosene is used for cleaning the parts. 1) Install eyebolts [10] (2 pieces) to the
Handle the material carefully because it mounting bolt hole of spindle (2).
may ignite and cause fire or burn.
a Install eyebolts [10] (2 pieces)
1) Get full understanding of the testing items symmetrically.
and the existing abnormal conditions before
disassembly. Proceed with the disassembly
work according to the procedures.
2) Handle each part carefully because they are
extremely precise parts. Do not hit the parts
each other or drop them.
3) Do not pat or pry the parts forcibly during
disassembly. Otherwise, burr or damage
PC88MR-10 50-85
Power train system
2) Install hexagonal socket head bolts [1a] (2

pieces) symmetrically.
k Tighten hexagonal socket head bolts

[1a] (2 pieces). (To protect the travel
motor assembly from falling off the
work stand when inverting it.
2) Sling travel motor assembly (1a) and move it

to the cleaning tank.
4 Travel motor assembly (1a):

85 kg
3) Use a brush to securely clean travel motor
assembly (1a).
a Soil or sand is entered into the area 3. Draining oil in final drive case
between hub (1) and spindle (2) (floating a When disassembling the rear flange only,
seal mounting portion). Therefore, proceed to "8. Removal of rear flange".
securely clean the assembly.
1) Invert the travel motor assembly so that the
final drive faces upward.
2) Remove flange plug (33) and plug (39).
a Remove O-ring (37) of plug (39). Do not
reuse it.
2. Setting travel motor

1) Sling travel motor assembly (1a) and set it to
work stand [1].
a Set travel motor assembly (1a) while
aligning the bolt hole of hub (1) with the 3) Invert travel motor assembly (1a) gradually,
hole of work stand [1]. and drain the oil.
a Set the oil pan [2a] under the travel motor
to receive the oil.
6 Final drive case:

1.1 l
50-86 PC88MR-10
Power train system
5. Removal of No.1 sun gear

1) Remove No.1 sun gear (4).
2) Remove ball (41) from No.1 sun gear (4).
4. Removal of cover
1) Invert travel motor assembly (1a) so that the
2) Remove ring (45).
6. Removal of carrier assembly
1) Remove the carrier assembly from hub (1).
2) Disassembly of carrier assembly
1] Remove bolts (40) (3 pieces), and
remove No.1 thrust washers (12) (3
pieces).
a Do not reuse removed bolts (40).
3) Set jig [13], and install bolts [3a] (2 pieces).

a Use the screw holes where flanged plug
(33) and plug (39) were removed. (For
details, see ""Component parts figure"".)
4) Set block [4a], tighten bolt [5a], and remove
cover (13).
a If it is difficult to remove cover (13) due to
2] Remove No.1 planetary gears (5) (3
resistance of O-ring (35), remove it while
pieces), needle bearing cage (27) (3
lightly tapping the boundary of cover (13)
pieces), and inner bearings (29) (3
by using a plastic hammer. (For details,
pieces) from carrier (3)
see ""Component parts figure"".
5) Remove O-ring (35) of cover (13). Do not
reuse the O-ring. (For details, see
""Component parts figure"".
3] Remove snap ring (50) from No.2 sun

gear (6).
PC88MR-10 50-87
Power train system
4] Remove No.2 sun gear (6) from carrier a The following work is preparation for
(3). disassembling the internal rear flange.
a Loosen the plug so that it can be rotated
by hand.
a Do not loosen the plug when not
disassembling the internal rear flange.
2) Loosen plugs (324) (2 pieces).
7. Removal of No.2 planetary gear

1) Remove bolts (51) (4 pieces) from spindle
(2).
a Do not reuse removed bolts (51).
3) Loosen plugs (382) (2 pieces).
2) Remove No.2 planetary gears (7) (4 pieces),

needle bearing cage (28) (4 pieces), and
inner bearings (30) (4 pieces). 4) Remove hexagonal socket head bolts (345)
3) Remove No] thrust washers (11) (4 pieces). (8 pieces) from rear flange (301).
(For details, see ""Component parts figure"".)
4) Remove No.1 thrust collar (9). (For details,
see ""Component parts figure"".)
5) Remove rear flange (301) from spindle (2).

a Lift rear flange (301) slowly and straight
8. Removal of rear flange by both hands, and remove it.
travel motor faces upward.
50-88 PC88MR-10
Power train system
a If forcibly prying and patting rear flange a If timing plate (109) is firmly contacted
(301), timing plate (109) may fall and may due to oil, insert spatula [11] to the groove
be damaged. (For details, see on rear flange (301) side to remove the
""Component parts figure"".) plate. (For details, see "Tools "4")
Manufacturing tools".
a Sharp tools such as a flat-head
screwdriver may damage mating surface
(a). Do not use them.
6) Remove dowel pins (42) (2 pieces) from

spindle (2).
3) Remove dowel pin (342) from rear flange

(301).
7) Remove O-rings (43) (2 pieces) and O-ring

(44) from spindle (2).
a Do not reuse removed O-rings (43) and
(44).
4) Remove ball bearing (150) from rear flange
(301).
9. Disassembly of rear flange

1) Set rear flange (301) on the work stand so
that mating surface (a) to the spindle faces 10.Disassembly of brake valve
upward. 1) Remove plugs (324) (2 pieces) from rear
2) Remove timing plate (109) from rear flange flange (301).
(301).
PC88MR-10 50-89
Power train system
2) Remove spring retainers (325) (2 pieces) 6) Remove springs (330) (2 pieces) and valves
and springs (328) (2 pieces) from rear flange (327) (2 pieces) from rear flange (301).
(301).
3) Remove spool (323) from rear flange (301).
a Spool (323) can be removed by inclining
rear flange (301). Pinch the tip of the
spool, and remove it.
7) Remove O-ring (338) from plug (382).

a Do not reuse removed O-rings (338).
4) Remove O-ring (336) from plug (324).

a Do not reuse removed O-rings (336).
11.Removal of pilot valve

1) Press stopper (364) by using steel bar [6a].
2) Keep the above state, and press the notch of
ring (365) by using pin punch [9].
3) Remove ring (365) from rear flange (301).
5) Remove plugs (382) (2 pieces) from rear a Do not reuse ring (365).
flange (301).
a Remove ring (365) only for replacement
of valve (363).
a Repair the holes cleanly after
disassembly because the holes are
damaged after removing ring (365).
50-90 PC88MR-10
Power train system
a If valve (363) does not come out even

when the hole faces downward, blow
compressed air from the 2nd travel speed
selector port to remove it.
k If compressed air is blew in strongly, it

is dangerous because the part may
leap out. Slowly blow compressed air.
13.Disassemble travel motor

1) Rotate spindle (2) 90deg., and it faces
sideways.
a The oil is drained from spindle (2).
Prepare the oil container under it.
2) Drain the oil from spindle (2).
3) Remove plates (116) (3 pieces) and discs
(115) (2 pieces) from spindle (2).
12.Disassemble parking brake
1) Blow in compressed air through oil passage
(c) for parking brake of spindle (2) to remove
piston (112).
k If compressed air is blew in strongly, it

is dangerous because piston (112)
may leap out. Slowly blow
compressed air. For safety, put
protection cover [7a] before working.
2) Remove O-rings (135) and (139) from piston
(112).
a Do not reuse removed O-rings (135) and 4) Rotate cylinder blocks (104) 2 to 3 turns
(139). alternately, and disconnect the firm oil
contact between swash plate (103) and shoe
(106). (For details, see ""Component parts
figure"".) 5) Remove cylinder block (104)
from shaft (102).
PC88MR-10 50-91
Power train system
a Be careful not to drop the parts (piston

(105), shoe (106), etc.) in cylinder block
(104) into spindle (2) due to the tight
contact between swash plate (103) and
shoe (106). (For details, see
""Component parts figure"".)
7) Remove thrust ball (108) from cylinder block

(104).
5) Remove piston assembly (piston (105), shoe

(106), and retainer plate (107)) as a whole.
a Remove retainer plate (107) by both
hands.
a Piston (105) integrates with shoe (106)
because they are tied at the spherical
part of the piston. Therefore, they cannot
be separated each other.
8) Remove washer (111) and needles (151) (3
a To replace piston (105) and shoe (106), pieces) from cylinder block (104).
replace them together. (Called as a piston
assembly hereafter.)
14.Remove spring inside cylinder block

6) Remove piston assemblies (piston (105) and 1) Set cylinder block (104) on the press stand.
shoe (106)) (9 units) from retainer plate a Remove spring (114) only for
(107). replacement.
a To remove spring (114), align the center
of No.1 holder [3] and that of washer
(110), and prevent cylinder block (104)
from being damaged.
a Cover cylinder block (104) with vinyl
sheet [8a] to protect from damages
during the work.
2) Set No.1 holder [3] to upper side washer
(110) and hold it by using the press.
50-92 PC88MR-10
Power train system
3) Remove THS snap ring (145) from the snap a When removing swash plate (103), pivot
ring groove of cylinder block (104). (167) may be attached. Be careful not,
and remove it. (For details, see
k If suddenly loosening the press, it is ""Component parts figure"".)
dangerous because spring (114) leaps
out. Therefore, slowly loosen the
press.
2) Remove shaft (102) from spindle (2).

a Remove ball bearing (149) together with it
at this time. (For details, see
a Lightly tap shaft (102) by using a plastic
hammer from the final drive side to
remove the ball bearing easily.
3) Remove pivots (167) (2 pieces) and pins
(171) (2 pieces) from spindle (2). (For details,
see ""Component parts figure"".)
4) Remove THS snap ring (145), washer (110),

spring (114), and washer (110) from cylinder
block (104). (For details, see ""Component
parts figure"".)
4) Remove spring (190) and 2-stage speed

selector piston assembly (piston (161) and
shoe (162)) from spindle (2). (For details, see
15.Remove swash plate

1) Rotate spindle (2) 90 deg. so that it faces
sideways. Remove swash plate (103) from
shaft (102).
PC88MR-10 50-93
Power train system
16.Remove ball bearing 4) Loosen ring nut (22) by using jig [8].
a Remove the ball bearing only for
replacement.
1) Set No.2 holder [4] on the press stand and
set shaft (102) to the inside.
2) Hold shaft (102) by using the press to pull out
it from ball bearing (149).
a Do not reuse ball bearing (149).
17.Remove ring nut (27).

1) Install fixing tools [9a] (3 pieces or 1 piece) to
hub (1) and spindle (2), and fix them.
a Install fixing tools [9a] evenly.
5) Remove ring nut (22) from spindle (2).
a Do not reuse removed ring nut (22)
because the tooth surface may be
damaged.

3) Remove hexagonal socket head bolts (47) (2
pieces) from spindle (2).
50-94 PC88MR-10
Power train system
18.Removal of spindle 4) Similarly, remove another ball bearing (24)

1) Invert travel motor assembly (1a) so that the from hub (1).
travel motor faces upward.
2) Remove fixing tools [9a] (3 pieces or 1 piece)
that were installed in Step 17.
3) Install eyebolts (M16) [10] (2 pieces) to
spindle (2).
4) Sling spindle (2), and remove it from hub (1).
a At this time, floating seal (31) and oil seal
(132) come with it. (For details, see
4 Spindle (2):
25 kg
19.Remove ball bearing 20.Remove spindle accessory parts

1) Remove floating seal (31) from hub (1). 1) Remove floating seal (31) from spindle (2).
a Do not reuse removed floating seal (31). a Do not reuse removed floating seal (31).
2) Remove ball bearing (24) from hub (1) by 2) Remove oil seal (132) from spindle (2) by
using pin punch [12]. using pin punch [10a].
a Lightly and evenly drive in pin punch [12] a Do not reuse removed oil seal (132).
to remove ball bearings (24) at 3 or 4
places on circumference of the outer
race.
a Ball bearing (24) may fall if hub (1)
removes from the mating portion. Protect
the hub by spreading the rubber sheet on
the floor.
3) Invert hub (1) so that the final drive faces
upward.
PC88MR-10 50-95
Power train system
3) Blow with compressed air to dry the inside of

hub (1) and spindle (2) in dust-free and
moisture-free place.
4) Naturally dry the travel motor parts and gears
in dust-free and moisture-free place.
a After drying the parts, apply power line oil
(TO30).
21.Simple cleaning of parts

1) Hub (1), spindle (2) cover (13), and rear
flange (301) are distinguished from other
parts (called as built-in parts hereafter). (For
details, see ""Component parts figure"".)
2) Put hub (1), spindle (2) cover (13), and rear
flange (301) in the cleaning tank to clean
them.
a Soil and sand are attached to the outside
of the parts. Therefore, securely clean
them.
3) Put the built-in parts in the simple cleaning
container that contains JIS No.1 kerosene.
k Flammable material such as JIS No.1

kerosene is used for cleaning the parts.
Handle the material carefully because
it may ignite and cause fire or burn.
a If cleaning the parts in the kerosene at
first, they are damaged. Soak them in the
kerosene and then clean them when
dusts and oil are loosened and float.
22.Finishing of cleaning
1) Put the parts in the finishing cleaning
container that contains JIS No.1 kerosene
and rotate the parts slowly to clean them up
to the inside.
2) Wipe the kerosene off the parts with clean
cloth.
a Maintenance standard
50-96 PC88MR-10
Power train system
To disassemble and test the travel motor, perform the maintenance work according to the following standard.
The moving and sliding parts are precise parts. Be careful not to damage them.
1. Handling seals
If the seals (O-ring, oil seal, and floating seal) are disassembled once, be sure to replace all of them with
new ones regardless of damages.
2. Maintenance standard of wear parts
1) Replace all the visibly and significantly worn parts with new ones.
2) If the parts are abnormal as described below, replace all of them with new ones.
Part Standard Allowable
Part name Phenomenon
number value value
• Significant damage is found on the appearance.
• Pitching occurs on the tooth surface of the ring
1 Hub - -
gear.
• It is abnormally worn, such as scuffing.
• Significant damage is found on the appearance.
2 Spindle - -
• It is abnormally worn, such as scuffing.
3
Carrier assembly • It is abnormally worn, such as scuffing. - -
Others
No.1 sun gear
4 No.2 sun gear
• Pitching occurs on the tooth surface.
6 No. 1 planetary • Flaking phenomenon is found on the rail surface - -
5 gear of the bearing.
7 No. 2 planetary
gear
No.2 thrust
washer
10
No.3 thrust • The sliding surface is discolored and worn.
11
washer
12
No.1 thrust
washer
• Indentation is found.
• Flaking phenomenon is found on the rail surface
24 Ball bearing - -
of the ball bearing.
• It is unevenly worn.
27 • Pitching occurs on the needle bearing.
Needle bearing • The bearing cage end surface is abnormally - -
28 worn.
29 • Flaking phenomenon is found on the rail surface
Bearing inner race - -
30 of the bearing.
• Scratches are found on sliding surfaces of spool
301 Rear flange - -
(323) and valve (363).
• Mating face with oil seal (132) is worn.
102 Shaft - -
• The spline part is worn.
103 Swash plate • Seizure phenomenon is found. - -
• The spline part is worn.
• Inner bore significantly wears.
104 Cylinder block - -
• The sliding surface with timing plate (109) is
scratched or unevenly worn.
• Clearance is found between piston (105) and
105 Piston assembly Clearance Clearance
shoe (106) in direction of the shaft.
106 (piston + shoe) 0.05 mm 0.15 mm
• The shoe is worn abnormally and unevenly.
• The sliding surface with shoe (106) is unevenly
worn.
107 Retainer plate - -
• The sliding surface with thrust ball (108) is
damaged and unevenly wears.
• The spherical sliding surface with retainer plate
108 Thrust ball - -
(107) is unevenly worn.
PC88MR-10 50-97
Power train system
Part Standard Allowable

Part name Phenomenon
number value value
Timing plate • Seizure and uneven wear is found on sliding - -
109
surface.
Braking Braking
115 Disc • Both end surface is worn unevenly. torque torque
• Braking torque is insufficient.
116 Plate • Seizure phenomenon is found. Min. 145 Nm Min. 120 Nm
{14.8 kgm} {12.3 kgm}
105 Piston • Periphery is scratched. - -
• Indentation is found.
149 • Flaking phenomenon is found on the rail surface
Ball bearing - -
150 of the bearing.
• It is worn.
2-stage speed
161 • The periphery part is abnormally worn.
piston assembly - -
162 • The shoe is worn abnormally and unevenly.
(piston + shoe)
323 • The shoe is worn abnormally and unevenly.
Spool - -
363 • Periphery is scratched.
Assembly (PC88MR-DF10-710-K-01-A)
• Perform installation in the reverse order to removal.

1. Preparation before assembling
Prepare the same tools and equipment as the preparation items in "Disassembly" section.
2. General precautions for working
1) Same as "2. General precautions for working" in "Disassembly" section.
2) Clean all parts, remove metal particles and foreign matters, and check for burrs and damages before
assembly. If burrs or damages are found on the parts, remove them using an oil abrasive wheel.
3) Do not reuse the O-ring, oil seal, and floating seal. Replace them with new ones.
4) Pass tap (M10, P1.25) through the screw hole of the carrier shafts (4 places) of spindle (2), and
remove the remaining adhesive.
Clean the screw hole and degrease it, and then blow compressed air to dry it. Replace bolt (51) with a
new one.
5) Pass tap (M8, P1.25) through the screw hole of the shafts (3 places) of carrier (3), and remove the
remaining adhesive.
Clean the screw hole and degrease it, and then blow compressed air to dry it. Replace hexagonal
head bolt (40) with a new one.
6) When installing the O-ring, oil seal, and floating seal, lightly grease, and perform the work carefully to
prevent them from being damaged.
7) Be sure to apply power line oil (TO30) to the moving and sliding surfaces of each part of the travel
motor for assembling.
8) Do not wear cloth gloves during the assembly work.
(This is because to prevent the malfunction due to entry of particles of the cloth glove fiber)
9) Tighten the bolts and plugs. For details, see "Standard tightening torque table".
10)After completion of assembly, immediately install the plugs to all the ports to prevent dusts from
entering.
11)Illustration shown of this section is a typical model. Therefore, disassembly procedure is not changed
even if the shown parts are partially different from the actual machine.
3. Assembly procedures
a To replace and then reassemble the parts, adjustment of the bearing preload is required. Therefore,
check that the following parts have been replaced with new ones.
Hub (1)
Spindle (2)
Ball bearing (24)
a To replace the above parts and then reassemble them, be sure to use the parts "Adjustment of each
part" have been already performed. Otherwise, the travel motor malfunction or early damage may
occur.
1. Assemble hub
50-98 PC88MR-10
Power train system
1) Set hub (1) on cylinder [7a] on the press

table.
2) Install ball bearing (24) to hub (1) and press-
fit the bearing by using push tool [6].
3) Rotate hub (1) reversely and install ball
bearing (24) to the opposite side similarly.
a Check the direction of ball bearing (24),
8) Install hexagonal socket head bolts [1a] (2

pieces) symmetrically.
k Tighten hexagonal socket head bolts

[1a] (2 pieces). (To protect the travel
motor assembly from falling off the
work stand when inverting it.
4) Apply grease (G2-LI) to the O-ring of floating

seal (31), and install it to hub (1).
a Remove the O-ring and thinly apply
grease to the periphery.
5) Set No.1 installation jig [14] and then No.2
installation jig [15] to hub (1) in this order,
and push No.2 installation jig [15] until it
contacts to No.1 installation jig [14].
a Remove No.1 installation jig [14] and
No.2 installation jig [15].
a Check that the parallelism of the end 2. Assemble spindle
surface of hub (1) and the seal surface of 1) Apply grease (G2-LI) to the O-ring of floating
floating seal (31) is 1 mm or less. seal (31), and install it to spindle (2).
a Remove the O-ring and thinly apply
grease to the periphery.
2) Set No.3 installation jig [16] and then No.2
installation jig [15] to spindle (2) in this order,
and push No.2 installation jig [15] until it hits
a Remove No.3 installation jig [16] and
a Check that the parallelism of the end
surface of spindle (2) and the seal
surface of floating seal (31) is 1 mm or
less.
6) Install eyebolts [10] (2 pieces) to the
mounting bolt hole of hub (1).
symmetrically.
7) Sling hub (1) and set it to work stand [1].
4 Hub (1): 25 kg
PC88MR-10 50-99
Power train system
2 Ring nut (22):

Adhesive (LT-2)
a Apply adhesive (LT-2) 30 to 40 mm in
width to 3 or 4 places on circumference of
the external thread.
a Install ring nut (22) so that the larger
chamfer faces the bearing side.
3 Ring nut (22):
588 ± 55.8 Nm {60 ± 6.0 kgm}
3) Install eyebolts [10] (2 pieces) to the

mounting bolt hole of spindle (2).
symmetrically.
4) Sling spindle (2), and install it to hub (1).
4 Spindle (2): 25 kg
a At this time, be careful not to drop the
floating seal.
5) Install fixing tools [9a] (3 pieces or 1 piece) to

hub (1) and spindle (2), and fix them. 9) Install hexagonal socket head bolts (47) (2
a Install fixing tools [9a] evenly. pieces).
3 Hexagonal socket head bolt (47):
9.81 ± 1.60 Nm {1.0 ± 0.2 kgm}
10)Tighten hexagonal socket head bolt (47),
and then caulk screw hole (d) on spindle (2)
side.

7) Install ring nut (22) to spindle (2).
8) Tighten ring nut (22) by using jig [8].
50-100 PC88MR-10
Power train system
4) Install spring (190) to piston assembly (piston

(161) and shoe (162)). (For details, see
"Component parts figure".)
2 Spring (190):
Grease (G2-LI)
11)Remove fixing tools [9a] (3 pieces or 1 piece)

fixing hub (1) and spindle (2).
4. Install shaft
1) Heat ball bearing (149) by using the heating
tank, and press-fit it to shaft (102).
Heating of ball bearing (149): 100 ±10°C, for
10 minutes
k Heating and installing ball bearing

(149) may cause burn. Be sure to wear
leather gloves during the work.
3. Assembly of inner spindle
2) Set No.2 holder [4] on the press stand and
1) Press-fit oil seal (132) to spindle (2) by using set ball bearing (149) and shaft (102) to the
push tool [5]. inside.
2 Lip of oil seal (132): 3) Press the shaft (102) by using the press to
Grease (G2-LI) press-fit it to ball bearing (149).
a Check the installation direction of oil seal

(132), and then install it.
4) Install shaft (102) to spindle (2).

a When installing shaft (102), be careful not
2) Install pins (171) (2 pieces) to pin hole (e) of to damage the lip of previously-installed
spindle (2). oil seal (132).
3) Install pivots (167) (2 pieces) to pins (171). a Damage of oil seal (132) lip may cause oil
2 Spherical part of pivot (167): leakage and premature damage to the
travel motor.
Grease (G2-LI) 5) Rotate spindle (2) 90 deg., and it faces
sideways.
PC88MR-10 50-101
Power train system
a To push spring (114), align the center of

No.1 holder [3] with that of washer (110),
and protect cylinder block (104) from
damages.
a Cover cylinder block (104) with vinyl
sheet [8a] to protect it from damages
during the work.
6) Install swash plate (103) to shaft (102).

2 Mating surfaces of spindle (2) and
swash plate (103):
Grease (G2-LI)
a Align pivots (167) (2 pieces) with the
installation hole position on swash plate
side, and install them. (For details, see
5. Assembly of cylinder block

1) Install washer (110), spring (114), washer
(110), and THS snap ring (145) to cylinder
block (104) in order.
a Face the sharp side of washer (110) on
THS snap ring (145) side upward.
a Face the sharp side of THS snap ring
upward.
2) Set cylinder block (104) on the press stand.
3) Set No.1 holder [3] to upper side washer
(110) and hold it by using the press.
6. Assemble travel motor
4) Install THS snap ring (145) to the snap ring
groove of cylinder block (104). 1) Install needles (151) (3 pieces) and washer
(111) to cylinder block (104).
k If the tip of the snap ring pliers
removes from the hole of THS snap
ring (145), it is dangerous because
THS snap ring (145) leap out. Be
careful when installing it.
50-102 PC88MR-10
Power train system
2) Install thrust ball (108) to cylinder block 5) Install cylinder block (104) to shaft (102).
(104).
a Align spline of shaft (102) to install
cylinder block (104).
3) Install piston assemblies (piston (105) and

shoe (106)) (9 units) to retainer plate (107).
6) After installation of cylinder block (104),
a After installation, soak the parts as a unit rotate cylinder block (104) by hand to check
in power line oil (TO30). that there is no play of the block around shaft
(102).
a Check it if any play is found.
a (For details, see "Component parts
figure".)
4) Install piston assembly (piston (105), shoe

(106), and retainer plate (107)) to cylinder
block (104) together.
a Install retainer plate (107) by both hands.
a Securely align retainer plate (107) with 7. Assemble parking brake
the spherical portion of thrust ball (108) 1) Rotate travel motor assembly (1a) 90 deg. so
(For details, see "Component parts that the travel motor faces upward.
figure".) 2) Install plate (116) to cylinder block (104).
3) Install disc (115) and plate (116) alternately
to cylinder block (104).
PC88MR-10 50-103
Power train system
a Soak disc (115) in power line oil (TO30) in 2 O-ring (338):

advance. Grease (G2-LI)
2) Install valve (327) and spring (330) to rear

flange (301).
a Apply grease (G2-LI) to valve (327) and
spring (330), and then install them to
prevent from being separated.
4) Install O-rings (135) and (139) to piston

(112).
2 O-rings (135) and (139):
Grease (G2-LI)
5) Install piston (112) to spindle (2).
a If it is difficult to install piston (112), lightly 3) Install plug (382) to rear flange (301), and
tap by using a plastic hammer to install it. lightly tighten it.
a Be careful not to damage O-rings (135)
and (139) when installing them.
4) Install spool (323) to rear flange (301).

2 Spool (323):
8. Assemble brake valve Power line oil (TO30)
1) Install O-rings (338) (2 pieces) to plugs (382) a Carefully insert spool (323) to the center
(2 pieces). of the spool hole of rear flange (301).
50-104 PC88MR-10
Power train system
a Damaging spool (323) and the spool 1) Install pilot valve in rear flange
holes of rear flange (301) during insertion 1] Set rear flange (301) so that the mating
may cause the oil leakage and surface with spindle (2) faces upward.　
deterioration of the travel motor (For details, see "Component parts
performance. figure".)
5) Install spring retainers (325) (2 pieces) and 2] Install valve (363) to rear flange (301).
springs (328) (2 pieces) to rear flange (301). 3] Install spring (366) and stopper (364).
(For details, see "Component parts
figure".)
4] Install ring (365) to the ring groove of rear
flange (301).
a Use a new ring (365).
6) Install O-ring (336) to plug (324).

2 O-ring (336):
Grease (G2-LI)
7) Install spring retainer (325) installed above

and plug (324) of spring (328) to rear flange
(301). a Lightly bend ring (365), and then
8) Tighten plug (324) lightly by using a wrench. install it.
a Be careful not to deform spring (328)
when tightening plug (324).
2) Install ball bearing (150) to rear flange (301).
9. Assemble rear flange
PC88MR-10 50-105
Power train system
2 Ball bearing (150) 10.Install rear flange

Power line oil (TO30) 1) Install O-rings (43) (2 piece) and O-ring (44)
(1 piece) to spindle (1).
2 O-ring (44):
Grease (G2-LI)
a Do not apply grease to O-ring (43).
(Grease may leak from the mating
surfaces of rear flange (301) and spindle
(2) during operation. This phenomenon
may be mistaken as oil leakage.) (See
3) Install dowel pin (342) to rear flange (301).
2) Install dowel pins (42) (2 pieces) to spindle

(2).
3) Add oil to spindle (2).
4) Install timing plate (109) to rear flange (301). 5 Inside of spindle (2) (power line
oil):
2 Timing plate (109) (on (a) surface
side of rear flange (301)) 1.2 l (TO30)
Grease (G2-LI) 2 Mating surface of cylinder block
(104) with timing plate (109):
a
5) Install springs (113) (10 pieces) to rear flange Power line oil (TO30) (For details,
(301).　(For details, see "Component parts see "Component parts figure".)
figure".)
2 Spring (113):
Grease (G2-LI)
a (To prevent spring (113) from falling off
during installation of rear flange (301))
4) Install rear flange (301) to spindle (2).

a Install rear flange (301), align it with the
positions of dowel pins (42). (For details,
see "Component parts figure".)
50-106 PC88MR-10
Power train system
5) Install hexagonal socket head bolts (345) (8 11.Assemble carrier assembly

pieces) to rear flange (301). 1) Install No.2 sun gear (6) to carrier (3).
3 Hexagonal socket head bolt (345): a Adhesive (LT-2) is applied to screw hole
102 ± 15.7 Nm {10.4 ± 1.6 kgm} (f) on the shaft tip end of carrier (3). Set
tap (M8, P1.25) to the screw hole, and
blow compressed air to remove dust.
2) Install snap ring (50) to No.2 sun gear (6).
6) Tighten plugs (382) (2 pieces).

3 Plug (382):
98.1 ± 19.6 Nm {10 ± 2.0 kgm} 3) Install inner bearings (29) (3 pieces), needle
bearing gauges (27) (3 pieces), No.1
planetary gears (5) (3 pieces) to carrier (3) in
this order.
7) Tighten plugs (324) (2 pieces).

3 Plug (324):
353 ± 39.2 Nm {36 ± 4.0 kgm} 4) Set jig [17] to carrier (3), and install No.1
thrust washers (12) (3 pieces).
5) Tighten bolts (40) (3 pieces).
3 Bolt (40):
33.3 ± 4.9 Nm {3.4 ± 0.5 kgm}
PC88MR-10 50-107
Power train system
a When not using positioning jig [17] of 3) Install inner bearings (30) (4 pieces), needle
No.1 thrust washer (12), carefully tighten bearing gauges (28) (4 pieces), No.2
bolt (40) to prevent No.1 thrust washer planetary gears (7) (4 pieces).
(12) from drag turning with the bolt.
a Install No.2 planetary gear (7) so that it
a After tightening bolt (40), remove engages with the hub inner tooth.
positioning jig [17].
4) Set jig [18] to the carrier, and install No.2

12.Install No.2 planetary gear thrust washers (10) (4 pieces).
1) Install No.1 thrust collar (9) to spindle (2). 5) Tighten bolts (51) (4 pieces).
3 Bolt (51):
57.9 ± 9.81 Nm {5.9 ± 1.0 kgm}
a When not using positioning jig [18] of
No.2 thrust washer (10), carefully tighten
bolt (51) to prevent No.2 thrust washer
(10) from drag turning with the bolt.
a After tightening bolt (51), remove
positioning jig [18].
2) Install No.2 thrust washers (11) (4 pieces) to

spindle (2).
a Adhesive (LT-2) is applied to screw hole
(g) on the shaft tip end of spindle (2). Set
tap (M8, P1.25) to the screw hole, and
blow compressed air to remove dust.
a Install No.2 thrust washer (11) with larger
chamfered side (h) facing downward.
13.Install carrier assembly
1) Install carrier assembly (11a) assembled
above to hub (1).
a Install the planetary gear so that it
engages with the hub inner tooth.
50-108 PC88MR-10
Power train system
a Slide the installing position to prevent

mating part of ring (45) is caught by the
notch part of hub (1), and then install the
ring.
2) Install No.1 sun gear (4).

3) Install ball (41) to No.1 sun gear (4).
a Lightly apply grease (G2-LI) to ball (41) to
prevent from falling off, and then install it.
4) Refill the final drive case with oil from the oil
filler port of cover (13).
5 Final drive case (power train oil):

1.1 l (TO30)
14.Install cover
1) Install O-ring (35) to cover (13).
2 O-ring (35):
Grease (G2-LI)
2) Install cover (13) to hub (1). 5) Install O-ring (37) to plug with flange (33) and
a Lightly tap the periphery of cover (13) by plug (39).
using a plastic hammer to install it. 6) Install plug with flange (33) and plug (39).
a If pressing cover (13) suddenly, O-ring 2 O-ring (37):

may be damaged. Additionally, the oil Grease (G2-LI)
may flow out of the screw hole.
3 Plug with flange (33):
58.8 ± 9.81 Nm {6.0 ± 1.0 kgm}
3 Plug (39):
58.8 ± 9.81 Nm {6.0 ± 1.0 kgm}
3) Install ring (45) to cover (1).
PC88MR-10 50-109
Power train system
a Perform the piping so that a pressure

gauge (main circuit) can be installed or
drain amount of the hydraulic motor can
be measured.
a Do not tap travel motor when installing.
Gently install it by means of the bolt
holes.
2) Run-in travel motor
Travel
motor Running Running
Selection Pressure
speed direction time
Low
15.Remove travel motor speed 10 rpm 1 minute
running Right or longer
1) Invert travel motor assembly (1a) so that the No load
High and left respec-
travel motor faces upward. tively
speed 20 rpm
2) Remove mounting bolts of hub (1) and work running
stand [1], sling travel motor assembly (1a),
and remove it. 3) Performance check test of travel motor
Preparation for running-in before test
4 Travel motor assembly (1a):
a Perform running-in until reaching the
85 kg following temperatures
1]
• Reduction gear hub external temperature:
40 to 80°C
Check test
a Measure the following items at low speed
to determine pass or fail.
2] • Passing standard — Travel motor drive
pressure difference
Max. 1.57 MPa {16 kg/cm2} / 10 rpm
• Hydraulic motor drain amount
Max. 0.6 l/min. / 10 rpm
a Test result
a Performance check test Accepted: Track shoe can be installed.
• After completion of the travel motor maintenance, Unaccepted: Disassemble and adjust
perform the performance check test according to again.
the following procedure.
1. Required instruments
No. Part name Q'ty
Pressure gauge (3.43 MPa {35 kg/
1 cm2}) 2
2 Measuring cylinder (5 l) 1
3 Stopwatch 1
2. Test procedure
1) Install travel motor and piping
Install the travel motor to the machine, and
set the piping. However, do not install the
track.
(For performance test (operation without
load) of the travel motor)
50-110 PC88MR-10
Power train system
Removal and installation of swing motor and swing machinery

assembly (PC88MR-J120-924-K-00-A)
stable posture.

Removal (PC88MR-J120-520-K-00-A)
a Record the disconnected position of the hose 5. Sling swing motor and swing machinery
and wiring connector to avoid misplacing. assembly (8), and remove it. [*1]
4 Swing motor and swing machinery
assembly (8):
90 kg
2. Disconnect the following hoses from the swing

motor.
(2): MB port hose (band color: brown)
(3): T drain hose (band color: white/green)
(4): MA port hose (band color: white) Installation (PC88MR-J120-720-K-00-A)
(5): S port hose • Perform installation in the reverse order to
(6) B port hose (swing lock) (band color: red) removal.
[*1]
• Determine the position of the swing motor and
swing machinery assembly according to dowel
pin (9).
2 Swing machinery mating face:
3 Mounting bolt of swing motor and
swing machinery assembly (8):
333 to 372 Nm {34 to 38 kgm}
3. Remove mounting bolts (7) (11 pieces).

