Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00301 PDF

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Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00301 –  PDF DOWNLOAD

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Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00301 –  PDF DOWNLOAD

Language : English
Pages : 2806
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00301 –  PDF DOWNLOAD

SERIAL NUMBERS

• 85006 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
40
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 40
PRECAUTIONS FOR ADDING 40
PRECAUTIONS FOR STORING . 40
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 40
THE OTHER PRECAUTIONS . 41
STORE DEF . 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 56
PRACTICAL USE OF KOMTRAX 57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 60
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 72
HOW TO READ ELECTRICAL WIRE CODE 73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 77
STANDARD TIGHTENING TORQUE TABLE 80
CONVERSION TABLE 87
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC490,PC490LC-11 . 101
WORKING RANGE DRAWINGS 103
WORKING RANGE: PC490/PC490LC-11 . 103
SPECIFICATIONS 104
SPECIFICATIONS: PC490/PC490LC-11 104
WEIGHT TABLE 107
WEIGHT TABLE: PC490,PC490LC-11 107
TABLE OF FUEL, COOLANT, AND LUBRICANTS 109
10 STRUCTURE AND FUNCTION . 111
CONTENTS 112
ABBREVIATION LIST . 116
UREA SCR SYSTEM . 122
LAYOUT DRAWING OF UREA SCR SYSTEM . 122
UREA SCR SYSTEM DIAGRAM . 126
FUNCTION OF UREA SCR SYSTEM . 127
FUNCTION OF AdBlue/DEF SYSTEM . 127
INDUCEMENT STRATEGY . 129
COMPONENT PARTS OF UREA SCR SYSTEM 137
AdBlue/DEF MIXING TUBE 137
SCR ASSEMBLY 137
AdBlue/DEF TANK . 140
AdBlue/DEF PUMP . 142
AdBlue/DEF INJECTOR . 143
AdBlue/DEF HOSE . 144
AdBlue/DEF TANK HEATING VALVE . 145
BOOT-UP SYSTEM 146
LAYOUT DRAWING OF BOOT-UP SYSTEM 146
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH . 149
FUNCTION OF BATTERY DISCONNECT SWITCH . 149
ENGINE SYSTEM . 150
LAYOUT DRAWING OF ENGINE SYSTEM . 150
SPECIFICATIONS OF ENGINE SYSTEM . 151
FUNCTION OF ENGINE SYSTEM . 152
ENGINE CONTROL SYSTEM . 153
ENGINE CONTROL SYSTEM DIAGRAM . 153
FUNCTION OF ENGINE CONTROL SYSTEM . 154
AUTO-DECELERATION SYSTEM 156
AUTO-DECELERATION SYSTEM DIAGRAM 156
FUNCTION OF AUTO-DECELERATION SYSTEM 156
OPERATION OF AUTO-DECELERATION SYSTEM . 157
ENGINE AUTOMATIC WARM-UP SYSTEM . 158
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 158
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 159
OVERHEAT PREVENTION SYSTEM 160
OVERHEAT PREVENTION SYSTEM DIAGRAM 160
FUNCTION OF OVERHEAT PREVENTION SYSTEM 161
TURBOCHARGER PROTECTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 163
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM 165
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 165
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 165
COMPONENT PARTS OF ENGINE SYSTEM 168
VGT . 168
EGR SYSTEM 171
EGR VALVE . 173
EGR COOLER 175
KCCV SYSTEM . 176
KCCV VENTILATOR . 177
KDPF 179
COOLING SYSTEM 184
LAYOUT DRAWING OF COOLING SYSTEM 184
SPECIFICATIONS OF COOLING SYSTEM 185
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 187
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 187
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN . 188
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 189
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN . 189
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN . 190
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 192
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 192
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 192
COMPONENT PARTS OF COOLING SYSTEM . 194
COOLING FAN PUMP 194
COOLING FAN MOTOR . 201
CONTROL SYSTEM 208
LAYOUT DRAWING OF CONTROL SYSTEM 208
MACHINE MONITOR SYSTEM 211
MACHINE MONITOR SYSTEM DIAGRAM 211
KOMTRAX SYSTEM 212
KOMTRAX SYSTEM DIAGRAM 212
FUNCTION OF KOMTRAX SYSTEM 212
PPC LEVERS 213
