Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00300 PDF

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Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00300 –  PDF DOWNLOAD

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Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00300 –  PDF DOWNLOAD

Language : English
Pages : 2724
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00300 –  PDF DOWNLOAD

SERIAL NUMBERS

• 85006 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
FOREWORD, SAFETY, BASIC INFORMATION . 21
HOW TO READ THE SHOP MANUAL . 21
SAFETY NOTICE FOR OPERATION . 23
PRECAUTIONS TO PREVENT FIRE . 31
ACTIONS IF FIRE OCCURS 33
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 34
34
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 34
PRECAUTIONS FOR ADDING 34
PRECAUTIONS FOR STORING . 34
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 34
THE OTHER PRECAUTIONS . 35
STORE DEF . 36
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 37
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 39
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 45
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 47
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 48
PRACTICAL USE OF KOMTRAX 49
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 50
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 51
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 52
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 54
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 58
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 61
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 62
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 64
HOW TO READ ELECTRICAL WIRE CODE 65
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 69
ABBREVIATION LIST . 72
STANDARD TIGHTENING TORQUE TABLE 77
CONVERSION TABLE 84
01 SPECIFICATIONS . 89
CONTENTS 90
SPECIFICATIONS 91
SPECIFICATION DRAWING . 91
SPECIFICATION DRAWING: PC490,PC490LC-11 . 91
WORKING RANGE DRAWINGS 93
WORKING RANGE: PC490/PC490LC-11 . 93
SPECIFICATIONS 94
SPECIFICATIONS: PC490/PC490LC-11 94
WEIGHT TABLE 97
WEIGHT TABLE: PC490,PC490LC-11 97
TABLE OF FUEL, COOLANT, AND LUBRICANTS 99
10 STRUCTURE AND FUNCTION . 101
CONTENTS 102
UREA SCR SYSTEM . 106
LAYOUT DRAWING OF UREA SCR SYSTEM . 106
UREA SCR SYSTEM DIAGRAM . 110
FUNCTION OF UREA SCR SYSTEM . 111
FUNCTION OF AdBlue/DEF SYSTEM . 111
INDUCEMENT STRATEGY . 113
COMPONENT PARTS OF UREA SCR SYSTEM 121
AdBlue/DEF MIXING TUBE 121
SCR ASSEMBLY 121
AdBlue/DEF TANK . 124
AdBlue/DEF PUMP . 126
AdBlue/DEF INJECTOR . 127
AdBlue/DEF HOSE . 128
AdBlue/DEF TANK HEATING VALVE . 129
BOOT-UP SYSTEM 130
LAYOUT DRAWING OF BOOT-UP SYSTEM 130
SYSTEM OPERATING LAMP SYSTEM 132
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 132
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 132
BATTERY DISCONNECT SWITCH . 133
FUNCTION OF BATTERY DISCONNECT SWITCH . 133
ENGINE SYSTEM . 134
LAYOUT DRAWING OF ENGINE SYSTEM . 134
SPECIFICATIONS OF ENGINE SYSTEM . 135
FUNCTION OF ENGINE SYSTEM . 136
ENGINE CONTROL SYSTEM . 137
ENGINE CONTROL SYSTEM DIAGRAM . 137
FUNCTION OF ENGINE CONTROL SYSTEM . 138
AUTO-DECELERATION SYSTEM 140
AUTO-DECELERATION SYSTEM DIAGRAM 140
FUNCTION OF AUTO-DECELERATION SYSTEM 140
OPERATE AUTO-DECELERATION SYSTEM 141
ENGINE AUTOMATIC WARM-UP SYSTEM . 142
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 142
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 143
OVERHEAT PREVENTION SYSTEM 144
OVERHEAT PREVENTION SYSTEM DIAGRAM 144
FUNCTION OF OVERHEAT PREVENTION SYSTEM 145
TURBOCHARGER PROTECTION SYSTEM 147
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 147
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 148
AUTOMATIC IDLE STOP SYSTEM 149
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 149
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 149
COMPONENT PARTS OF ENGINE SYSTEM 152
KVGT 152
EGR SYSTEM 155
EGR VALVE . 157
EGR COOLER 159
KCCV SYSTEM . 160
KCCV VENTILATOR . 161
KDPF 162
COOLING SYSTEM 167
LAYOUT DRAWING OF COOLING SYSTEM 167
SPECIFICATIONS OF COOLING SYSTEM 168
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 170
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 170
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 171
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 172
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 172
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 173
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 175
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 175
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 175
COMPONENT PARTS OF COOLING SYSTEM . 176
COOLING FAN PUMP 176
COOLING FAN MOTOR . 183
CONTROL SYSTEM 190
LAYOUT DRAWING OF CONTROL SYSTEM 190
MACHINE MONITOR SYSTEM 193
MACHINE MONITOR SYSTEM DIAGRAM 193
KOMTRAX SYSTEM 194
KOMTRAX SYSTEM DIAGRAM 194
FUNCTION OF KOMTRAX SYSTEM 194
PPC LEVERS 195
LH PPC LEVER 195
RH PPC LEVER 196
AUTOMATIC GREASE SYSTEM . 197
OUTLINE OF AUTO GREASE SYSTEM . 197
COMPONENT PARTS OF CONTROL SYSTEM . 212
MACHINE MONITOR . 212
KOMTRAX TERMINAL 224
PUMP CONTROLLER . 226
RESISTOR FOR PC-EPC VALVE . 230
CAN TERMINATING RESISTOR 231
ENGINE CONTROLLER . 232
FUEL CONTROL DIAL . 238
FUEL FEED PUMP 240
FUEL FEED PUMP SWITCH . 241
241
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 241
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 242
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 242
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 242
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 243
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 243
STRUCTURE OF OVERLOAD CAUTION SENSOR 243
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 243
FUNCTION OF OVERLOAD CAUTION SENSOR . 243
HYDRAULIC SYSTEM 244
LAYOUT DRAWING OF HYDRAULIC SYSTEM 244
CLSS 246
STRUCTURE OF CLSS . 246
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 248
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 249
PRESSURE COMPENSATION CONTROL . 262
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 265
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 265
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 267
PUMP AND VALVE CONTROL SYSTEM . 272
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 272
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 273
COMPONENT PARTS OF HYDRAULIC SYSTEM . 275
HYDRAULIC TANK 275
MAIN PUMP . 277
PILOT OIL FILTER 303
CONTROL VALVE . 303
WORK EQUIPMENT SYSTEM . 365
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 365
STRUCTURE OF VALVE CONTROL 370
ONE-TOUCH POWER MAXIMIZING SYSTEM . 371
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 371
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 372
MACHINE PUSH-UP SYSTEM 373
MACHINE PUSH-UP SYSTEM DIAGRAM 373
FUNCTION OF MACHINE PUSH-UP SYSTEM 374
PPC LOCK SYSTEM . 375
PPC LOCK SYSTEM DIAGRAM . 375
FUNCTION OF PPC LOCK SYSTEM . 375
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 376
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 376
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 376
OPERATE WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 377
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 378
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT . 378
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 379
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 380
WORK EQUIPMENT AND SWING PPC VALVE 380
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 385
SOLENOID VALVE 390
VARIABLE PRESSURE COMPENSATION VALVE 392
ATTACHMENT CIRCUIT SELECTOR VALVE . 393
ATT EPC VALVE ASSEMBLY 396
RETURN OIL FILTER . 397
QUICK COUPLER CONTROL VALVE . 399
PILOT CIRCUIT ACCUMULATOR . 401
SWING SYSTEM 402
LAYOUT DRAWING OF SWING SYSTEM 402
SWING CONTROL SYSTEM DIAGRAM 408
FUNCTION OF SWING CONTROL SYSTEM 408
COMPONENT PARTS OF SWING SYSTEM . 412
SWING MOTOR . 412
SWING MACHINERY . 423
SWING CIRCLE 425
TRAVEL SYSTEM . 427
LAYOUT DRAWING OF TRAVEL SYSTEM . 427
TRAVEL CONTROL SYSTEM DIAGRAM . 431
FUNCTION OF TRAVEL CONTROL SYSTEM . 432
COMPONENT PARTS OF TRAVEL SYSTEM 433
TRAVEL MOTOR 433
FINAL DRIVE . 446
TRAVEL PPC VALVE 447
CENTER SWIVEL JOINT . 452
UNDERCARRIAGE AND FRAME . 454
LAYOUT DRAWING OF UNDERCARRIAGE . 454
SPECIFICATIONS OF UNDERCARRIAGE . 454
WORK EQUIPMENT 455
STRUCTURE OF WORK EQUIPMENT . 455
FUNCTION OF WORK EQUIPMENT 456