4. Install the forcing screws to "a" portions (2
locations), and disconnect swing motor and
swing machinery assembly (8) from the machine
body.
PC88MR-10 50-111
Power train system
• Refill with oil (Hydraulic tank)

again.
5 Hydraulic oil:
• Bleed air
Bleed air from the swing motor. For details, see
part".
50-112 PC88MR-10
Power train system
Disassembly and assembly of swing machinery assembly (PC88MR-J120-926-K-01-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 790-201-2750 Spacer t 1
2 790-201-2730 Spacer t 1
790-101-2501 Push puller kit q 1
790-101-2510 • Block 1
790-101-2550 • Leg 1
790-101-2560 • Nut 2
3 790-101-2570 • Plate 4 3. No.1 sun gear
790-101-2901 • Bearing puller q 1 Remove No.1 sun gear (6).
• Puller
790-101-4200 (294 kN {30 ton}) q 1
F Hydraulic pump
790-101-1102 q 1
790-101-5401 Push tool kit (C) q 1
790-101-5461 • Plate 1
4 790-101-5441 • Plate 1
790-101-5421 • Grip 1
01010-81240 • Bolt 1
5 790-201-2850 Spacer t 1
6 790-201-2750 Spacer t 1
796T-426-1140 Push tool t 1
7
790-201-2680 Plate q 1
Disassembly (PC88MR-J120-530-K-01-A)
4. Ring gear
Remove ring gear (2).
1. Draining oil
Remove the drain plug, and drain the oil from
the swing machinery.
6 Swing machinery case:

2.8 l
2. Swing motor assembly
1) Remove swing motor mounting bolt (4).
2) Tighten the forcing screw in tapped hole (a)
for lifting, disconnect swing motor assembly
(1), and remove it.
a To correctly position these parts during
assembly, put the matchmark between swing 5. No.1 carrier and No.2 sun gear assembly
motor assembly (1) and ring gear (2), and 1) Remove No.1 carrier and No.2 sun gear
between ring gear (2) and machinery case assembly (7) from shaft and case assembly
(3) with paint before disassembly. (3).
PC88MR-10 50-113
Power train system
2) Disassemble No.1 carrier and No.2 sun gear 4] Remove snap ring (14), and remove No.2
assembly (7) according to the following sun gear (8).
procedure.
1] Remove snap ring (9), thrust washer (10),
No.1 planetary gear (11), needle roller
bearing (12), and thrust washer (13).
a Do not reuse snap ring (9).
6. No.2 carrier assembly

1) Remove spacer (17).
2) Remove No.2 carrier assembly (18) from
case (3).
3) Disassemble No.2 carrier assembly

2] Drive pin (15) into shaft (16), and remove according to the following procedure.
shaft (16) from No.1 carrier (7a). 1] Drive pin (19) into shaft (20), and remove
3] Pull out pin (15) driven into shaft (16). shaft (20) from No.2 carrier (18a).
2] Pull out pin (19) driven into shaft (20).
a Do not reuse pin (15).
a Do not reuse pin (19).
3] Remove thrust washer (21), planetary
gear (22), and needle bearing (23) from
No.2 carrier (18a).
50-114 PC88MR-10
Power train system
8. Shaft assembly
1) Set shaft and case assembly (3) on block [1],
and remove shaft assembly (28) by using
tool F2 and press.
2) Remove sub bearing inner race (26a).
7. Split collar
Remove split collar (25).
a When the split collar cannot be removed,

push it into the bearing by using tool F1.
a Do not push the split collar more than 1 mm 3) Set shaft assembly (28) on block [2], and
because the clearance of the split collar remove main bearing inner race (29a) and
insertion groove is approximately 1 mm. collar (30) from shaft (28).
• Pushing force: Max. 11.8 kN {Max. 1.2 ton}
PC88MR-10 50-115
Power train system
a Press-fitting force: Sub bearing outer race

(26b):
Max. 7.7 kN {Max. 0.78 ton}
9. Oil seal and bearing outer race

1) Remove oil seal (31) from case (3).
2. Shaft assembly
1) Install O-ring to inside of collar (30), and
install them to shaft (28).
2) Press-fit main bearing inner race (29a) to
shaft (28) by using tool F5 and press.
a Press-fitting force: 11.8 to 31.4 kN {1.2 to
3.4 ton}
a Be careful not to damage the bearing
retainer.
2) Remove sub bearing outer race (26b) and

main bearing outer race (29b) from case (3)
by using tool F3.
3) Set case (3) to shaft assembly (28).

4) Press-fit sub bearing inner race (26a) up to
the position where split collar (25) can be
inserted by using tool F6 and press.
Assembly (PC88MR-J120-710-K-01-A) a The press-fitting force of the bearing inner

race must be Max. 11.8 kN {1.2 ton}.
a Clean each part and check them for dirt or Rotate the case 2 or 3 turns for running in
damage. Apply engine oil to their sliding of the bearing roller.
surfaces before installing.
a If the bearing inner race is not press-fit
1. Bearing outer race
sufficiently and split collar (25) cannot be
Press-fit main bearing outer race (29b) and sub
inserted, press-fit the bearing inner race
bearing outer race (26b) to case (3) by using tool
again by the press-fitting force (Max. 14.7
F4.
kN {1.5 ton}) after completing running in
a Press-fitting force: Bearing outer race (29b): of the bearing roller.
Max. 10.8 kN {Max. 1.1 ton}
50-116 PC88MR-10
Power train system
a Apply grease without being mounted on the

lip.
a Fill "b" part of the oil seal lip with the grease
up to 40 to 60% of the volume.
2 Oil seal lip:
Grease (G2-LI)
5) Install split collar (25).

6) Install split collar (25), lightly install No.2
carrier, and check the starting torque.
a Starting torque: Max. 19.6 Nm {Max. 2.0
kgm}
a Starting torque is the maximum torque to
start the bearing rotation.
4. No.2 carrier assembly
1) Assemble No.2 carrier assembly
1] Install bearing (23) to No.2 planetary gear
(22).
2] Install thrust washers (21) and (24) to
No.2 planetary gear (22), and set them to
No.2 carrier (18a).
3] While aligning the pin hole of No.2 carrier
(18a) with shaft (20), tap shaft (20) by
using a plastic hammer, etc. to install the
shaft.
a Be careful not to damage the thrust
3. Oil seal washer when rotating the planetary
Press-fit oil seal (31) to case (3) by using tool F7. gear while inserting the shaft.
a Use a new oil seal.

a Lightly apply liquid gasket to inside of the
case when press-fitting the oil seal, and wipe
off the protruded liquid gasket. Be careful for
the liquid gasket not to contact to the oil seal
lip and the shaft.
2 Outer periphery of oil seal:
PC88MR-10 50-117
Power train system
4] Insert pin (19) from No.2 carrier (18a) to 5. No.1 carrier and No.2 sun gear assembly
shaft (20). 1) Assembly of No.1 carrier and No.2 sun gear
a Use a new pin (19). assembly
1] While aligning the pin hole of No.1 carrier
a Insert the edge of narrower pin groove
(7a) with shaft (16), tap shaft (16) by
(b).
using a plastic hammer, etc. to install the
a After inserting the pin, caulk 2 places (a) shaft.
of the No.2 carrier pin holes. 2] Insert pin (15) from No.1 carrier (7a) to
shaft (16).
a Use a new pin.
a Use a new pin (15).
a Insert the edge of narrower pin groove
(b).
a After inserting the pin, caulk 2 places
(a) of the No.1 carrier pin holes.
3] Install No.2 sun gear (8) to No.1 carrier
(7a), and install snap ring (14).
2) Install No.2 carrier assembly (18) to shaft

and case assembly (3).
3) Install spacer (17).
4] Install bearing (12) to gear (11).

5] Install thrust washers (13) and (10) to the
top end and bottom end of gear (11), and
set them to No.1 carrier (7a).
6] Install snap ring (9).
a Measure distance (c) between the upper end a Use a new snap ring.
of No.2 planetary gear (22) and top end of
a When installing the snap ring, do not
case (3), and check the press-fitting state of
expand the mating clearance larger than
split collar (25).
8 mm to prevent the ring from being
• Distance (c): 24.8 mm deformed.
50-118 PC88MR-10
Power train system
a Install snap ring (d) so that edge side (e)

and dropping side (f) of the snap ring are
as shown in the figure.
a Check that snap ring is fitted to the
groove completely.
2) Install ring gear (2).

a Align the ring gear with the mark on the
machinery case when disassembling.
7. No.1 sun gear

Install No.1 sun gear (6).
2) Install No.1 carrier and No.2 shaft assembly

(7) to shaft and case assembly (3).
8. Swing motor assembly

1) Install the snap ring to the output shaft of the
swing motor.
6. Ring gear
1) Apply liquid gasket to the mating surfaces of a Use a new snap ring.
ring gear (2) and machinery case. 2) Apply liquid gasket to the mating surfaces of
ring gear (2) and swing motor.
a Apply liquid gasket to the hatched area in
the figure. a Apply liquid gasket to the hatched area in
the figure.
a f x e = 2 to 5mm
a f x e = 2 to 5mm
2 Mating surfaces of ring gear and
case:
PC88MR-10 50-119
Power train system
2 Mating surfaces of ring gear and

swing motor:
3) Install swing motor assembly (1).

a Align the swing motor assembly with the
mark on the ring gear when
disassembling.
4) Tighten swing motor mounting bolts (4) (13
pieces).
3 Swing motor mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
• Refilling with oil

Tighten the drain plug and supply power train oil
(TO30) from the oil filler port.
6 Swing machinery case: 2.8 l
50-120 PC88MR-10
Power train system
Removal and installation of swing circle assembly (PC88MR-J110-924-K-00-A)
k Place the machine on a level ground and 2 Swing circle sealing amount:
lower the work equipment to the ground in a 5.5 l (G2–L1)
stable posture.

Removal (PC88MR-J110-520-K-00-A)
1. Remove the revolving frame assembly. For

revolving frame assembly".
2. Sling swing circle assembly (1), hold it, and • Sufficiently apply grease (G2-L1) to the internal
remove mounting bolts (24 pieces). [*1] gear and part "P".
3. Sling swing circle assembly (1), and remove it.
[*2]
4 Swing circle assembly (1):

120 kg
Installation (PC88MR-J110-720-K-00-A)

removal.
[*1]
2 Swing circle mounting bolt:
Adhesive (LT-2)
3 Swing circle mounting bolt:
235 to 285 Nm {23.5 to 29.5 kgm}
Target 260 Nm {26.5 kgm}]
[*2]
• Sling the swing circle assembly, and direct "S"
mark of the inner ring soft zone of the inner race
toward the position shown in the figure, and
install the track frame.
• "T" is the position of outer race soft zone.
2 Swing circle mounting surface:
PC88MR-10 50-121
Separation and connection of track (PC88MR-DTL0-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
Remover and ■ 1
791-620-3000
installer
791-635-3110 • Frame 1
791-635-3120 • Support 1
791-635-3130 • Nut 1
791-635-3140 • Screw 1
791-635-3150 • Hook 1
791-635-3160 • Extension 1 Installation (PC88MR-DTL0-720-K-00-A)
791-635-3170 • Nut 4
R • Perform installation in the reverse order to
791-635-3180 • Screw 2
removal.
791-635-3190 • Screw (for fixing) 1
[*1]
791-635-3210 • Pilot 1
791-620-3220 • Adapter 1 a Adjust the track tension. For details, see "Testing
791-615-7161 Pin pusher 1 and adjusting", "Test and adjust track tension".
796T-226– [*2]
Guide t 1
1120
a Press-fit the master pin by using tool R so that
Cylinder (980 kN
790-101-1300 {100 ton}) t 1 the projection amount the master pin is
dimension (a).
Protrusion of master pin (a): 3 ± 2 mm
Separation (PC88MR-DTL0-520-K-00-A)
1. Lower the work equipment to the ground, loosen

lubricator (1) and slacken the track tension. [*1]
k Since the internal pressure of the

adjustment cylinder is very high, do not
loosen the lubricator more than 1 turn. If
the grease does not come out sufficiently,
move the machine backward and forward.
[*3]
a When installing the dust seal, apply grease (G2-
LI) to the mating surfaces of the seal and
bushing.
a If the mounting bolt heads are damaged due to
the worn and damaged rubber parts of the road
liner (rubber packet type), replace the shoes
with new ones immediately. If the bolt head is
2. Move the machine forward so that the master crushed, the bolt can not be removed and
pin is in the front of the idler, and set block [1]. installed.
3. Remove master pin (2) by using tool R. [*2]
4. Remove tool R, pull out the temporal pin,
remove the dust seal, and separate track shoe
(2) while traveling REVERSE the machine. [*3]
50-122 PC88MR-10
Removal and installation of sprocket (PC88MR-DT60-924-K-00-A)
Removal (PC88MR-DT60-520-K-00-A)
1. Separate the track shoe assembly. For details,

see "Separation of track shoe assembly".
2. Swing the work equipment 90 deg. and raise the
machine off the ground by using the work
equipment to set block [1] between the track
frame and track shoe.
3. Remove mounting bolts (14 pieces) to sling

sprocket (1), and remove it.
4 Sprocket:
20 kg
Installation (PC88MR-DT60-720-K-00-A)

removal.
[*1]
2 Threaded part of sprocket (1) mounting
bolt:
Adhesive (LT-2)
3 Sprocket (1) mounting bolt:
186.3 to 225.6 Nm {19 to 23 kgm}
PC88MR-10 50-123
Removal and installation of idler and idler cushion assembly (PC220-DTA0-924-K-00-

A)
Removal (PC138-DTA0-520-K-00-A)
1. Separate the track shoe assembly. For details,

see "Separation and connection of track shoe
assembly".
2. Pull idler and idle cushion assembly (1) forward
and remove it while slinging it.
4 Idler and idler cushion assembly:

155 kg
3. Disconnect idler cushion assembly (3) from idler

(2).
4 Idler assembly:
80 kg
4 Idler cushion assembly:

75 kg
Installation (PC138-DTA0-720-K-00-A)

removal.
50-124 PC88MR-10
Disassembly and assembly of idler assembly (PC88MR-DT90-926-K-00-A)
a Special tools
N-
e-
c-
Sym- e-
Part No. Part name
bol s- Q'ty
si-
ty
790–101–5041 • Plate 1
790–101–5021 • Grip 1
L 1
01010–50816 • Bolt 1 5. Remove support (7) from shaft (5) with dowel pin
(8).
6. Remove bushings (9) and (10) from idler (4).
Disassembly (PC88MR-DT90-530-K-00-A)
1. Remove dowel pin (1) and support (2).

2. Remove floating seal (3) from support (4) and
idler (4).
3. Remove idler (4) from shaft (5) and support
assembly (7).
a Since oil (60 cc) is sealed in the idler, spread
the cloth, etc. on the floor to prevent the floor
from being dirt by oil falling down when
disassembling.
Assembly (PC88MR-DT90-710-K-00-A)
1. Press-fit to idlers (4) and (10) by using tool L1.

a Press-fitting force: 26 to 53 kN {2.6 to 5.4
ton}
2. Install O-ring and install support (7) to shaft (5)

with dowel pin (8).
4. Remove floating seal (6) of idler (4), shaft (5),

and support assembly (7) on the opposite side.
PC88MR-10 50-125
3. Install floating seal (6) to idler (4), shaft (5), and

a The metallic faces of the floating seal which
support assembly (7) by using tool L2.
are in contact with each other must be free
a Apply oil to the sliding surface of the floating from dirt.
seal, and take care not to have any dirt stuck
a After inserting, check that the seal tilt is Max.
on it.
1 mm. Seal protrusion are as follows.
a When installing the floating seal, clean, 4. Install shaft (5) and support (7) assembly to idler
degrease and dry the parts indicated with (4).
thick lines (load ring and mating face of the
load ring) completely.
5. Refill the space between shaft (5) and idler (4)

with oil.
a When inserting the floating seal assembly to
5 Amount of oil:
the housing, use the pushing tool. Be sure to
use the jig that can push the load ring for 60 cc (EO-30CD) l
insertion.
[1]: Cylinder-shape pushing tool.
50-126 PC88MR-10
6. Install floating seal (5) to idler (4) and support (2)

by using tool L2.
a Degrease the contact surfaces of the O-ring
and the floating seal.
7. Install the O-ring with support (2) and dowel pin

(1).
8.
PC88MR-10 50-127
Disassembly and assembly of idler cushion assembly (PC138-DTBP-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name

bol
791-600-2001 Compressor (A)

or t 1
Compressor (B)
791-685-8006
791-635-3160 Extension t 1
2 790-201-2770 • Spacer t 1
Cylinder
790-101-1600 t 1
(686 kN {70 ton})
L 790-101-1102 Pump t 1
• Plate (outer
790-201-1590 diameter: 74 mm) 1
3 • Plate (outer
790-201-1610 diameter: 79 mm) 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
Disassembly (PC138-DTBP-530-K-00-A)
1. Remove lock plate (1) and remove seat (2) and k Since the load at installed length of the
valve (3). spring is large and dangerous, set the
recoil spring assembly securely to the
a Do not remove grease fitting (17) from valve
tool.
(3).
2. Remove yoke and piston assembly (5) from • Load at installed length of spring:
recoil spring 84,300 N {8,600 kg}
assembly (4).
3. Disassembly of recoil spring assembly (4)
1) Set recoil spring assembly (4) to tool L2.
50-128 PC88MR-10
2) Slowly apply hydraulic pressure to compress

the spring and then tighten nut (6).
a Compress the spring until the nut is
loose.
a Slowly release hydraulic pressure to
relieve tension of the spring.
3) Remove pilot (8) and spring (7).
4) Remove snap ring (10), dust seal (11), and
bushing (12) from cylinder (9).
4. Disassembly of yoke and piston assembly
1) Remove snap ring (14) to remove U-packing
(15).
2) Remove wear ring (16) from yoke and piston
(13).
Assembly (PC138-DTBP-710-K-00-A)
1. Assembly of yoke and piston assembly

1) Install wear ring (16) to yoke and piston (13).
2) Install U-packing (15) and fix it with snap ring
(14).
2. Assembly of recoil spring assembly
1) By using tool [1], press-fit bushing (12) to
cylinder (9).
2) By using tool L3, press-fit dust seal (11) to
cylinder (9).
3) Install cylinder (9) and pilot (8) to spring (7)

and set them to tool L2.
4) Apply hydraulic pressure slowly to compress
the spring and to tighten nut (6) so that the
installed length of the spring becomes
dimension "a".
PC88MR-10 50-129
a Standard installed length (a) of spring:

390 mm
5) Remove recoil spring assembly (4) from tool

L2.
3. Install yoke and piston assembly (5) to recoil
spring
assembly (4).
2 Sliding surface of yoke and piston,
wear ring:
Grease (G2-LI)
4. Apply valve (3) and seat (2) and fix them by
using lock plate (1).
a Install the valve so that grease fitting (17)
faces outward.
5. Fill the inside of the cylinder with approximately
120 cc of grease from the grease fitting.
2 Cylinder inside:
Grease (G2-LI)
50-130 PC88MR-10
Disassembly and assembly of track roller assembly (PC88MR-DTD0-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol

790–101–5111 • Plate 1
790–101–5021 • Grip 1
3
01010–50816 • Bolt 1
L
6. Remove floating seal (9a) from roller (5), and

remove floating seal (9b) from shaft and collar
786T-230– t 1
4 Installer assembly (8).
1210
Disassembly (PC88MR-DTD0-530-K-00-A)
1. Remove pin (2) from track roller assembly (1),

and remove collar (3).
7. Remove bushings (10) and (11) from roller (5).
2. Remove floating seal (4a) from collar (3).

3. Remove floating seal (4b) from roller (5).
Assembly (PC88MR-DTD0-710-K-00-A)
a When installing the floating seal, clean,

degrease and dry the parts indicated with thick
lines (load ring and mating face of the load ring)
completely.
4. Remove O-ring (7) from shaft and collar

assembly (6).
5. Remove shaft and collar assembly from roller
(5).
PC88MR-10 50-131
1. Press-fit bushings (11) to roller (5) by using tool

L3.
a Press-fit bushing (10) in the same way.
a When inserting the floating seal assembly to the

housing, use the following installer.
Tool L4
a After inserting, check that the seal tilt is Max. 1 2. Press-fit floating seal (9a) to shaft (6) by using
mm. Seal protrusion (a) are as follows. tool L4.
3. Press-fit floating seal (9a) to roller (5) by using
(a): 6 to 10 mm
tool L4.
a Similarly press-fit floating seal (4b).
a The metallic faces of the floating seal which are

in contact with each other must be free from dirt.
4. Install shaft and collar assembly (8) to roller (5).
a Thoroughly clean the part contacting the 5. Invert roller (5) and shaft assembly (6).
insertion oil. After cleaning, amount of dust
remaining in the related area must be Max. 25
mg per roller assembly set.
a Direct plug (2) toward the outside of the machine
when assembling.
6. Install floating seal (4a) to collar (3) by using tool

L4.
50-132 PC88MR-10
7. Install O-ring (7) to shaft and collar assembly (6).
8. Install collar (3) to shaft (6), and install pin (2).

9. Fill the roller with oil, and tighten plug (12).
5 Track roller:
160 to 180 cc (G085W140)
PC88MR-10 50-133
Removal and installation of revolving frame assembly (PC88MR-H110-924-K-00-A)
k Loosen the cap of the hydraulic tank to 4 Engine hood assembly:

release the pressure inside the hydraulic
tank. 25 kg


hydraulic circuit referring to "Testing and
adjusting", "Releasing remaining pressure in
hydraulic cylinder circuit".
1. Remove the work equipment assembly. For

details, see "Removal and installation of work 5. Remove the operator's cab assembly. For
equipment assembly". details, see "Removal and installation of
2. Disconnect hoses (2 pieces) from the boom operator's cab assembly."
cylinder. 6. Disconnect the hose from the center swivel joint.
(1): Boom cylinder head hose (band color: red) a Check the connection positions with the band
(2): Boom cylinder bottom hose (band color: colors.
yellow) (8): Drain hose (band color: white/blue)
(9): Right reverse travel hose (band color: green/
yellow)
(10): Left reverse travel hose (band color:
orange/yellow)
3. Remove the lock plate, pull out pin (3), and

remove boom cylinder assembly (4).
a Check the quantity and installing positions of
installed shims in advance.
(11): Right forward travel hose (band color:
black/yellow)
(12): Left forward travel hose (band color: brown/
yellow)
(13): Blade LOWER hose (band color: red/black)
(14): Blade RAISE hose (band color: yellow/
blue)
(15): 2nd travel speed selector hose (band color:
yellow/yellow)
7. Remove pin (16) from the center swivel joint.
4. Remove engine hood (7).
50-134 PC88MR-10

removal.
[*1]
2 Mounting pin sliding surface (when
assembling)
Hyper white grease (G2-T)
2 Mounting pin (greasing after assembly)
k When aligning pin holes, never insert your
8. Leave mounting bolts (17) (2 pieces each on the
front and rear sides), and then remove all the finger into the holes.
remaining bolts. [*2]
• Adjust clearance between boom foot pin (19)
and boom bracket (20) to Max. 1.0 mm by using
shims.
Clearance: t = 1.0 mm, 2.0 mm
9. Sling revolving frame assembly (18), hold it, and

remove the remaining mounting bolts. [*3]
a Sling the assembly and hold it so that the
front-and-rear balance and right-and-left
[*2], [*3]
balance can be adjusted.
2 Revolving frame mounting bolt:
k Do not use a tap hole on the Adhesive (LT-2)
counterweight top.
3 Revolving frame mounting bolt:
10.Sling revolving frame assembly (18), and 235 to 285 Nm {23.5 to 29.5 kgm}
remove it.
a Be careful not to interfere with the center Refill it with oil to the specified level through the
swivel joint when removing it. oil filler port. Run the engine to circulate the oil
through the piping, and check the oil level again.
4 Revolving frame assembly: • Bleed air
Approx. 3100 kg Bleed air. For details, see "Testing and
adjusting", "Bleed air from each part".
PC88MR-10 50-135
Removal and installation of counterweight assembly [For machines with

additional counterweight] (PC88MR-H700-924-K-00-A)
stable posture.

3 Set the lock lever in LOCK position.

1. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood 6. Remove right and left eyebolt caps (6).
assembly".
2. Remove the engine controller assembly. For
details, see "Removal and installation of engine
controller assembly."
remove bracket (2).
7. Remove muffler cover (7).

8. Loosen mounting nuts (8) and (8a), and remove
muffler (9). [*1]
a Fix KCCV assembly in advance to prevent it
from interfering.

remove KCCV mounting bracket (4).
50-136 PC88MR-10
a Sling the assembly while sliding it parallel

and backward to prevent it from interfering
with the machine body.
3 Counterweight assembly (10):
850 kg

removal.
[*1]
3 Mounting nut (8):
9. Install eyebolts (M24 x 3 mm) (2 pieces) for 41 to 46 Nm {4.2 ± 4.7 kgm}
eyebolt holes, sling counterweight assembly
3 Mounting nut (8a):
(10) and hold it.
59 to 74 Nm {6 ± 7.5 kgm}
[*2]
Adhesive (LT-2)
1150 to 1440 Nm {118 to 147 kgm}
10.Remove mounting bolts (11) (3 pieces) from the

bottom of the counterweight. [*2]
11.Sling counterweight assembly (10), and remove

it. [*2]
PC88MR-10 50-137
Hydraulic system
Removal and installation of center swivel joint assembly (PC88MR-J8E0-924-K-00-A)
k Stop the engine, turn the battery disconnect 3. Disconnect hoses (10) to (19) between the
switch to OFF position, and remove the key. bottom of the center swivel joint and travel
(For details, see "Testing and adjusting", motor.
"Handling battery disconnect switch".) 4. Remove elbow (20).
Place the machine on a level ground, lower 5. Sling the swivel joint , and remove mounting
the work equipment to the ground, stop the bolts (21) (4 pieces). [*1]
engine, and set the lock lever in LOCK
position.
k Loosen the cap of the hydraulic tank to

tank.
Removal (PC88MR-J8E0-520-K-00-A)
1. Disconnect the hose from the center swivel joint.

(1): Drain hose (band color: white/blue)
(2): Right reverse travel hose (band color: green/
yellow)
(3): Left reverse travel hose (band color: orange/
yellow) 6. Sling center swivel joint assembly (22) and
(4): Blade RAISE hose (band color: yellow/blue) remove it.
(5): 2nd travel speed selector hose (band color:
4 Center swivel joint assembly:
yellow/yellow)
17 kg
(6): Right forward travel hose (band color: black/

yellow) Installation (PC88MR-J8E0-720-K-00-A)
(7): Left forward travel hose (band color: brown/
yellow) • Perform installation in the reverse order to
(8): Blade LOWER hose (band color: red/black) removal.
2. Remove pin (9) from the center swivel joint. [*1]
3 Center swivel joint mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
again.
5 Hydraulic oil:
56 l (Specified capacity: 102 l)
• Bleed air
50-138 PC88MR-10
Hydraulic system
Bleed air from the swing motor. For details, see

part".
PC88MR-10 50-139
Hydraulic system
Disassembly and assembly of center swivel joint assembly (PC88MR-J8E0-926-K-00-

A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
790-101-2501 Push puller ● 1

790-101-2510 • Block 1
790-101-2520 • Screw 1
790-101-2540 • Washer 1
T 791-112-1180 • Nut 1
790-101-2630 • Leg 2
790-101-2570 • Washer 4
790-101-2560 • Nut 2 Assembly (PC88MR-J8E0-710-K-00-A)
790-112-2650 • Adapter 2 1. Install slipper seal (7) and O-ring (6) to the
Disassembly (PC88MR-J8E0-530-K-00-A) swivel rotor.
2. Place swivel shaft (5) on the block. Install swivel
1. Remove cover (1). rotor (4) to the shaft by using the push tool while
2. Remove snap ring (2). tapping the swivel rotor lightly with a plastic
3. Pull out swivel rotor (4) and ring (3) from swivel hammer.
rotor (5) by using tool T.
4. Remove O-ring (6) and slipper seal (7) from the 2 Rotor and shaft contact surface:
swivel shaft. Grease (G2-LI)
a Take extreme care not to damage the slipper
seal and O-ring when installing the rotor.
3. Install ring (3) and fix it with snap ring (2).
4. Install cover (1) together with the O-ring.
3 Mounting bolt:
31.4 ± 2.94 Nm {3.2 ± 0.3 kgm}
50-140 PC88MR-10
Hydraulic system
Removal and installation of hydraulic tank assembly (PC88MR-PM30-924-K-00-A)
a Special tools
Necessity
S-
y-
Q'ty
Part No. Part name
mbol
2796-460-1210 Oil stopper t 1
D
796T-460-1240 Lot ● 1

stable posture.
3. Disconnect tube (2).
k Stop the engine, turn the battery disconnect 4. Disconnect connector M06 (2a).
switch to OFF position, and remove the key. 5. Remove clamp (3).
(For details, see "Testing and adjusting", 6. Remove mounting bolt (4), and remove the tank
"Handling battery disconnect switch".) together with bracket (5).
a Keep bracket (5) out of the way of the work.
k Disconnect the cable from the negative (-)

terminal of the battery.
Removal (PC88MR-PM30-520-K-00-A)
a Record the disconnected position of the hose

and wiring connector to avoid misplacing.
1. Open the cover, loosen hydraulic oil drain plug
(1) , and drain the hydraulic oil. [*1]
6 Hydraulic oil:
7. Disconnect hoses (6) and (7).
2. Remove the fuel tank assembly. For details, see
"Removal and installation of fuel tank assembly".
remove bracket (9) together with selector valve
(10).
a Fix bracket (9) and selector valve (10) by

using rope, etc.
PC88MR-10 50-141
Hydraulic system
9. Remove clamp (11) of the fuel hose from the 14.Loosen clamp (23) of suction hose (22). [*2]
hydraulic oil tank.
a Pull out the suction hose when removing the
10.Disconnect hoses (5 pieces) from the hydraulic
hydraulic oil tank.
oil tank.
(12): Main valve shield drain (Ts) hose
(13): T-block drain hose (band color: black/
green)
(14): Swing motor drain hose (band color: white/
green)
(15): Solenoid drain hose (band color: black/
blue)
(16): Swivel joint drain hose (band color: white/
blue)
15.Disconnect oil pressure pump drain hose (24)

on the oil pressure pump side. [*3]
a Remove the oil pressure pump drain hose
with the hydraulic oil tank installed.
11.Remove clamps (18) from 3 locations of the

hydraulic oil tank.
16.Remove hydraulic oil tank mounting bolts (25) (4

pieces). [*4]
12.Remove mounting bolt (19), and remove clamp

(20).
13.Remove wiring clamp (21).
a Wiring clamp (21) is insertion type.
50-142 PC88MR-10
Hydraulic system
3 Suction hose clamp (22):

10.8 ± 0.5 Nm {1.1± 0.05 kgm}
[*3]
• If oil pressure drain hose (24) was disconnected
from the hydraulic oil tank, connect the drain
hose to the hydraulic oil tank when installing the
hydraulic oil tank.
[*4]
2 Hydraulic oil tank mounting bolt (25):
Adhesive (LT-2)
3 Hydraulic oil tank mounting bolt (25):
a Remove clamp (26), and then remove the 98 to 123 Nm {10.0 to 12.5 kgm}
mounting bolt at the rear left of the hydraulic
oil tank.
again.
5 Hydraulic oil:
• Bleed air
Bleed air. For details, see "Testing and
17.Sling hydraulic tank assembly (27), and remove

it.
a Remove the assembly while pulling out
suction hose (22).
4 Hydraulic tank assembly (27):

70 kg
Installation (PC88MR-PM30-720-K-00-A)

removal.
[*1]
58.8 to 78.4 Nm {6 to 8 kgm}
[*2]
PC88MR-10 50-143
Hydraulic system
Removal and installation of main pump assembly (PC88MR-C200-924-K-00-A)
a Special tools
Necessity
S-
y-
Q'ty
Part No. Part name
mbol
796-460-1210 Oil stopper t 1
D
796T-460-1240 Lot ● 1

stable posture. 3. Open coolant drain cock (3), and drain the
coolant.
switch to OFF position, and remove the key. 6 Coolant:
13 l
Removal (PC88MR-C200-520-K-00-A)
1. Open cover (1a), and turn valve (1b) at the

bottom of the main pump to CLOSE position (S).
a Remove connector POIL of wiring (4).
4. Loosen mounting bolt (4), and remove cover (5).
5. Loosen drain plug (6) of the hydraulic oil tank,

and drain the oil. [*1]
6 Hydraulic oil:
2. Remove mounting bolts (1) (3 pieces), and tank strainer, install tool D and stop draining
remove cover (2). the oil.
50-144 PC88MR-10
Hydraulic system

assembly".
remove engine oil filter (13) together with the
bracket.
a Bind the removed oil filter on the engine.
6. Loosen mounting bolts (7) (3 pieces), and

remove cover (8).
7. Loosen damper drain plug (9), and drain the

remaining oil in the piping.
13.Rotate frame (17) according to the following

procedure.
PC88MR-10 50-145
Hydraulic system
14.Disconnect hoses (18) to (24) (7 pieces) from

the oil pressure pump.
(18): P3 port hose
(19): P2 port hose
(20): P1 port hose
(21): PLS port hose
(22): PPLS port hose

disconnect suction hose (35) from the oil
pressure pump. [*2]
(23): PEPC source pressure input port hose

(24): Pd (drain) port hose

15.Disconnect clamps (25) and (26).