LH PPC LEVER 213
RH PPC LEVER 214
AUTOMATIC GREASE SYSTEM . 215
COMPONENT PARTS OF CONTROL SYSTEM . 216
MACHINE MONITOR . 216
KOMTRAX TERMINAL 229
PUMP CONTROLLER . 231
RESISTOR FOR PC-EPC VALVE . 235
CAN TERMINATING RESISTOR 235
ENGINE CONTROLLER . 237
FUEL CONTROL DIAL . 243
FUEL FEED PUMP 245
FUEL FEED PUMP SWITCH . 246
246
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 246
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 247
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 247
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 248
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 248
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 248
STRUCTURE OF OVERLOAD CAUTION SENSOR 248
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 249
FUNCTION OF OVERLOAD CAUTION SENSOR . 249
HYDRAULIC SYSTEM 250
LAYOUT DRAWING OF HYDRAULIC SYSTEM 250
CLSS 252
STRUCTURE OF CLSS . 252
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 254
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 255
PRESSURE COMPENSATION CONTROL . 268
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 271
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 271
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 273
PUMP AND VALVE CONTROL SYSTEM . 278
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 278
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 279
COMPONENT PARTS OF HYDRAULIC SYSTEM . 281
HYDRAULIC TANK 281
MAIN PUMP . 283
PILOT OIL FILTER 309
CONTROL VALVE . 309
WORK EQUIPMENT SYSTEM . 371
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 371
STRUCTURE OF VALVE CONTROL 376
ONE-TOUCH POWER MAXIMIZING SYSTEM . 377
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 377
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 378
MACHINE PUSH-UP SYSTEM 379
MACHINE PUSH-UP SYSTEM DIAGRAM 379
FUNCTION OF MACHINE PUSH-UP SYSTEM 380
PPC LOCK SYSTEM . 381
PPC LOCK SYSTEM DIAGRAM . 381
FUNCTION OF PPC LOCK SYSTEM . 381
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 382
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 382
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 382
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 383
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 384
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT . 384
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 385
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 386
WORK EQUIPMENT AND SWING PPC VALVE 386
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 391
SOLENOID VALVE 397
VARIABLE PRESSURE COMPENSATION VALVE 399
ATTACHMENT CIRCUIT SELECTOR VALVE . 400
ATT EPC VALVE ASSEMBLY 403
PILOT CIRCUIT ACCUMULATOR . 404
SWING SYSTEM 406
LAYOUT DRAWING OF SWING SYSTEM 406
SWING CONTROL SYSTEM DIAGRAM 412
FUNCTION OF SWING CONTROL SYSTEM 412
COMPONENT PARTS OF SWING SYSTEM . 416
SWING MOTOR . 416
SWING MACHINERY . 427
SWING CIRCLE 429
TRAVEL SYSTEM . 431
LAYOUT DRAWING OF TRAVEL SYSTEM . 431
TRAVEL CONTROL SYSTEM DIAGRAM . 435
FUNCTION OF TRAVEL CONTROL SYSTEM . 436
COMPONENT PARTS OF TRAVEL SYSTEM 437
TRAVEL MOTOR 437
FINAL DRIVE . 451
TRAVEL PPC VALVE 452
CENTER SWIVEL JOINT . 457
UNDERCARRIAGE AND FRAME . 459
LAYOUT DRAWING OF UNDERCARRIAGE . 459
SPECIFICATIONS OF UNDERCARRIAGE . 459
WORK EQUIPMENT 460
STRUCTURE OF WORK EQUIPMENT . 460
FUNCTION OF WORK EQUIPMENT 461
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 462
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 462
BUCKET CLEARANCE ADJUSTMENT SHIM 463
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 463
CAB AND ITS ATTACHMENTS . 464
ROPS CAB 464
STRUCTURE OF ROPS CAB . 464
FUNCTION OF ROPS CAB 464
CAB MOUNT . 465
STRUCTURE OF CAB MOUNT 465
FUNCTION OF CAB MOUNT . 465
CAB TIPPING STOPPER . 466
STRUCTURE OF CAB TIPPING STOPPER 466
FUNCTION OF CAB TIPPING STOPPER . 466
20 STANDARD VALUE TABLE . 467
CONTENTS 468
ABBREVIATION LIST . 469
STANDARD VALUE TABLE FOR ENGINE . 475