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 457
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 457
BUCKET CLEARANCE ADJUSTMENT SHIM 458
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 458
CAB AND ITS ATTACHMENTS . 459
ROPS CAB 459
STRUCTURE OF ROPS CAB . 459
FUNCTION OF ROPS CAB 459
CAB MOUNT . 460
STRUCTURE OF CAB MOUNT 460
FUNCTION OF CAB MOUNT . 460
CAB TIPPING STOPPER . 461
STRUCTURE OF CAB TIPPING STOPPER 461
FUNCTION OF CAB TIPPING STOPPER . 461
20 STANDARD VALUE TABLE . 463
CONTENTS 464
STANDARD VALUE TABLE FOR ENGINE . 465
STANDARD VALUE TABLE FOR ENGINE: PC490LC-11 . 465
STANDARD VALUE TABLE FOR MACHINE 468
STANDARD VALUE TABLE FOR MACHINE: PC490LC-11 468
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 484
STANDARD VALUE TABLE FOR ELECTRICAL . 488
STANDARD VALUE TABLE FOR ELECTRICAL . 488
30 TESTING AND ADJUSTING 499
CONTENTS 500
RELATED INFORMATION ON TESTING AND ADJUSTING 503
TOOLS FOR TESTING AND ADJUSTING . 503
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 509
510
TEST ENGINE SPEED . 511
METHOD FOR TESTING ENGINE SPEED . 511
TEST BOOST PRESSURE . 513
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 513
METHOD FOR TESTING BOOST PRESSURE . 514
TEST EXHAUST GAS COLOR 515
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 515
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 516
TEST AND ADJUST VALVE CLEARANCE . 517
METHOD FOR TESTING VALVE CLEARANCE 517
METHOD FOR ADJUSTING VALVE CLEARANCE 519
TEST COMPRESSION PRESSURE . 520
METHOD FOR TESTING COMPRESSION PRESSURE . 520
TEST BLOWBY PRESSURE 523
METHOD FOR TESTING BLOWBY PRESSURE 523
TEST ENGINE OIL PRESSURE 525
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR . 525
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 525
TEST EGR VALVE AND KVGT OIL PRESSURE 527
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE 527
TEST FUEL PRESSURE 529
METHOD FOR TESTING FUEL PRESSURE 529
TEST FUEL RETURN RATE AND LEAKAGE . 531
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE . 531
BLEED AIR FROM FUEL SYSTEM 534
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 534
TEST FUEL CIRCUIT FOR LEAKAGE . 536
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 536
HANDLE CYLINDER CUT-OUT MODE OPERATION 538
HANDLE NO-INJECTION CRANKING OPERATION 539
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 540
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 540
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 540
CLEAN FUEL DOSER 542
METHOD FOR CLEANING FUEL DOSER 542
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 544
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 544
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 550
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 550
TEST SCR RELATED FUNCTIONS 551
TEST AdBlue/DEF PUMP RAISED PRESSURE 554
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 556
TEST AdBlue/DEF LINE HEATER RELAY 1 . 559
TEST AdBlue/DEF LINE HEATER RELAY 2 . 561
TEST AdBlue/DEF PUMP HEATER RELAY . 564
TEST AdBlue/DEF TANK HEATER VALVE . 567
TEST DENITRATION EFFICIENCY OF SCR 570
CLEAN AdBlue/DEF TANK . 573
METHOD FOR CLEANING AdBlue/DEF TANK . 573
576
TEST SWING CIRCLE BEARING CLEARANCE . 577
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 577
577
TEST AND ADJUST TRACK TENSION . 578
METHOD FOR TESTING TRACK TENSION 578
METHOD FOR ADJUSTING TRACK TENSION 578
579
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 580
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 580
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 581
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 582
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 588
TEST OIL PRESSURE OF CONTROL CIRCUIT 592
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 592
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 594
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 594
TEST PC-EPC VALVE OUTLET PRESSURE . 595
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 596
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 597
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 597
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 598
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 599
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 600
METHOD FOR ADJUSTING LS VALVE . 601
TEST OUTLET PRESSURE OF SOLENOID VALVE 602
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 602
OPERATING CONDITION OF SOLENOID VALVE . 603
TEST PPC VALVE OUTLET PRESSURE 605
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 605
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 607
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 607
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 608
TEST PUMP SWASH PLATE SENSOR 610
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 610
TEST COOLING FAN SPEED 611
METHOD FOR TESTING COOLING FAN SPEED 611
TEST OIL PRESSURE IN FAN PUMP CIRCUIT . 612
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT . 612
TEST FAN PUMP EPC ELECTRIC CURRENT 614
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 614
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 615
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 615
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 616
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 616
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 616
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 617
TEST OIL LEAKAGE 618
TEST OIL LEAKAGE OF BOOM CYLINDER . 618
TEST OIL LEAKAGE OF ARM CYLINDER 618
TEST OIL LEAKAGE OF BUCKET CYLINDER . 619
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR . 619
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 619
BLEED AIR FROM HYDRAULIC CIRCUIT 621
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 622
624
TEST CAB TIPPING STOPPER 625
METHOD FOR TESTING CAB TIPPING STOPPER 625
METHOD FOR ADJUSTING MIRRORS 626
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 626
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 627
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 628
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 629
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 630
ELECTRICAL SYSTEM . 632
SETTING AND OPERATION OF MACHINE MONITOR 632
OPERATOR MODE . 635
SERVICE MODE 640
METHOD FOR STARTING UP KOMTRAX TERMINAL . 715
ADJUST REARVIEW CAMERA ANGLE 720
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 720
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 723
HANDLE BATTERY DISCONNECT SWITCH 724
TEST DIODES . 725
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 725
METHOD FOR TESTING DIODE USING ANALOG TESTER 725
Pm CLINIC . 726
Pm CLINIC SERVICE . 726
Pm CLINIC CHECK SHEET . 727
40 TROUBLESHOOTING 739
CONTENTS 740
RELATED INFORMATION ON TROUBLESHOOTING 751
GENERAL TROUBLESHOOTING POINTS 751
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 752
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 764
CHECKS BEFORE TROUBLESHOOTING . 766
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 768
WALK-AROUND CHECK . 768
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 770
CHECK FUEL LEVEL AND TYPE . 770
CHECK IMPURE INGREDIENT IN FUEL . 771
CHECK FUEL PREFILTER 771
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 771
FUEL PREFILTER CARTRIDGE – REPLACE 772
CHECK MAIN FILTER . 773
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 774
CHECK COOLANT LEVEL (RESERVOIR TANK) 776
CHECK CLOGGING OF AIR CLEANER . 776
OUTER ELEMENT – CLEAN . 777
ELEMENTS – REPLACE 779
CHECK HYDRAULIC OIL LEVEL . 780
CHECK HYDRAULIC OIL STRAINER 780
CHECK HYDRAULIC FILTER 781
CHECK OIL LEVEL IN SWING MACHINERY CASE . 782
CHECK OIL LEVEL IN DAMPER CASE 783
CHECK OIL LEVEL IN FINAL DRIVE CASE . 783
BLEED AIR FROM FUEL SYSTEM 784
BLEED AIR FROM HYDRAULIC SYSTEM . 784
ELECTRICAL EQUIPMENT – CHECK METHOD . 784
AUTOMATIC GREASE SYSTEM . 791
FINDING MALFUNCTIONS 791
MALFUNCTION FINDING PROCEDURES 793
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 795
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 805
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 808
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 812
CONNECTOR LIST AND LAYOUT . 814
CONNECTOR CONTACT IDENTIFICATION 827
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 867
FUSE LOCATION TABLE . 873
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 875
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 879