16.Remove clamp (28) and bracket (29) as a unit,
disconnect hydraulic oil temperature sensor
connector P22 (30) and PC-EPC valve
connector V11 (31) from bracket (33).
bracket (33) for easier operation.
20.Sling main pump assembly (38), hold it, and

remove mounting bolts (39) (12 pieces).
50-146 PC88MR-10
Hydraulic system
21.Remove main pump assembly (38).
4 Main pump assembly (38):

67 kg
Installation (PC88MR-C200-720-K-00-A)

removal.
[*1]
58.8 to 78.4 Nm {6 to 8 kgm}
[*2]
54 to 89 Nm {5.5 to 9 kgm}
5 Coolant:
13 l
• Refill with oil
again.
5 Hydraulic oil:
• Adjusting air conditioner compressor belt
details, see "Testing and adjusting", "Test and
adjust air conditioner compressor belt tension".
• Adjust fan belt
details, see "Testing and adjusting", "Replace
fan belt".
• Bleed air (Hydraulic system)
Bleed air from the hydraulic pump circuit. For
details, see "Testing and adjusting", "Bleed air
from hydraulic circuit".
PC88MR-10 50-147
Hydraulic system
Removal and installation of control valve assembly (PC88MR-C030-924-K-00-A)
a Special tools
6 Hydraulic oil:
Necessity
S- 56 l (specified capacity: 100 l )
y-
Q'ty
Part No. Part name a When using tool D, remove the hydraulic
mbol tank strainer, install tool D and stop draining
the oil.
2796-460-1210 Oil stopper t 1
D
796T-460-1240 Lot ● 1

stable posture.

k Loosen the cap of the hydraulic tank to

tank.

hydraulic circuit referring to "Testing and
adjusting", "Releasing remaining pressure
from hydraulic system".

3. Disconnect hoses (2) and (3).
a Note the position where the hose and wiring
connector were disconnected so that they can
be installed correctly.
Removal (PC88MR-C030-520-K-00-A)
1. Loosen mounting bolt (1), and remove cover

(1a).
4. Disconnect tube (4).

5. Disconnect connector M06 (4a).
7. Remove mounting bolts (6), and remove the
tank together with bracket (7).
a Keep bracket (7) out of the way of the work.
2. Loosen drain plug (1b) of the hydraulic tank, and
drain the oil. [*2]
50-148 PC88MR-10
Hydraulic system
a If there is difficulty in performing the work,

disconnect the hose, and then remove the
nipple. At this time, note the removed
position of them.
8. Disconnect all wiring (8) installed around the

control valve assembly.
9. Remove clamps (9) and (10).

10.Disconnect hoses (11) to (15).
(11): PR port hose 12.Disconnect hoses (22) to (24).
(12): P1 port hose (22): LS port hose
(13): P2 port hose (23): A5 port hose
(14): P3 port hose (24): B5 port hose
(15): PP port hose
13.Disconnect hoses (25) and (26).

11.Disconnect hoses (16) to (19). (25): A4 port hose
(16): A8 port hose (26): B4 port hose
(17): A7 port hose
(18): B8 port hose
(19): B7 port hose
(20): A6 port hose
(21): B6 port hose
PC88MR-10 50-149
Hydraulic system
14.Disconnect hoses (27) and (28). 17.Disconnect TSW port hose (39), and install the
(27): A3 port hose eyebolt to bolt hole (40).
(28): B3 port hose 18.Remove mounting bolts (41) (4 pieces) and
remove control valve assembly (42).
4 Control valve assembly (42):

73 kg

(29): A2 port hose
(30): B2 port hose
16.Disconnect hoses (31) to (38).

(31): A2 port hose
(32): B2 port hose
Installation (PC88MR-C030-720-K-00-A)
(33): TS port hose • Perform installation in the reverse order to

(34): PA1 port hose removal.
(35): PA5 port hose a Be careful not to connect the hose to the
(36): PA4 port hose incorrect installation position.
(37): PA3 port hose
(38): PA2 port hose [*1]
58.8 to 78.4 Nm {6 to 8 kgm}
50-150 PC88MR-10
Hydraulic system

again.
5 Hydraulic oil:
• Bleed air
PC88MR-10 50-151
Hydraulic system
Disassembly and assembly of control valve assembly (PC88MR-C030-926-K-00-A)
a Since the service valves are single add-on type, they can be added and removed one by one at any time.
Assembly (PC88MR-C030-710-K-00-A)
This section explains only the precautions for assembling the 9-spool valve.
a Only figures for related items are shown.
a For figures not shown in this section, see "Control valve" OF "Facility standard" section in "Structure and
function".
• Control valve top/bottom cover
a Tighten stud mounting nuts (01580-11008) (2) (4 pieces) of control valve top cover (1) in the order of
[1] to [4] in 3 times.
3 1st time:
19.6 to 29.4 Nm {2 to 3 kgm}
2nd time:
39.2 to 49.0 Nm {4 to 5 kgm}
3rd time:
58.8 to 73.5 Nm {6 to 7.5 kgm}
• Be sure to loosen and tighten the following bolts while the spool is in the valve.
(3): 723-11-17361
(4): 723-11-27910
50-152 PC88MR-10
Hydraulic system
PC88MR-10 50-153
Hydraulic system
50-154 PC88MR-10
Hydraulic system
Disassembly and assembly of work equipment PPC valve

assembly (PC88MR-PL28-926-K-00-A)
a This section explains only the precautions for disassembling and assembling the work equipment PPC
valve.
Disassembly (PC88MR-PL28-530-K-00-A)
a 2 each of 2 different types of springs with

different mounting load are installed to springs
(6) and (7). Check the mounting position
(hydraulic port) to prevent any wrong installation.
Assembly (PC88MR-PL28-710-K-00-A)
a Carefully clean and inspect the parts to prevent • Load at installed height
failure due to dust, rust, and scratch, etc., and Spring (6) (P1, P2): {2.22 kg}
then take extreme care when assembling them. Spring (7) (P3, P4): {1.42kg}
a Plugs (2) and (3) are not supplied. 3 Bolt (11):
a When assembling piston (8), apply grease (G2- 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
L1) to the piston periphery and inner periphery of a When installing joint (12) to body (1), apply
body (1) hole. Loctite according to the following procedure.
a When installing spring (5), install the end surface 1. When installing the joint, apply 1 drop
of the smaller end turn diameter to shim (4) side. (approximately 0.02g) of Loctite (No.648) to the
• End turn diameter of spring (inside diameter) female threaded part (A) (2 places) of the body.
Small diameter side: 4.9 mm, large diameter Before installing, thoroughly degrease and dry
side: 5.55 mm the male threaded part of the joint and the
female threaded part of the body by using
a As springs (6) and (7), different springs are used Drysol.
for hydraulic ports. Check it before installing. 2. The positions where a drop of Loctite is applied
• Installed height: 32 mm (all) are as follows.
PC88MR-10 50-155
Hydraulic system
2 Female threaded part of body (A):

Loctite (No. 648)
3 Joint (12):
39 to 49 Nm {4 to 5 kgm}
a Apply grease (G2-LI) to the contact surfaces of

disc (13) and piston (8).
2 Application amount:
Grease (G2-LI)
Joint sliding surface: 0.3 to 0.8 cc/entire
circumference
Contact portions of disk and piston: 0.3
to 0.8 ml/1 place
a When assembling disc (13), adjust play of the
lever end so that the play is within the range
from 0.5 to 3 mm at the point of 200 mm from the
rotation center.
• See "Testing and adjusting", "Adjusting play
of work equipment and swing PPC valves".
3 Nut (14):
69 to 88 Nm {7 to 9 kgm}
50-156 PC88MR-10
Hydraulic system
Disassembly and assembly of travel PPC valve assembly (PC88MR-C6V0-926-K-00-A)

2 Grease (G2-LI)
Contact surfaces of lever and piston: 0.3
to 0.8 cc/place
Contact surfaces of damper and pin: 0.3
to 0.8 cc/place
• If difference between right and left at lever full
stroke is larger than 0.7 deg. when installing
washer (12) (t = 1.6), change the washer
thickness to reduce the difference to 0.7 deg. or
less. (By reducing washer thickness by 0.3 mm,
full stroke angle increases by 0.39 deg.)
• Washer type and thickness = 1.0, 1.3, 1.6, 1.9,
2.2 mm
Disassembly (PC88MR-C6V0-530-K-00-A)
a Tightening torque of each part is as following.
1. Remove screws (20), and remove damper • Bolt (17): 25 to 30 Nm {2.5 to 3.2 kgm}
assembly (19). • Bolt (11): 27 to 34 Nm {2.8 to 3.5 kgm}
2. Remove mounting bolt (17), and remove case
(16), shaft (15), and lever (13) together as a unit.
3. Remove mounting bolt (11), and remove plate
(10).
a Check and record the thickness and
installing position of washer (12).
a Pull out pin (22) from body (1).
4. Remove seal (9) and collar (8).
5. Pull out piston (7) and remove retainer (6),
springs (5), (4), and shim (3).
a Check the thickness and quantity of the
shims at each installing position, and store
them.
6. Pull out valve (2) from body (1).
Assembly (PC88MR-C6V0-710-K-00-A)
Only precautions for assembly is described.

a Carefully clean and inspect the parts to prevent
failure due to dust, rust, and scratch, etc., and
then take extreme care when assembling them.
a When assembling piston (7), apply grease (G2-

L1) to the piston periphery and inner periphery of
body (1) hole.
a When installing spring (4), install the end surface

of the smaller end turn diameter to shim (3) side.
• End turn diameter of spring (inside diameter)
Small diameter side: 4.9 mm, large diameter
side: 5.55 mm
• Apply grease (G2-LI) to the sliding surface of
shaft (15), to the contact surfaces of lever (13)
and piston (7) and to the contact surfaces of
damper (19) and pin (18).
PC88MR-10 50-157
Hydraulic system
Disassembly and assembly of work equipment cylinder assembly (PC88MR-

PPZ0-926-K-00-A)
a Special tools 01010-50816 • Bolt 1

Disassembly
Necessity
(PC88MR-PPZ0-530-K-00-A)
Sy-
Q'ty
Part No. Part name 1. Cylinder assembly
mbol
1) Set cylinder assembly (1) on tool U1.
790-502-1003 Repair stand t 1 2) Loosen head assembly (2) by using a
1 hydraulic pump or a torque multiplier wrench
with tool U2.
2
Socket
mm)
Socket
mm)
3
Socket
mm)
Socket
mm)
4 790-720-1000 Expander q 1 3) Pull out the piston rod assembly.
790-720-1650 Band q 1
07281-01029 Clamp q 1
796-720-1670 Band q 1
5
07281-01154 Clamp q 1
796-720-1670 Band q 1
07281-01274 Clamp q 1
U 790-201-1702 Push tool kit q 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1791 • Push tool 1
790-101-5021 • Grip 1
6
01010-50816 • Bolt 1 2. Piston rod assembly
790-201-1781 • Push tool 1 1) Set piston rod assembly (3) on tool U1.
790-201-1702 Push tool kit q 1 2) Remove nut (4) by using a hydraulic pump or
790-101-5021 • Grip 1 a torque multiplier wrench and tool U3.
01010-50816 • Bolt 1 a Width across flats of nut
790-201-1771 • Push tool 1
Cylin- Swing
790-201-1500 Push tool kit q 1 Boom Arm Bucket Blade
der
790-201-1610 • Plate 1 Width
790-201-5021 • Grip 1 across
70 65 60 75 70
01010-50816 • Bolt 1 flats of
790-201-1500 Push tool kit q 1 nut
7 790-201-1590 • Plate 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
790-201-1580 • Plate 1
790-101-5021 • Grip 1
50-158 PC88MR-10
Hydraulic system
4. Disassemble cylinder head assembly

3) Remove piston assembly (6) from piston rod
(5). 1) Remove the O-ring and backup ring (11).
4) Remove head assembly (2). 2) Remove O-ring (12).
3) Remove snap ring (13), and remove dust
seal (14).
4) Remove rod packing (15).
5) Remove bushing (16).
5) Remove cap (6), pull out balls (7) (9 pieces),

and remove plunger (8).
• Only for arm cylinder
a Since cap (6) is made of nylon, screw in a
screw, etc. and pull the cap by using Assembly (PC88MR-PPZ0-710-K-00-A)
pliers. a Apply engine oil to the sliding surface of each
part, and take care not to damage the packing,
dust seals, O-rings, etc..
a When installing the backup ring, do not install it
forcibly. Warm it in hot water at approximately 50
to 60 deg., and install it.
1. Assembly of cylinder head assembly
1) Press-fit bushing (16) by using tool U6.
2) Install rod packing (15).
3) Install dust seal (14) and secure it with snap
ring (13) by using tool U7.
4) Install the backup ring and O-ring (11).
5) Install O-ring (12).
3. Disassemble piston assembly
1) Remove wear ring (9).
2) Remove piston ring (10).
a Set a driver, etc. to the piston ring, and
tap it by using a hammer to cut and
remove it.
PC88MR-10 50-159
Hydraulic system
3. Piston rod assembly

1) Set plunger (8) on the piston rod, install balls
(7) (9 pieces), and secure them with cap (6).
a Make sure that the plunger end has a
certain play.
• Only for arm cylinder
2. Assembly of piston assembly

1) Set it on tool U4, rotate the handle 8 to 10
turns, and expand it.
2) Compress piston ring (10) by using tool U5.
2) Install head assembly (2) to piston rod (5).

3) Install piston assembly (6) to piston rod (5).
3) Install wear ring (9).

a Take care not to expand the ring mating
part excessively.
4) Set piston rod assembly (3) on tool U1.

5) Tighten nut (4) by using tool U3.
2 Nut (4):
Loctite No. 262
50-160 PC88MR-10
Hydraulic system
3 Nut (4): 3 Head assembly (2):

Cylinder name Tightening torque Cylinder name Tightening torque
Boom 3.33 ± 0.33 kNm {340 ± 34 Boom 961 ± 96.1 Nm {98 ± 9.8
kgm} kgm}
Arm 2.65 ± 0.26 kNm {270 ± 27 Arm 785 ± 78.5 Nm {80 ± 8.0
kgm} kgm}
Bucket 2.16 ± 0.22 kNm {220 ± 22 Bucket 1st: Tighten to 1,176 to
kgm} 1.372 kNm {120 to 140
Blade 3.14 ± 0.31 kNm {320 ± kgm}.
32.0 kgm} 2nd: Tighten up to 0 kNm
Swing 2.6 ± 0.26 kNm {265 ± 26.5 {0 kgm}
kgm} 3rd: Tighten up to 392 Nm
{40 kgm}
a Tighten the nut as directing its machined 4th: Angle tighten the
surface toward the piston. cylinder head
(Rotation amount: 3.5 to
4.5 mm)
Blade 1.03 ± 0.10 kNm {105 ±
10.5 kgm}
4. Cylinder assembly
1) Set cylinder (5) on tool U1.
2) Install piston rod assembly (3).
a Fully push the piston rod.
a After assembly, clean each part, and
perform masking of piping ports and pin
insertion parts.
3) Tighten head assembly (2) by using a

hydraulic pump or a torque multiplier wrench
with tool U2.
PC88MR-10 50-161
Work equipment
Removal and installation of work equipment assembly (PC88MR-L410-924-K-00-A)

stable posture.

Removal (PC88MR-L410-520-K-00-A)
1. Remove bracket (1). 4. Remove clamps (12) (3 places).

2. Disconnect hoses (2) to (8).
a Plug up the disconnected hose.
(2): Attachment hose
(3): Bucket cylinder bottom hose (band color:
blue)
(4): Arm cylinder bottom hose (band color:
green)
(5): Arm cylinder head hose (band color: orange)
(6): Bucket cylinder head hose (band color: red)
(7): Arm crane hose
(8): Drain hose
5. Disconnect connector A08 (13).

6. Remove clamp (14a), and disconnect wiring (14).
3. Remove clamp (9), and remove hoses (2

pieces).
a Plug up the disconnected hose.
(10): Boom cylinder head hose (band color: red) 7. Remove lock plate (15) on the head side, and
(11): Boom cylinder bottom hose (band color: pull off pin (16). [*1]
yellow)
a Check the shim insertion amount and its
position.
50-162 PC88MR-10
Work equipment
8. Lower boom cylinder assembly (17) on support 12.Sling work equipment assembly (18), and
stand [1]. remove it from the machine body.
9. Sling work equipment assembly (18), and hold it.
4 Work equipment assembly (18):
1000 kg
10.Remove handrail (19).
Installation (PC88MR-L410-720-K-00-A)

removal.
[*1]
assembling)
2 Mounting pin (greasing after assembly)
11.Remove plate (20), and pull off lock pin (21). [*2] k When aligning pin holes, never insert your
a Check the shim insertion amount and its finger into the holes.
position.
• Adjust clearance between boom cylinder rod
(27) and boom (28) to Max. 1mm by using
shims.
• Shim thickness for (a) part insertion: t = 1.0mm
PC88MR-10 50-163
Work equipment
• [*2]
assembling)
2 Mounting pin (greasing after
assembly)
k When aligning pin holes, never insert

your finger into the holes.
• Be sure to insert shim to (b) and (c) parts of
the clearance between boom (28) and
bracket (29).
• Shim thickness for (b) part insertion: t =
1.0mm
• Shim thickness for (c) part insertion: t =
1.0mm, t = 1.5mm
a Be sure to insert Min. one shim.

again.
5 Hydraulic oil:
• Bleed air
50-164 PC88MR-10
Work equipment
Removal and installation of boom swing bracket (PC88MR-L4D0-924-K-00-A)

stable posture.

Removal (PC88MR-L4D0-520-K-00-A)
1. Remove the work equipment assembly. For 8. Sling pin (11) and boom swing bracket (12), and
details, see "Removal and installation of work hold them.
equipment assembly". 9. Sling pin (11), and remove it.
remove swing cylinder P-bar mounting pin (2). 4 Pin (11):
66 kg

remove covers (4) and (5).
10.Sling boom swing bracket (12) while sliding it
forward, and remove it.
remove cover (7).
5. Place hoses (8) (7 pieces) at the bottom so as a Prevent hose (8) from interfering with boom
not to disturb operation. swing bracket (12).
4 Boom swing bracket (12):

200 kg

7. Insert pin (11) to the eyebolt.
Installation (PC88MR-L4D0-720-K-00-A)

removal.
PC88MR-10 50-165
Work equipment
Removal and installation of anti-drop valve for boom assembly (PC88MR-LA1Q-

924-K-00-A)
k Place the machine on a level ground.
k Remove the anti-drop valve assembly from

the machine body, and then perform
disassembling of the anti-drop valve
assembly.
k High pressure may remain in the anti-drop

valve assembly even after performing normal
releasing procedure. Be sure to perform this
procedure, and then perform the releasing
procedure.
2) Keep the arm cylinder and bucket cylinder at
k When the arm cylinder moves only in one
the most retracted position. Turn the starting
direction inside the anti-drop valve for arm,
switch to OFF position to stop the engine.
operate the cylinder to the stroke end in a
3) Turn the starting switch to ON position.
movable direction. Lower the bucket to the
4) Set the work equipment lock lever in FREE
ground, and then perform releasing the
position.
remaining pressure.
5) Check that the work equipment is lowered to
k If the bucket is not lowered and the anti-drop the ground by slowly operating the work
valve is removed from the cylinder, the high equipment control lever to the boom LOWER
pressurized oil may spurt out. It is very direction fully to the stroke end.
dangerous.
a Wash around the anti-drop valve assembly in

order to prevent any dust or dirt from entering it,
and then perform the work.
a Install a plug or flange in the place where a
hydraulic hose is disconnected to prevent oil
from flowing out.
a Check the connector numbers and installed
positions before disconnecting wirings and
hoses, and record them.
Removal (PC88MR-LA1Q-520-K-00-A)
1. Check for the function of PPC circuit k Perform the step3. to 5 in 15 seconds
accumulator. after the engine stopped, since the battery
1) Set the arm cylinder and bucket cylinder to charge in the PPC accumulator lowers
the most retracted position (maximum arm gradually.
OUT/bucket DUMP position), and hold the
work equipment at the height (a) off from the k If the work equipment is not lowered or
ground. stops on the way, the battery charge of
the PPC accumulator may be lowered. In
a (a) : 1.5 m such case, the remaining pressure cannot
be released with this procedure.
a If the work equipment is lowered by its own
weight to the ground, the battery charge of
the PPC accumulator is normal.
a PPC accumulator is a periodic inspection
item and an important periodic replacement
part.
2. Releasing the remaining pressure in hydraulic
cylinder circuit
50-166 PC88MR-10
Work equipment
1) Start the engine. 8) Set the work equipment lock lever in LOCK
2) Set the arm cylinder and bucket cylinder to position.
the most extended position (maximum arm 9) Loosen the oil filler cap of the hydraulic tank
IN/bucket CURL position) or the most slowly, and bleed the air in the hydraulic tank.
retracted position (maximum arm OUT/
a Leave the oil filler cap of the hydraulic
bucket DUMP position), and lower the work
tank removed.
equipment to the ground.
3. Anti-drop valve assembly
a Anti-drop valve is installed to the bottom 1) Place an oil container under the anti-drop
side of the boom cylinder. valve assembly to receive oil.
When the work equipment is lowered with
this posture, the oil in the bottom side of k Place an oil mat as well in case the oil
the boom cylinder is drained, and the leaks.
remaining pressure is low.
2) Remove the clamp (1).
3) Disconnect the connector P46 (2).
5) Disconnect the hoses (4), and (5).

3) Turn the starting switch to OFF position.
k The remaining pressure may damage
position, and operate the R.H. and L.H. work the O-ring, and the oil may be
equipment control levers forward and splashed. Therefore, loosen the hose
backward, and to the right and left. while pressing the fitting and around it
with a cloth, etc.
a The work equipment can be operated
with the battery charged in the PPC 6) Disconnect the tube (6).
accumulator, but the battery charged in it
will be discharged after the work k The remaining pressure may damage
equipment control lever is operated a the O-ring, and the oil may be
couple of times. splashed. Therefore, loosen the tube
6) Start the engine, run it with the fuel control while pressing the fitting and around it
dial in MIN (low idle) position for more than with a cloth, etc.
10 seconds so that the PPC accumulator is
accumulated.
7) Repeat the steps 4. to 6. to release the
remaining pressure in the hydraulic cylinder
circuit.
PC88MR-10 50-167
Work equipment
7) Remove the adapter (7). 6) Install the clamp (3).

8) Disconnect the tube (8).
k Slowly loosen the fitting of the tube so

that the remaining pressure in the
circuit between the anti-drop valve and
the cylinder is released.
The remaining pressure may damage
the O-ring, and the oil may be
splashed. Therefore, loosen the tube
while pressing the fitting and around it
with a cloth, etc.
7) Connect the connector P46 (2).
9) Remove the bolts (9) (4 pieces), and remove 8) Install the clamp (1).
the anti-drop valve assembly (10).
2. Refilling with oil

Installation (PC88MR-LA1Q-720-K-00-A)
a Refill with oil to the specified level through
1. Anti-drop valve assembly the oil filler port of the hydraulic tank. Start
1) Install the anti-drop valve assembly (10) with the engine to circulate the oil through the
the bolts (9) (4 pieces). piping. Then check the oil level again.
2) Connect the tube (8). 3. Air bleeding
3) Install the adapter (7). a Bleed air from the hydraulic circuit. See
TESTING AND ADJUSTING, “BLEED AIR
FROM HYDRAULIC CIRCUIT”.
4) Connect the tube (6).

5) Connect the hoses (5), and (4).
50-168 PC88MR-10
Work equipment
Removal and installation of anti-drop valve for arm assembly (PC88MR-LA1B-924-K-

00-A)
k Place the machine on a level ground.

the machine body, and then perform
disassembling of the anti-drop valve
assembly.
k High pressure may remain in the anti-drop

valve assembly even after performing normal
releasing procedure. Be sure to perform this
procedure, and then perform the releasing
procedure.
2) Keep the arm cylinder and bucket cylinder at
k Anti-drop valve assembly is installed to the
the most retracted position. Turn the starting
high place. Set the scaffolding and wear the
switch to OFF position to stop the engine.
safety belt always when performing this
work.
k When the arm cylinder moves only in one position.
direction inside the anti-drop valve for arm, 5) Check that the work equipment is lowered to
operate the cylinder to the stroke end in a the ground by slowly operating the work
movable direction. Lower the bucket to the equipment control lever to the boom LOWER
ground, and then perform releasing the direction fully to the stroke end.
remaining pressure.
k If the arm cylinder is not at the stroke end

and it is removed from the cylinder of the
anti-drop valve, it is very dangerous.
a Wash around the anti-drop valve assembly in

order to prevent any dust or dirt from entering it,
and then perform the work.
a Install a plug or flange in the place where a
hydraulic hose is disconnected to prevent oil
from flowing out.
a Check the connector numbers and installed
positions before disconnecting wirings and k Perform the step3. to 5 in 15 seconds
hoses, and record them. after the engine stopped, since the battery
charge in the PPC accumulator lowers
Removal (PC88MR-LA1B-520-K-00-A)
gradually.
1. Check for the function of PPC circuit
accumulator. k If the work equipment is not lowered or
1) Set the arm cylinder and bucket cylinder to stops on the way, the battery charge of
the most retracted position (maximum arm the PPC accumulator may be lowered. In
OUT/bucket DUMP position), and hold the such case, the remaining pressure cannot
work equipment at the height (a) off from the be released with this procedure.
ground. a If the work equipment is lowered by its own
a (a) : 1.5 m weight to the ground, the battery charge of
the PPC accumulator is normal.
a PPC accumulator is a periodic inspection
item and an important periodic replacement
part.
2. Releasing the remaining pressure in hydraulic
cylinder circuit
PC88MR-10 50-169
Work equipment
1) Start the engine. 2) Disconnect the hoses (1), (2), and (3).
2) Set the arm cylinder to the most extended
position (maximum arm IN position), and k The remaining pressure may damage
lower the work equipment to the ground. the O-ring, and the oil may be
a Anti-drop valve is installed to the arm splashed. Therefore, loosen the hose
cylinder, its head side. while pressing the fitting and around it
with a cloth, etc.
When the work equipment is lowered with
this posture, the oil in the head side of the
arm cylinder is drained, and the
remaining pressure is low.
Remaining oil amount on the head side is
low.

4) Disconnect the tubes (5).
5) Remove the U-bolt (7).
6) Disconnect the tubes (6).
3) Turn the starting switch to OFF position.

position, and operate the R.H. and L.H. work
equipment control levers forward and
a The work equipment can be operated
with the battery charged in the PPC 7) Disconnect the tube (8).
accumulator, but the battery charged in it
will be discharged after the work k Slowly loosen the fitting of the tube so
equipment control lever is operated a that the remaining pressure in the
couple of times. circuit between the anti-drop valve and
6) Start the engine, run it with the fuel control the cylinder is released.
dial in MIN (low idle) position for more than The remaining pressure may damage
10 seconds so that the PPC accumulator is the O-ring, and the oil may be
accumulated. splashed. Therefore, loosen the tube
7) Repeat the steps 4. to 6. to release the while pressing the fitting and around it
remaining pressure in the hydraulic cylinder with a cloth, etc.
circuit.
8) Set the work equipment lock lever in LOCK 8) Remove the bolts (9) (4 pieces), and remove
position. the anti-drop valve assembly (10).
9) Loosen the oil filler cap of the hydraulic tank
slowly, and bleed the air in the hydraulic tank.
a Leave the oil filler cap of the hydraulic
tank removed.
1) Place an oil container under the anti-drop
valve assembly to receive oil.
k Place an oil mat as well in case the oil

leaks.
50-170 PC88MR-10
Work equipment
Installation (PC88MR-LA1B-720-K-00-A)

1) Install the anti-drop valve assembly (10) with
the bolts (9) (4 pieces).
2) Connect the tube (8).
3) Tighten the tubes (6), and (5) lightly.

4) Install the U-bolt (7).
5) Install the clamp (4).
6) Tighten the tubes (6), and (5) to the specified
torque.
7) Connect the hoses (1), (2), and (3).
2. Refilling with oil

a Refill with oil to the specified level through
the oil filler port of the hydraulic tank. Start
the engine to circulate the oil through the
piping. Then check the oil level again.
3. Air bleeding
a Bleed air from the hydraulic circuit. See
TESTING AND ADJUSTING, “BLEED AIR
FROM HYDRAULIC CIRCUIT”.
PC88MR-10 50-171
Work equipment
Disassembly and assembly of anti-drop valve assembly (PC88MR-LA1P-924-K-00-A)

the machine body always before
disassembling it. Never disassemble the
anti-drop valve when it is installed to the
machine. Otherwise, oil or parts will spurt
out due to the high remaining pressure.
k Slowly loosen the cover on the spool portion

or check valve when they are to be removed.
k There is a spring inside them. Be careful that

the inside part may jump out.
k Do not stand in a direction where the inside

part may jump out when performing
disassembly, otherwise the inside part that
will jump out may hit your body.
k Insert a wooden piece or a thick cloth to fix

the anti-drop valve to the vise when
performing the disassembly.
k Wash the parts thoroughly with clean

hydraulic oil when performing assembly.
Replace the O-ring with the new one.
Disassembly (PC88MR-LA1P-530-K-00-A)
1. Do not stand in a direction where the inside part

may jump out with the reaction force of the
spring when removing the bolts (1), (2), and the
check valve (3). Otherwise the inside part that
will jump out may hit your body.
Assembly (PC88MR-LA1P-710-K-00-A)
1. Wash the parts thoroughly with clean hydraulic

oily. Replace the O-ring with the new one.
50-172 PC88MR-10
Work equipment
Removal and installation of blade assembly (PC88MR-LD10-924-K-00-A)

stable posture.

Removal (PC88MR-LD10-520-K-00-A)
1. Sling blade cylinder (1), and hold it.

2. Remove lock plate (2), and remove mounting pin Installation (PC88MR-LD10-720-K-00-A)
(3). • Perform installation in the reverse order to
a Sling the blade cylinder to the frame. removal.
[*1]
2 Mounting pin: Grease (G2-T)
finger into the holes.
• Adjust clearance (a) between blade (4) and

blade cylinder piston rod (7) to 1.0 mm by using
shims.
a Shim thickness: t = 1.0 mm
3. Sling blade (4), and hold it.
[*2]
2 Mounting pin: Grease (G2-T)
4. Remove right and left lock plates (5), and
remove the blade and frame mounting pin (6). finger into the holes.
5. Sling the blade assembly and remove it.
• Adjust clearance (a) between blade (4) and
blade cylinder frame (8) to 1.0 mm by using
4 Blade assembly:
shims.
365 kg (standard specification)
a Shim thickness: t = 1.0 mm
4 Blade assembly:
380 kg (wide specification)
4 Blade assembly:
400 kg (B.O.C specification)
PC88MR-10 50-173
Work equipment
50-174 PC88MR-10
Removal and installation of operator's cab assembly (PC88MR-K000-924-K-00-A)

stable posture.

Removal (PC88MR-K000-520-K-00-A)
1. Remove the operator's seat. For details, see 9. Remove covers (11) and (12) in the rear side of
"Removal and installation of operator's seat." the operator's seat.
2. Remove floor mat (1). 10.Disconnect connectors M04 (13), M13A (14)
3. Remove covers (2) and (3). and M13B (15).
4. Remove the machine monitor assembly. For

machine monitor assembly".
5. Remove clips (4) (2 pieces), and remove ducts
(5) and (6).
6. Remove cover (7), and remove duct assembly
(8). [*1]
11.Open cover (16), and remove air conditioner

outer air filter (17).
7. Remove harness clamp (9).

8. Disconnect wiper washer hose (10).
PC88MR-10 50-175
16.Disconnect connectors H09 (28), H16 (29) and

H08 (30).
17.Remove connector T02 (31).
18.Remove harness clamps (32), (33) and (34).
12.Remove bracket (18), clip (19) and harness

clamp (20), and then remove duct (21).
19.Disconnect connectors M09 (35) and M1A (36).

20.Remove harness clamp (37).
13.Disconnect radio antenna cable (22).
21.Disconnect connectors CK01 (38), CK02 (39)

and M10 (40).
22.Remove harness clamps (41) and (42).
14.Disconnect connectors AC01 (24), AC02 (25)

and ACECU (26) from air conditioner controller
(23).
23.Disconnect connector H15 (43).