STANDARD VALUE TABLE FOR ENGINE: PC490LC-11 . 475
STANDARD VALUE TABLE FOR MACHINE 478
STANDARD VALUE TABLE FOR MACHINE: PC490LC-11 478
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 494
STANDARD VALUE TABLE FOR ELECTRICAL . 498
STANDARD VALUE TABLE FOR ELECTRICAL . 498
30 TESTING AND ADJUSTING 509
CONTENTS 510
ABBREVIATION LIST . 513
RELATED INFORMATION ON TESTING AND ADJUSTING 519
TOOLS FOR TESTING AND ADJUSTING . 519
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 526
527
TEST ENGINE SPEED . 528
METHOD FOR TESTING ENGINE SPEED . 528
TEST BOOST PRESSURE . 531
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 531
METHOD FOR TESTING BOOST PRESSURE . 532
TEST EXHAUST GAS COLOR 533
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 533
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 534
TEST AND ADJUST VALVE CLEARANCE . 535
METHOD FOR TESTING VALVE CLEARANCE 535
METHOD FOR ADJUSTING VALVE CLEARANCE 538
TEST COMPRESSION PRESSURE . 539
METHOD FOR TESTING COMPRESSION PRESSURE . 539
TEST BLOWBY PRESSURE 542
METHOD FOR TESTING BLOWBY PRESSURE 542
TEST ENGINE OIL PRESSURE 544
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR . 544
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 544
TEST EGR VALVE AND VGT OIL PRESSURE . 546
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 546
TEST FUEL PRESSURE 548
METHOD FOR TESTING FUEL PRESSURE 548
TEST FUEL RETURN RATE AND LEAKAGE . 550
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE . 550
BLEED AIR FROM FUEL SYSTEM 553
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 553
TEST FUEL CIRCUIT FOR LEAKAGE . 555
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 555
HANDLE CYLINDER CUT-OUT MODE OPERATION 557
HANDLE NO-INJECTION CRANKING OPERATION 558
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 559
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 559
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 559
CLEAN FUEL DOSER 561
METHOD FOR CLEANING FUEL DOSER 561
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 563
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 563
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 569
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 569
TEST SCR RELATED FUNCTIONS 570
TEST AdBlue/DEF PUMP RAISED PRESSURE 573
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 576
TEST AdBlue/DEF LINE HEATER RELAY 1 . 580
TEST AdBlue/DEF LINE HEATER RELAY 2 . 582
TEST AdBlue/DEF PUMP HEATER RELAY . 585
TEST AdBlue/DEF TANK HEATER VALVE . 588
TEST DENITRATION EFFICIENCY OF SCR 591
CLEAN AdBlue/DEF TANK . 595
METHOD FOR CLEANING AdBlue/DEF TANK . 595
598
TEST SWING CIRCLE BEARING CLEARANCE . 599
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 599
599
TEST AND ADJUST TRACK TENSION . 600
METHOD FOR TESTING TRACK TENSION 600
METHOD FOR ADJUSTING TRACK TENSION 600
601
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 602
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 602
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 608
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 609
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 615
TEST OIL PRESSURE OF CONTROL CIRCUIT 619
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 619
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 621
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 621
TEST PC-EPC VALVE OUTLET PRESSURE . 622
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 623
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 625
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 625
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 626
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 627
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 628
METHOD FOR ADJUSTING LS VALVE . 629
TEST OUTLET PRESSURE OF SOLENOID VALVE 630
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 630
OPERATING CONDITION OF SOLENOID VALVE . 631
TEST PPC VALVE OUTLET PRESSURE 633