FAILURE CODES TABLE . 881
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 899
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit . 899
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 900
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit . 901
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 903
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit . 905
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 906
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit . 907
FAILURE CODE [879EMC] Ventilation Damper Malfunction 909
FAILURE CODE [879FMC] Air Mix Damper Malfunction 910
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 911
FAILURE CODE [989L00] Engine Controller Lock Caution 1 913
FAILURE CODE [989M00] Engine Controller Lock Caution 2 914
FAILURE CODE [989N00] Engine Controller Lock Caution 3 915
FAILURE CODE [A1U0N3] HC Desorb Request 1 . 916
FAILURE CODE [A1U0N4] HC Desorb Request 2 . 918
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3 920
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1 921
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2 922
FAILURE CODE [AA10NX] Air Cleaner Clogging 923
FAILURE CODE [AB00KE] Charge Voltage Low 925
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) . 928
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) 930
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) 932
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) . 933
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality) . 934
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality) . 935
FAILURE CODE [AS00R6] Temporary Recovery of Inducement 936
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5 937
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning 938
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning 939
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution 940
FAILURE CODE [B@BAZG] Eng Oil Press Low . 941
FAILURE CODE [B@BAZK] Eng Oil Level Low . 942
FAILURE CODE [B@BCNS] Eng Water Overheat 944
FAILURE CODE [B@BCZK] Eng Water Level Low . 945
FAILURE CODE [B@HANS] Hyd Oil Overheat 947
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error 948
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error 949
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error . 951
FAILURE CODE [CA131] Throttle Sensor High Error . 953
FAILURE CODE [CA132] Throttle Sensor Low Error 955
FAILURE CODE [CA135] Engine Oil Pressure Sensor High Error 957
FAILURE CODE [CA141] Engine Oil Pressure Sensor Low Error . 959
FAILURE CODE [CA144] Coolant Temperature Sensor High Error 961
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error . 963
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error . 965
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error 968
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error 971
FAILURE CODE [CA221] Ambient Pressure Sensor High Error . 973
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error 975
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error . 977
FAILURE CODE [CA234] Engine Overspeed . 978
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error . 979
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error 981
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error . 983
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error 985
FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error . 987
FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error 989
FAILURE CODE [CA273] PCV 2 Short Circuit Error 990
FAILURE CODE [CA274] PCV 2 Open Circuit Error . 992
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error 993
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error 995
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error 997
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error 999
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error 1001
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error 1003
FAILURE CODE [CA343] Engine Controller Internal Failure .1005
FAILURE CODE [CA351] Injectors Drive Circuit Error 1006
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error 1007
FAILURE CODE [CA356] MAF Sensor High Error 1010
FAILURE CODE [CA357] MAF Sensor Low Error .1012
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error .1014
FAILURE CODE [CA441] Battery Voltage Low Error 1015
FAILURE CODE [CA442] Battery Voltage High Error .1017
FAILURE CODE [CA449] Common Rail Pressure High Error 2 1018
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error .1019
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error 1021
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error 1023
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error .1025
FAILURE CODE [CA553] Common Rail Pressure High Error 1 1027
FAILURE CODE [CA555] Crankcase Pressure High Error 1 1028
FAILURE CODE [CA556] Crankcase Pressure High Error 2 1029
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 .1030
FAILURE CODE [CA595] Turbocharger Speed High Error 2 1035
FAILURE CODE [CA687] Turbocharger Speed Low Error .1036
FAILURE CODE [CA689] Engine NE Speed Sensor Error .1038
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error .1040
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error 1042
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error .1044
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error 1045
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error .1046
FAILURE CODE [CA778] Engine Backup Speed Sensor Error .1047
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error .1050
FAILURE CODE [CA1664] KDOC Abnormality 1051
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error 1054
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3 1055
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error .1056
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error 1057
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error .1058
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error 1060
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error .1062
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error 1064
FAILURE CODE [CA1691] Defective Regeneration 1065
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error 1068
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error 1070
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error .1071
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error .1073
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error .1076
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error 1078
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error 1079
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error 1080
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error .1083
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error 1086
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error .1088
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error 1091
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error .1094
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error 1096
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error .1099
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error .1101
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 .1103
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2 .1106
FAILURE CODE [CA1923] Fuel Doser Solenoid 1 High Error 1111
FAILURE CODE [CA1924] Fuel Doser Solenoid 1 Low Error .1113
FAILURE CODE [CA1925] Fuel Doser Solenoid 1 In Range Error 1115
FAILURE CODE [CA1927] Dosing Fuel Pressure Sensor High Error 1117
FAILURE CODE [CA1928] Dosing Fuel Pressure Sensor Low Error .1119
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error 1121
FAILURE CODE [CA1963] Fuel Doser Solenoid 1 Servo Error .1122
FAILURE CODE [CA1977] Fuel Doser Open Error or Short Error 1125
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error 1128
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error .1131
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error 1133
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 1135
FAILURE CODE [CA2265] Fuel Feed Pump Open Error .1136
FAILURE CODE [CA2266] Fuel Feed Pump Short Error 1138
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error 1140
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error .1142
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error .1144