50-176 PC88MR-10
27.Remove mounting bolt (49) at the front right of

the operator's cab, rear mounting bolt (50), and
mount rubber (51). [*3]
a Mounting bolts (49) and (50) are tightened
together with the floor frame.
a The following figure shows the front right.
25.Remove bracket (45).
26.Remove mounting bolts (46) (3 pieces) on the

left side of the operator's cab. [*2]
a Mounting nuts (47) and (48) are tightened
together with the floor frame.
29.Sling operator's cab assembly (53), and remove

it.
a Check that all the wiring and piping are
disconnected, and remove it.
4 Operator's cab assembly (53):

340 kg
Installation (PC88MR-K000-720-K-00-A)

removal.
PC88MR-10 50-177
[*1]
• Insert ducts (5) and (6) (2 pieces) until they hit
the root of duct (54) in advance. Install the
machine monitor, pull up the ducts, and then
insert them to duct (55).
[*2]
• Bolt (46) of mounting nuts (47) and (48) is
tightened together from the floor frame bottom.
Be careful for them not to rotate together when
tightening.
3 Mounting nuts (47) and (48):
235 to 309 Nm {24 to 31.5 kgm}
235 to 309 Nm {24 to 31.5 kgm}
[*3]
235 to 309 Nm {24 to 31.5 kgm}
235 to 309 Nm {24 to 31.5 kgm}
50-178 PC88MR-10
Removal and installation of operator's cab door (PC138-K160-924-K-00-A)
a This section explains only precautions for

installation of the operator's cab door.
1. Check that step (1) from the cab side is Max. ±3

mm when closing the door.
a When the step is not Max. ±3 mm, adjust the
mounting part of upper roller (2) in the lateral
direction (3) of the machine.
3 Upper roller (2) mounting bolt:
34 to 74 Nm {3.5 to 7.5 kgm}
2. Check that clearance (4) between cab and door 4. Check that there is clearance (8) between the
side is Max. 5 ± 2 mm. cab and lower bracket (7).
a When the clearance is not Max. ± 3 mm, a If the cab and lower bracket interfere each
adjust the mounting position of center roller other, slide the lower bracket mounting
(5) in the longitudinal direction of the position downward for adjustment.
machine.
3 Lower bracket (7) mounting bolt:
3 Center roller (5) mounting bolt:
14.7 to 34.3 Nm {1.5 to 3.5 kgm}
14.7 to 34.3 Nm {1.5 to 3.5 kgm} 5. When stopper (9) is not tightly contact with the
3. Check that vertical step (6) of door is Max. ±3 inner surface of the closed door, loosen nut (10)
mm. and adjust the stopper mounting position.
a When the step is not Max. 3 mm, adjust the 3 Stopper (9) mounting bolt:
mounting position of center roller (5) in the
59 to 74 Nm {6 to 7.5 kgm}
vertical direction of the machine.
PC88MR-10 50-179
settled to the cab side simultaneously when

closing the door.
a When the dovetails at the top and bottom of
the front side of the door are not settled to
the cab side simultaneously, adjust the
dovetail mounting positions.
3 Mounting bolts of dovetails (14a),
(14b), (14c), (14d)
14.7 to 34.3 Nm {1.5 to 3.5 kgm}
2 Mounting bolts of dovetails (14a),
(14b), (14c), (14d)
6. Check that the center of the striker (12) is at
Adhesive (LT-2)
center (13) of the lock assembly groove when
9. Check that there is not clearance between the
the door is closed.
door trim and cab when the door is closed,
3 Striker (12) mounting bolt: 10.Check that the door smoothly opens and closes
34 to 74 Nm {3.5 to 7.5 kgm} without play.
11.Check that the latches are engaged when the

a If the door is not closed well, slide striker (12) dovetails at the top and bottom of the closed
outward by approximately 0.5 mm to 1 mm, door are settled.
and then adjust the position again.
a If the latches are not engaged, adjust rear
striker (15) mounting position.
7. Check that dovetails (14a) and (14b) at the top

and bottom of the front side of the door are
settled to the cab side simultaneously when 12.Check that stopper (16) reaches center (18) of
closing the door. supporting portion (17) on the door side.
a When the dovetails at the top and bottom of a When the center position is not aligned,
the front side of the door are not settled to loosen the nut while it is locked, and adjust
the cab side simultaneously, adjust the the stopper mounting position in the lateral
dovetail mounting positions. direction (19) of the machine to align the
8. Check that dovetails (14c) and (14d) at the top center. Then, tighten the nut at the position
and bottom of the rear side of the door are where the stopper deflection is 0.5 mm.
50-180 PC88MR-10
3 Stopper (16) mounting bolt:

98 to 123 Nm {10 to 12.5 kgm}
13.Check that the door opens and closes smoothly

without unusual noise or interference.
14.Apply grease to the rails (top, center, and
bottom), dovetails (front and rear), and stopper.
2 Dovetail, stopper:
Grease (G2-LI)
PC88MR-10 50-181
Removal and installation of operator's cab glass (adhered glass) (PC138-K183-

924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part name
bol
1 793-498-1210 Lifter (suction cup) t 2

X
2 22B-54–38320 Stopper rubber t 3
a There are some figures not applicable to the

related machine model. However, the
replacement procedure is basically the same.
a Among the window glasses on 4 sides of the
operator's cab glasses, the stuck type is 5
glasses from (1) to (5) in the figure.
a This section describes the replacement
procedure of the stuck glass.
a Always remove front window assembly (6) when
front window glasses (5) is to be replaced. (If the
front glass is installed to the operator's cab, it
cannot be replaced.)
a For replacement procedure of the front window
assembly, see "Removal and installation of front
window assembly".
50-182 PC88MR-10
a Figure of structure
(1): R.H. window glass

(2): L.H. rear window glass
(3): Upper door window glass
(4): Lower door window glass
(5): Front window glass
(6): Front window assembly (front window glass + front frame)
(7): Dam rubber
(16): Center trim seal
Removal (PC138-K183-520-K-00-A)
a Remove the window glass to be replaced 1. By using seal cutter [1], cut off the adhesive
according to the following procedure. between damaged window glass (9) and
operator' cab (sheet metal) (8).
PC88MR-10 50-183
2. Remove the window glass.

a When a seal cutter is not available, drill a
hole in the adhesive and dam rubber with a
gimlet, then pass one end of an ultrafine wire
(such as piano wire) [2] through the hole. Clip
both ends of the ultrafine wire passed
through the hole with pliers [3] (or wind the
wire around pliers), then cut off the adhesive
and dam rubber by shuttling the wire.
Since the wire may be broken by the
frictional heat, apply lubricant to it.
(Figure shows the operator's cab on a wheel
loader.)
a If the window glass is broken in small pieces,

it may be removed with knife [4] and a flat-
head screwdriver.
a While widening the cut with a flat-head
screwdriver, cut the adhesive and dam
rubber with knife [4].
(Figure shows the operator's cab on a wheel
loader.)
Installation (PC138-K183-720-K-00-A)
1. Remove the remaining adhesive and dam

rubber from the sheet metal (adhesion surfaces)
of the operator's cab by using a knife and
scraper [5].
50-184 PC88MR-10
a Do not scrape excessively and damage the 1) Stir both primers for paint surface and glass
coating surface. Even if the adhesive and thoroughly before use.
dam rubber are left on the sheet metal
a If a primer was chilled-stored in a
surface, it is OK as long as they do not
depository, leave it at least half a day in
prevent the bonding effect of new adhesive.
room temperature before stirring it. (If you
(If the coating surfaces are damaged,
open the lid of a primer immediately after
adhesion will be lowered.)
having been chilled-stored, dew will
(Figure shows the operator's cab on a wheel condense on the surface of primer. So
loader.) allow a sufficient period of time for the
primer to be settled in the room
temperature.)
2) When reusing a brush (11) for applying a
primer, clean it with white gasoline before
use.
a After cleaning, check again that the brush
is free from stains or fouling.
a Provide a brush for the primer for paint
surface and another for glass.
2. By using white gasoline, remove oil, dusts and

stains from bonding surfaces on operator's cab
(8) and window glass (9).
a Clean them thoroughly since insufficient
cleaning induces defective adhesion.
a Clean all the black part on the back of the
window glass.
a After cleaning, leave them for more than 5
minutes for natural drying.
3) Apply primer for paint surface uniformly to
the mounting position of the dam rubber of
operator's cab (8) and the portion outside of
it to which adhesive is applied.
2 Primer for surface to be coated:
SUNSTAR paint surface primer
580 SUPER
a Primer is applied for up to 2 times.
(Application more than 2 times cause
degradation.)
a Area to be coated: Entire area of
3. Apply primer (10). dimension (a).
• Primer coating dimension (a): 25 mm
a Since useful life of primer is 4 months from
the date of production, do not use an
overdue primer (10).
a Make sure to use primer within 2 hours from
opening its cap.
a Even when putting the lid again immediately
after opening, be sure to use it within 24
hours from opening. (A primer must be
disposed when 24 hours have elapsed from
opening.)
PC88MR-10 50-185
2 Primer for glass:

SUNSTAR Glass Primer 580
SUPER
a Primer is applied for up to 2 times.
(Application beyond 2 times cause
degradation.)
a Area to be coated: Apply the primer to the

entire area of installation position (d)
which is a periphery of whole area of
window glass relative to dam rubber (7)
mounting position and operator's cab (8).
a For right side window glass (1), apply the a Do not apply the primer to about 5 mm of
primer only to the mounting position of the border area between the black and
the dam rubber in the outer periphery transparent portions on the window glass.
side and the portion to which adhesive is a After coating, leave the coated surface for
applied outside. more than 5 minutes (but no longer than
• Part of (b) 8 hours) for natural drying.
a After coating, leave the coated surface for a Be careful not to use wrong primer for
more than 5 minutes (but no longer than coating. If a wrong primer such as paint
8 hours) for natural drying. surface primer is applied, wipe it out
completely using white gasoline.
a Be careful not to use wrong primer for
coating. If a wrong primer such as glass
primer is applied, wipe it out completely
using white gasoline.
4. Attach dam rubber (double-coated adhesion

tape) (7) along the inner edge of window glass
mounting surface.
4) Apply a glass primer to the mounting surface
a Do not remove the release tape on glass-
of window glass (9).
adhering side of the dam rubber until
installation of the window glass is started.
50-186 PC88MR-10
a When sticking the dam rubber, do not touch

the cleaned surface.
a Be sure that the dam rubber in each sticking
corner sticks thoroughly to the corner.
2) Attach dam rubber (7) for left side rear

window glass (2) to the position indicated in
the figure.
a When bonding dam rubber (7) around a

window, be careful to prevent its overlapping
in the meeting area of the starting and ending
points. Or provide a clearance of 5 mm or so
in meeting area (e).
1) Attach dam rubber (7) for right side window
glass (1) to the position indicated in the
figure.
3) Attach dam rubbers (7) for door upper

window glass (3) and door lower window
glass (4) to the position indicated in the
figure.
(Figure shows the door upper window glass)
a Attach additional dam rubber (7a) for right

side window glass (1).
• Right side window glass additional dam
rubber mounting position:
(f): 140 mm
(g): 500 mm
(Figure shows the door lower window glass.)
PC88MR-10 50-187
4) Attach dam rubber (7) for front window glass

(5) to the position indicated in the figure.
a Dam rubber: 1,004 mm x 2
5. Position the new window glass.

1) Check clearance between a window glass
• The details of the mounting positions are and operator's cab in the right, left, top and
as follows: bottom. Then adjust the window glass
(h): Mount it along the inner end surface position so that the clearance is even in
of left and right front frames (17). every direction.
(i): Recess it from the front frame (17) end 2) Attach tape [6] between window glass (9)
surface by "3.0 mm." and operator' cab (8), and draw a line (n) on
the tape for the position alignment.
a Apply tapes [6] at 3 positions, right side
window glass, rear left side window glass,
and door lower window glasses (top and
bottom) , for position alignment.
3) Cut the tape at a position between window
glass (9) and operator's cab (8) by using a
cutter knife, and remove the window glass.
a Do not remove the tapes left on the
window glass and the operator's cab until
the window glass is installed
50-188 PC88MR-10
a Since useful life of adhesive is 4 months from

the date of production, do not use an
overdue adhesive.
a Adhesives must be stored at 25°C or lower in
a dark and cool place.
a Never heat an adhesive more than 30°C.
a When reusing the adhesive, remove
hardened adhesive at the nozzle tip
completely.
1) Break aluminum dehumidification membrane
(13) at the mouth of adhesive cartridge (12)
a The left/right and top/bottom mounting and attach there the dedicated nozzle.
positions for positioning of front window
glass (5) are as shown below.
(m) part (right): Protruded from the frame
end surface by "3.8 mm."
(o) part (top): Recessed from the frame
end surface by "3.0 mm."
2) Cut the tip of adhesive nozzle (14) to

dimensions (q) and (r) shown in the figure.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
3) Set adhesive cartridge (12) on caulking gun

[7].
6. Apply adhesive.
a 2 types of adhesives must be selectively
used depending on the season.
2 Adhesive (summer):
SUNSTAR Penguin Seal 580 SUPER
"S"
2 Adhesive (winter):
SUNSTAR Penguin Seal 580 SUPER
"W"
PC88MR-10 50-189
4) Remove the protective tape on the glass- 7. Install window glass.

bonding side of dam rubber. 1) Install the window glass (9) aligning it to the
5) Apply adhesive (15) to the outside portion of lines drawn on the tapes in the process of
dam rubber (7) on the operator's cab. step 5 above.
a Since the window glass cannot be
removed and adhered again, adhere it
with utmost care.
a Adhere the glass within 5 minutes after
applying the adhesive.
a Apply adhesive (15) to dam rubber (7) of

operator's cab (8) according to the
dimensions (s) and (t) indicated in the
figure.
• Dimension (s): 10 mm
• Dimension (t): 15 mm
2) After bonding window glass (9), press down
a Height of applied adhesive (15) must be entire circumference of the window glass
thicker than that of dam rubber (7). until it firmly sticks to dam rubber.
a Height of applied adhesive must be even. a Especially, press the corners of the
window glass firmly.
a For right side window glass, apply the
primer to the outside of the dam rubber in a Pulling window glass (9) from inside of
the outside perimeter side. the operator's cab by using of the suction
cup X1 will facilitate your work.
(Figure shows the operator's cab of
PC200-7.)
50-190 PC88MR-10
(Figure shows the operator's cab of PC200-

7.)
a Attach a center trim seal(16) to the lower

part of front window glass (5) after
mounting it. (Figure shows the operator's cab of PC200-
Also, caulk the entire periphery of the U- 7.)
shaped part between the glass and
center trim seal to eliminate any gap.
a When caulking, shape the adhesive on
the left and right end surfaces using a
rubber spatula.
2 Adhesive: Sika Japan
Sikaflex 256HV
2) Make the window glass and dam rubber stick

together by clamping them with expanded
styrene foam [9] and rubber band [10], and
cure them in that state.
(Figure shows the operator's cab of PC200-
7.)
9. Clean the remaining primer and adhesive on the

window glass and operator's cab after
completing the installation of the window glass.
8. Fix the window glass.
1) For right window glass (1) after installing it in a Wipe off adhesives before it is dried up by
the operator's cab, install sheet X2 for using white gasoline.
fixation in 2 portions (v) at the bottom of the a After cleaning the glass, do not give an
glass. impact to it.
10.Cure the adhered window glass.
PC88MR-10 50-191
1) Keep the stopper rubbers, styrene foam

blocks, and rubber bands installed for 10
hours of curing period.
(Ambient temperature 20°C / Humidity 60 %)
2) Before actual operation of the machine, let it
cure for 14 hours after the stopper rubbers,
styrene foam blocks, and rubber bands are
removed, and for a total of 24 hours after the
adhesive is applied.
50-192 PC88MR-10
Removal and installation of front window assembly (PC138-K181-924-K-00-A)
k Lower the work equipment to the ground,

Removal (PC138-K181-520-K-00-A)
a To replace the front window glass, the front

window assembly must be removed from the
operator's cab. Procedure for installing and
removing the front window assembly (front
frame + front glass) are described as following.
1. Fix the rear locks (right and left) with the front
window assembly put up to the ceiling.
2. Remove lower left block (1) and lower right block
(2).
3. Unlock the lock at the rear of the cab.

4. Carefully and slightly lower front window
assembly (3) and remove rollers (4) and (5) out
from the removal portion (lowest end of the rail)
of the lower right and lower left blocks removed
in above step 2.
5. Remove upper right and lower left rollers (6) and
(7) by twisting front window assembly (3)
rightward and leftward to remove front window
assembly (3).
a For (6) and (7), see the right figure.

removal.
PC88MR-10 50-193
Removal and installation of floor frame assembly (PC88MR-H1H0-924-K-00-A)

stable posture.

k Loosen the cap of the hydraulic tank slowly,

and release the pressure inside the hydraulic
tank. 3. Open radiator coolant drain cock (2), and drain
the coolant.
terminal of the battery. 6 Coolant:
13 l
k If you occasionally disconnect the heater
hose without draining the coolant, you may
be scalded with hot water due to high coolant
temperature in the radiator. Wait until the
coolant temperature drops before starting
the work.
k Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit.
a Ask a qualified person for collecting, adding and

filling operations of the refrigerant (air
conditioner gas: R134a).
(Only qualified persons can work.) 4. Remove the air cleaner assembly. For details,
a Never release the refrigerant (air conditioner
assembly".
gas: R134a) to the atmosphere.
5. Remove machine front and left side covers (3) (2
k If refrigerant (air conditioner gas: R134a) pieces).
gets in your eyes, you may lose your sight.
Put on protective eyeglasses during
collecting or filling operation.
a Note the position where the piping, wiring and

connectors were disconnected so that they can
be installed correctly.
Removal (PC88MR-H1H0-520-K-00-A)
1. Remove the operator's cab assembly. For

operator's cab assembly."
2. Open engine hood (1).
6. Remove + terminal (4) and - terminal (5) from
switch (6).
7. Disconnect operation system connector L19 (6a).
50-194 PC88MR-10
8. Disconnect the following connectors. 13.Disconnect travel PPC valve pressure sensor
(7): V04 (merge-divider selector) connector P26 (21).
(8): V03 (swing brake) 14.Disconnect the hoses (4 pieces) from travel
(9): V02 (travel Hi/Lo selector) PPC valve (22).
(10): V01 (PPC oil pressure lock) (23): P2 port hose (front-left travel) (band color:
9. Remove toolbox (11). brown/yellow)
(24): P1 port hose (rear-left travel) (band color:
orange/yellow)
(25): P4 port hose (front-right travel) (band color:
black/yellow)
(26): P3 port hose (rear-right travel) (band color:
green/black)
10.Disconnect PPC hoses (2 pieces) from PPC

valve (12) on the right side of the operator's
seat.
(13): P2 port (blade RAISE) (color band: blue/
yellow)
(14): P2 port (blade LOWER) (color band: red/
black) 15.Remove ground wiring terminal (27).
a Do not disconnect hoses (15) (2 pieces).
16.Disconnect hoses (8 pieces) from block (28).

(29): Bucket DUMP (band color: red)
11.Disconnect horn connector M07 (16).
(30): Boom RAISE (band color: yellow)
12.Disconnect hoses (17), (18) and (19) from T-
(31): Swing RIGHT (band color: brown)
block (20).
(32): Swing LEFT (band color: white)
(33): Bucket CURL (band color: blue)
(34): Boom LOWER (band color: black)
PC88MR-10 50-195
(35): Arm IN (band color: green)

(36): Arm OUT (band color: orange)

(47): Swing LEFT (band color: white/black)
(48): Swing RIGHT (band color: white/red)
17.Disconnect hoses (38) and (39) from P block
(37).
24.Pull out wiring fixing pad (49) from the floor

frame, and pull out wiring (50).
18.Remove air conditioner high/low pressure switch
25.Disconnect the connector from switch S18 (50b),
connector P17 (40), and disconnect air
and remove clip (50a).
conditioner refrigerant hoses (41) and (42) from
the air conditioner unit. [*1]
19.Disconnect air conditioner heater hoses (43)
and (44) from the air conditioner unit.
26.Remove clips (51), (52), (53), (53a) and (53b).
20.Remove ground wiring terminal T01 (45) and

safety ground terminal (45a).
21.Remove plates (46). (M10 bolts, 3 pieces)
22.Disconnect clamps (46a) and (46b).
50-196 PC88MR-10
27.Remove clamps (54), (55), (56) and (57) at the Reference: Precautions for removing work
bottom of the floor frame. equipment control lever
Push lock (62) of plastic frame (61) in boot (60) with
a flat-head screwdriver, etc., and remove boot (60)
from console plastic cover (63).
a If you pull a portion other than lock (62) of plastic
frame (61) forcibly, you may break plastic frame
(61).
28.Remove mounting bolts (58) (2 pieces) at the

front and rear of the floor frame. [*2]
29.Sling floor frame assembly (59), and remove it.

a Gradually sling the floor frame assembly, and
remove it while checking all the wiring and
piping are disconnected.
4 Floor frame assembly (60):

Installation (PC88MR-H1H0-720-K-00-A)
220 kg
removal.
[*1]
a When installing the hose for the air conditioner
circuit, be careful to prevent any dirt, dusts and
water from entering into the hose.
PC88MR-10 50-197
a Check that the O-ring is installed for the air

conditioner refrigerant hose connection before
installation.
a Check that the O-ring is not damaged or
deteriorated.
• When connecting the air conditioner refrigerant
hose, apply compressor oil (DENSO: ND-OIL8,
VALEO THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) for refrigerant (R134a) to
O-ring.
[*2]
a See "REMOVE AND INSTALL OPERATOR
CAB ASSEMBLY", since the floor frame
mounting bolts are tightened together with the
operator's cab assembly.
a Tighten front and rear mounting bolts (58) on the
front and rear left sides to the specified torque
from the bottom side.
235 to 309 Nm {24 to 31.5 kgm}

again.
5 Hydraulic oil:
5 Coolant:
10 l
• Filling of refrigerant (air conditioner gas: 134a)
Refill the air conditioner circuit with refrigerant
(air conditioner gas: R134a).
a Filling: 730 ± 50 g
50-198 PC88MR-10
Removal and installation of air conditioner unit assembly (PC88MR-K500-924-K-00-A)

stable posture.

1. Collect the refrigerant (air conditioner gas: 2) Open harness clamp (3), and remove the
R134a) from the air conditioner circuit. [*1] harness.
a Refill amount: 730 ± 50g 3) Disconnect connectors V04 (4), V03 (5), V02
(6) and V01 (7).
k If refrigerant gas (air conditioner gas: 4) Remove toolbox (8).
R134a) gets in your eyes, you may lose
your sight. And if it touches your skin,
you may suffer from frostbite. Put on
protective eyeglasses, gloves and
working clothes with long sleeves while
collecting the refrigerant or filling the air
conditioner circuit with the refrigerant.
a Ask a qualified person for collecting, adding
and filling operations of the refrigerant (air
5) Disconnect high/low pressure switch
a Remove the undercover under the cooling connector P17 (9).
system. 6) Disconnect refrigerant hoses (10) (2 pieces).
2. Set coolant drain valve (1) to "OPEN" position, [*2]
and drain the coolant. 7) Disconnect heater hoses (11) (2 pieces).
8) Disconnect drain hoses (12) (2 pieces).
6 Coolant:
12 l
4. Remove front window assembly (13). For details,

see "Removal and installation of front window
3. Disconnect wiring and piping at the bottom assembly".
1) Remove cover (2) on the left side of the
machine.
PC88MR-10 50-199
9. Tilt operator's seat (25) forward, and remove

rear covers (26) and (27).
5. Remove floor mat (14), and remove cover (15).

6. Remove machine monitor assembly (16). For
10.Open cover (28) on the left side of the machine,
machine monitor assembly".
and remove air conditioner outer air filter (29).
7. Remove covers (20) and (21) on the right side.

11.Remove harness clamps (30) (3 pieces).
12.Remove air conditioner outer duct (31).
8. Remove clips (22) (2 pieces), and pull down

ducts (23) and (24) in the direction of arrow. [*3]
13.Remove rear-right duct (32).
50-200 PC88MR-10
14.Remove harness clamps (33) (2 pieces), and 3) Rotate machine monitor cover (42) in the
remove the harness. direction of arrow having mounting bolt (44)
15.Disconnect harness connectors AC01 (34) and as a fulcrum.
N10 (35).
a Fix it at the position where it does not
16.Disconnect harness connectors (37) and (38)
interfere with right side duct (45).
from air conditioner controller (36).
4) Remove front mounting bolt (46) of right side
duct (45).
17.Remove the right side duct according to the

following procedure.
5) Remove rear mounting bolt (47) of right side
1) Remove cable clip (39), and disconnect duct (45).
cable (40) from duct lever (41).
a Insert a flat-head screwdriver between
the clips, lower it and remove cable clip
(39).
6) Pull out right side duct (45) in the direction of

arrow, and remove it.
2) Remove mounting bolts (3 pieces) of

machine monitor cover (42) and lightly
loosen mounting bolt (44).
PC88MR-10 50-201
18.Remove left cover (47) from seat mounting

bracket (46).
22.Install forcing screws [1] (1 piece on the right

side, 2 pieces on the left side).
23.Tighten forcing screws [1] evenly on the right
19.Remove harness clamp (48). and left sides, lift seat mounting bracket (46) and
20.Remove mounting bolts (49) (3 pieces each on secure clearance (a) between the bracket and
right and left sides) of seat mounting bracket floor.
(46). Clearance (a): 90 mm
a Secure clearance (a) to prevent the
interference when pulling out the air
conditioner unit assembly.
21.Remove front mounting bolts (50) (3 places) of

the air conditioner unit, and then remove rear
mounting bolts (51) (2 pieces).
24.Pull out air conditioner unit assembly (52) in the

direction of arrow, and remove it.
a Check that all the wiring and piping are
disconnected, and remove it.
50-202 PC88MR-10
a Be sure to fit the cap to the air conditioner unit

side and piping side when removing the air
conditioner piping.
a When installing the heater core hose, install it so
that the white line (mark) on the heater hose
becomes a straight line to avoid any twist of the
heater hose.
a Be sure to fit the cap to the air conditioner unit
side and hose side when removing the heater
hose.
Hose outer diameter: 24 mm, Hose inner
diameter: 15.7 mm
Air conditioner outer diameter: 17 mm, Air
• Perform installation in the reverse order to conditioner inner diameter: 15 mm
removal.
[*3]
[*1], [*2]
• Install ducts (23) and (24) according to the
a When installing the hose for the air conditioner following procedure.
circuit, be careful not to let dirt, dusts and water
1. Insert ducts (23) and (24) until they hit the
going into the hose.
root of right side duct (45) in advance.
a Check that O-ring (70) is installed to the joints of 2. Rotate machine monitor cover (42) in the
connecting the air conditioner piping when direction of arrow having mounting bolt (44)
connecting the piping. as a fulcrum, and then return the cover to the
original position.
a Do not reuse an O-ring because it is deformed
3. Pull up ducts (23) and (24) in the direction of
and deteriorated if used once.
arrow, and insert them.
a When removing the O-rings, use a soft tool so
that the piping is not damaged.
a Check that O-ring (70) is free from flaws and
deterioration.
a When connecting the refrigerant pipes, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8) to O-ring (70).
3 Refrigerant tube mounting bolt (M6 x 1.0)
(width across flats: 10):
3.9 to 6.9 Nm {0.4 to 0.7 kgm}
3 Hose clamp (M6 x 1.0) (width across flats:
10): • Refill refrigerant (air conditioner gas: R134a)
Refill the air conditioner circuit with refrigerant
8 to 12 Nm {0.8 to 1.2 kgm} (air conditioner gas: R134a).
Refill amount: 730 ± 50g
• Refill air conditioner compressor oil
See Air conditioner, "Handling of compressor oil".
through the water filler port. Run the engine to
5 Coolant:
12 l (For details, see "Table of fuel,
coolant and lubricants")
PC88MR-10 50-203
Removal and installation of air conditioner compressor assembly (PC88MR-

K590-924-K-00-A)

stable posture.

1. Collect the refrigerant (air conditioner gas: 5. Remove mounting bolts (3) (3 pieces), and
R134a) from the air conditioner circuit. [*1] remove cover (4).
a Refill amount: 730 ± 50 g
k If refrigerant gas (air conditioner gas:

R134a) gets in your eyes, you may lose
your sight. And if it touches your skin,
you may suffer from frostbite. Put on
protective eyeglasses, gloves and
working clothes with long sleeves while
collecting the refrigerant or filling the air
conditioner circuit with the refrigerant.
a Ask a qualified person for collecting, adding 6. Remove clamps (5) (2 pieces), and disconnect
and filling operations of the refrigerant (air solenoid clutch connector AC03 (6).
2. Open engine hood (1a), and fix it by using lock
bar (1b).

remove air conditioner hoses (8) and (8a). [*2]
8. Loosen mounting bolt (9), tilt air conditioner
3. Remove mounting bolts (1) (2 pieces), and compressor assembly (10), loosen V-belt (11)
remove air conditioner hose clamp (2a). and disconnect it from air conditioner
4. Remove fan guard (2). compressor assembly (10).
50-204 PC88MR-10
Refill the air conditioner circuit with air

conditioner gas (R134a).
• Refill amount: 730 ± 50g
[*2]
8 to 12 Nm {0.8 to 1.2 kgm}
9. Remove mounting bolt (9), and remove air

conditioner compressor assembly (10) together
with bracket (12).
remove air conditioner compressor assembly
(10) from bracket (12).

removal.
[*1]
a When installing the hose for the air conditioner
circuit, be careful to prevent any dirt, dusts and
water from entering into the hose.
a When connecting the air conditioner piping,
apply compressor oil (DENSO: ND-OIL8 or
equivalent) to the threaded part.
• Refill air conditioner gas
PC88MR-10 50-205
Removal and installation of air conditioner condenser assembly (PC88MR-K580-

924-K-00-A)
k Place the machine on a level ground and a Be careful not to damage the core portion of
lower the work equipment to the ground in a the air conditioner condenser assembly
stable posture. when removing.

1. Collect the refrigerant (air conditioner gas:

R134a) from the air conditioner circuit. [*1]
a Refill amount: 730 ± 50 g
k If refrigerant gas (air conditioner gas: Installation (PC88MR-K580-720-K-00-A)
R134a) gets in your eyes, you may lose • Perform installation in the reverse order to
your sight. And if it touches your skin, removal.
you may suffer from frostbite. Put on [*1]
protective eyeglasses, gloves and • Refill refrigerant (air conditioner gas: R134a)
working clothes with long sleeves while Refill the air conditioner circuit with refrigerant
collecting the refrigerant or filling the air (air conditioner gas: R134a).
conditioner circuit with the refrigerant. • Refill amount: 730 ± 50 g
a Never release the refrigerant (air conditioner • Refill air conditioner compressor oil
gas: R134a) to the atmosphere. [*2]
a Ask a qualified person for collecting, adding a When installing the hose for the air conditioner
and filling operations of the refrigerant (air circuit, be careful not to let dirt, dusts and water
conditioner gas: R134a). going into the hose.
a Check that the O-rings are fitted to the joints
when connecting the air conditioner piping.
assembly".
3. Remove mounting bolts (1) and (2), and remove a Do not reuse an O-ring because it is deformed
hoses (3) and (4). [*2] and deteriorated if used once.
a Plug up the hose to prevent dust and water a When removing the O-rings, use a soft tool so
from entering. that the piping is not damaged.
a Be careful not to damage or lose O-ring. a Check that the O-ring is not damaged or
deteriorated.
2 O-ring:
Refrigerant (R134a) compressor oil
(DENSO: ND-OIL8)
3 Mounting bolts (1) and (2):
4 to 7 Nm {0.4 to 0.7 kgm}

remove air conditioner condenser assembly (6).
[*3]
50-206 PC88MR-10
[*3]
a Install air conditioner condenser assembly with
the cushion.
PC88MR-10 50-207
Removal and installation of operator's seat (PC138-K2Q0-924-K-00-A)

the work equipment to the ground in a stable
posture, and stop the engine.

k Removal and installation work must be done

by a pair of workers.
a Note the connector numbers and installed

positions before disconnecting wiring harnesses
and hoses.
Removal (PC138-K2Q0-520-K-00-A)
1. Pull lever (1) to your side and move operator's

seat (2) backward.
2. Remove mounting bolts (3) (4 pieces).
a Move the operator's seat forward, and
remove mounting bolts (2 pieces) at the rear.
3. Disconnect connector S19 (4) at the rear of the

operator's seat.
4. Remove operator's seat (2) while slowly lifting it
by 2 persons.
4 Operator's seat assembly:

30 kg
Installation (PC138-K2Q0-720-K-00-A)

removal.
50-208 PC88MR-10
Removal and installation of seat belt (PC138-K2Q3-924-K-00-A)

the work equipment to the ground, and stop
the engine.

Removal (PC138-K2Q3-520-K-00-A)
1. Remove the operator's seat. For details, see

"Removal and installation of operator's seat".
2. Remove mounting bolts (2) (one each on right
and left sides) of seat belt (1), and remove seat
belt (1). [*1]
Installation (PC138-K2Q3-720-K-00-A)

removal.
PC88MR-10 50-209
Removal and installation of front wiper assembly (PC138-K710-924-K-00-A)

the engine.
k Place the work equipment lock lever in LOCK

position.

Removal (PC138-K710-520-K-00-A)
1. Check that wiper arm (1) is stowed in the right

stay.
2. While holding grips (2) on the right and left of the

front window, pull lever (3) forward to release the
lock.
3. Pull up lower grip (4) by left hand and upper grip

(5) by right hand, and push them to lock catch
(6) at the rear of the cab to lock.
4. Check that lever (3) is securely at LOCK

position.
50-210 PC88MR-10
a Check that the arrow on lock case (7) is

aligned with that of lever (3).
8. Disconnect connector P31 (14) inside of cover

(12).
5. Hold and pull up knob (8) to remove lower

window (9).
6. Remove cover (10) and floor mat (11).
10.Remove cover (17).

a Insert a flat-head screwdriver to slit (18) at
the lower left and pull it up to remove the
7. Remove cover (12). cover while avoiding protrusion (19).
a 1 out of the mounting screws (4 pieces) is
covered with cap (13).
PC88MR-10 50-211
13.Move harness (23) and disconnect connector

M05 (24).
14.Open cap (25) and remove nut (26) to remove

wiper arm (27).
15.Remove cap (28), nut (29), washer (30) and
packing (31).
11.Remove duct (20).
16.Remove mounting bolts (32) (6 pieces) to

remove wiper motor assembly (33).
12.Remove the mounting bolt of bracket (21), and

move it backward together with machine monitor
(22).
a The connector of the machine monitor needs
not to be disconnect .
1. Install wiper motor assembly (33).

Liquid adhesive (LT-2)
50-212 PC88MR-10
2. Install packing (31) and washer (30), and tighten

nut (29).
a When installing washer (30), direct the
chamfered side toward the front of the cab.
3 Nut (29):
10.8 to 12.7 Nm {1.10 to 1.30 kgm}
3. Install cap (28) and wiper arm (27).

a Install the wiper arm (27) so that the
clearance (a) between the washer nozzle
(34) and wiper blade (35), and overlap (d)
between the end surface (c) of the stopper
(41) and end surface (b) of the slider (43) are
the following dimensions. a Details of part P
• Dimension (a): 22 mm • Install the wiper arm with the stopper and
• Dimension (d): 8mm slider are overlapped.
4. Tighten nut (26) to close cap (25).
3 Nut (26):
11.8 to 15.7 Nm {1.20 to 1.60 kgm}
PC88MR-10 50-213
2) Hold knob (8) and install lower window (9).
a The state is as the following drawing when

storing the wiper arm (wiper switch to OFF
3) While holding grips (2) on the right and left of
position).
the front window set to the ceiling, pull down
lever (3) to release the lock.
5. To check the wiper arm operation, preform the

following works.
1) Connect connectors M05 (24) and P31 (14). 4) Securely hold lower grip (4) by left hand and
upper grip (5) by right hand, and slowly push
down them forward.
a Check that the bottom of the front window
does not touch the wiper arm.
50-214 PC88MR-10
2] Perform step 1] again.

a Between steps 1] and 2], the rotation
5) When the bottom of the front window direction of the motor crank is different.
reaches the top of lower window, push the Therefore, check the operation 2
top of the front window to front lock catches times.
(36) and engage the lock. 3] When the tip of wiper blade (35) is at the
highest position by pressing wiper switch
(37), check that clearance (b) between
trim seal (38) and wiper is the following
dimension.
• Dimension (b): Max. 130 mm
6) Check that lever (3) is securely at LOCK

position.
a Check that the arrow on lock case (7) is
aligned with that of lever (3).
7) Turn battery disconnect switch to ON

position.
8) Check that the work equipment lock lever is
in LOCK position and start the engine.
9) Check the operation of the wiper arm with the
front window dried.
1] Press the wiper switch (37) three times
continuously, and check that the wiper
arm (27) swings one round-trip, and then
is stored in the part (e) of the R.H. stay.
PC88MR-10 50-215
10)Check the operation of the wiper arm when

the front window is wet with washer fluid.
1] Hold down window washer switch (39) for
a few seconds to wet the front window
sufficiently, and then release the switch.
2] Check that wiper arm (27) swings 2
round-trips and then is stowed in the right
stay.
3] Perform step 1] again.
4] Check that wiper arm (27) swings odd
number of round-trips and then is stowed
in the right stay.
5] Hold down window washer switch (39) to
operate the wiper and check the 11)In case of abnormality as results of the
followings. above checks, adjust the wiper arm
• When the tip of wiper blade (35) is at installation as described in step 3.
the highest position, wiper slider (40) 6. Perform the subsequent installation in the
and stopper (41) do not interfere each reverse order to removal.
other (clicks in case of interference).
• When the tip of wiper blade (35) is at
the lowest position, wiper blade (35)
and front window seal (42) do not
interfere each other.
50-216 PC88MR-10
Electrical system
Removal and installation of starting motor assembly (PC88MR-AK70-924-K-00-A)

stable posture.