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 633
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 635
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 635
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 636
TEST PUMP SWASH PLATE SENSOR 638
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 638
TEST COOLING FAN SPEED 639
METHOD FOR TESTING COOLING FAN SPEED 639
TEST OIL PRESSURE IN FAN PUMP CIRCUIT . 640
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT . 640
TEST FAN PUMP EPC ELECTRIC CURRENT 642
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 642
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 643
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 643
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 645
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 645
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 645
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 646
TEST OIL LEAKAGE 647
TEST OIL LEAKAGE OF BOOM CYLINDER . 647
TEST OIL LEAKAGE OF ARM CYLINDER 647
TEST OIL LEAKAGE OF BUCKET CYLINDER . 648
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR . 648
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 648
BLEED AIR FROM HYDRAULIC CIRCUIT 650
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 652
654
TEST CAB TIPPING STOPPER 655
METHOD FOR TESTING CAB TIPPING STOPPER 655
METHOD FOR ADJUSTING MIRRORS 656
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 656
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 657
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 658
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 659
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 660
ELECTRICAL SYSTEM . 662
SETTING AND OPERATION OF MACHINE MONITOR 662
OPERATOR MODE . 665
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 666
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 666
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 667
CHECKING FUNCTION OF SERVICE METER 667
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 667
SERVICE MODE 670
METHOD FOR OPERATING SERVICE MODE . 670
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 672
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 679
690
METHOD FOR CONFIRMING MAINTENANCE RECORD 695
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 696
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 700
701
709
718
METHOD FOR PERFORMING NO-INJECTION CRANKING . 740
741
METHOD FOR DISPLAYING SERVICE MESSAGE . 744
METHOD FOR STARTING UP KOMTRAX TERMINAL . 745
ADJUST REARVIEW CAMERA ANGLE 750
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 750
ADJUST KomVision CAMERA ANGLE . 753
754
SETTING OF KomVision (CAMERA CALIBRATION) . 754
KomVision screen – Check 12 m visibility 767
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 770
HANDLE BATTERY DISCONNECT SWITCH 771
TEST DIODES . 772
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 772
METHOD FOR TESTING DIODE USING ANALOG TESTER 772
Pm CLINIC . 773
Pm CLINIC SERVICE . 773
Pm CLINIC CHECK SHEET . 774
40 TROUBLESHOOTING 787
CONTENTS 788
ABBREVIATION LIST . 799
RELATED INFORMATION ON TROUBLESHOOTING 805
GENERAL TROUBLESHOOTING POINTS 805
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 807
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 819
CHECKS BEFORE TROUBLESHOOTING . 821
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 823
WALK-AROUND CHECK . 823
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 825
CHECK FUEL LEVEL AND TYPE . 825
CHECK IMPURE INGREDIENT IN FUEL . 826
CHECK FUEL PREFILTER 826
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 826
FUEL PREFILTER CARTRIDGE – REPLACE 827
CHECK MAIN FILTER . 828
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 829
CHECK COOLANT LEVEL (RESERVOIR TANK) 831
CHECK CLOGGING OF AIR CLEANER . 831
OUTER ELEMENT – CLEAN . 832
ELEMENTS – REPLACE 834
CHECK HYDRAULIC OIL LEVEL . 835
CHECK HYDRAULIC OIL STRAINER 835