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error 1146
FAILURE CODE [CA2357] EGR Valve Servo Error .1148
FAILURE CODE [CA2381] KVGT Position Sensor High Error .1149
FAILURE CODE [CA2382] KVGT Position Sensor Low Error 1151
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error 1153
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error .1155
FAILURE CODE [CA2387] KVGT Servo Error 1157
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error 1158
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error .1161
FAILURE CODE [CA2637] KDOC Face Plugging 1163
FAILURE CODE [CA2639] Manual Stationary Regeneration Request 1165
FAILURE CODE [CA2732] Fuel Doser Solenoid 2 High Error 1168
FAILURE CODE [CA2733] Fuel Doser Solenoid 2 Low Error .1170
FAILURE CODE [CA2741] Fuel Dozer Solenoid Valve Swap Error 1172
FAILURE CODE [CA2765] Injector Trim Data Mismatch .1173
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error 1174
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable 1180
FAILURE CODE [CA2878] Fuel Doser Solenoid 2 Servo Error .1183
FAILURE CODE [CA2881] Dosing Fuel Pressure Low Error 1 1186
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error .1189
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error 1191
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error .1193
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error 1195
FAILURE CODE [CA3142] SCR Temperature Sensor High Error .1198
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error 1199
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error .1200
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error 1202
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error .1203
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error 1204
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2 .1206
FAILURE CODE [CA3165] SCR Outlet Temperature High Error .1212
FAILURE CODE [CA3167] Fuel Doser Degradation 1214
FAILURE CODE [CA3229] SCR Temperature High Error 1217
FAILURE CODE [CA3231] SCR Temperature High Error – Non Regeneration .1219
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error 1221
FAILURE CODE [CA3235] SCR Outlet Temperature High Error – Non Regeneration 1225
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error .1227
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error 1230
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error .1233
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error .1236
FAILURE CODE [CA3253] KDOC Temperature Error – Non Regeneration .1238
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1 1241
FAILURE CODE [CA3255] KDPF Temperature Error – Non Regeneration .1244
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 1248
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2 1250
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2 1252
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error .1255
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error 1257
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error 1258
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error 1261
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error .1263
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error .1264
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error .1266
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error 1267
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error .1269
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error 1272
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error .1274
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1 1276
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2 1277
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) 1278
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error 1284
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4 1286
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error 1287
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error .1289
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error 1291
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error .1293
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error .1296
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction .1299
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error 1303
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error .1305
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error 1307
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error .1309
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error .1311
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error 1313
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1 .1315
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error .1321
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error .1323
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error .1325
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error .1327
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error .1332
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error .1338
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error 1341
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error 1342
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error 1343
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error 1346
FAILURE CODE [CA3751] SCR Catalyst Degradation Error 1348
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error .1350
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 1352
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1 1355
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error .1358
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error 1362
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error .1364
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error 1368
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error 1370
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error .1372
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error 1374
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error 1377
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error .1379
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error .1381
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error .1385
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error .1389
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error 1392
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction 1395
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error .1397
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error .1398
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error .1399
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error 1402
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error .1405
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error .1408
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error 1410
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error .1412
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error .1414
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error 1417
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error .1419
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error .1422
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error .1424
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error 1426
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error 1428
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error .1431
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error .1434
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error 1437
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error .1440
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error .1443
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error .1447
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error .1448
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error 1449
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error .1450
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible .1452
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error .1455
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller) .1458
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error 1460
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error .1463