Removal (PC88MR-AK70-520-K-00-A)
1. Remove the KCCV assembly. For details, see 5. Remove mounting bolts (6) (2 pieces), and
"Removal and installation of KCCV assembly". remove starting motor assembly (7).
remove cover (2).
3. Remove clamps (3) (2 pieces).Place fuel hose

(4), wiring (4a) to starting motor B terminal and
wiring (4b) to starting motor C terminal aside.
Installation (PC88MR-AK70-720-K-00-A)

removal.
4. Disconnect connector 5C (5).
PC88MR-10 50-217
Electrical system
Removal and installation of engine controller assembly (PC88MR-AP70-924-K-00-A)

stable posture.

Removal (PC88MR-AP70-520-K-00-A)

remove rubber cover (2). Installation (PC88MR-AP70-720-K-00-A)

removal.
[*1]
3 Connector CE03 (3) mounting bolt
with hexagonal socket
2.55 to 3.11 Nm {0.26 ± 0.32 kgm}
2. Remove mounting bolt (1 piece) with hexagonal

socket of connector CE03 (3), and disconnect
bolt connector CE03 (3). [*1]
3. Disconnect connector K02 (4), and disconnect
ground (5).
4. Remove clamp (6)and mounting bolt (7) (1

piece) and then disconnect connector (8).
remove engine controller assembly (10).
50-218 PC88MR-10
Electrical system
Removal and installation of pump controller assembly (PC88MR-C3V1-924-K-00-A)

stable posture.


and hoses. Installation (PC88MR-C3V1-720-K-00-A)
Removal (PC88MR-C3V1-520-K-00-A) • Perform installation in the reverse order to
1. Remove upper side cover (1) at the rear side of removal.
the operator's seat. a Remove all dirt from the harness connectors,
and then install the assembly.
2. Remove mounting bolt (2), and remove bracket

(3).
3. Open harness clip (4), and remove the harness.
4. Disconnect harness connectors P01 (6) and P02
(7) from pump controller assembly (5).
a Press connector release portions (a) of
harness connectors (6) and (7), and pull
levers (8) inward.
remove pump controller assembly (5).
Installation
PC88MR-10 50-219
Electrical system
Removal and installation of machine monitor assembly (PC138-Q170-924-K-00-A)

the engine.


and hoses.
Removal (PC138-Q170-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling,

and lock it. 6. Remove duct (10) (1 bolt).
a Be sure that the assembly is certainly locked.
2. Remove front lower window (2).
3. Remove rubber panel (3) (2 bolts).
7. Insert a flat-head screwdriver in slit (7), and pull

it upward to remove cover (9) while avoiding
protrusion (8).
4. Remove 3 mounting screws of cover (4).
a One of the 3 screws is covered with cap (5).
a Claw (17) is attached to the back side of

cover (9).
5. Disconnect connector P31 (6) of sunlight sensor
and then remove cover (4).
50-220 PC88MR-10
Electrical system
8. Loosen mounting bolts (19) of cover and duct

assembly (18).
a By loosening mounting bolt (19), the machine
monitor mounting bolt can be removed
easily.
Installation (PC138-Q170-720-K-00-A)

removal.
9. Remove mounting bolts (11) (4 pieces) of

machine monitor (12).
10.Disconnect connectors (13) to (16).

a By disconnecting connector (15) in advance,
other connectors can be disconnected easily.
• Connector (13): Machine monitor (CM01)
• Connector (14): Machine monitor (CM02)
• Connector (15): Machine monitor (unused)
(CM03)
• Connector (16): Machine monitor (for camera
connection) (CM03)
PC88MR-10 50-221
Electrical system
Removal and installation of mass air flow and temperature sensor (PC88MR-
A96H-924-K-00-A)

stable posture.

Removal (PC88MR-A96H-520-K-00-A)
1. Open engine hood (1), and fix it by using lock

bar (2).
2. Disconnect connector P55 (3).

3. Disconnect screw (4), and remove mass air flow
and temperature sensor (5). [*1]
Installation (PC88MR-A96H-720-K-00-A)

removal.
[*1]
3 Mass air flow and temperature sensor (3)
screw:
0.98 ± 1.27 Nm {0.1 to ± 0.13 kgm}
50-222 PC88MR-10
Electrical system
Removal and installation of KOMTRAX terminal assembly (PC88MR-Q210-924-K-00-A)

stable posture.


Removal (PC88MR-Q210-520-K-00-A)
1. Remove upper side cover (1) at the rear side of

the operator's seat.
2. Disconnect antenna cable (2).

3. Disconnect connector (3).
4. Disconnect connectors CK01 (4) and CK02 (5).
remove KOMTRAX terminal assembly (7).
Installation (PC88MR-Q210-720-K-00-A)

removal.
PC88MR-10 50-223
Electrical system
50-224 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
60 Maintenance standard
8 60 Maintenance standard
PC88MR-10 60-1
Table of contents

60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
PTO.................................................................................................................................... 60-4
Cooling system .................................................................................................................... 60-5
Power train system ..................................................................................................................... 60-7
Swing circle ......................................................................................................................... 60-7
Swing machinery ................................................................................................................. 60-9
Sprocket............................................................................................................................ 60-11
Track frame ....................................................................................................................... 60-12
Idler cushion ...................................................................................................................... 60-13
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-15
Carrier roller ...................................................................................................................... 60-16
Track shoe ........................................................................................................................ 60-17
Hydraulic tank.................................................................................................................... 60-23
Main pump ........................................................................................................................ 60-24
Control valve ..................................................................................................................... 60-28
Swing motor ...................................................................................................................... 60-37
Travel motor ...................................................................................................................... 60-39
PPC valve................................................................................................................................ 60-40
Work equipment and swing PPC valve................................................................................. 60-40
Travel PPC valve ............................................................................................................... 60-43
Blade PPC valve ................................................................................................................ 60-45
Boom swing PPC valve ...................................................................................................... 60-47
Solenoid valve ................................................................................................................... 60-49
Anti-drop valve for boom ..................................................................................................... 60-51
Anti-drop valve for arm ....................................................................................................... 60-53
Center swivel joint .............................................................................................................. 60-55
Cab mount and cab tipping stopper ..................................................................................... 60-56
Work equipment ....................................................................................................................... 60-57
Work equipment................................................................................................................. 60-57
Boom cylinder.................................................................................................................... 60-68
Arm cylinder ...................................................................................................................... 60-69
Bucket cylinder .................................................................................................................. 60-70
Boom swing cylinder .......................................................................................................... 60-71
Blade cylinder .................................................................................................................... 60-72
60-2 PC88MR-10
Engine mount
Engine mount (PC88MR-H320-034-K-00-A)
PC88MR-10 60-3
PTO
PTO (PC88MR-D400-034-K-00-A)
60-4 PC88MR-10
Cooling system
Cooling system (PC88MR-B000-034-K-00-A)
PC88MR-10 60-5
Cooling system
60-6 PC88MR-10
Swing circle
Power train system (ALL-C100-001-K-60-A)
Swing circle (PC88MR-J110-034-K-00-A)
PC88MR-10 60-7
Swing circle
Unit: mm
No. Item Criteria Remedy
Axial clearance of Standard clearance Allowable clearance
1 bearing(when mounted Replace
on machine) 0.3 to 1.2 2.0
60-8 PC88MR-10
Swing machinery
Swing machinery (PC88MR-J130-034-K-00-A)
Unit: mm
Backlash between swing Standard clearance Allowable clearance
1 motor shaft and No. 1 sun
gear 0.06 to 0.15 -
Backlash between No. 1
2 sun gear and No. 1 0.10 to 0.27 0.6
planetary gear
3 planetary gear and ring 0.13 to 0.42 0.8 Replace
gear
4 planetary carrier and No. 0.10 to 0.28 -
2 sun gear
5 sun gear and No. 2 0.10 to 0.27 0.6
planetary gear
PC88MR-10 60-9
Swing machinery
Unit: mm
6 planetary gear and ring 0.13 to 0.42 0.8
gear
7 planetary carrier and 0.07 to 0.21 -
swing pinion
Backlash between swing
8 pinion and swing circle 0.22 to 0.81 1.6
Outside diameter of oil Tolerance Repair by hard
dimension
9 seal contact surface of chrome plating
0
swing pinion collar 145 144.8 or replace
-0.100
60-10 PC88MR-10
Sprocket
Sprocket (PC88MR-DT60-034-K-00-A)
Unit: mm
Tolerance
dimension
1 Root outside diameter +1.0
433.004 421
-2.0 Rebuild by
2 Tip outside diameter 483.7 ±2.0 472 build-up
3 Width of tooth tip 28 — 23 welding or
+ 0.5 replace
4 Width of tooth root 38 33
-2.5
Thickness of tooth +0.475
5 84.002 78
bottom -1.150
PC88MR-10 60-11
Track frame
Track frame (PC88MR-DT20-034-K-00-A)
Unit: mm
Standard dimension Repair limit Rebuild by
Track build-up
74 78 welding
Vertical width of frame
1 idler guide Rebuild by
Idler build-up
support 73 69 welding or
replace
Rebuild by
Track build-up
158 162
frame welding
Lateral width of
2 idler guide Rebuild by
Idler build-up
support 156 152 welding or
replace
60-12 PC88MR-10
Idler cushion
Idler cushion (PC88MR-DTBP-034-K-00-A)
Unit: mm
Standard dimension Repair limit
Steel Load at Load at
Installed
shoe Free height height
installed Free height installed
Road height height
1 Recoil spring liner 47.3kN 42.1 kN Replace
412.3 323 402
{4,826 kg} {4,295 kg}
Rub- 68.5 kN 61.0 kN
ber 412.3 283 402
shoe {6,985 kg} {6,217 kg}
PC88MR-10 60-13
Idler
Idler (PC88MR-DT90-034-K-00-A)
Unit: mm
Outside diameter of Standard dimension Repair limit
1 protrusion 460 —
2 Outside diameter of tread 415 407 Rebuild by
3 Depth of tread 22.5 26.5 build-up
Width of protruding welding or
4 43 — replace
portion
5 Overall width 100 —
6 Width of tread 28.5 —
Standard Tolerance Standard Allowable
Clearance between idler dimension Shaft Hole clearance clearance
7 shaft and bushing -0.250 +0.062 0.250 to
44 —
-0.290 0 0.352
Tolerance Standard Allowable Replace
Standard
interfer- interfer- bushing
Interference between dimension Shaft Hole
8 ence ence
idler and bushing
+0.117 +0.025 0.062 to
50 —
+0.087 0 0.117
Side clearance of idler Standard clearance Allowable clearance
9 (one side) 0.19 to 0.395 —
Tread thickness build-up
10 (tread center part) welding or
13.8 9.8
replace
60-14 PC88MR-10
Track roller
Track roller (PC88MR-DTD0-034-K-00-A)
Unit: mm
Outside diameter of Standard dimension Repair limit Rebuild by
1 protrusion 139 — build-up
2 Outside diameter of tread 110 103 welding or
3 Width of flange 43 — replace
4 Overall width 136.6 — —
Rebuild by
build-up
5 Width of tread 46.8 —
welding or
replace
Clearance between shaft dimension Shaft Hole clearance clearance
6 and bushing -0.250 +0.165 0.230 to
40 —
-0.270 -0.020 0.435
Tolerance Standard Allowable
Standard
interfer- interfer- Replace
7 ence ence
roller and bushing
+0.150 +0.025 0.075 to
44 —
+0.100 -0.020 0.170
Side clearance of the Standard clearance Allowable clearance
8 track roller (one side) 0.26 to 0.445 —
Tread thickness build-up
9 (tread center part) welding or
33 29.5
replace
PC88MR-10 60-15
Carrier roller
Carrier roller (PC88MR-DTJ0-034-K-00-A)
Unit: mm
build-up
1 Outside diameter of tread welding or
82 72
replace
2 Width of tread 100 — —
Tolerance Standard Allowable
Standard
interfer- interfer-
3 ence ence
shaft and bearing
+0.009 0 -0.004 to Replace
30 —
-0.004 -0.010 0.019
Interference between 0 +0.018 -0.031 to
4 62 —
roller and bearing -0.013 -0.012 0.012
build-up
5 Tread thickness welding or
10 5
replace
60-16 PC88MR-10
Track shoe
Track shoe (PC88MR-DTL0-034-K-00-A)

Road liner, rubber pad shoe, and triple grouser shoe
a Portion P shows the link in which the bushing is press-fitted.

*1: Road liner
*2: Rubber pad shoe (if equipped)
Triple grouser shoe (if equipped)
PC88MR-10 60-17
Track shoe
Unit: mm
1 Link pitch Turn 180
154.3 157.3
deg. or
Outside diameter of Standard dimension Invert replace
2 bushing 41.3 37.3
3 Link height
74 70 Repair or
Thickness of link replace
4 (bushing press-fit part) 20 16
5 89
6 Shoe bolt pitch 73 Replace
7 57
Inside
8 45
width
Overall Repair or
9 Link 30 replace
width
Tread
10 26.3
width
11 Protrusion of pin 3
Protrusion of regular
12 bushing 3.15
13 Overall length of pin 131
Overall length Adjust or
14 of bushing Master 74.6 replace
15 Thickness of bushing
8.4 4.4
16 Thickness of spacer —
17 Bushing 49.0 to 62.8 kN {5 to 6.4 ton}
Regular
18 Press-fitting 49.0 to 117.7 kN {5 to 12 ton}
pin —
force
(*1) Master
39.2 to 78.5 kN {4 to 8 ton}
19 pin
Tightening torque Retightening angle
(Nm {kgm}) (deg.)
• Rubber pad 117.7 ±
a: shoe 19.6
Regular • Triple grouser 90 ± 10
link shoe {12 ± 2}
20 Shoe bolt 117.7 ± Retighten
• Road liner 19.6 60 ± 5
{12 ± 2}
Tightening torque Retightening angle Lower limit torque
b:
Master (Nm {kgm}) (deg.) (Nm {kgm})
link —
— —
60-18 PC88MR-10
Track shoe
Unit: mm
Standard Tolerance Standard
Interference between dimension Shaft Hole interference
21 bushing and link +0.314 +0.042
41 0.232 to 0.334
+0.274 –0.020
Interference between +0.150 -0.198
22 regular pin and link 24 0.198 to 0.400
0 -0.250
Clearance between dimension Shaft Hole clearance
23 regular pin and bushing +0.150 +0.830 Adjust or
24 0.180 to 0.830 replace
0 +0.330
(*1) Interference between dimension Shaft Hole interference
24 master pin and link +0.020 -0.198
24 0.178 to 0.270
–0.020 -0.250
(*1) Clearance between dimension Shaft Hole clearance
25 master pin and bushing -0.150 +0.630
24 0.380 to 0.880
-0.250 +0.230
*1: For dry track.
PC88MR-10 60-19
Track shoe
Triple grouser shoe (PC138-DTL8-034-K-00-A)
Unit: mm
1 Grouser height
20 12
2 Overall height of shoe 26 18
3 Plate thickness 6 Rebuild by
build-up
4 Lower base length of 20 welding or
5 grouser 16 replace
6 14
Upper base length of
7 grouser 10
8 12
60-20 PC88MR-10
Track shoe
Road liner (PC88MR-DTLK-034-K-00-A)
Unit: mm
1 Grouser height Replace
42 19
PC88MR-10 60-21
Track shoe
Rubber shoe (PC88MR-DTLJ-041-K-00-A)
(if equipped)
Unit: mm
1 Wear of lug height
30 5
2 Wear of roller guide 42 58 Replace
Wear of sprocket mesh Tolerance
3 dimension
part
22.5 ±0.5 27
60-22 PC88MR-10
Hydraulic tank
Hydraulic tank (PC88MR-PM30-034-K-00-A)
PC88MR-10 60-23
Main pump
Main pump (PC88MR-C200-034-K-00-A)
60-24 PC88MR-10
Main pump
PC88MR-10 60-25
Main pump
Servo valve (PC88MR-C2B0-034-K-00-A)
60-26 PC88MR-10
Main pump
PC-EPC valve (PC88MR-C2E5-034-P-00-A)
PC88MR-10 60-27
Control valve
Control valve (PC88MR-C030-034-K-00-A)
60-28 PC88MR-10
Control valve
PC88MR-10 60-29
Control valve
Unit: mm
Procedure:
Tightening torque of nut 1. 19.6 to 29.4 Nm {2 to 3 kgm}
1
2. 39.2 to 44.0 Nm {4 to 5 kgm}
3. 58.8 to 73.5 Nm {6 to 7.5 kgm}
Adjust
Procedure:
Tightening torque of nut 1. 9.8 to 14.7 Nm {1 to 1.5 kgm}
2
2. 19.2 to 29.5 Nm {2 to 2.5 kgm}
3. 29.4 to 34.3 Nm {3 to 3.5 kgm}
Free Load at Load at
height x Installed Free
installed installed
3 Piston return spring outside height height
height height
diameter
30.4 N 28.6 N
29 x 18.3 28.5 —
{3.1 kg} {2.9 kg}
30.4 N 28.6 N
4 Suction valve spring 29 x 18.4 28.5 —
{3.1 kg} {2.9 kg}
22.6 N 21.2 N
5 Spool return spring 29 x 17.5 28.5 —
{2.3 kg} {2.16 kg}
27.1 N 25.4 N
6 Spool return spring 41.5 x 19.3 28.5 —
{2.76 kg} {2.59 kg} Replace
44.2 N 41.5 N spring if
{4.51 kg} {4.2 kg} damaged or
34.7 N 32.2 N deformed
{3.5 kg} {3.29 kg}
44.2 N 41.5 N
{4.51 kg} {4.2 kg}
54.6 N 51.6 N
{5.6 kg} {5.26 kg}
54.6 N 51.6 N
{5.6 kg} {5.26 kg}
32.8 N 30.8 N
{3.34 kg} {3.1 kg}
183.7 N 172.5 N
13 Spool return spring 41.3 x 15 33.5 —
{18.7 kg} {17.5 kg}
60-30 PC88MR-10
Control valve
PC88MR-10 60-31
Control valve
Unit: mm
installed installed
1 Valve spring outside height height
height height
diameter
27.6 N 25.8 N
30.9 x 5.2 20 —
{2.8 kg} {2.63 kg}
55.9 N 52.5 N
2 Valve spring 34.4 x 14.4 21.5 —
{5.7 kg} {5.36 kg} Replace
3 Valve spring 20 x 8.4 12 —
{0.7 kg} {0.66 kg} damaged or
2N 1.84 N deformed
4 Check valve spring 28.5 x 5.4 25 —
{0.2 kg} {0.19 kg}
3.9 N 3.68 N
5 Check valve spring 27.2 x 6.9 22 —
{0.4 kg} {0.38 kg}
3.9 N 3.68 N
6 Check valve spring 12.3 x 11.4 10.5 —
{0.4 kg} {0.38 kg}
2N 1.84 N
7 Check valve spring 21.9 x 5 15.8 —
{0.2 kg} {0.19 kg}
60-32 PC88MR-10
Control valve
PC88MR-10 60-33
Control valve
Unit: mm
installed installed
1 Check valve spring outside height height Replace
height height
diameter spring if
2N 1.84 N damaged or
21.9 x 5 15.8 —
{0.2 kg} {0.19 kg} deformed
17.2 N 16.1 N
{1.75 kg} {1.65 kg}
60-34 PC88MR-10
Control valve
PC88MR-10 60-35
Control valve
60-36 PC88MR-10
Swing motor
Swing motor (PC88MR-J610-034-K-00-A)
PC88MR-10 60-37
Swing motor
Unit: mm
installed installed
1 Shuttle valve spring outside height height Replace
height height
diameter spring if
0.9 N 0.72 N damaged or
15.5 x 9 11.5 —
{00.9 kg} {0.07 kg} deformed
1.8 N 1.44 N
2 Check valve spring 33 x 13.8 19.5 —
{0.18 kg} {0.14 kg}
60-38 PC88MR-10
Travel motor
Travel motor (PC88MR-C400-034-K-00-A)
PC88MR-10 60-39
PPC valve (ALL-CW10-001-P-00-A)
Work equipment and swing PPC valve (PC88MR-PL28-034-K-00-A)
60-40 PC88MR-10
PC88MR-10 60-41
Unit: mm
Centering spring installed installed
1 outside height height
(for P3, P4 port) height height
diameter Replace
38.7 x 15.5 34.0 —
{1 kg} {0.8 kg} damaged or
Centering spring 17.7 N 14.1 N deformed
2 42.5 x 15.5 34.0 —
(for P1, P2 port) {1.8 kg} {1.44 kg}
16.7 N 13.3 N
3 Metering spring 26.5 x 8.15 24.9 —
{1.7 kg} {1.36 kg}
60-42 PC88MR-10
Travel PPC valve
Travel PPC valve (PC88MR-C6V0-034-K-00-A)
PC88MR-10 60-43
Travel PPC valve
Unit: mm
installed installed
1 Centering spring outside height height Replace
height height
diameter spring if
48.57 x 108 N 86.3 N damaged or
32.5 — deformed
15.5 {11 kg} {8.8 kg}
26.53 x 16.7 N 13.3 N
2 Metering spring 24.9 —
8.15 {1.7 kg} {1.36 kg}
60-44 PC88MR-10
Blade PPC valve
Blade PPC valve (PC88MR-LTJ0-034-K-00-A)
PC88MR-10 60-45
Blade PPC valve
Unit: mm
Free height Installed Load at Load at
x outside installed Free height installed
1 Centering spring height Replace
diameter height height
spring if
33.88 x 125 N 100 N damaged or
28.4 —
15.3 {12.7 kg} {10.2 kg} deformed
16.7 N 13.3 N
2 Metering spring 22.73 x 8.1 22 —
{1.7 kg} {1.36 kg}
60-46 PC88MR-10
Boom swing PPC valve (PC88MR-L518-034-K-00-A)
PC88MR-10 60-47
Unit: mm
Free height Installed Load at Load at
x outside installed Free height installed
1 Centering spring height Replace
diameter height height
spring if
42.36 x 147 N 118 N damaged or
32.5 —
15.5 {15 kg} {12.0 kg} deformed
16.7 N 13.3 N
2 Metering spring 22.73 x 8.1 22 —
{1.7 kg} {1.36 kg}
60-48 PC88MR-10
Solenoid valve
Solenoid valve (PC88MR-PQPT-034-K-00-A)
PC88MR-10 60-49
Solenoid valve
Attachment flow adjustment EPC valve

a EPC: Abbreviation for Electromagnetic Proportional Control
60-50 PC88MR-10
Anti-drop valve for boom (PC88MR-LA1Q-034-K-01-A)
(Machine with anti-drop valve for boom)
PC88MR-10 60-51
Unit: mm
No. Item Judgment criteria Remedy
Standard dimensions Repair limit
length x Installed Free
installed installed
1 Spool return spring outside height length Replace
height height
diameter (Replace
24.8×16.8 22.5 — damaged or
{5.65 kg} {4.52 kg}
deformed as
24.7 N 18.04 N
2 Spool return spring 19.1×8 13.5 — well)
{2.52 kg} {1.84 kg}
16.5 N 12.1 N
3 Check valve spring 31.90×5.4 26 —
{1.68 kg} {1.23 kg}
60-52 PC88MR-10
Anti-drop valve for arm (PC88MR-LA1B-034-K-01-A)
(Machine with anti-drop valve for arm)
PC88MR-10 60-53
Unit: mm
No. Item Judgment criteria Remedy
Standard dimensions Repair limit
length x Installed Free
installed installed
1 Spool return spring outside height length Replace
height height
diameter (Replace
24.8×16.8 22.5 — damaged or
{5.65 kg} {4.52 kg}
deformed as
24.7 N 18.04 N
2 Spool return spring 19.1×8 13.5 — well)
{2.52 kg} {1.84 kg}
16.5 N 12.1 N
3 Check valve spring 31.90×5.4 26 —
{1.68 kg} {1.23 kg}
60-54 PC88MR-10
Center swivel joint
Center swivel joint (PC88MR-J8E0-034-K-00-A)
Unit: mm
Standard Standard Allowable
Clearance between rotor dimension clearance clearance Replace
1
and shaft
70 0.056 to 0.105 0.111
PC88MR-10 60-55
Cab mount and cab tipping stopper (PC88MR-K138-034-K-00-A)
60-56 PC88MR-10
Work equipment
Work equipment (PC88MR-L410-034-K-00-A)
PC88MR-10 60-57
Work equipment
60-58 PC88MR-10
Work equipment
Unit: mm
Boom Standard Tolerance Standard Allowable
Clearance dimension clearance clearance Replace pin
swing Shaft Hole
1 between
bracket -0.043 +0.063 0.043 to and bushing
mounting pin 140 1.0
and bushing of side -0.106 0 0.169
revolving frame Revol-
and boom ving -0.043 +0.134 0.094 to Replace pin
2 140 1.0 and bushing
swing bracket. frame -0.106 +0.051 0.240
side
Clearance
between
Boom
mounting pin -0.030 +0.100 Replace pin
swing 0.030 to
3 and bushing of 65 1.0 and bushing
bracket -0.100 0 0.200
boom swing
side
bracket and
boom
Inside diameter of
bushing insertion portion +0.03 Build up by
4 on boom swing bracket 75 - - - welding, then
side in joint of boom 0 work
swing bracket and boom
Clearance
between
mounting pin -0.030 +0.174 Replace pin
Boom 0.130 to
5 and bushing of 65 1.0 and bushing
side -0.100 +0.100 0.274
boom swing
bracket and
boom
Inside diameter of
bushing insertion portion +0.03 Build up by
6 on boom side in joint of 80 - - - welding, then
boom swing bracket and 0 work
boom
Clearance between -0.030 +0.174 Replace pin
0.130 to
7 mounting pin and bushing 60 1.0 and bushing
-0.100 +0.100 0.274
of boom and arm
Inside diameter of hole to
+0.03 Build up by
insert bushing on arm - - -
8 75 welding, then
side at joint of boom and 0 work
arm
Clearance between -0.225 -0.062 Replace pin
0.105 to
-0.285 -0.120 0.223
of arm and bucket
-0.03 Build up by
10 65 welding, then
side at joint of arm and -0.06 work
bucket
0.105 to
-0.285 -0.120 0.223
of arm and link
-0.03 Build up by
12 65 welding, then
side at joint of arm and -0.06 work
link
0.131 to
-0.285 -0.094 0.245
of link and bucket
PC88MR-10 60-59
Work equipment
Unit: mm
0.130 to
-0.100 +0.100 0.273
of links
0.105 to
-0.087 +0.080 0.229
of track frame and blade
Unit: mm
Criteria
Width of boss Width of hinge Remedy
No. Item Standard
Standard Standard clearance
Tolerance Tolerance
dimension dimension
0 +0.5 Adjust
393 396.5 3.5 to 5.0 clearance to
Joint of revolving frame -1 0
16 and boom swing bracket U16: – 0.5 mm or
less by using
L16: Insert shims 1.0 mm thick (3) and 0.5 mm thick (2) shims
0 +2
389.5 392 2.5 to 5.0
-0.5 0
L17: Insert shim 1.0 mm thick (1)
Joint of boom swing -
17 R17: Insert shims 1.5 mm thick (1) and 1.0 mm thick (1)
bracket and boom
a Be sure to insert one shim 1.0 mm thick on L17 side.
a Be sure to insert one shim 1.5 mm thick on R17 side.
0 +1.5
75 75 0.5 to 2.0 Adjust
Joint of boom swing -0.5 +0.5 clearance to
18 cylinder and swing 1.0 mm or
U18: Insert shim 1.0 mm thick (1)
bracket less by using
L18: – shims
0 +2 Adjust
75 78 3.0 to 5.5 clearance to
Joint of revolving frame -0.5 0
19 and boom swing cylinder U19: Insert shim 1.0 mm thick (3) 1.0 mm or
less by using
L19: – shims
0 +2
75 77 2.0 to 4.5 Adjust
Joint of boom swing -0.5 0 clearance to
20 bracket and boom L20: Adjust by combining shims 2.0 mm thick (1) and 1.0 mm 1.0 mm or
cylinder thick (1) less by using
R20: — shims
+1
70 ±1.2 71.5 0.3 to 3.7
Joint of boom and boom 0
21 -
cylinder L21: –
R21: Insert shim 1.0 mm thick (1)
0 +1
65 66.5 1.5 to 3.0
Joint of boom and arm -0.5 0
22 -
cylinder L22: —
+1
70 ±1.2 71.5 0.3 to 3.7 Adjust
0 clearance to
Joint of arm cylinder and
23 1.0 mm or
arm L23: Insert shim 1.0 mm thick (2)
less by using
R23: — shims
-0.5 +0.5
220 220 0.5 to 1.5
-1.0 0
24 Joint of boom and arm L24: Adjust by combining shims 1.0 mm thick (1) and 0.5 mm -
thick (1)
R24: —
60-60 PC88MR-10
Work equipment
Unit: mm
Criteria
Width of boss Width of hinge Remedy
No. Item Standard
Standard Standard clearance
Tolerance Tolerance
dimension dimension
0 +1 Adjust
60 61.5 2.5 to 4.5 clearance to
Joint of arm and bucket -0.5 0
25 cylinder L25: — 1.0 mm or
less by using
R25: Insert shim 1.0 mm thick (2) shims
-0.5 +4 Adjust
-1.4 0
26 Joint of arm and bucket L26: — 0.5 mm or
less by using
R26: Adjust by combining shims 0.5 mm thick (20) shims
0
186 — — —
–0.5
27 Joint of arm and link L27: —
+1 +2 Adjust
200 200 -1.0 to 4.0 clearance to
-2 0 1.0 mm or
28 Joint of link and bucket
L28: Insert shim 1.0 mm thick (2) less by using
R28: — shims
— — — — —
L29: —
29 Joint of links
R29: Adjust by combining shims 2.0 mm thick (1) and 1.0 mm
thick (1)
0 +1
75 80 5.0 to 6.5
Joint of track frame and -0.5 0
30 blade cylinder L30: —
0 +1 Adjust
Joint of blade and blade -0.5 0
31 cylinder 1.0 mm or
L31: —
less by using
R31: Insert shim 1.0 mm thick (5) shims
0 +1
61 65 4.0 to 6.0
Joint of track frame and -1 0
32
blade L32: Insert shim 1.0 mm thick (4)
R32: —
*1: Use split-type iron shims.
a The number in ( ) after each shim thickness indicates a rough target quantity of shim to be prepared.
PC88MR-10 60-61
Work equipment
Dimensions of arm (PC88MR-L412-034-K-00-A)

2,100 mm arm
60-62 PC88MR-10
Work equipment
Unit: mm
Tolerance
No. Measuring point Standard dimension
Shaft Hole
-0.030 +0.100
1 — 60
-0.100 0
+1.0
Arm side 71.5
2 0
Cylinder head side 70 ±1.2
-0.030 +0.100
3 60
-0.100 0
+0.5
Boom side 220
0
4
-0.5
Arm side 220
-1.0
5 — 228.2 ±2.0
6 — 239.5 ±1.0
7 — 465.5 ±1.0
8 — 2,100 —
9 — 2,567.9 ±3.0
10 — 1,652.1 ±1.3
11 — 259 ±0.3
12 — 7.6 ±0.5
13 — 395.1 ±0.1
14 — 342 ±0.1
15 — 312.2 —
16 — 1,066.9 —
-0.225 0
17 — 50
-0.285 -0.150
-1.0
Link side 200
-2.0
18
+2.0
Bucket side 200
0
-0.225 0
19 — 50
-0.285 -0.150
-0.5
Arm side 188
-1.0
20
+3.0
Bucket side 211
0
Min. 1,055 ±1.5
21
Max. 1,765 —
PC88MR-10 60-63
Work equipment
1,650 mm arm
60-64 PC88MR-10
Work equipment
Unit: mm
Tolerance
No. Measuring point Standard dimension
Shaft Hole
-0.030 +0.100
1 — 60
-0.100 0
+1.0
Arm side 71.5
2 0
Cylinder head side 70 ±1.2
-0.030 +0.100
3 60
-0.100 0
+0.5
Boom side 220
0
4
-0.5
Arm side 220
-1.0
5 — 142.4 ±2.0
6 — 218.8 ±1.0
7 — 458.6 ±1.0
8 — 1,650 —
9 — 2,093.9 ±3.0
10 — 1,661.2 ±1.3
11 — 258.7 ±0.3
12 — 15.1 ±1.0
13 — 395.1 ±0.1
14 — 342 ±0.1
15 — 312.2 —
16 — 1,066.9 —
-0.225 0
17 — 50
-0.285 –0.150
-1.0
Link side 200
-2.0
18
+2.0
Bucket side 200
0
-0.225 0
19 — 50
-0.285 -0.150
-0.5
Arm side 188
-1.0
20
+3.0
Bucket side 211
0
Min. 1,055 ±1.5
21
Max. 1,765 —
PC88MR-10 60-65
Work equipment
Dimensions of bucket (PC88MR-LBK0-034-K-00-A)
60-66 PC88MR-10
Work equipment
Unit: mm
No. Measuring point Standard dimension Tolerance
1 — 309.8 ±0.5
2 — 38.6 ±0.5
3 — 97.1 deg. —
4 — 312.2 —
5 — 1,057.2 —
6 — 143.7 —
7 — 8 —
8 — 5.2 —
0
9 — 50
-0.15
10 — 60 —
+0.2
11 — 70
0
+2.0
12 — 200
0
13 — 40 —
14 — 71 —
+1.0
15 — 296
0
16 — 18 —
17 — 100 —
18 — 115 —
19 — 95 —
+3.0
20 — 211
0
21 — 40 —
22 — 24 —
23 — 89.3 —
24 — 87.9 —
25 — 60 —
26 — 66 —
PC88MR-10 60-67
Boom cylinder
Boom cylinder (PC88MR-L541-034-K-00-A)
Unit: mm
Clearance between dimension Shaft Hole clearance clearance Replace
1 piston rod and bushing bushing
-0.030 +0.262 0.097 to
65 0.638
-0.076 +0.067 0.338
Clearance between -0.030 +0.174
piston rod support shaft 0.130 to
2 60 1.0
and bushing -0.100 +0.100 0.274
Replace pin or
Clearance between bushing
-0.030 +0.174 0.130 to
3 cylinder bottom support 65 1.0
shaft and bushing -0.100 +0.100 0.274
Tightening torque of
4 961 ± 96.1 Nm {98 ± 9.8 kgm}
cylinder head bolt
Retighten
Tightening torque of 3.33 ± 0.33 kNm {340 ± 34.0 kgm} (width across flats: 70
5 cylinder piston mm)
60-68 PC88MR-10
Arm cylinder
Arm cylinder (PC88MR-L950-034-K-00-A)
Unit: mm
-0.030 +0.163 0.036 to
60 0.539
-0.076 +0.006 0.239
2 60 1.0
and bushing -0.100 +0.100 0.274
Replace pin or
-0.030 +0.174 0.130 to
4 785 ± 78.5 Nm {80 ± 8.0 kgm}
cylinder head bolt
Retighten
PC88MR-10 60-69
Bucket cylinder
Bucket cylinder (PC88MR-LCD0-034-K-00-A)
Unit: mm
-0.030 +0.163 0.036 to
55 0.539
-0.076 +0.006 0.239
2 60 1.0
and bushing -0.100 +0.100 0.274
Replace pin or
-0.030 +0.142 0.110 to
Procedure:
1. Tighten the bolts to 1.18 to 1.37 kNm {120 to 140 kgm}.
Tightening torque of 2. Loosen the bolts to 0 Nm {0 kgm}.
4 cylinder head bolt 3. Tighten the bolts to 0.39 kNm {40 kgm}.
Retighten
4. Angle tighten the cylinder head (rotation amount: 3.5 to
4.5 mm)
60-70 PC88MR-10
Boom swing cylinder
Boom swing cylinder (PC88MR-L561-034-K-00-A)
Unit: mm
-0.030 +0.163 0.036 to
60 0.539
-0.076 +0.006 0.239
Clearance between
-0.030 +0.174 0.130 to
2 piston rod support shaft 65 1.0
and bushing -0.100 +0.100 0.274
Replace pin
Clearance between and bushing
-0.030 +0.174 0.130 to
4 981 ± 98.1 Nm {100 ± 10.0 kgm}
cylinder head bolt
Retighten
PC88MR-10 60-71
Blade cylinder
Blade cylinder (PC88MR-LD11-034-K-00-A)
Unit: mm
-0.030 +0.262 0.097 to
65 0.638
-0.076 +0.067 0.338
2 70 1.0
and bushing -0.104 +0.100 0.278
Replace pin or
-0.030 +0.174 0.130 to
4 1,030 ± 103 Nm {105 ± 10.5 kgm}
cylinder head bolt
Retighten
60-72 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
80 Appendix
9 80 Appendix
PC88MR-10 80-1
80 Appendix
Table of contents