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error 1465
FAILURE CODE [CA5383] Ash Accumulation High Error .1467
FAILURE CODE [D110KB] Battery Relay Output Short Circuit 1469
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit .1471
FAILURE CODE [D811MC] KOMTRAX Malfunction .1474
FAILURE CODE [D862KA] GPS Antenna Open Circuit 1475
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX) 1476
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .1478
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX) .1480
FAILURE CODE [DA20MC] Pump Controller Malfunction .1482
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error 1483
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error .1486
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller) .1489
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller) 1491
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller) .1493
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller) .1495
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller) .1498
FAILURE CODE [DAF0MB] Monitor ROM Abnormality .1499
FAILURE CODE [DAF0MC] Monitor Malfunction .1500
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit .1501
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor) .1503
FAILURE CODE [DAFGMC] GPS Module Malfunction 1504
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) 1505
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) .1507
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor) .1509
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) .1510
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU) .1511
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller) .1516
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller) .1521
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit 1525
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit .1527
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On 1529
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit .1531
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault .1533
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1535
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen 1537
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen 1539
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function .1541
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function 1544
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function .1547
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function 1550
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function .1553
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function .1556
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function 1559
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function .1562
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function 1565
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function 1568
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function 1571
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function .1574
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function 1577
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function .1580
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function 1583
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function .1586
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit .1589
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit 1591
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit 1593
FAILURE CODE [DLM3KA] Fan Speed Sensor Open Circuit .1594
FAILURE CODE [DLM3KB] Fan Speed Sensor Short Circuit 1596
FAILURE CODE [DLM3MB] Fan control:Mismatch 1598
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range .1599
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range .1601
FAILURE CODE [DV20KB] Travel Alarm Short Circuit 1603
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit 1605
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit .1607
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit .1609
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit 1611
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit 1614
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit 1617
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit .1619
FAILURE CODE [DW7BKA] Fan Reverse Solenoid Open Circuit .1620
FAILURE CODE [DW7BKB] Fan Reverse Solenoid Short Circuit 1622
FAILURE CODE [DW7BKY] Fan Reverse Solenoid Hot Short Circuit 1624
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit .1625
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit 1627
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit 1629
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit .1631
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit 1633
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit 1635
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit 1637
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit 1639
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit .1641
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit 1643
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit .1645
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit .1647
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit .1649
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit 1651
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit 1653
FAILURE CODE [DX16KA] Fan Pump EPC Solenoid Open Circuit 1655
FAILURE CODE [DX16KB] Fan Pump EPC Solenoid Short Circuit .1657
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit .1659
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit 1661
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit 1663
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit .1665
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit 1667
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit .1669
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit 1671
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit .1673
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit .1675
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit 1677
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit .1679
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit 1681
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit .1683
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit 1685
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit .1687
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit 1689
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit 1691
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit .1693
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit 1695
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit 1697
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit .1699
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit 1701
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit 1703
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit .1705
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 5 Hot Short Circuit 1707
FAILURE CODE [DY20KA]Wiper Motor Open Circuit .1709
FAILURE CODE [DY20MA] Wiper Motor Defective Function 1711
FAILURE CODE [DY2CKB] Washer Motor Short Circuit 1713
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit .1716
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit 1718
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1720
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1720
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1726
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1729
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1731
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1733
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1736
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1737
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1738
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1739
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1740
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1741
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1742
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1743
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1744
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1745
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1746
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1748
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1749
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1750
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1751
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1753
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1754
E-23 FUNCTION SWITCH DOES NOT OPERATE .1755
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1756
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1757
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1758
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1759
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1760
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1761
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1762
E-31 ALARM BUZZER CANNOT BE CANCELED 1764
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1765
E-33 SERVICE MODE CANNOT BE SELECTED 1766
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1767
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1769
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1770
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1773
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1775
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1777
E-40 ALARM DOES NOT SOUND DURING TRAVEL .1778
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1780
E-42 HORN DOES NOT SOUND 1781
E-43 HORN DOES NOT STOP SOUNDING 1785
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1787
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1788
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1790
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1791
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1792
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1793
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1794
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1795
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1796
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1797
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1798
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1799
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1801
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1802
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1803
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1805
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1806
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1806
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1807
FAILURE MODE AND CAUSE TABLE 1809
H-1 ANY OF WORK EQUIPMENT, SWING AND TRAVEL DOES NOT WORK .1817
H-2 ALL OF WORK EQUIPMENTS, SWING AND TRAVEL OPERATION LACK SPEED OR POWER 1818
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1820
H-4 UNUSUAL SOUND IS HEARD FROM AROUND HYDRAULIC PUMP .1821
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1822
H-6 SPEED OR POWER OF BOOM IS LOW .1824
H-7 SPEED OR POWER OF ARM IS LOW 1830
H-8 SPEED OR POWER OF BUCKET IS LOW .1835
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1838
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1839
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1841
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1843
H-13 OTHER WORK EQUIPMENT MOVES WHEN ONE OF WORK EQUIPMENT IS RELIEVED 1844
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1845
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK 1846
H-16 MACHINE PUSH-UP FUNCTION DOES NOT WORK .1847
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1848
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CONTROLLED 1849
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT , EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER .1850
H-20 TRAVEL SPEED DROPS LARGELY IN COMBINED OPERATION OF SWING AND TRAVE 1851
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1852
H-22 MACHINE DOES NOT TRAVEL STRAIGHT .1853
H-23 MACHINE IS HARD TO STEER OR TRAVEL POWER IS LOW 1855
H-24 TRAVEL SPEED IS LOW 1858
H-25 ONE OF TRACKS DOES NOT RUN .1860
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO LOW OR HIGH .1861
H-27 UPPER STRUCTURE DOES NOT SWING IN BOTH RIGHT AND LEFT DIRECTIONS .1862
H-28 UPPER STRUCTURE SWING IN ONLY ONE DIRECTION 1863
H-29 SWING ACCELERATION OR SWING SPEED OF UPPER STRUCTURE IS LOW IN BOTH RIGHT AND LEFT DIRECTIONS 1864
H-30 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION .1865
H-31 OVERRUN OF UPPER STRUCTURE IS LARGE IN BOTH RIGHT AND LEFT DIRECTIONS 1866
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING IN ONLY ONE DIRECTION .1867
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1868
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1869
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1870
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1871
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1872
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1873
H-39 Quick coupler cylinder will not extend .1874
H-40 Quick coupler cylinder will not retract (but buzzer does not sound) 1876
H-41 Buzzer does not sound (but quick coupler cylinder does retract) 1878
H-42 Quick coupler cylinder extends and retracts slowly .1880
TROUBLESHOOTING OF ENGINE (S-MODE) 1881
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1881
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1882
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1883
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1884
S-4 ENGINE STARTABILITY IS POOR .1885
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1887
S-6 ENGINE STOPS DURING OPERATION .1889
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1891
S-8 ENGINE LACKS POWER 1892
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1894
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1896
S-11 OIL BECOMES CONTAMINATED QUICKLY .1897
S-12 FUEL CONSUMPTION IS EXCESSIVE 1898
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1899
S-14 OIL PRESSURE DROPS .1900
S-15 FUEL MIXES INTO ENGINE OIL .1902
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1903
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1904
S-18 UNUSUAL NOISE IS HEARD .1905
S-19 VIBRATION IS EXCESSIVE .1906
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1907
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1908
S-22 ACTIVE REGENERATION TAKES TIME .1910
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1911
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1912
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1914
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1915
50 DISASSEMBLY AND ASSEMBLY .1917
CONTENTS 1918
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1922
HOW TO READ THIS MANUAL .1922
COATING MATERIALS LIST 1924
SPECIAL TOOLS LIST 1929
SKETCHES OF SPECIAL TOOLS .1941
ENGINE AND COOLING SYSTEM .1947
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1947
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1947
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1953
REMOVE AND INSTALL INJECTOR ASSEMBLY 1962
METHOD FOR REMOVING INJECTOR ASSEMBLY .1962
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1968
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 1978
METHOD FOR REMOVING FUEL DOSER 1978
METHOD FOR INSTALLING FUEL DOSER 1979
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1981
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1982
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1990
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2004
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2004
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2006
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2008
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2008
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2012
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2017
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY .2017
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY .2018
REMOVE AND INSTALL ALTERNATOR BELT 2020
METHOD FOR REMOVING ALTERNATOR BELT .2020
METHOD FOR INSTALLING ALTERNATOR BELT .2023
REMOVE AND INSTALL RADIATOR ASSEMBLY 2028
METHOD FOR REMOVING RADIATOR ASSEMBLY .2028
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2030
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY .2033
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2033
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2037