80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Dual pressure switch .......................................................................................................... 80-15
Air conditioner controller ..................................................................................................... 80-16
Compressor....................................................................................................................... 80-17
Condenser ........................................................................................................................ 80-18
Sunlight sensor .................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-26
Input and output signals of the air conditioner controller ......................................................... 80-27
Parts and connectors layout................................................................................................ 80-31
Testing air leakage (duct) .................................................................................................... 80-37
Testing with self-diagnosis function ...................................................................................... 80-39
Testing vent (mode) changeover.......................................................................................... 80-42
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-47
Failure code list related to air conditioner.............................................................................. 80-53
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit.............................................. 80-54
Failure code [879AKB] A/C Recirc Air Temp Sens Short ........................................................ 80-55
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit............................................... 80-56
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit ............................................... 80-58
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-60
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-61
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-62
Failure code [879EMC] Ventilation Damper Malfunction ........................................................ 80-64
Failure code [879FMC] Air Mix Damper Malfunction .............................................................. 80-65
Failure code [879GKX] Refrigerant Press Input Sig Out of Range........................................... 80-66
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-67
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-69
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-72
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-74
Troubleshooting with gauge pressure................................................................................... 80-76
Connection of service tool................................................................................................... 80-79
Precautions for disconnecting and connecting refrigerant piping............................................. 80-81
Handling of compressor oil.................................................................................................. 80-83
80-2 PC88MR-10
80 Appendix
Precautions for refrigerant
Air conditioner components (ALL-K500-001-K-02-A)
Precautions for refrigerant (ALL-K512-012-K-00-A)
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
PC88MR-10 80-3
80 Appendix
Air conditioner component
Air conditioner component (PC88MR-K500-04D-K-00-A)
80-4 PC88MR-10
80 Appendix
1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Outside air temperature sensor
10. Air conditioner unit
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
A. Front vent
B. Rear vent
C. Foot area vent
D. Defroster vent
PC88MR-10 80-5
80 Appendix
E: Recirculation air inlet

F: Fresh air inlet
Specifications (PC88MR-K500-030-K-00-A)
Refrigerant R134a
Refrigerant refill amount (g) 730 ± 50
80-6 PC88MR-10
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle (ALL-K500-042-K-00-A)
Cycle Compression Condensation Expansion Evaporation

(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator's cab In operator's cab
Engine
Location compartment Front of radiator (Built in air conditioner (Built into air
unit) conditioner unit)
Circulates Lowers temperature
By evaporating
refrigerant gas and Condenses and pressure of
refrigerant, absorb
increases its refrigerant to refrigerant liquid and
heat from the air
temperature and discharge heat gas for easy
around the evaporator,
Function pressure so that it absorbed in evaporation with
and cools the
can be liquefied evaporator. throttle. Controls flow
surrounding air.
easily in condenser. (condensation of rate, too.
(Evaporation of
(Compression of refrigerant) (Throttle action of
refrigerant)
refrigerant) refrigerant)
Gas o gas Gas o liquid Liquid, gas o gas
State of Liquid o liquid, gas
refrigerant Adiabatic Constant pressure Constant pressure
Adiabatic expansion
compression change change
PC88MR-10 80-7
80 Appendix
Outline of refrigeration cycle
Outline of refrigeration cycle (ALL-K500-04A-K-00-A)
• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
Compression (Compressor)
• The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
• The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
• The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
• The heat released to the outside from the condenser is called condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency.
• In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
(The condensation pressure varies depending on the condensation temperature of the refrigerant)
Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
• The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
*1: Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
• The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
• The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
Relationship between refrigerant and defective air conditioning

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
80-8 PC88MR-10
80 Appendix
Outline of refrigeration cycle
• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
• If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.
PC88MR-10 80-9
80 Appendix
Air conditioner unit
Air conditioner unit (PC138-K540-041-K-00-A)
80-10 PC88MR-10
80 Appendix
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
C: Hot water inlet
D: Hot water outlet
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan and blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor
8. Mode changeover door
9. FRESH/RECIRC air changeover servomotor
11. Power transistor
12. Evaporator temperature sensor
13. Inner sensor (inside air temperature sensor)
14. Recirculation air filter
a "Doors" are sometimes called "dampers".
Function (PC88MR-K540-042-K-00-A)
• The air conditioner unit consists of evaporator (1) and heater core (2), and is used to cool down or warm
up the air in the cab.
Temperature control
• When the temperature control switch on the machine monitor is operated, the set temperature data is sent
to the air conditioner controller that is located at the rear of the operator's seat. The air conditioner
controller controls air mix servomotor (5) to change the angle of air mix door (6) so that the set
temperature is reached
Over-cooling (Freezing) prevention

• Evaporator temperature sensor (12) varies the resistance of its resistor according to temperature.
• The air conditioner controller converts the change in resistance of evaporator temperature sensor (12) into
the change in voltage to determine the temperature of evaporator (1).
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: See "Testing relays" for details regarding the compressor clutch relay.
Air flow adjustment

• When the air flow adjusting switch on the machine monitor is operated, the set air flow data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) by using power transistor
(11) in order to adjust the air flow.
Vent (mode) changeover

• When a vent selector switch on the machine monitor is operated, mode data is sent to the air conditioner
controller. The air conditioner controller controls vent (mode) changeover servomotor (7) to adjust the
opening and closing angles of mode changeover doors so that the selected vents are available.
FRESH/RECIRC air changeover

• When the FRESH/RECIRC air selector switch on the machine monitor is operated, the set data of
FRESH/RECIRC air changeover is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (9) to open or close FRESH/RECIRC air
changeover door (10).
PC88MR-10 80-11
80 Appendix
Automatic mode of air conditioner

• Inside air temperature sensor (13) detects the temperature inside operator's cab based on changes in
resistance. The air conditioner controller converts the change in resistance of inside air temperature
sensor (13) into the change in voltage to determine the room temperature.
The air conditioner controller checks the voltage of inside air temperature sensor (13) and controls the
room temperature so that it matches the setting made on the machine monitor.
The air conditioner controller also takes into consideration data from the sunlight sensor and the outer
sensor (outside air temperature sensor) when adjusting the room temperature.
Functions of major components (ALL-K540-001-K-00-A)
a For details of the numbers in the following sentence, see “Air conditioner unit”.
Evaporator (ALL-K549-042-K-00-A)
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3).
• Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.
Heater core (ALL-K547-042-K-00-A)

• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through fins of the heater core (2).
Evaporator temperature sensor (PC138-K5FF-042-K-00-A)

• Evaporator temperature sensor (12) is installed to evaporator (1) with the holder. Its resistance changes in
accordance with the temperature change of the evaporator. The air conditioner controller determines the
temperature of evaporator (1) from voltage changes of evaporator temperature sensor (12) to prevent
freeze of the evaporator.
Servomotor (ALL-K5D2-042-K-00-A)
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.
• When a switch on the machine monitor is operated, the air conditioner controller applies 24V power
between servomotor terminal B (6) and servomotor terminal A (7). (Rotation direction switches according
to the polarity of supply voltage.) )
• The servomotor contains a variable resistor, and its resistance value changes as the motor rotates.
• The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor
rotation angle from the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the air conditioner controller cannot recognize the potential difference that corresponds to the
command to the servomotor, it generates a air conditioner failure code to inform the machine monitor of
failure in air conditioner system. Failure code [879EMC] or [879FMC] is displayed on the electrical system
failure record screen of the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
80-12 PC88MR-10
80 Appendix
a Do not try to drive a servomotor by supplying power directly between servomotor terminals (6) and (7)
during inspection.
Expansion valve (ALL-K548-041-K-00-A)
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Structure
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).
Function (ALL-K548-042-K-00-A)
• The expansion valve (1) converts high-pressure and high-temperature liquid refrigerant from the receiver
drier to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).
PC88MR-10 80-13
80 Appendix
Operation (ALL-K548-044-K-00-A)
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).
When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve
(1a) is moved rightward by the reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)
80-14 PC88MR-10
80 Appendix
Dual pressure switch
Dual pressure switch (ALL-K5FG-044-K-00-A)
a The dual pressure switch is mounted on the air conditioner hose under the floor.
• The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay "OFF". As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function (ALL-K5FG-042-K-00-A)
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC88MR-10 80-15
80 Appendix
Air conditioner controller
Air conditioner controller (ALL-K5G4-041-K-00-A)
a See "System Diagrams" for details regarding input/output signals.
80-16 PC88MR-10
80 Appendix
Compressor
Compressor (ALL-K590-041-K-00-A)
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Specification (ALL-K590-044-K-00-A)
Number of cylinders - Bore x Stroke (mm) 10 - 32 x 20.8

Piston capacity (cc/rev) 157.3
Max. allowable speed (rpm) 6,000
Compressor oil DENSO: ND-OIL8 (For R134a)
Compressor oil refill capacity (cc) 180
Function (ALL-K590-042-K-00-A)
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When magnetic clutch (2) is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.
PC88MR-10 80-17
80 Appendix
Condenser
Condenser (PC400-K580-041-K-00-A)
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to receiver drier)
Specification (PC400-K580-030-K-00-A)
Fin pitch (mm) 4.0

Height x width x thickness (mm) 357 x 540 x 16
Max. working pressure (MPa {kg/cm2}) 3.6 {36}
Function (PC400-K580-042-K-00-A)
• The condenser cools and liquefies the high pressure and high temperature misty refrigerant sent from the
compressor.
a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction
of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pressure in the refrigerant circulation circuit will be increased,
applying extra load to the engine or reducing the cooling effect. Take extreme care not to crush or damage
the fins when hangling it or performing daily inspection.
80-18 PC88MR-10
80 Appendix
Condenser
Receiver drier (PC400-K5E2-041-K-00-A)
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to air conditioner unit)
Function (PC400-K5E2-042-K-00-A)
• The receiver drier temporarily stores the high pressure and high temperature liquid refrigerant from the
condenser so that it can be supplied to the evaporator according to the need of cooling.
• It sends the stored refrigerant from its bottom to the evaporator, allowing the refrigerant to be liquefied
completely ever when it contains bubbles due to the lower heat dissipation of the condenser.
• The built-in filter and desiccating agent eliminate foreign substances in the circulation circuit and water
content in the refrigerant.
Specification (PC400-K5E2-044-K-00-A)
Effective volume (cc) 370
Weight of desiccating agent (g) 290
PC88MR-10 80-19
80 Appendix
Sunlight sensor
Sunlight sensor (ALL-K5FH-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K5FH-042-K-00-A)
• The sunlight sensor is mounted on top of the machine monitor.

• It detects the strength of incident sunlight and sends signals to the air conditioner controller.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
80-20 PC88MR-10
80 Appendix
Outer temperature sensor (outside air temperature
sensor)
Outer temperature sensor (outside air temperature sensor) (ALL-K55C-041-K-00-A)
1. Connector
2. Sensor
Function (PC138-K55C-042-K-00-A)
• The outside air temperature sensor is installed on the top of the battery.
• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller determines the ambient temperature by converting the changes in the
resistance of the outer sensor resistor into voltage changes.
• Only when the air conditioner is on AUTO mode, the air conditioner controller controls the blower motor
and the air mix servomotor with the data of the outer sensor in order to adjust the temperature and air flow.
PC88MR-10 80-21
80 Appendix
Procedure for testing and troubleshooting
Procedure for testing and troubleshooting (ALL-K500-422-K-00-A)
The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air
conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air
conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with
the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
80-22 PC88MR-10
80 Appendix
Procedure for testing and troubleshooting
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no
refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC88MR-10 80-23
80 Appendix
Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins (PC88MR-K500-051-K-00-A)
80-24 PC88MR-10
80 Appendix
Circuit diagram and arrangement of connector pins
a Diffuser servomotor means vent (mode) changeover servomotor.

a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.
PC88MR-10 80-25
80 Appendix
System diagram
System diagram (PC88MR-K5F0-051-K-00-A)
a This air conditioner unit is auto temperature control type.
80-26 PC88MR-10
80 Appendix
Input and output signals of the air conditioner controller
Input and output signals of the air conditioner controller (ALL-K5G4-03C-K-00-A)
Controller connector: AMP 025 - 32PM

Wiring harness connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply (5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA Fresh/recirculated air servomotor terminal A Output
14 MRFB Fresh/recirculated air servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
Function (ALL-K5G4-042-K-00-A)
• Operation of air conditioner controller

1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
PC88MR-10 80-27
80 Appendix
Input and output signals of the air conditioner controller
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the air conditioner controller controls the inside (air)
temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor,
the outside air temperature sensor, and the inside air temperature sensor.
8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the controller
notifies it to the machine monitor by the CAN communication. Then, failure code [879***] is displayed on
the "Electrical Systems" screen of the electrical system on the machine monitor.
80-28 PC88MR-10
80 Appendix
Air conditioner unit (PC88MR-K500-04D-K-02-A)
1. Foot door
3. Inner sensor (inside air temperature sensor)
PC88MR-10 80-29
80 Appendix
4. Expansion valve
A: Recirculation air port
B: Fresh air port
ACECU: Control amplifier connector

[1]: Blower (fan) motor connector
[2]*: Power transistor (PTR) connector
[3]*: Blowing out (Mode) servomotor connector
[4]*: Temperature control (air mix) servomotor connector
[5]: FRESH/RECIRC air changeover servomotor connector
[6]: Inner sensor (inside air temperature sensor) connector
[7]: Evaporator temperature sensor connector
*: Although shown in the circuit diagram, these connectors cannot be seen from outside.
a Connectors [1], [5], and [7] also cannot be seen with the air conditioner unit assembled.
80-30 PC88MR-10
80 Appendix
Parts and connectors layout
Parts and connectors layout (PC88MR-K500-055-K-00-A)
• Three fuses related to the air conditioner are located in the fuse box at the rear left of the operator's seat.
• The air conditioner unit is installed in the rear cover at the rear side of the operator's seat.
k Park the machine on a level surface, lower the work equipment to the ground so that it is stable,
k Turn the battery disconnect switch to "OFF" position, and remove the key.
a Note the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Item to be
Connector No. Remarks Location
referred
AC01 Intermediate connector Rear left of the cab 2.
AC02 Intermediate connector Rear left of the cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Air conditioner controller Rear left of the cab 2.
CM01* Machine monitor Front side of the cab 5.
CM02 Machine monitor Front side of the cab 5.
CM04* Machine monitor Front side of the cab 5.
F01 Fuse box Rear left of the cab 1.
P17 Dual pressure switch Under cab 6.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear left of the cab 2.
[1] Blower motor Air conditioner unit –
[2] Power transistor Air conditioner unit 3.
[3] Vent (mode) servomotor Air conditioner unit –
[4] Temperature control (air mix) servomotor Air conditioner unit –
[5]* FRESH/RECIRC air changeover servomotor Air conditioner unit 3.
[6]* Inside air temperature sensor Air conditioner unit 3.
[7]* Evaporator temperature sensor (frost sensor) Air conditioner unit 3.
*: Connectors not identified in the troubleshooting
Details (PC88MR-K500-04D-K-01-A)
1. Fuses in fuse box F01

Open the cover of fuse box at the rear left of the operator's seat.
• No. 10 (20 A): Fuse for power supply to blower (fan) and air conditioner compressor
• No. 14 (5 A): Fuse for air conditioner unit, air conditioner controller and primary side power supply of
electromagnetic clutch relay of air conditioner compressor
• No. 19 (5 A): Fuse for power supply (backup power supply) to air conditioner controller

1) Remove covers (1) and (2) in the rear side of the operator's seat.
PC88MR-10 80-31
80 Appendix
2) Disconnect connectors M04, M13A and M13B in the backside.
• AC01: Air conditioner unit connector for connecting machine monitor and CAN communication
(communication lines shared with engine controller and pump controller), compressor, pressure switch,
sunlight sensor, ambient temperature sensor, and relay (primary side)
• AC02: Air conditioner unit connector for power supply, ground, and relay (secondary side)
• ACECU: Air conditioner controller connector
• R21: Air conditioner compressor solenoid clutch relay connector
80-32 PC88MR-10
80 Appendix

1) Remove floor mat (3).
2) Remove covers (4) and (5).
3) Remove pin (P1) and remove ducts (D1) to (D4).
PC88MR-10 80-33
80 Appendix
4) By using bolt (B), raise seat bracket (6).

• A/C U: Air conditioner unit
[6]: Inside air temperature sensor connector
4. Sunlight sensor
P31: Sunlight sensor connector
5. Machine monitor
• CM01 to CM04: Machine monitor connector
a Connector CM04: (for camera connection)
80-34 PC88MR-10
80 Appendix
6. Dual pressure switch

1) Remove cover (7).
2) Disconnect wiring harness clamp (8).

3) Remove toolbox (9).
• P17: Pressure switch connector
7. Air conditioner compressor
PC88MR-10 80-35
80 Appendix
a Open the engine hood.

• ACC: Air compressor
• AC03: Air conditioner compressor connector
• E: Ground
8. Outer temperature sensor (outside air temperature sensor)

Open the cover on the rear left side of the machine.
P18: Outside air temperature sensor connector
80-36 PC88MR-10
80 Appendix
Testing air leakage (duct)
Testing air leakage (duct) (ALL-K5D0-001-K-00-A)
k Place the machine on a level ground, lower the work equipment to the ground and stop the engine.
k Turn the battery disconnect switch to the OFF position and remove the key.
Testing (PC88MR-K5D0-360-K-00-A)
1. Remove front window (1).

2. Remove front mat (2).
3. Remove cover (3) from the machine monitor.
5. Remove rear covers (6) to (8).
6. Check the below ducts.

1) Check rear duct (9) for disconnection.
2) Check pin (P) and fresh air duct (10) for disconnection.
3) Check pin (P1), defroster duct (11) and face duct (12) for disconnection.
4) Check defroster duct (13) for disconnection.
PC88MR-10 80-37
80 Appendix
Testing air leakage (duct)
80-38 PC88MR-10
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function (ALL-Q19Y-001-K-00-A)
Testing outline (ALL-Q19Y-360-K-00-A)
The air conditioner controller performs various self-diagnosis such as inside air temperature sensor, outside
air temperature sensor, evaporator temperature sensor, temperature control system, vent (mode) changeover
system, sunlight sensor, and refrigerant pressure with the dual pressure switch. If an error is detected on the
temperature control system, vent (mode) changeover system, or refrigerant, the machine monitor
momentarily shows a warning screen and then "Air conditioner system state monitor" lights up continuously.
a The machine monitor displays the system state monitor "!" when an error occurs in the communication
between the machine monitor and the air conditioner controller.
a The system performs self-diagnosis of various sensors. If any failure is detected, a failure code is
displayed on the "Electrical Systems Abnormality Record" screen in the service mode of the machine
monitor.
a Once a failure is detected in the self-diagnosis, the error condition is not canceled even if the failed part
returns to normal.
Turning the starting switch "OFF" clears a failure.
a FRESH/RECIRC air changeover servomotor is not checked in the self-diagnosis.
How to open the electrical system abnormality record screen in service mode
of the machine monitor (PC220-Q19Y-100-K-00-A)
• Overview of machine monitor operating procedure
Standard screen
Press [1], [2], and [3] in this order while holding down O [4].
Service menu (Mode)
Press O [F3] twice. Press [F6].
03 Abnormality Record
Press O [F3] once. Press [F6].
02 Electrical systems abnormality record screen
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. Validate the selection by pressing [F6].
PC88MR-10 80-39
80 Appendix
3. Press [F3] twice on the Service Menu screen to select 03 "Abnormality Record".
5. Press [F3] once on the Failure Record screen to select 02 "Electrical System Abnormality Record".
a For details, see the failure code list related to air conditioner.
Failure code Failure (Displayed on screen) Remarks
Air Conditioner Inner Sensor Open
879AKA
Circuit
*
Air Conditioner Inner Sensor Short
879AKB
Circuit
Air Conditioner Outer Sensor Open
879BKA
Circuit
Air Conditioner Outer Sensor Short
879BKB
Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
Sunlight Sensor Open or Short
879DKZ
Circuit
80-40 PC88MR-10
80 Appendix
Failure code Failure (Displayed on screen) Remarks

879EMC Ventilation Damper Abnormality *
879FMC Air Mix Damper Abnormality *
879GKX Refrigerant Abnormality
Air Conditioner Model Selection
DAZ9KQ Abnormality See Chapter 40, "Troubleshooting
CAN2 Disconnection (Air by failure code" **
DAZQKR Conditioner ECU)
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector
cannot be checked.
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
PC88MR-10 80-41
80 Appendix
Testing vent (mode) changeover
Testing vent (mode) changeover (ALL-K5FR-001-K-00-A)
Testing (PC88MR-K5FR-360-K-00-A)
The vents (mode) are switched by changing the angle of the 2 doors (dampers) at the inside of the air
conditioner unit and the door (damper) inside the duct. The angles of the doors (dampers) are changed by
using a mode changeover servo motor but this motor cannot be seen from the outside. The mode changeover
servo motor is still not visible from the outside even when the air conditioner unit is removed. Therefore,
visually check the opening and closing of the foot door (damper) and the lever angle of the defroster/face
changeover door (damper) in the duct.
a To reset the self-diagnosis system (to clear the "A/C Controller Error" displayed on the air conditioner
screen of the machine monitor), the starting switch must be turned OFF (While "A/C Controller Error" is
displayed with self-diagnosis system, no signals are output to the servomotor).
1. Remove front window (1).
2. Remove floor mat (2).
3. Remove covers (3) to (5).
4. Check the connection of cable (6) and lever (L).

(Check whether it is securely in place.)
5. Check clip (7) for coming off.
6. Start the engine and turn on the air conditioner power.
7. Press the vent selector switch on the air conditioner screen of the machine monitor to change the mode,
and visually check that lever (L) moves smoothly between face mode (F) and defroster mode (D) shown in
the figure.
8. Press the vent selector switch on the air conditioner screen of the machine monitor to change the mode,
and visually check that foot door (8) opens and closes.
9. Stop the engine.
80-42 PC88MR-10
80 Appendix
Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover (ALL-K5D2-001-K-00-A)
Testing (PC88MR-K5D2-360-K-00-A)
FRESH/RECIRC air is selected by changing the FRESH/RECIRC air changeover door (damper) angle in the
air conditioner unit with the FRESH/RECIRC air changeover servo motor. Check the opening and closing
operation of the door visually.
a The system does not have self-diagnosis function for FRESH/RECIRC air changeover servo motor.
1. Open cover (1) and remove outside air filter (2).
2. Start the engine and turn on the air conditioner power.

3. Press FRESH/RECIRC air selector switch on the machine monitor's air conditioner control screen, and
then check the opening and closing operation of FRESH/RECIRC air changeover door (4) by using mirror
(3).
a As the connector for FRESH/RECIRC air changeover servo motor is located on the floor of the air
conditioner unit, its connection condition cannot be checked.
PC88MR-10 80-43
80 Appendix
Testing sunlight sensor
Testing sunlight sensor (PC220-K5FH-001-K-00-A)
Testing (PC88MR-K5FH-360-K-00-A)
1. Remove the machine monitor cover. For details, see "Testing air leakage (duct)".
2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.)
3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals
on the sensor side using a circuit tester in voltage range.
• Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
80-44 PC88MR-10
80 Appendix
Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant (PC220-K5FG-001-K-00-A)
Testing (PC88MR-K5FG-360-K-00-A)
• If [879GKX] "Refrigerant Press Input Sig Out of Range" is displayed by the self-diagnosis (on "03 Air-
conditioning System" screen of "Abnormality Record" in the machine monitor), test the dual pressure
switch connector P17.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
• The dual pressure switch is ON when the refrigerant pressure is normal, and OFF when it is abnormal.
a If ambient temperature drops to 0 °C or below, refrigerant pressure will also subsequently decrease.
Accordingly, there is a possibility that the dual pressure switch is OFF. In such a case, the dual pressure
switch unit is not defective but normal.
1. Referring to "Parts and connectors layout" "6. Dual pressure switch", remove the tool box.
2. Disconnect the dual pressure switch connector P17.
3. Check if the resistance between the switch-side terminals of connector P17 are shorted (ON). (If not
shorted (OFF), dual pressure switch is detecting an abnormal refrigerant pressure.)
a If the dual pressure switch is OFF, attach a pressure gauge to the high-pressure line of the air
conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and
"Troubleshooting with gauge pressure".
a If the refrigerant pressure is normal, the dual pressure switch is defective.
• (Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC88MR-10 80-45
80 Appendix
Testing (dual) pressure switch for refrigerant
k When replacing the dual pressure switch, refrigerant must be collected in advance.
a If resistance between the switch-side terminals from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant system".
80-46 PC88MR-10
80 Appendix
Testing relays
Testing relays (PC220-K5FE-001-K-00-A)
Testing (PC88MR-K5FE-360-K-00-A)
a If air conditioner compressor is normal (air is cooled), skip the test.

• Compressor clutch relay R21:
Turns the air conditioner compressor (clutch) ON/OFF.
a See Step 2 in "Parts and connectors layout".
1. Check the condition of contact of connector R21. (Check whether it is securely in place.)
2. Turn the starting switch ON (engine stopped), turn on the main power to the air conditioner, then turn the
air conditioner switch ON. The compressor relay is turned on if the air conditioner status is normal. Check
that a click is heard.
a The air conditioner controller will not turn on the compressor clutch relay in the following cases.
• When the evaporator temperature is 3 °C or below (indicated by the evaporator temperature sensor)
• When the dual pressure switch detects abnormal pressure (the dual pressure switch is OFF)
• Checking relay unit

a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil
actually.
Compressor clutch relay (R21), air conditioner compressor connector (AC03)
• Coil resistance between terminals (1) and (2) is 300 to 500 z
• While voltage (20 to 30 VDC) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are
connected.
• While voltage (20 to 30 VDC) is applied between terminals (1) (+) and (2), terminals (3) and (5) are
connected.
PC88MR-10 80-47
80 Appendix
Troubleshooting chart 1
Troubleshooting chart 1 (PC220-3840-421-A-00-A)
Numbers in T represent the item numbers in the troubleshooting quick reference table.
1. Lowered cooling performance
2. Lowered heating performance
80-48 PC88MR-10
80 Appendix
Troubleshooting chart 2 (PC220-3840-421-A-01-A)
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check the connector for disconnection. Repair broken parts
Wire breakage or defective and connect
connection See "Parts and connectors layout". correctly
Operate the fan switches in order and check the fan
Defective blower fan motor speed. Replace
See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check duct joints.
Repair
joints See "Testing air leakage (duct)".
Obstruction at evaporator Check evaporator for stain and obstruction Remove obstruction
inlet and clean
Defective evaporator Evaporator is frozen.
temperature sensor, Sensor fixing clip inspection, sensor contaminated
defective contact of Repair or replace
evaporator temperature Inspect the air conditioner hose around the pressure
switch for frost.
sensor, defective expansion
valve* (when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass. refrigerant again
Specifically, perform checking with the gauge manifold Collect refrigerant,
connected. then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/
cm2 }
Judgment by pressure at See Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2 with gauge pressure
}
Temperature in operator's cab: 30 to 35 °C , Engine
speed: Approx. 1,500 rpm
PC88MR-10 80-49
80 Appendix
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
part
Deflection of belt is large.
Compressor See "Checking and adjusting air
belt
Slack of belt conditioner compressor belt tension" in Adjust tension
the "Testing and adjusting" in Chapter
30.
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 to 20 z) Replace
Magnet
Check ground cable and joints.
clutch Wire breakage or defective
connection of ground wire See "Troubleshooting for compressor Repair
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging.
engine coolant Bleed air and correct
(Hose, pipe and core)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
See "Replacing fan belt" in "Testing and adjusting" in
Fan speed is low Replace
Chapter 30.
80-50 PC88MR-10
80 Appendix
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Select manual mode and change temperature setting.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible. and heating
FRESH/RECIRC air cannot
See "Testing FRESH/RECIRC air changeover".
be changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
PC88MR-10 80-51
80 Appendix
Information in troubleshooting table
Information in troubleshooting table (ALL-5170-421-A-03-A)

Information in troubleshooting table
Failure Failure symptom that appears on machine
Related information Information on occurred failure or troubleshooting
Cause Procedure, measuring location, criteria and remarks
[Information described]
• Procedure
• Measuring location
1
a "Between A and B" denotes measuring voltage or resistance, etc.
Probable cause of failure between A and B.
(Perform troubleshooting • Criteria to determine probable causes
according to these.) • Remarks for judgment of Good or No good
[Notes on troubleshooting]
2 (1) pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) tester leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (-) lead to a pin or harness indicated in the
rear.
3 Defective — (2) Example of troubleshooting done by testing multiple items
a Normal in 1 but abnormal in 2
At this time, "Defective component" shown at left 3 is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit
accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with another independent wire. (poor
insulation at connector and others)
Related circuit diagram

This is the extracted circuit diagram related to failure
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location
• The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
• N.C.: Normally closed (Normally ON)
• [1], [2], ... are numbers of unlabeled connectors.
• The arrow (io) indicates their rough installation position on the machine.
80-52 PC88MR-10
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner (PC88MR-K500-441-K-00-A)