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2042
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2042
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2044
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2046
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2046
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2048
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2052
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2053
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2070
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2089
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2090
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2092
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2096
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2097
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2100
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2106
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2106
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2114
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2123
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2123
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2127
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2131
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2131
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2137
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2142
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2142
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2149
REMOVE AND INSTALL KDPF ASSEMBLY 2154
METHOD FOR REMOVING KDPF ASSEMBLY .2154
METHOD FOR INSTALLING KDPF ASSEMBLY .2158
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2163
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2164
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2169
REMOVE AND INSTALL SCR ASSEMBLY .2176
METHOD FOR REMOVING SCR ASSEMBLY 2176
METHOD FOR INSTALLING SCR ASSEMBLY 2179
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2183
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2183
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2188
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2193
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2193
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2197
REMOVE AND INSTALL KCCV ASSEMBLY 2207
METHOD FOR REMOVING KCCV ASSEMBLY .2207
METHOD FOR INSTALLING KCCV ASSEMBLY .2208
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2212
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2212
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2217
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2223
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2223
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2227
REMOVE AND INSTALL AdBlue/DEF PUMP 2231
METHOD FOR REMOVING AdBlue/DEF PUMP .2231
METHOD FOR INSTALLING AdBlue/DEF PUMP .2233
REMOVE AND INSTALL AdBlue/DEF HOSE 2234
METHOD FOR REMOVING AdBlue/DEF HOSE .2234
METHOD FOR INSTALLING AdBlue/DEF HOSE .2239
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2248
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2248
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2249
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2252
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2252
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2255
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2259
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2259
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2260
POWER TRAIN .2262
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2262
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2262
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2263
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2264
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2264
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2269
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2275
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2275
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2276
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2278
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2278
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2282
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2288
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2288
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2288
UNDERCARRIAGE AND FRAME .2290
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2290
METHOD FOR SEPARATING TRACK ASSEMBLY 2290
METHOD FOR INSTALLING TRACK ASSEMBLY 2292
REMOVE AND INSTALL SPROCKET .2295
METHOD FOR REMOVING SPROCKET 2295
METHOD FOR INSTALLING SPROCKET 2295
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2297
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2297
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2298
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2300
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2300
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2302
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2307
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2308
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2310
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2313
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2314
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2315
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2319
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2319
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2321
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2324
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2324
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2326
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2329
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2329
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2330
HYDRAULIC SYSTEM 2332
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2332
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2332
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2334
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2336
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2337
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2337
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2339
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2339
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2344
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2350
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2350
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2354
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2360
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2360
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2365
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2371
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2372
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2373
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2378
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2378
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2379
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2381
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2381
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2382
REMOVE AND INSTALL QUICK COUPLER VALVE 2384
WORK EQUIPMENT 2386
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2386
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2387
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2390
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2394
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2394
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2397
CAB AND ITS ATTACHMENTS .2401
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2401
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2401
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2407
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) .2414
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2416
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2416
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2426
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2426
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2429
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2435
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2435
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2442
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2450
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2450
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2455
REMOVE AND INSTALL OPERATOR’S SEAT 2461
METHOD FOR REMOVING OPERATOR’S SEAT .2461
METHOD FOR INSTALLING OPERATOR’S SEAT .2463
REMOVE AND INSTALL SEAT BELT 2466
METHOD FOR REMOVING SEAT BELT .2466
METHOD FOR INSTALLING SEAT BELT .2467
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2468
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2468
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2473
ELECTRICAL SYSTEM .2481
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2481
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2481
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2482
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2484
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2484
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2487
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2492
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2492
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2495
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2499
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2499
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2500
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2501
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2501
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2502
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2504
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2504
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2505
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2507
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2507
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2509
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2511
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2511
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2514
60 MAINTENANCE STANDARD .2517
CONTENTS 2518
ENGINE AND COOLING SYSTEM .2519
MAINTENANCE STANDARD OF ENGINE MOUNT 2519
MAINTENANCE STANDARD OF COOLING SYSTEM 2520
MAINTENANCE STANDARD OF COOLING FAN PUMP 2521
MAINTENANCE STANDARD OF SERVO VALVE .2522
MAINTENANCE STANDARD OF COOLING FAN MOTOR .2523
POWER TRAIN .2524
MAINTENANCE STANDARD OF SWING CIRCLE 2524
MAINTENANCE STANDARD OF SWING MACHINERY .2525
MAINTENANCE STANDARD OF FINAL DRIVE .2527
MAINTENANCE STANDARD OF SPROCKET 2529
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2530
UNDERCARRIAGE AND FRAME .2532
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2532
MAINTENANCE STANDARD OF IDLER .2534
MAINTENANCE STANDARD OF TRACK ROLLER 2536
MAINTENANCE STANDARD OF CARRIER ROLLER 2538
MAINTENANCE STANDARD OF TRACK SHOE 2539
MAINTENANCE STANDARD OF TRIPLE SHOE .2542
HYDRAULIC SYSTEM 2543
MAINTENANCE STANDARD OF MAIN PUMP .2543
MAINTENANCE STANDARD OF SWING MOTOR .2545
MAINTENANCE STANDARD OF TRAVEL MOTOR 2548
MAINTENANCE STANDARD OF CONTROL VALVE .2551
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2562
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2565
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2568
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2569
MAINTENANCE STANDARD OF SOLENOID VALVE 2571
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2572
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE .2574
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2575
WORK EQUIPMENT 2576
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2576
DIMENSION OF ARM 2581
DIMENSIONS OF BUCKET 2583
MAINTENANCE STANDARD OF BOOM CYLINDER .2585
MAINTENANCE STANDARD OF ARM CYLINDER 2586
MAINTENANCE STANDARD OF BUCKET CYLINDER .2587
80 APPENDIX .2589
CONTENTS 2590
AIR CONDITIONER SYSTEM 2592
PRECAUTIONS FOR REFRIGERANT .2592
AIR CONDITIONER COMPONENT .2593
SPECIFICATIONS OF AIR CONDITIONER .2595
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2596
OUTLINE OF REFRIGERATION CYCLE 2597
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2599
AIR CONDITIONER UNIT 2599
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2599
FUNCTION OF AIR CONDITIONER UNIT 2601
COMPONENT PARTS OF AIR CONDITIONER UNIT .2603
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2604
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2604
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2604
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2604
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2605
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2605
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2605
FUNCTION OF DUAL PRESSURE SWITCH 2606
AIR CONDITIONER CONTROLLER 2607
STRUCTURE OF AIR CONDITIONER CONTROLLER .2607
COMPRESSOR 2608
STRUCTURE OF COMPRESSOR .2608
SPECIFICATIONS OF COMPRESSOR 2608
FUNCTION OF COMPRESSOR 2609
CONDENSER .2610
STRUCTURE OF CONDENSER 2610
SPECIFICATIONS OF CONDENSER .2610
FUNCTION OF CONDENSER .2610
RECEIVER DRIER 2611
STRUCTURE OF RECEIVER DRIER .2611
SPECIFICATIONS OF RECEIVER DRIER 2611
FUNCTION OF RECEIVER DRIER 2611
SENSORS FOR AIR CONDITIONER SYSTEM 2612
STRUCTURE OF SUNLIGHT SENSOR 2612
FUNCTION OF SUNLIGHT SENSOR .2612
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2612
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2612
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2614
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2616
AIR CONDITIONER SYSTEM DIAGRAM 2618
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2619
FUNCTION OF AIR CONDITIONER CONTROLLER 2620
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2621
TESTING AIR LEAKAGE (DUCT) 2625
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2625
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2627
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2628
TEST VENT (MODE) CHANGEOVER .2629
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2629
TESTING FRESH/RECIRC AIR CHANGEOVER .2631
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2631
TEST SUNLIGHT SENSOR 2632
METHOD FOR TESTING SUNLIGHT SENSOR 2632
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2633
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2633
TEST RELAYS .2634
METHOD FOR TESTING RELAYS .2634
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2635
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2636
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2639
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit .2641
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 2642
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit .2643
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 2645
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit .2647
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 2648
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit .2649
FAILURE CODE [879EMC] Ventilation Damper Malfunction 2651
FAILURE CODE [879FMC] Air Mix Damper Malfunction 2652
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 2653
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2655
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2656
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2657
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2658
TROUBLESHOOTING USING GAUGE PRESSURE 2659
CONNECTION OF SERVICE TOOL 2662
METHOD FOR CONNECTING SERVICE TOOL 2662
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2664
HANDLE COMPRESSOR OIL .2666
90 CIRCUIT DIAGRAMS .2669
CONTENTS 2670
HYDRAULIC CIRCUIT DIAGRAM .2671
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2671
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2675
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2677
ELECTRICAL CIRCUIT DIAGRAM 2679
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2679
ELECTRICAL CIRCUIT DIAGRAM (1/9) 2683
ELECTRICAL CIRCUIT DIAGRAM (2/9) 2685
ELECTRICAL CIRCUIT DIAGRAM (3/9) 2687
ELECTRICAL CIRCUIT DIAGRAM (4/9) 2689
ELECTRICAL CIRCUIT DIAGRAM (5/9) 2691
ELECTRICAL CIRCUIT DIAGRAM (6/9) 2693
ELECTRICAL CIRCUIT DIAGRAM (7/9) 2695
ELECTRICAL CIRCUIT DIAGRAM (8/9) 2697
ELECTRICAL CIRCUIT DIAGRAM (9/9) 2699
INDEX .2701

DESCRIPTION:

Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00300 –  PDF DOWNLOAD

SERIAL NUMBERS

• 85006 and up
• K70001 and up

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

G.B 29/12/24