Applicable History
code level
nent
A/C Recirc Air Temp Sens Electrical Troubleshooting cannot be
879AKA Open Circuit MON –
system performed while the controller
is mounted on the machine
A/C Recirc Air Temp Sens Electrical
879AKB MON – since the connector cannot
Short system
be checked.
A/C Fresh Air Temp Sens Electrical
879BKA Open Circuit MON –
system
A/C Fresh Air Temp Sens Electrical
879BKB MON –
Short Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot
Circuit system
be checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Short Circuit system
Ventilation Damper Electrical Troubleshooting cannot be
879EMC MON L01 system performed while the controller
Malfunction
Electrical
879FMC Air Mix Damper Malfunction MON L01 since the connector cannot
system
be checked.
Refrigerant Press Input Sig Electrical
879GKX Out of Range MON L01 system
Air Conditioner Model Electrical
DAZ9KQ Selection Abnormality MON –
system See Chapter 40,
"Troubleshooting by failure
CAN2 Disconnection (Air Electrical
DAZQKR Conditioner ECU) MON L01 code" **
system
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover
PC88MR-10 80-53
80 Appendix
Failure code [879AKA] A/C Recirc Air Temp Sens Open
Circuit
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit (PC88MR-879AKA-
400-A-Z0-A)
Action level Failure code Aircon Recirc Air Temperature Sensor Open Circuit
Failure
― 879AKA (Machine monitor system)
Detail of • Air conditioner controller detected open circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of open circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
Related
• Check whether this failure code is displayed on the electrical system abnormality record
information
screen in service mode of the machine monitor.
Defective inside air 2. Disconnect connector [6].
temperature sensor
1 Approx. 1.6
(Replacement of air Between connector [6] (male) (1) and 0 °C
kz
conditioner unit) Resistance (2)
Approx. 5
25 °C
kz
Defective air conditioner Air conditioner controller may be defective. (Since this is an internal defect,
controller
Defective air conditioner Air conditioner unit may be defective. (Since this is an internal defect,
unit
Circuit diagram related to air conditioner inside air temperature sensor
80-54 PC88MR-10
80 Appendix
Failure code [879AKB] A/C Recirc Air Temp Sens Short
Failure code [879AKB] A/C Recirc Air Temp Sens Short (PC88MR-879AKB-400-A-Z0-A)
Action level Failure code Aircon Recirc Air Temperature Sensor Short Circuit
Failure
― 879AKB (Machine monitor system)
Detail of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
Related
information
Defective internal air 2. Disconnect connector [6].
sensor
1 Approx. 1.6
(Defective air Between connector [6] (male) (1) and 0 °C
kz
conditioner unit) Resistance (2)
Approx. 5
25 °C
kz
Defective air conditioner Air conditioner controller may be defective. (Since this is an internal defect,
controller
Defective air conditioner Air conditioner unit may be defective. (Since this is an internal defect,
unit
Circuit diagram related to air conditioner inside air temperature sensor
PC88MR-10 80-55
80 Appendix
Failure code [879BKA] A/C Fresh Air Temp Sens Open
Circuit
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit (PC88MR-879BKA-
400-A-Z0-A)
Action level Failure code Aircon Fresh Air Temperature Sensor Open Circuit
Failure
― 879BKA (Machine monitor system)
Detail of • An open circuit is detected in the air conditioner controller outside air temperature sensor
failure
• The air conditioner controller sends information about the outside air temperature sensor
Action of open circuit to the machine monitor via CAN communication.
controller • When the air conditioner is in Auto mode, the controller continues controlling the air
conditioner irrespective of any data received from the external air temperature sensor.
• Due to an open circuit in the outside air temperature sensor of the air conditioner, external
Problem on air temperature is not taken into consideration for the air conditioner in Auto mode.
machine (The air conditioner is not affected in the manual mode)
• For each connector, see "Parts and connectors layout".
Related • Since T-adapter is not provided for the connector ACECU of the air conditioner controller
information and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
also not provided for the intermediate connector, however, the pin size is larger).
• When replacing the air conditioner wiring harness between connector ACECU of the air
conditioner controller and the intermediate connector, you must replace the entire air
conditioner unit.
Defective outside air 2. Disconnect connector P18.
1 temperature sensor Approx. 1.7
Resistance Between P18 (male) (1) and (2) 25 °C
kz
2. Disconnect connector AC01.
2 wiring harness a If normal, the resistance is the same as above.
Approx. 1.7
Resistance Between AC01 (female) (3) and (4) 25 °C
kz
3 (wire breakage or 2. Disconnect connectors P18 and AC01.
defective contact of Between AC01 (female) (4) and P18A (female) (1) Max. 1 z
Between AC01 (female) (3) and P18 (female) (2) Max. 1 z
If no failures are found by the above checks, the air conditioner controller may
Defective air conditioner be defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air conditioner defective. (Since this is an internal defect, troubleshooting cannot be
5
unit performed.)
80-56 PC88MR-10
80 Appendix
Failure code [879BKA] A/C Fresh Air Temp Sens Open
Circuit
Circuit diagram related to air conditioner outside air temperature sensor
PC88MR-10 80-57
80 Appendix
Failure code [879BKB] A/C Fresh Air Temp Sens Short
Circuit
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit (PC88MR-879BKB-
400-A-Z0-A)
Action level Failure code Aircon Fresh Air Temperature Sensor Short Circuit
Failure
― 879BKB (Machine monitor system)
Detail of • The air conditioner controller detected short circuit in the outside air temperature sensor.
failure
• The air conditioner controller sends information about the short circuit of the outside air
Action of temperature sensor to the machine monitor via CAN communication.
controller • When the air conditioner is in Auto mode, the controller continues controlling the air
conditioner irrespective of any data received from the external air temperature sensor.
• Due to a short circuit in the outside air temperature sensor of the air conditioner, outside
Problem on air temperature is not taken into consideration for the air conditioner in Auto mode.
machine (The air conditioner is not affected in the manual mode)
conditioner unit.
Defective outside air 2. Disconnect connector P18.
1 temperature sensor Approx. 1.7
Resistance Between P18 (male) (1) and (2) 25°C
kz
2. Disconnect connector AC01.
2 wiring harness a If normal, the resistance is the same as above.
Approx. 1.7
Resistance Between AC01 (female) (3) and (4) 25°C
kz
Short circuit in wiring 1. Turn starting switch to OFF position.
3 2. Disconnect connectors P18 and AC01.
harness
Between AC01 (female) (3) and (4), or between
Resistance P18 (female) (1) and (2) Min. 1 Mz
harness 2. Disconnect connectors P18 and AC01.
4
(Contact with ground Between ground and AC01 (female) (4) or P18
5
6
unit performed.)
80-58 PC88MR-10
80 Appendix
Failure code [879BKB] A/C Fresh Air Temp Sens Short
Circuit
Circuit diagram related to air conditioner outside air temperature sensor
PC88MR-10 80-59
80 Appendix
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit (D155-879CKA-400-A-00-A)
Action level Failure code Open circuit in evaporator temperature (frost) sensor
Failure
- 879CKA (Machine monitor system)
Detail of • Air conditioner controller detected open circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor open circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to an open circuit in the evaporator temperature
machine (frost) sensor.
Related screen in service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
Defective air conditioner Air conditioner controller may be defective. (Since this is an internal
1 defect, troubleshooting cannot be performed.)
controller
Air conditioner unit may be defective. (Since this is an internal defect,
2 Defective air conditioner unit troubleshooting cannot be performed.)
80-60 PC88MR-10
80 Appendix
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit (D155-879CKB-400-A-00-A)
Action level Failure code Short circuit in evaporator temperature (frost) sensor
Failure
- 879CKB (Machine monitor system)
Detail of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
controller
PC88MR-10 80-61
80 Appendix
Failure code [879DKZ] Sunlight Sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit (PC88MR-879DKZ-400-

A-Z0-A)
Action level Failure code Sunlight Sensor Open or Short Circuit

Failure
― 879DKZ (Machine monitor system)
Detail of • The air conditioner controller detects open circuit or short circuit in the sunlight sensor
failure
• The air conditioner controller sends information about open or short circuit of the sunlight
Action of sensor to the machine monitor via CAN communication.
controller • When the air conditioner is on Auto mode, the controller continues controlling the air
conditioner neglecting data from the sunlight sensor.
• Due to an open circuit or a short circuit in the sunlight sensor for the air conditioner, the
Problem on amount of sunshine is not taken into consideration for the air conditioner in Auto mode.
machine (The air conditioner in manual mode is not affected by this failure.)
conditioner unit.
1. See "Testing sunlight sensor".
Direct Approx.
Defective sunlight sunlight 0.55 V
1 Approx.
sensor Voltage Between sunlight sensor terminals Cloudy
0.45 V
Approx. 0.4
Indoor
V
harness 2. Disconnect connector P31.
2 (Wire breakage or a See "Testing sunlight sensor".
defective contact of Between P31 (female) (1) and AC01 (female) (1) Max. 1 z
Between P31 (female) (2) and AC01 (female) (2) Max. 1 z
3
4
unit performed.)
80-62 PC88MR-10
80 Appendix
Failure code [879DKZ] Sunlight Sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
PC88MR-10 80-63
80 Appendix
Failure code [879EMC] Ventilation Damper Malfunction
Failure code [879EMC] Ventilation Damper Malfunction (PC88MR-879EMC-400-A-Z0-A)
Action level Failure code Ventilation Damper Malfunction

Failure
L01 879EMC (Machine monitor system)
Detail of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
controller
80-64 PC88MR-10
80 Appendix
Failure code [879FMC] Air Mix Damper Malfunction
Failure code [879FMC] Air Mix Damper Malfunction (PC88MR-879FMC-400-A-Z0-A)
Action level Failure code Air Mix Damper Malfunction

Failure
L01 879FMC (Machine monitor system)
Detail of • The air conditioner controller judged from the potentiometer voltage of the servomotor that
failure the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
Related
information
• Troubleshooting cannot be performed since the connector portion of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
controller
PC88MR-10 80-65
80 Appendix
Failure code [879GKX] Refrigerant Press Input Sig Out
of Range
Failure code [879GKX] Refrigerant Press Input Sig Out of Range (PC88MR-
879GKX-400-A-Z1-A)
Action level Failure code Refrigerant Pressure Input Signal Out of Range
Failure
L01 879GKX (Machine monitor system)
Detail of • Air conditioner controller detected that dual pressure switch was OFF (abnormal).
failure
• The air conditioner controller sends information about the refrigerant pressure abnormality
to the machine monitor via CAN communication.
Action of • The air conditioner controller turns OFF compressor clutch relay, since refrigerant
controller pressure is abnormal.
(The air compressor stops.)
Problem on • The air conditioner (for cooling) does not work.
machine
conditioner unit.
Cause Procedure, measuring location, criteria, and remarks
1. See "Testing (dual) pressure switch for refrigerant".
Defective refrigerant
1 (dual) pressure switch k Before replacing the dual pressure switch, be sure to collect
refrigerant. See "Precautions for refrigerant".
harness 2. Disconnect connectors AC01 and P17.
2 (Wire breakage or Between P17 (female) (1) and AC01 (female) (5) Max. 1 z
defective contact of Resistance Between P17 (female) (2) and ground
connector) Max. 1 z
a Looseness and rust of T06
3
4
unit performed.)
Circuit diagram related to (dual) pressure switch for refrigerant
80-66 PC88MR-10
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)
A-1 Troubleshooting for power supply system (Air conditioner does not
operate) (PC88MR-FJ0-400-A-Z0-A)
Failure Air conditioner does not operate due to power supply system failure.
Problem on • [DAZQKR] is displayed on the operation screen of machine monitor.　
machine • No air blows out (Blower motor does not rotate).
• If failure code [DAZQKR] is displayed on the machine monitor, perform this
troubleshooting first.
a The machine monitor, engine controller, pump controller, and air conditioner controller are
connected via CAN communication.
• [DAZQKR] is displayed on the operation screen of machine monitor in the following
cases. 1) and 2) of these will be covered here.
1. The air conditioner controller is receiving no power.
2. The air conditioner controller is broken.
3. No communication is possible between the air conditioner controller and the machine
monitor.
a For 3), see failure code [DAZQKR].
• Turn the starting switch ON, and check whether failure code [DAZQKR] for an abnormality
Related in CAN communication is displayed. An abnormality in CAN communication refers to the
information state in which CAN communication between the air conditioner controller on the air
conditioner unit and the machine monitor is disabled.
• Referring to "Parts and connectors layout", check fuse No. 14 (5A) in fuse box F01 for
breakage.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system."
• Since T-adapter is not provided for the connector ACECU of the air conditioner controller
and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
conditioner unit.
Defective wiring 2. Turn the battery disconnect switch to OFF position.
1 harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on harness side of connector
Resistance AC02 and chassis ground Max. 1 z

2 Blown fuse 2. Referring to "Parts and connectors layout", check fuse No. 14 (5A) in fuse
box F01 for breakage.
a If fuse described in Related information is blown, replace it.
Defective wiring 3. Disconnect connector AC02.
3
harness 4. Turn battery disconnect switch to ON position.
Between connector AC02 (female) (4) (blue) and 20 to 30 V
Voltage
(1) (black)
PC88MR-10 80-67
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

a If a fuse is blown again in the above test, perform the following procedure.
Ground fault in wiring 1.Turn starting switch to OFF position.
harness 2.Turn the battery disconnect switch to OFF position.
4 3.Disconnect connector AC02.
circuit) 4.Remove fuse No. 14 in fuse box F04.
Between ground and connector AC02 (female) (4)
Resistance (blue) or F01-14 Min. 1 Mz

2.Turn the battery disconnect switch to OFF position.
Open circuit in wiring 3.Disconnect connector AC02.
5
harness 4.Remove fuse No. 14 in fuse box F01.
Between connector AC02 (female) (4) (red) and
Resistance Max. 1 z
F01-14
Defective air conditioner Replace the air conditioner controller.
6
controller
Defective air conditioner If no failure is found by the above checks, the air conditioner unit may be
7
unit defective.
8
monitor
Circuit diagram related to power supply system
80-68 PC88MR-10
80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)
A-2 Troubleshooting for compressor and refrigerant system (Air is not

cooled) (PC88MR-FKE-400-A-Z0-A)
Failure Air is not cooled due to compressor or refrigerant system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine
Problem on monitor, air is not cooled as displayed on screen.
machine • Air conditioner compressor does not operate.
• Referring to inspection by self-diagnosis function, display the "Electrical Systems" screen
on the machine monitor to check whether an inappropriate refrigerant is being used by
confirming that failure code [879GKX] is displayed. If an inappropriate refrigerant is being
used, the compressor will not be turned on, and air will not be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the
dual pressure switch is not grounded".
• In certain cases, the air conditioner will not turn on at 3 °C or lower (normal).
Related • When air does not come out, see "Troubleshooting of blower motor system".
information • For each connector and fuse, see "Parts and connectors layout".
a A T-adapter is provided only for the connector AC03.
conditioner unit.
a This troubleshooting is performed when failure code [879GKX] is
displayed on the "Electrical Systems" screen of the machine monitor.
See failure code [879GKX].
Defective dual pressure a In certain cases, the dual pressure switch may be operating normally and
1 switch system set to OFF position, therefore, if abnormality is indicated (i.e., switch OFF),
attach a pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure.")
k Before replacing pressure switch, collect refrigerant.
2. Disconnect the connector AC03 from the air conditioner compressor and
connect a T-adapter to the male side.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2 compressor (See "Parts and connectors layout".)
Between connector AC03 (male) (1) and the
Approx. 15
Resistance chassis ground (i.e., air conditioner compressor coil
resistance) z
• Referring to "Testing relays", check sound when compressor clutch relay
is turned ON.
Clicking sound is heard: A
a When A above is abnormal and B below is abnormal and C is normal (if
the relay is normal), go to cause 4.
Defective compressor 2. Disconnect connector R21.
3 clutch relay (does not 3. Use a wire to short-circuit (3) (yellow) and (5) (blue) of connector R21
turn ON) (wiring harness side). (This forces the compressor to operate without
using the relay.)
Air is cooled: B
2. Disconnect connector R21 and troubleshoot in that condition.
Between R21 (male) (1) and (2) (coil Approx. 300
Resistance resistance) C
to 500 z
PC88MR-10 80-69
80 Appendix

2. Disconnect connector R21.
a Make sure that result of check of cause 2 is normal (air conditioner
compressor is normal).
Between connector R21 (female) (5) and F01-10
Open circuit in wiring Max. 1 z
4 (Pressure switch is turned ON)
harness
Between connector R21 (female) (3) and chassis
Approx. 15
Resistance ground z
(Air conditioner compressor coil resistance)
Between F01-14 and AC01 (female) (7) 300 to 500
a Relay coil resistance z
Ground fault in wiring a If the fuse is not blown, skip troubleshooting.

5 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the
circuit) female side of AC03.
Resistance Between AC03 (female) (1) and chassis ground Min. 1 Mz
2. Disconnect connectors AC01, AC02, and R21.
6 a Ensure that test result for cause 2 is normal.
harness
Between wiring harness side (2) of connector R21
Resistance and AC02 (female) (2), (3), and (4) Min. 1 Mz

2. Disconnect connector R21.
Defective air conditioner 3. Turn starting switch to ON position.
7 4. Display the air conditioner operation screen on the machine monitor and
controller
press the A/C switch.
Voltage Between connector R21 (female) (2) and ground Max. 1 V
Defective machine 1. Turn starting switch to ON position.
8 monitor 2. Display the air conditioner operation screen on the machine monitor.
(defective switch) Press A/C switch. "A/C ON" is displayed
9
unit defective.
80-70 PC88MR-10
80 Appendix
Circuit diagram related to compressor and refrigerant system
PC88MR-10 80-71
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal) (PC88MR-FK3-400-A-Z0-A)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
• LCD of machine monitor on air conditioner operation screen lights up normally but air
Problem on does not come out.
machine • Air flow does not match fan switch setting on air conditioner operation screen.
• This failure is not checked with self-diagnosis function.
• During cooling, if the air flow becomes abnormal after a certain time, the evaporator may
be frozen.
This may be due to the followings.
1. Defective compressor clutch relay (remains turned ON) (see Item 3-A of
"Troubleshooting for compressor and refrigerant system")
2. Evaporator temperature sensor mounting holder has come off (replace air conditioner
unit).
3. Improper adjustment of expansion valve (replace air conditioner unit)
• When air comes out, fuses and motor are normal, and failure of wiring harness is unlikely.
Related • For each connector and power transistor, see "Parts and connectors layout".
information • When air comes out but air flow is abnormal during heating, the power transistor is
defective. In this case replace the air conditioner unit. (The power transistor may also be
defective when no air comes out.)
a The power transistor and the blower motor cannot be replaced.
conditioner unit.
Defective fuse No. 10 in If fuse is blown, circuit probably has ground fault.
1
fuse box F01
harness 2. Disconnect connector AC02.
2 (wire breakage or 3. Remove fuse No. 10 in fuse box F01.
connector) Resistance Between AC02 (female) (2) and F01-10 Max. 1 z
3
(contact with ground 3. Remove fuse No. 10 in fuse box F01.
circuit) Resistance Between AC02 (female) (2) or F01-10 and ground Max. 1 z
4
5
unit defective.
80-72 PC88MR-10
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
Circuit diagram related to blower motor system
PC88MR-10 80-73
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
A-4 Troubleshooting for FRESH/RECIRC air changeover (PC138-FKF-400-A-Z0-A)
Failure FRESH/RECIRC air changeover does not work.

• When FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or
Problem on fresh air does not change over.
machine (FRESH/RECIRC air changeover door (damper) does not rotate)
• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Referring to "Testing FRESH/RECIRC air changeover", operate the FRESH/RECIRC air
selector switch and check operation of FRESH/RECIRC air changeover door (damper).
a The T-adapter is not prepared for the connector.
Related and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
information also not provided for the intermediate connector, however, the pin size is larger).
conditioner unit.
• Troubleshooting cannot be performed since the connector portion of the servomotor
cannot be checked while it is installed on machine.
Defective fuse No. 19 in If fuse is blown, circuit probably has ground fault.
1
fuse box F01.
2 (wire breakage or 3. Remove fuse No. 19 in fuse box F01.
connector) Resistance Between F01-19 and AC02 (female) (3) Max. 1 z

Between F01-19 and ground, or between AC02
circuit) Resistance (female) (3) and ground Max. 1 z
4
5
unit performed.)
Defective machine 1. Turn starting switch to ON position.
monitor 2. Display the air conditioner operation screen on the machine monitor.
6
(defective switch) Display of Recirc/Fresh
Press FRESH/RECIRC air selector switch. changes.
80-74 PC88MR-10
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
PC88MR-10 80-75
80 Appendix
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure (PC220-3840-362-A-00-A)
Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• Pressure of high-pressure line is too high: Min. approx. 2.5 MPa {25 kg/cm 2}
• Pressure of high-pressure line is too low: Max. approx. 1 MPa {10 kg/cm 2}
• Pressure of low-pressure line is too high: Min. approx. 0.3 MPa {3 kg/cm 2}
• Pressure of low-pressure line is too low: Max. approx. 0.05 MPa {0.5 kg/cm 2}
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-pressure line is abnormal.
[Measurement condition for pressure]
Item Condition value
Ambient temperature 25 to 50 °C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Cool-Max
• Dual pressure switch
a The switch is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-76 PC88MR-10
80 Appendix
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If any problem (poor cooling) is recognized, the cause
is in other system.
Pressure is normal Pressure of high-pressure line: Approx. 1.5 to -1.7 ―
MPa {15 to 17 kg/cm2}
Pressure of low-pressure line: Approx. 0.13 to 0.2
MPa {1.3 to 2.0 kg/cm2}
Collect refrigerant, then fill
Bubbles can be seen
Insufficient refrigerant up with proper quantity of
through sight glass. *1, *3
refrigerant again. *2
Temperature difference is
recognized between inlet
Clogging of receiver drier and outlet pipes of Replace *2
receiver drier.
Tank is frosty.
Clogging of expansion Expansion valve is frosty. Clean or replace *2
valve
Gas leakage at
<Pressure of both high- Low-pressure line gauge Replace *2
thermoprobe of expansion
pressure and low- reads vacuum.
valve
pressure lines are too
Evaporator is frozen.
low>
Flow rate of refrigerant is Repair or replace
Low-pressure line gauge Defective evaporator
reduced due to freezing.
reads vacuum temperature sensor or Replace receiver drier.
defective contact of (If air conditioner is set to
sensor (coming off of Cool Max. and HI fan
up with proper quantity of
mounting clip) speed modes, later its
cooling performance
lowers.)
Piping between receiver
drier and compressor is
clogged or crushed.
Clogged or crushed piping Clean or replace *2
If clogged completely, low-
pressure line gauge reads
vacuum
Filling of too much
Connect gauge manifold. up with proper quantity of
refrigerant
Check condenser for dirt, Clean condenser, repair
Defective cooling of fins for clogging or fins, or repair or replace
condenser crushing, and cooling fan cooling fan *2
<Pressure of both high- for defective rotation.
pressure and low- Defective adjustment of
pressure lines are too expansion valve Bubbles can be seen
high> Replace *2
(Valve is excessively through sight glass. *3
opened.)
Evacuate air from air
Air sucked in cooling Bubbles can be seen conditioner and then fill up
cycle parts through sight glass. *3 with proper quantity of
PC88MR-10 80-77
80 Appendix
Indicated gauge pressure Cause Check method Remedy

<Pressure of high- Piping between Remarkable temperature Clean inside of cooling
pressure line is too high compressor and difference is recognized cycle parts or replace
and that of low-pressure condenser is Clogged or across clogged part. them.*2
line is too low> crushed.
Pressures of high-
pressure and low-
<Pressure of high- pressure lines are almost
Defective compressor
pressure line is too low the same while
(compression trouble of Replace *2
and that of low-pressure compressor is running.
compressor)
line is too high>
Compressor has seized
and is extremely hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for
refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant.
*3: Sight glass is on the air conditioner hose near the condenser.
80-78 PC88MR-10
80 Appendix
Connection of service tool
Connection of service tool (PC300-K500-061-K-00-A)
k Park the machine on a level surface, lower the work equipment to the ground so that it is stable,
k Turn the battery disconnect switch to OFF position, and remove the key.
a Following service tool kit is used for work with refrigerant R134a.
Symbol Part No. Part name
X 799-703-1200 Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): Red high-pressure line charging hose
(3): Blue low-pressure line charging hose
(4): Large diameter quick joint (for high-pressure line)
(5): Small diameter quick joint (for low-pressure line)
(a): Note that the threads are coarse and the hoses are relatively easy to loosen.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect red high-pressure line charging hose (2) to the gauge manifold (HI side) and blue low-pressure
line charging hose (3) to the gauge manifold (LO side).
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
PC88MR-10 80-79
80 Appendix
Connection of service tool
A: From operator's cab

B: To condenser
80-80 PC88MR-10
80 Appendix
Precautions for disconnecting and connecting
refrigerant piping
Precautions for disconnecting and connecting refrigerant piping (PC88MR-

K5B0-924-K-00-A)
k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier,
etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered persons can work.)
a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and
working clothes with long sleeves while collecting the refrigerant or filling the air conditioner
circuit with the refrigerant.
Disconnection
k Although the refrigerant (air conditioner gas: R134a) used on the machine's air conditioner is less
destructive to the ozone layer for environmentally friendliness, it is not allowed to be released into
the atmosphere as is. Whenever disconnecting the air conditioner gas circuit, be sure to recover
the refrigerant gas to reuse it.
a Ask a qualified person for collection and charge of the refrigerant (air conditioner gas: R134a).
a Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k If the refrigerant (air conditioner gas: R134a) gets in your eyes, you may lose your sight. Also, if
your skin is exposed to the gas, you may suffer from frostbite. Accordingly, put on protective
eyeglasses, gloves and working suits with long sleeves while you are collecting or filling
refrigerant.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
• For the disconnected air conditioner piping, plug ends to prevent dirt, dust, and water from entering the
hose.
Connection
• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it.
• When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil (ND–OIL8) for refrigerant (R134a) to the O-ring. (See item 4 of "Handling of
compressor oil".)
a However, do not apply oil to the threaded portion of a bolt, nut or union.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench
to fix and tighten the nut with the other wrench to the specified torque (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.
PC88MR-10 80-81
80 Appendix
Precautions for disconnecting and connecting
refrigerant piping
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque: Nm {kgm}
8 to 12 {0.8 to 1.2} (compressor)
M6 x 1.0
4 to 7 {0.4 to 0.7} (condenser)
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
80-82 PC88MR-10
80 Appendix
Handling of compressor oil
Handling of compressor oil (PC88MR-K594-212-K-00-A)

Check compressor oil amount
• Although compressor oil (ND–OIL8) differs from engine oil in that it does not need frequent checking or
filling, the following types of problem can occur if the amount in the system is excessive or too insufficient.
Condition Content
Insufficient oil Lubrication trouble and seizure of compressor
Lowered cooling performance
Excess oil
(Excess oil stick to parts and lower heat exchange performance)
• Accordingly, compressor oil (ND–OIL8) must be filled to the specified level, similarly to refrigerant.
Filling of compressor oil

a Refrigerant may be dangerous if not handled with care. Discharging refrigerant into the atmosphere is
harmful to the environment. Before disconnecting air conditioner hoses, refer to "Precautions for
disconnecting and connecting refrigerant piping" and ask a qualified person for the work.
a If oil for use with CFC–12 (R–12) is used, lubrication trouble will occur and the compressor may be broken
or seized. Be sure to use the oil (ND–OIL8) for R134a.
a Oil (ND–OIL8) for use with R134a is extremely hygroscopic, and therefore, put the cap the oil container
immediately after use to limit contact with air.
Avoid damp places for storage and store the oil can in a ventilated place.
a Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (except
a baked finish) as it may dissolve these plastics.
If any of the following is true, check the oil level and add oil as necessary.
• Refrigerant is lost in a short time due to a large leakage.
• The compressor had a problem and was replaced.
(Refer to "Replacement of compressor" in this section.)
• Component(s) of the refrigeration cycle such as air conditioner unit, condenser, modulator, or refrigerant
pipings has been changed.
Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added
Air conditioner unit, evaporator Approx. 40 cc
Condenser Approx. 40 cc
Receiver drier Approx. 20 cc
Hose (between compressor and cab) Approx. 25 cc
Hose (between compressor and condenser) Approx. 5 cc
Hose (between cab and receiver drier) Approx. 10 cc
Replacement of compressor
In case of compressor seizure or breakage
• Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
• Flush the refrigerant circuit and replace the compressor and condenser (modulator).
PC88MR-10 80-83
80 Appendix
Handling of compressor oil
• Compressor oil will be drained from the air conditioner circuit by flushing.
• Install the new compressor, which is filled with the specified capacity (180 cc) of compressor oil.
Other cases
a A new compressor is filled with 180 cc of compressor oil.
1. Prepare an oil container and drain oil from the old compressor.
2. Measure the quantity of the drained oil with a measuring cylinder, and note the quantity.
3. Drain below-mentioned quantity of oil from the new compressor.

Quantity to be drained = 180 cc - "Noted quantity"
Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new
compressor would be 150 cc (i.e., 180 - 30 cc).
Applying compressor oil to O-rings

• Whenever connecting piping or hoses, the compressor oil (ND–OIL8) must be applied to O-rings in order
to prevent the leakage of refrigerant.
80-84 PC88MR-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC88MR-10
Model Serial Number
90 Diagrams and drawings

10 90 Diagrams and drawings
PC88MR-10 90-1
Table of contents

90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
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
90-2 PC88MR-10
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram (ALL-C000-001-K-90-A)
Symbols in hydraulic circuit diagram (PC220-0000-007-K-00-A)
(Rev. 2013/09)
Symbols Substances
Main piping line
Pilot or drain line
Flexible pipe (hose etc.)
Lines intersecting without jointing
Lines jointing (junction with a black dot)
Direction of flow
Throttle in passage
Variable
Electricity
Spring
Take-off port
Take-off port and pressure gauge
PC88MR-10 90-3
Symbols Substances
Check valve
Suction (with strainer)
Tank and return pipe
Filter
Oil cooler
Stop valve
Drive shaft (unidirectional)
Drive shaft (bidirectional)
Hydraulic pump
Note: Black triangle shows outlet port
Variable capacity hydraulic pump
Hydraulic motor
Note: Two black triangles in the figure show direction of oil entering
hydraulic motor depending on the oil entry port, the direction of rotation is
reversed.
Servo piston
PPC valve
90-4 PC88MR-10
Symbols Substances
Control valve
Single-acting solenoid valve
Single-acting proportional solenoid valve
Hydraulic pilot valve
Hydraulic two-stage pilot valve
Lock valve
Drain valve
Pressure regulator valve, Safety valve, Abnormal pressure prevention

valve
Pressure regulator valve, Safety valve, Abnormal pressure prevention

valve
(when the figure shows air pressure, being released to atmosphere)
Bypass valve
Accumulator
PC88MR-10 90-5
Symbols Substances
Cylinder
Component group
90-6 PC88MR-10
Hydraulic circuit diagram Hydraulic circuit diagram
PC88MR-10
PC88MR-10
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC88MR-10 90-7
Symbols in electric circuit diagram
Electric circuit diagram (ALL-0000-001-K-90-A)
Symbols in electric circuit diagram (PC220-0000-008-K-00-A)
(Rev. 2013/09)
Symbols Substances
Electric wire
Electric wire (wires intersecting without connecting)
Electric wire (wires intersecting and connecting (junction) with a black

dot)
Electric wire (bundled drawing style)
Terminal
Chassis ground
Chassis ground using terminal
Contact, Switch
Push-button type switch (N.O. type)

N.O.: Normally Open
Push-button type switch (N.C. type)

N.C.: Normally Close
Pull-button type switch (N.O. type)

N.O.: Normally Open
Pull-button type switch (N.C. type)

PC88MR-10 90-9
Symbols Substances
Variable
Resistor
Variable resistor
Diode
Light emitting diode (LED)
Photo diode
Constant voltage diode (zener diode)
Transistor (PNP type)
Transistor (NPN type)
Coil
Battery
Fuse
Connector
Note:
• Concave side of connecting portion (left in figure): female
• Convex side of connecting portion (right in figure): male
a Figure shows a line disconnection status
90-10 PC88MR-10
Symbols Substances
Plug and receptacle type connector (left: male, right: female)

a Figure shows a line connection status
Solenoid
Motor
Lamp
Pressure switch (N.O. type)

N.O.: Normally Open
Pressure switch (N.C. type)

Potentiometer, Fuel control dial
Temperature sensor
Starting switch
Back up alarm
Horn
Buzzer
Antenna
PC88MR-10 90-11
90-12 PC88MR-10
Electrical circuit diagram (1/5) Electrical circuit diagram (1/5)
PC88MR-10
PC88MR-10
PC88MR-10 90-13
PC88MR-10
PC88MR-10
PC88MR-10 90-15
PC88MR-10
PC88MR-10
PC88MR-10 90-17
PC88MR-10
PC88MR-10
PC88MR-10 90-19
PC88MR-10
PC88MR-10
PC88MR-10 90-21
Electrical circuit diagram of air conditioner unit Electrical circuit diagram of air conditioner unit
PC88MR-10
PC88MR-10
a In the drawing, full line shows air conditioner wiring harness, and dashed line shows cab and chassis wiring harness. (For the detail of cab and chassis harness, see "Electrical circuit diagram")
a In the drawing, dot and dash line shows machine monitor wiring, and using twisted line (AVSS 0.5 x 2, pitch 45 mm or less).
PC88MR-10 90-23
INDEX
INDEX
A Disassembly and assembly of center swivel

joint assembly........................................... 50-140
A-1 Troubleshooting for power supply system
Disassembly and assembly of control valve
(Air conditioner does not operate) ................. 80-67
assembly.................................................. 50-152
A-2 Troubleshooting for compressor and
Disassembly and assembly of idler assembly......50-
refrigerant system (Air is not cooled) ............. 80-69
125
A-3 Troubleshooting for blower motor system
Disassembly and assembly of idler cushion
(No air comes out or air flow is abnormal) ...... 80-72
assembly.................................................. 50-128
A-04 Troubleshooting for FRESH/RECIRC air
Disassembly and assembly of swing
changeover ................................................ 80-74
machinery assembly ................................. 50-113
Accumulator ............................................... 10-161
Disassembly and assembly of track roller
Adjusting mirrors........................................... 30-69
assembly.................................................. 50-131
Adjusting play of work equipment and swing
Disassembly and assembly of travel motor and
PPC valves ................................................ 30-57
final drive assembly..................................... 50-78
Adjusting rearview camera angle ................. 30-125
Disassembly and assembly of travel PPC
Air conditioner component ............................... 80-4
valve assembly ......................................... 50-157
Air conditioner controller ................................ 80-16
Disassembly and assembly of work equipment
Air conditioner unit .............................. 80-10, 80-29
PPC valve assembly ................................. 50-155
Anti-drop valve for arm ...................... 10-156, 60-53
Dual pressure switch..................................... 80-15
Anti-drop valve for boom ................... 10-152, 60-51
Attachment circuit accumulator (for low
pressure circuit) ........................................ 10-162 E
E-1 Engine does not start (Engine does not
B crank) ...................................................... 40-378
E-2 Manual preheating system does not work .....40-
Bleeding air from fuel system ......................... 30-20
384
Bleeding air from hydraulic circuit ................... 30-65
E-3 While preheating is working, preheating
monitor does not light up............................ 40-387
C E-4 When starting switch is turned to ON
position, machine monitor displays nothing.. 40-389
Carrier roller ................................................. 60-16 E-5 Engine coolant temperature monitor lights
Center swivel joint............................. 10-160, 60-55 up in white while engine is running.............. 40-392
Check fan belt, replace.................................. 30-26 E-6 Hydraulic oil temperature monitor lights up
Circuit diagram and arrangement of connector in white while engine is running .................. 40-393
pins ........................................................... 80-24 E-7 Charge level monitor lights up while engine
Classification and procedure for is running ................................................. 40-394
troubleshooting ........................................... 40-36 E-8 Fuel level monitor lights up in red while
CLSS........................................................... 10-44 engine is running....................................... 40-395
Coating materials list....................................... 50-6 E-9 Engine coolant temperature monitor lights
Compressor ................................................. 80-17 up in red while engine is running................. 40-396
Condenser ................................................... 80-18 E-10 Hydraulic oil temperature monitor lights
Configuration and function of refrigeration up in red while engine is running................. 40-397
cycle ............................................................ 80-7 E-11 Engine oil pressure monitor lights up in
Connection of service tool ............................. 80-79 red while engine is running......................... 40-398
Connector contact identification ..................... 40-55 E-12 Fuel gauge display does not move from
Connector list and layout ............................... 40-46 minimum or maximum ............................... 40-399
Control valve ...................................... 10-60, 60-28 E-13 Fuel gauge indicates incorrect amount
Conversion table .......................................... 00-59 (indicates neither full nor empty) ................. 40-400
Cooling system............................................. 10-24 E-14 Engine coolant temperature gauge
display does not move from minimum or
D maximum ................................................. 40-401
E-15 Engine coolant temperature gauge
Disassembly and assembly of anti-drop valve indicates incorrect temperature (indicates
assembly.................................................. 50-172 neither minimum nor maximum) ................. 40-402
PC88MR-10 1
INDEX
E-16 Hydraulic oil temperature gauge does not E-44 Arm IN is not displayed correctly with
move from minimum or maximum ............... 40-403 monitoring function.................................... 40-440
E-17 Hydraulic oil temperature gauge indicates E-45 Boom Raise is not displayed correctly
incorrect temperature (indicates neither with monitoring function ............................. 40-441
minimum nor maximum) ............................ 40-405 E-46 Bucket Curl is not displayed correctly with
E-18 Some areas of machine monitor screen monitoring function.................................... 40-442
are not displayed....................................... 40-406 E-47 Bucket Dump is not displayed correctly
E-19 Function switch does not work ............. 40-407 with monitoring function ............................. 40-443
E-20 Automatic warm-up system does not E-48 Boom swing left is not displayed correctly
operate (in cold season) ............................ 40-408 with monitoring function ............................. 40-444
E-21 Auto-deceleration monitor does not light E-49 Boom swing right is not displayed
up, or does not go out, while auto- correctly with monitoring function................ 40-445
deceleration switch is operated .................. 40-409 E-50 Swing is not displayed correctly with
E-22 Auto-deceleration function does not monitoring function.................................... 40-446
operate or is not canceled while lever is E-51 Travel is not displayed correctly with
operated................................................... 40-410 monitoring function.................................... 40-447
E-23 Working mode selection screen is not E-52 Blade RAISE is not displayed correctly
displayed while working mode selector switch with monitoring function ............................. 40-448
is operated ............................................... 40-412 E-53 Blade LOWER is not displayed correctly
E-24 Setting of engine and hydraulic pump is with monitoring function ............................. 40-450
not changed while working mode is changed .....40- E-54 KOMTRAX system does not operate
413 normally ................................................... 40-452
E-25 Travel speed monitor does not change EGR cooler .................................................. 10-15
while travel speed switch is operated .......... 40-414 EGR system circuit diagram .......................... 10-12
E-26 Travel speed does not change while EGR system piping drawing........................... 10-10
travel speed selection is changed ............... 40-415 EGR valve ................................................... 10-13
E-27 Alarm buzzer does not stop sounding ... 40-416 Electrical circuit diagram................................ 90-13
E-28 Service meter is not displayed, while Electrical circuit diagram of air conditioner unit 90-23
starting switch is in OFF position ................ 40-417 Electrical control system.............................. 10-170
E-29 Service mode cannot be selected......... 40-418 Engine controller......................................... 10-202
E-30 None of work equipment, swing or travel Engine related parts ........................................ 10-3
works ....................................................... 40-419 Explanation of terms for maintenance standard ...00-
E-31 Any of work equipment, swing and travel 22
cannot be locked....................................... 40-421
E-32 Upper structure does not swing while
swing parking brake cancel switch is set to
F
CANCEL position ...................................... 40-423 Failure code [879AKA] A/C Recirc Air Temp
E-33 Swing brake does not operate while Sens Open Circuit ........................... 40-108, 80-54
swing parking brake cancel switch is set to Failure code [879AKB] A/C Recirc Air Temp
NORMAL position ..................................... 40-425 Sens Short ..................................... 40-109, 80-55
E-34 Work equipment does not operate while Failure code [879BKA] A/C Fresh Air Temp
lock lever automatic release switch is in Sens Open Circuit ........................... 40-110, 80-56
release position ........................................ 40-427 Failure code [879BKB] A/C Fresh Air Temp
E-35 Alarm does not sound during travel....... 40-429 Sens Short Circuit ........................... 40-111, 80-58
E-36 Alarm does not stop sounding while Failure code [879CKA] Ventilating Sensor
machine is stopped ................................... 40-430 Open Circuit ............................................. 40-112
E-37 Horn does not sound ........................... 40-431 Failure code [879CKB] Ventilating Sensor
E-38 Horn does not stop sounding ............... 40-433 Short Circuit ............................................. 40-113
E-39 Wiper monitor does not light up, or does Failure code [879DKZ] Sunlight Sensor Open
not go out, while wiper switch is operated .... 40-434 or Short Circuit............................................ 80-62
E-40 Wiper does not operate while wiper Failure code [879DKZ] Sunlight Sensor Open
switch is operated ..................................... 40-435 Or Short Circuit ......................................... 40-114
E-41 Window washer does not operate while Failure code [879EMC] Ventilation Damper
window washer switch is operated .............. 40-437 Malfunction............................................... 40-115
E-42 Boom Lower is not displayed correctly Failure code [879FMC] Air Mix Damper
with monitoring function ............................. 40-438 Malfunction............................................... 40-116
E-43 Arm OUT is not displayed correctly with Failure code [879GKX] Refrigerant Press Input
monitoring function.................................... 40-439 Sig Out of Range ............................ 40-117, 80-66
2 PC88MR-10
INDEX
Failure code [989L00] Engine Controller Lock Failure code [CA222] Ambient Pressure
Caution 1 ................................................. 40-118 Sensor Low Error ...................................... 40-149
Failure code [989M00] Engine Controller Lock Failure code [CA2249] Common Rail Pressure
Caution 2 ................................................. 40-119 Low Error 2............................................... 40-223
Failure code [989N00] Engine Controller Lock Failure code [CA227] Sensor 2 Supply Voltage
Caution 3 ................................................. 40-120 High Error................................................. 40-151
Failure code [A900FR] Abrupt Engine Stop by Failure code [CA2272] EGR Valve Position
Auto Idle Stop 3 ........................................ 40-121 Sensor Low Error ...................................... 40-224
Failure code [A900N6] Abrupt Engine Stop by Failure code [CA2311] IMV Solenoid Error .... 40-226
Auto Idle Stop 1 ........................................ 40-122 Failure code [CA234] Engine Overspeed ...... 40-152
Failure code [A900NY] Abrupt Engine Stop by Failure code [CA2349] EGR Valve Solenoid
Auto Idle Stop 2 ........................................ 40-123 Open Circuit Error ..................................... 40-227
Failure code [AB00KE] Charge Voltage Low . 40-124 Failure code [CA2357] EGR Valve Servo Error ....40-
Failure code [B@BAZG] Eng Oil Press Low .. 40-126 231
Failure code [B@BCNS] Eng Water Overheat .....40- Failure code [CA2360] EGR Valve Solenoid
127 Short Circuit Error ..................................... 40-229
Failure code [CA1117] Engine Controller Failure code [CA238] NE Speed Sensor
Partial Data Lost Error ............................... 40-209 Supply Voltage Error ................................. 40-153
Failure code [CA115] Eng Ne and Bkup Speed Failure code [CA239] NE Speed Sensor
Sens Error ................................................ 40-128 Supply Voltage High Error.......................... 40-154
Failure code [CA122] Charge Air Pressure Failure code [CA271] PCV1 Short Circuit Error....40-
Sensor High Error ..................................... 40-129 155
Failure code [CA123] Charge Air Pressure Failure code [CA272] PCV1 Open Circuit Error....40-
Sensor Low Error ...................................... 40-131 156
Failure code [CA131] Throttle Sensor High Failure code [CA2765] Injector Trim Data
Error ........................................................ 40-133 Mismatch ................................................. 40-232
Failure code [CA132] Throttle Sensor Low Failure code [CA322] Injector #1 (L#1) Open or
Error ........................................................ 40-135 Short Circuit ............................................. 40-157
Failure code [CA144] Coolant Temperature Failure code [CA324] Injector #3 (L#3) Open or
Sensor High Error Failure code [CA144] Short Circuit ............................................. 40-159
Coolant Temperature Sensor High Error...... 40-137 Failure code [CA331] Injector #2 (L#2) Open or
Failure code [CA145] Coolant Temperature Short Circuit ............................................. 40-161
Sensor Low Error Failure code [CA145] Failure code [CA332] Injector #4 (L#4) Open or
Coolant Temperature Sensor Low Error ...... 40-139 Short Circuit ............................................. 40-163
Failure code [CA153] Charge Air Temperature Failure code [CA3419] MAF Sensor Supply
Sensor High Error ..................................... 40-141 Voltage High Error..................................... 40-233
Failure code [CA154] Charge Air Temperature Failure code [CA3421] MAF Sensor Supply
Sensor Low Error ...................................... 40-143 Voltage Low Error ..................................... 40-235
Failure code [CA1695] Sensor 5 Supply Failure code [CA343] Engine Controller
Voltage High Error..................................... 40-210 Internal Failure.......................................... 40-165
Failure code [CA1696] Sensor 5 Supply Failure code [CA351] Injectors Drive Circuit
Voltage Low Error ..................................... 40-211 Error ........................................................ 40-166
Failure code [CA1843] Crankcase Pressure Failure code [CA352] Sensor1 Supply Voltage
Sensor High Error ..................................... 40-212 Low Error ................................................. 40-167
Failure code [CA1844] Crankcase Pressure Failure code [CA356] MAF Sensor High Error .....40-
Sensor Low Error ...................................... 40-214 169
Failure code [CA187] Sensor 2 Supply Voltage Failure code [CA357] MAF Sensor Low Error 40-171
Low Error ................................................. 40-145 Failure code [CA3724] EGR/KVGT Motor
Failure code [CA1896] EGR Valve Stuck Error ....40- Driver Power Low Error ............................. 40-237
216 Failure code [CA386] Sensor1 Supply Voltage
Failure code [CA1942] Crankcase Pressure High Error................................................. 40-173
Sensor In Range Error............................... 40-217 Failure code [CA3918] KVGT Stuck Error ..... 40-239
Failure code [CA2185] Throttle Sensor Supply Failure code [CA3919] KVGT Motor Driver IC
Voltage High Error..................................... 40-219 Over Temp Error ........................... 40-218, 40-240
Failure code [CA2186] Throttle Sensor Supply Failure code [CA3921] KVGT Servo Error 2 .. 40-241
Voltage Low Error ..................................... 40-221 Failure code [CA3922] KVGT Motor Driver
Failure code [CA221] Ambient Pressure Open Error ............................................... 40-242
Sensor High Error ..................................... 40-147 Failure code [CA3923] KVGT Motor Driver
Short Error................................................ 40-244
PC88MR-10 3
INDEX
Failure code [CA435] Engine Oil Pressure SW Failure code [DA25KP] 5 V Sensor Power
Error ........................................................ 40-174 Supply Output 1 Voltage Low ..................... 40-261
Failure code [CA441] Battery Voltage Low Failure code [DA29KQ] Model Selection Sig
Error ........................................................ 40-175 Mismatch (Pump Con) ............................... 40-263
Failure code [CA442] Battery Voltage High Failure code [DA2LKA] Operating Lamp Open
Error ........................................................ 40-177 Circuit (Pump Con).................................... 40-265
Failure code [CA449] Common Rail Pressure Failure code [DA2LKB] Operating Lamp Short
High Error 2 .............................................. 40-178 Circuit (Pump Con).................................... 40-267
Failure code [CA451] Common Rail Pressure Failure code [DA2QKR] CAN2 Discon (Pump
Sensor High Error ..................................... 40-179 Con) ........................................................ 40-268
Failure code [CA452] Common Rail Pressure Failure code [DA2RKR] CAN 1 Defective
Sensor Low Error ...................................... 40-181 Communication (Pump Con) ...................... 40-270
Failure code [CA466] KVGT Motor Driver Failure code [DAF0MB] Monitor ROM
Position Error............................................ 40-183 Abnormality .............................................. 40-271
Failure code [CA515] Rail Pressure Sensor Failure code [DAF0MC] Monitor Malfunction . 40-272
Sup Volt High Error Failure code................. 40-185 Failure code [DAF8KB] Camera Power Supply
Failure code [CA516] Rail Pressure Sensor Short Circuit ............................................. 40-273
Sup Volt Low Error .................................... 40-187 Failure code [DAF9KQ] Model Selection Signal
Failure code [CA553] Common Rail Pressure Mismatch (Monitor) ................................... 40-274
High Error 1 .............................................. 40-189 Failure code [DAFGMC] GPS Module
Failure code [CA555] Crankcase Pressure Malfunction............................................... 40-275
High Error 1 .............................................. 40-190 Failure code [DAFLKA] Operating Lamp Open
Failure code [CA556] Crankcase Pressure Circuit (Monitor) ........................................ 40-276
High Error 2 .............................................. 40-191 Failure code [DAFLKB] Operating Lamp Short
Failure code [CA559] Common Rail Pressure Circuit (Monitor) ........................................ 40-278
Low Error 1............................................... 40-192 Failure code [DAFQKR] CAN 2 Defective
Failure code [CA689] Engine NE Speed Communication (Monitor)........................... 40-279
Sensor Error Failure code .......................... 40-195 Failure code [DAZ9KQ] Model Selection Sig
Failure code [CA691] Intake Air Temperature Mismatch (A/C) ......................................... 40-280
Sensor High Error ..................................... 40-197 Failure code [DAZQKR] CAN2 Defective
Failure code [CA692] Intake Air Temperature Communication (A/C ECU) ........................ 40-281
Sensor Low Error ...................................... 40-199 Failure code [DB2QKR] CAN2 Defective
Failure code [CA697] Engine Con Internal Communication (Engine Con) .................... 40-285
Temp Sens High Error ............................... 40-201 Failure code [DB2RKR] CAN1 Defective
Failure code [CA698] Engine Con Internal Communication (Engine Con) .................... 40-289
Temp Sens Low Error ................................ 40-202 Failure code [DDNRKA] WE Lever Lock SW
Failure code [CA731] Engine Backup Speed Open Circuit ............................................. 40-293
Sensor Phase Error................................... 40-203 Failure code [DDNRKY] Hot Short Circuit of
Failure code [CA778] Engine Backup Speed Work Equipment Control Lever Lock Switch 40-295
Sensor Error ............................................. 40-205 Failure code [DDNS00] Lock Lever Auto Lock
Failure code [D110KB] Battery Relay Output Release SW On ........................................ 40-297
Short Circuit ............................................. 40-246 Failure code [DGH2KB] Hydraulic Oil Temp
Failure code [D19JKZ] Personal Code Relay Sensor Ground Fault ................................. 40-299
Open or Short ........................................... 40-248 Failure code [DHPAMA] Front Pump Press
Failure code [D811MC] KOMTRAX Malfunction...40- Sens Defective Function ............................ 40-301
251 Failure code [DHS3MA] Arm IN PPC Press
Failure code [D862KA] GPS Antenna Open Sensor Def Function.................................. 40-303
Circuit ...................................................... 40-252 Failure code [DHS4MA] Bucket CURL PPC
Failure code [D8ALKA] Operating Lamp Open Press Sens Def Function ........................... 40-305
Circuit (KOMTRAX)................................... 40-253 Failure code [DHS5MA] Travel PPC Sensor
Failure code [D8ALKB] Operating Lamp Short Abnormality .............................................. 40-307
Circuit (KOMTRAX)................................... 40-255 Failure code [DHS8MA] Boom Raise PPC
Failure code [D8AQKR] CAN2 Discon Press Sens Def Function ........................... 40-309
(KOMTRAX) ............................................. 40-256 Failure code [DHS9MA] Boom Lower PPC
Failure code [DA20MC] Pump Controller Press Sens Def Function ........................... 40-311
Malfunction............................................... 40-258 Failure code [DHSAMA] Swing Right PPC
Failure code [DA22KK] Pump Con Solenoid Press Sens Def Function ........................... 40-313
Power Volt Low Erro .................................. 40-259 Failure code [DHSBMA] Swing Left PPC Press
Sensor Def Function.................................. 40-315
4 PC88MR-10
INDEX
Failure code [DHSCMA] Arm OUT PPC Press Failure code [DY2DKB] Wiper Motor (Normal)
Sens Def Function .................................... 40-317 Short Circuit ............................................. 40-374
Failure code [DHSDMA] Bucket DUMP PPC Failure code [DY2EKB] Wiper Motor (Reverse)
Press Sens Def Function ........................... 40-319 Short Circuit ............................................. 40-376
Failure code [DHSPMA] Boom Swing LH PPC Failure code [879CKA] Ventilating Sensor
Press Sensor Abnormality ......................... 40-321 Open Circuit ............................................... 80-60
Failure code [DHSQMA] Boom Swing RH PPC Failure code [879CKB] Ventilating Sensor
Press Sensor Abnormality ......................... 40-323 Short Circuit ............................................... 80-61
Failure code [DKULKA] PPC Lock Relay Open Failure code [879EMC] Ventilation Damper
Circuit ...................................................... 40-325 Malfunction................................................. 80-64
Failure code [DKULKB] PPC Lock Relay Short Failure code [879FMC] Air Mix Damper
Circuit ...................................................... 40-327 Malfunction................................................. 80-65
Failure code [DKULKY] PPC Lock Relay Hot Failure code list related to air conditioner ........ 80-53
Short Circuit ............................................. 40-329 Failure mode and cause table ...................... 40-457
Failure code [DV20KB] Travel Alarm Short Fuse location table........................................ 40-99
Circuit ...................................................... 40-331
Failure code [DW43KA] Travel Speed Solenoid
Open Circuit ............................................. 40-333
H
Failure code [DW43KB] Travel Speed Solenoid H-1 All of work equipment, swing and travel
Short Circuit ............................................. 40-335 operation lacks speed or power .................. 40-465
Failure code [DW43KY] Travel Speed Sol Hot H-2 Engine speed drops significantly or engine
Short Circuit ............................................. 40-337 stalls ........................................................ 40-467
Failure code [DW45KA] Swing Parking Brake H-3 Any of work equipment, swing and travel
Solenoid Open Circuit................................ 40-338 does not work ........................................... 40-468
Failure code [DW45KB] Swing Parking Brake H-4 Unusual sound is heard from around
Solenoid Short Circuit................................ 40-341 hydraulic pump ......................................... 40-469
Failure code [DW45KY] Swing Brake Sol Hot H-5 Fine control performance or response is
Short Circuit ............................................. 40-343 poor ......................................................... 40-470
Failure code [DW4CKY] PPC Lock Solenoid H-6 Boom speed or power is low .................. 40-471
System Hot short Circuit ............................ 40-345 H-7 Arm speed or power is low..................... 40-474
Failure code [DWJ0KA] Merge-divider Sol H-8 Bucket speed or power is low ................ 40-476
Open Circuit ............................................. 40-347 H-9 Boom swing speed or power is low......... 40-478
Failure code [DWJ0KB] Merge-divider Sol H-10 Blade speed or power is low ................ 40-480
Short Circuit ............................................. 40-349 H-11 Work equipment does not move in single
Failure code [DWJ0KY] Merge-divider Sol operation.................................................. 40-482
Short Circuit ............................................. 40-351 H-12 Hydraulic drift of boom is large ............. 40-483
Failure code [DXA8KA] Front Pump PC-EPC H-13 Hydraulic drift of arm is large................ 40-484
Solenoid Open Circuit................................ 40-352 H-14 Hydraulic drift of bucket is large............ 40-485
Failure code [DXA8KB] Front Pump PC-EPC H-15 Hydraulic drift of blade is large ............. 40-486
Solenoid Short Circuit................................ 40-354 H-16 Time lag of work equipment is large...... 40-487
Failure code [DXE7KA] Service Current EPC2 H-17 In combined operation of work equipment
Open Circuit ............................................. 40-356 , equipment having heavier load moves
Failure code [DXE7KB] Service Current EPC2 slower ...................................................... 40-489
Short Circuit ............................................. 40-358 H-18 In combined operation of swing and
Failure code [DXE7KY] Service Current EPC2 boom RAISE, boom rising speed is low....... 40-490
Hot Short Circuit........................................ 40-360 H-19 In combined operation of work equipment
Failure code [DXEAKA] Service Current EPC5 or swing and travel, travel speed drops largely...40-
Open Circuit ............................................. 40-362 491
Failure code [DXEAKB] Service Current EPC5 H-20 Machine does not travel straight........... 40-493
Short Circuit ............................................. 40-364 H-21 Travel speed is slow............................ 40-495
Failure code [DXEAKY] Service Current EPC5 H-22 Machine is hard to steer or travel power
Hot Short Circuit........................................ 40-366 is low ....................................................... 40-497
Failure code [DY20KA] Wiper Motor Open H-23 Travel speed does not change, or travel
Circuit ...................................................... 40-368 speed is too slow or fast ............................ 40-500
Failure code [DY20MA] Wiper Motor Defective H-24 One of tracks does not run................... 40-501
Function ................................................... 40-370 H-25 Upper structure does not swing to the
Failure code [DY2CKB] Washer Drive Short right or left ................................................ 40-503
Circuit ...................................................... 40-372 H-26 Upper structure swing only to the right or
left ........................................................... 40-504
PC88MR-10 5
INDEX
H-27 Swing acceleration or swing speed is low KOMTRAX system ..................................... 10-236
in both directions (right and left).................. 40-505 KOMTRAX terminal start-up procedure......... 30-121
H-28 Swing acceleration performance is poor
or swing speed is slow in only one direction. 40-506
H-29 Upper structure overruns excessively
L
when it stops swinging (both right and left) .. 40-507 List of abbreviation........................................ 00-54
H-30 Upper structure overruns excessively
when it stops swinging (either right or left) ... 40-508
H-31 Shock is large when upper structure
M
stops swinging .......................................... 40-509 Machine control ............................................ 20-23
H-32 Large unusual noise is heard when upper Machine monitor system.............................. 10-214
structure stops swinging ............................ 40-510 Main pump ................................................... 10-48
H-33 Swing drift on a slope is large while swing Method of disconnecting and connecting of
parking brake is applied ............................. 40-511 push-pull type coupler ................................. 00-28
H-34 Swing drift on a slope is large while swing Multi-control valve....................................... 10-151
parking brake is released ........................... 40-512
H-35 Oil flow in attachment circuit cannot be
controlled ................................................. 40-513
O
Handling cylinder cutout mode operation ........ 30-23 Outer temperature sensor.............................. 80-21
Handling equipment of fuel system devices..... 00-24 Outline of refrigeration cycle ............................ 80-8
Handling no injection cranking operation......... 30-24
Handling of compressor oil ............................ 80-83
Handling of electrical equipment .................... 00-31
P
Handling of hydraulic equipment .................... 00-26 Parts and connectors layout .......................... 80-31
Handling of intake system parts ..................... 00-25 Pm Clinic service ........................................ 30-130
Handling voltage circuit of engine controller .. 30-127 Power train system ....................................... 10-27
How to open the electrical system abnormality PPC circuit accumulator .............................. 10-161
record screen in service mode of the machine PPC valve.................................................... 60-40
monitor....................................................... 80-39 Practical use of KOMTRAX............................ 00-47
How to read electric wire code ....................... 00-39 Precautions for disconnecting and connecting
How to read the shop manual ........................ 00-20 refrigerant piping ......................................... 80-81
How to read this manual .................................. 50-4 Precautions for refrigerant ............................... 80-3
Hydraulic circuit diagram ................................. 90-7 Precautions when performing operation.......... 00-42
Hydraulic component layout........................... 10-36 Preparation for troubleshooting of electrical
Hydraulic tank .............................................. 10-40 system ....................................................... 40-31
Procedure for testing and troubleshooting ....... 80-22
PTO .............................................................. 10-5
I
Idler ............................................................. 60-14
Idler cushion....................................... 10-35, 60-13
R
Important safety notice .................................. 00-13 Receiver drier............................................... 80-19
Information described in troubleshooting table Releasing remaining pressure from hydraulic
(H-mode).................................................. 40-454 circuit ......................................................... 30-37
Information in troubleshooting table ...... 40-42, 80-52 Removal and installation of aftercooler
Information mentioned in troubleshooting table assembly.................................................... 50-46
(S mode) .................................................. 40-514 Removal and installation of air cleaner
Inspection procedure before troubleshooting... 40-14 assembly.................................................... 50-69
Isolating the parts causing hydraulic drift in Removal and installation of air conditioner
work equipment .......................................... 30-58 compressor assembly ............................... 50-204
Removal and installation of air conditioner
condenser assembly ................................. 50-206
K Removal and installation of air conditioner unit
KCCV layout drawing .................................... 10-17 assembly.................................................. 50-199
KCCV ventilator............................................ 10-20 Removal and installation of anti-drop valve for
KDOC muffler............................................... 10-22 arm assembly ........................................... 50-169
KOMTRAX Settings (GPS & Communication Removal and installation of anti-drop valve for
Status) ..................................................... 30-118 boom assembly ........................................ 50-166
KOMTRAX Settings (terminal setting status) . 30-117 Removal and installation of blade assembly .. 50-173
KOMTRAX Settings screen (Modem Status) . 30-119
6 PC88MR-10
INDEX
Removal and installation of boom swing Removal and installation of pump controller
bracket..................................................... 50-165 assembly.................................................. 50-219
Removal and installation of center swivel joint Removal and installation of radiator assembly . 50-39
assembly.................................................. 50-138 Removal and installation of revolving frame
Removal and installation of control valve assembly.................................................. 50-134
assembly.................................................. 50-148 Removal and installation of seat belt............. 50-209
Removal and installation of counterweight Removal and installation of sprocket ............ 50-123
assembly.................................................. 50-136 Removal and installation of starting motor
Removal and installation of cylinder head assembly.................................................. 50-217
assembly.................................................... 50-27 Removal and installation of supply pump
Removal and installation of EGR (Exhaust Gas assembly.................................................... 50-17
Recirculation) cooler assembly..................... 50-71 Removal and installation of swing circle
Removal and installation of EGR (Exhaust Gas assembly.................................................. 50-121
Recirculation) valve assembly ...................... 50-73 Removal and installation of swing motor and
Removal and installation of engine and main swing machinery assembly .........................50-111
pump assembly .......................................... 50-49 Removal and installation of travel motor and
Removal and installation of engine controller final drive assembly..................................... 50-76
assembly.................................................. 50-218 Removal and installation of work equipment
Removal and installation of engine front oil assembly...................................... 50-158, 50-162
seal ........................................................... 50-57 ROPS cab.................................................. 10-168
Removal and installation of engine hood
assembly.................................................... 50-63
Removal and installation of engine rear oil seal ...50-
S
58 S-1 Engine does not crank when starting
Removal and installation of fan belt ................ 50-74 switch is turned to START position.............. 40-515
Removal and installation of floor frame S-2 Engine cranks but no exhaust smoke
assembly.................................................. 50-194 comes out ................................................ 40-516
Removal and installation of front window S-3 Fuel is being injected but engine does not
assembly.................................................. 50-193 start (misfiring: engine cranks but does not
Removal and installation of front wiper start) ........................................................ 40-517
assembly.................................................. 50-210 S-4 Engine startability is poor....................... 40-518
Removal and installation of fuel cooler S-5 Engine does not pick up smoothly .......... 40-520
assembly.................................................... 50-60 S-6 Engine stops during operation................ 40-522
Removal and installation of fuel tank assembly....50- S-7 Engine runs rough or is unstable ............ 40-524
61 S-8 Engine lacks power............................... 40-525
Removal and installation of hydraulic oil cooler S-9 Exhaust smoke is black ......................... 40-527
assembly.................................................... 50-43 S-10 Engine oil consumption is excessive..... 40-529
Removal and installation of hydraulic tank S-11 Engine oil becomes contaminated early 40-530
assembly.................................................. 50-141 S-12 Fuel consumption is excessive............. 40-531
Removal and installation of idler and idler S-13 Oil is in coolant (or coolant spurts or
cushion assembly ..................................... 50-124 coolant level goes down) ........................... 40-532
Removal and installation of injector assembly . 50-20 S-14 Oil pressure drops............................... 40-533
Removal and installation of KCCV assembly ... 50-67 S-15 Fuel mixes into engine oil .................... 40-534
Removal and installation of KDOC muffler ...... 50-64 S-16 Water mixes into engine oil (milky)........ 40-535
Removal and installation of KOMTRAX S-17 Coolant temperature rises too high
terminal .................................................... 50-223 (overheating) ............................................ 40-536
Removal and installation of machine monitor S-18 Unusual noise is heard ........................ 40-537
assembly.................................................. 50-220 S-19 Vibration is excessive.......................... 40-538
Removal and installation of main pump S-20 Air cannot be bled from fuel circuit ........ 40-539
assembly.................................................. 50-144 Sensor....................................................... 10-238
Removal and installation of mass air flow and Separation and connection of track shoe
temperature sensor ................................... 50-222 assembly.................................................. 50-122
Removal and installation of operator's cab Sequence of events in troubleshooting ........... 40-10
assembly.................................................. 50-175 Service Message ........................................ 30-119
Removal and installation of operator's cab door...50- Sketch of tools for testing and adjusting ............ 30-6
179 Sketches of special tools ............................... 50-15
Removal and installation of operator's cab Solenoid valve.................................. 10-147, 60-49
glass (adhered glass) ................................ 50-182 Special functions of machine monitor.............. 30-73
Removal and installation of operator's seat ... 50-208 Special tools list............................................ 50-10
PC88MR-10 7
INDEX
Specification drawing ...................................... 01-3 Testing with self-diagnosis function................. 80-39

Specifications .........................................01-3, 01-5 Testing, cleaning and lubricating slide door rail
Sprocket ...................................................... 60-11 and roller .................................................... 30-68
Standard tightening torque table .................... 00-48 Tools for testing and adjusting.......................... 30-3
Standard value table for electrical system ....... 20-21 Track frame ........................................ 10-33, 60-12
Standard value table for engine........................ 20-3 Track roller ................................................... 60-15
Standard value table for machine ..................... 20-5 Track shoe ................................................... 60-17
Sunlight sensor............................................. 80-20 Travel motor ..................................... 10-119, 60-39
Swing circle..........................................10-29, 60-7 Travel PPC valve .......................................... 60-43
Swing machinery ..................................10-31, 60-9 Troubleshooting chart 1................................. 80-48
Swing motor ................................................. 60-37 Troubleshooting chart 2................................. 80-49
Symbols in electric circuit diagram.................... 90-9 Troubleshooting method for open circuit in
Symbols in hydraulic circuit diagram................. 90-3 wiring harness of pressure sensor system ..... 40-44
Symptom of probable failure and Troubleshooting points .................................... 40-8
troubleshooting No. ..................................... 40-39 Troubleshooting with gauge pressure ............. 80-76
System chart of hydraulic and mechanical
systems ................................................... 40-455
System component parts............................. 10-202
V
System diagram ........................................... 80-26 Valve control ................................................ 10-38
Variable flow turbocharger ............................... 10-6
T
T-boxes and T-adapters list............................ 40-94
W
Table of fuel, coolant, and lubricants ............... 01-11 Weight table ................................................... 01-9
Testing air leakage (duct)............................... 80-37 Work equipment ............................... 10-163, 60-57
Testing and adjusting air conditioner Work equipment and swing PPC valve ...10-130, 60-
compressor belt tension............................... 30-25 40
Testing and adjusting hood catcher ................ 30-71 Work equipment shim ................................. 10-164
Testing and adjusting oil pressure in pump LS Working range drawings.................................. 01-4
control circuit .............................................. 30-52 Writing compensation values at replacement of
Testing and adjusting oil pressure in pump PC injector and engine controller ....................... 30-31
control circuit .............................................. 30-49
Testing and adjusting oil pressure in work
equipment and travel circuits........................ 30-42
Testing and adjusting swing and blade circuit
oil pressure................................................. 30-45
Testing and adjusting track tension................. 30-36
Testing and adjusting travel deviation ............. 30-59
Testing and adjusting valve clearance ............ 30-10
Testing before troubleshooting ....................... 40-12
Testing blowby pressure ................................ 30-14
Testing compression pressure ....................... 30-12
Testing diodes ............................................ 30-129
Testing (dual) pressure switch for refrigerant ... 80-45
Testing engine oil pressure ............................ 30-15
Testing engine speed ...................................... 30-8
Testing exhaust gas color ................................ 30-9
Testing FRESH/RECIRC air changeover ........ 80-43
Testing fuel circuit for leakage ........................ 30-22
Testing fuel pressure ..................................... 30-16
Testing fuel return rate and leakage ................ 30-17
Testing oil leakage ........................................ 30-61
Testing oil pressure of control circuit ............... 30-48
Testing outlet pressure of solenoid valve......... 30-55
Testing PPC valve outlet pressure .................. 30-56
Testing relays ............................................... 80-47
Testing sunlight sensor.................................. 80-44
Testing swing circle bearing clearance............ 30-35
Testing vent (mode) changeover .................... 80-42
8 PC88MR-10
PC88MR-10 HYDRAULIC EXCAVATOR
Form No. SEN06467-05
©2017 KOMATSU
All Rights Reserved
Printed in Japan 11–17

PC 88 MR 10

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SEN06467-05

HYDRAULIC PC88MR -10

PC88MR-10 7001 and up

00 Index and foreword

Boom swing PPC valve .................................................................................................... 10-145

Testing PPC valve outlet pressure ....................................................................................... 30-56

Failure code [CA131] Throttle Sensor High Error................................................................. 40-133

E-29 Service mode cannot be selected .............................................................................. 40-418

H-24 One of tracks does not run ........................................................................................ 40-501

Removal and installation of air cleaner assembly .................................................................. 50-69

Engine mount ...................................................................................................................... 60-3

Testing with self-diagnosis function ...................................................................................... 80-39

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

Safety points before starting. While working, always keep

k Slinging with one rope may cause turning

Precautions for using mobile crane

Precautions for using overhead traveling crane

• When tightening nuts of the air conditioner

For tightening torques, see "Others",

Precautions to prevent fire (ALL-0000-17B-K-03-A)

Actions if fire occurs (ALL-0000-17A-K-01-A)

• Turn the starting switch to OFF position to stop

To prevent pollution, pay full attention to the way to

Some kinds of rubber and plastics may produce

How to read the shop manual (ALL-0320-010-A-01-A)

Composition of shop manual

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

the parts can not be used any longer. This value

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

Use care for working environment

How to clean parts when dirt is stuck

Precautions for replacing fuel filter cartridge

Handling of intake system parts (PC220-A900-2A4-K-00-A)

Be careful of working environment

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

Be careful of working environment

Disassembly and maintenance work in the field

Plugging of opening (prevention of flowing out

Method of disconnecting and connecting of push-pull type coupler (ALL-

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

blow it with compressed air and spray it with

High-pressure water entering connector

Entry of water, mud or dirt when disconnecting a

• Check that there is no oil, dirt or water stick

3. Action to take after removing connectors

• If the connector clamp is removed, be sure to Drying wiring harness

2. Dry the inside of the connector with a dryer.

3. Perform a continuity test on the connector.

2. While pressing lock (L2), pull out connector (1).

Slide, lock type

a If the lock is located on the underside, use

temperature even for a short period of time.

• Precautions when performing arc welding

Precautions for troubleshooting electrical

How to read electric wire code (ALL-E500-030-P-00-A)

Type, symbol, and material

Nominal No. 8 15 20 30 40 50 60 85 100

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

CAVS Standard — 1.6 — 1.8 — 2.1