CHECK HYDRAULIC FILTER 836
CHECK OIL LEVEL IN SWING MACHINERY CASE . 837
CHECK OIL LEVEL IN DAMPER CASE 838
CHECK OIL LEVEL IN FINAL DRIVE CASE . 838
BLEED AIR FROM FUEL SYSTEM 839
BLEED AIR FROM HYDRAULIC SYSTEM . 839
ELECTRICAL EQUIPMENT – CHECK METHOD . 839
AUTOMATIC GREASE SYSTEM . 845
FINDING MALFUNCTIONS 845
MALFUNCTION FINDING PROCEDURES 847
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 849
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 859
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 862
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 866
CONNECTOR LIST AND LAYOUT . 868
CONNECTOR CONTACT IDENTIFICATION 881
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 921
FUSE LOCATION TABLE . 927
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 929
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 933
FAILURE CODES TABLE . 935
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 953
FAILURE CODE [879AKA] . 953
FAILURE CODE [879AKB] . 954
FAILURE CODE [879BKA] . 955
FAILURE CODE [879BKB] . 957
FAILURE CODE [879CKA] . 959
FAILURE CODE [879CKB] . 960
FAILURE CODE [879DKZ] . 961
FAILURE CODE [879EMC] . 963
FAILURE CODE [879FMC] . 964
FAILURE CODE [879GKX] . 965
FAILURE CODE [989L00] . 967
FAILURE CODE [989M00] . 968
FAILURE CODE [989N00] . 969
FAILURE CODE [A1U0N3] . 970
FAILURE CODE [A1U0N4] . 972
FAILURE CODE [A900FR] . 974
FAILURE CODE [A900N6] . 975
FAILURE CODE [A900NY] . 976
FAILURE CODE [AA10NX] . 977
FAILURE CODE [AB00KE] . 979
FAILURE CODE [AQ10N3] . 982
FAILURE CODE [AS00N3] . 984
FAILURE CODE [AS00R2] . 986
FAILURE CODE [AS00R3] . 987
FAILURE CODE [AS00R4] . 988
FAILURE CODE [AS00R5] . 989
FAILURE CODE [AS00R6] . 990
FAILURE CODE [AS00ZK] . 991
FAILURE CODE [AS10KM] . 992
FAILURE CODE [AS10NR] . 993
FAILURE CODE [AS10NT] . 994
FAILURE CODE [B@BAZG] . 995
FAILURE CODE [B@BAZK] . 996
FAILURE CODE [B@BCNS] . 998
FAILURE CODE [B@BCQA] . 999
FAILURE CODE [B@BCZK] .1001
FAILURE CODE [B@HANS] .1003
FAILURE CODE [CA115] 1004
FAILURE CODE [CA122] 1005
FAILURE CODE [CA123] 1007
FAILURE CODE [CA131] 1009
FAILURE CODE [CA132] 1011
FAILURE CODE [CA135] 1013
FAILURE CODE [CA141] 1015
FAILURE CODE [CA144] 1017
FAILURE CODE [CA145] 1019
FAILURE CODE [CA153] 1021
FAILURE CODE [CA154] 1024
FAILURE CODE [CA187] 1027
FAILURE CODE [CA221] 1029
FAILURE CODE [CA222] 1031
FAILURE CODE [CA227] 1033
FAILURE CODE [CA234] 1034
FAILURE CODE [CA238] 1035
FAILURE CODE [CA239] 1037
FAILURE CODE [CA249] 1039
FAILURE CODE [CA256] 1041
FAILURE CODE [CA271] 1043
FAILURE CODE [CA272] 1045
FAILURE CODE [CA273] 1046
FAILURE CODE [CA274] 1048
FAILURE CODE [CA322] 1049
FAILURE CODE [CA323] 1051
FAILURE CODE [CA324] 1053
FAILURE CODE [CA325] 1055
FAILURE CODE [CA331] 1057
FAILURE CODE [CA332] 1059
FAILURE CODE [CA343] 1061
FAILURE CODE [CA351] 1062
FAILURE CODE [CA352] 1063
FAILURE CODE [CA356] 1066
FAILURE CODE [CA357] 1068
FAILURE CODE [CA386] 1070
FAILURE CODE [CA441] 1071
FAILURE CODE [CA442] 1073
FAILURE CODE [CA449] 1074
FAILURE CODE [CA451] 1075
FAILURE CODE [CA452] 1077
FAILURE CODE [CA515] 1079
FAILURE CODE [CA516] 1081
FAILURE CODE [CA553] 1083
FAILURE CODE [CA555] 1084
FAILURE CODE [CA556] 1085
FAILURE CODE [CA559] 1086
FAILURE CODE [CA595] 1091
FAILURE CODE [CA687] 1092
FAILURE CODE [CA689] 1094
FAILURE CODE [CA691] 1096
FAILURE CODE [CA692] 1098
FAILURE CODE [CA697] 1100
FAILURE CODE [CA698] 1101
FAILURE CODE [CA731] 1102
FAILURE CODE [CA778] 1103
FAILURE CODE [CA1117] .1106
FAILURE CODE [CA1664] .1107
FAILURE CODE [CA1669] .1110
FAILURE CODE [CA1673] .1111
FAILURE CODE [CA1677] .1112
FAILURE CODE [CA1678] .1113
FAILURE CODE [CA1682] .1114
FAILURE CODE [CA1683] .1116
FAILURE CODE [CA1684] .1118
FAILURE CODE [CA1686] .1120
FAILURE CODE [CA1691] .1121
FAILURE CODE [CA1694] .1124
FAILURE CODE [CA1695] .1126
FAILURE CODE [CA1696] .1127
FAILURE CODE [CA1712] .1129
FAILURE CODE [CA1713] .1132
FAILURE CODE [CA1714] .1134
FAILURE CODE [CA1715] .1135
FAILURE CODE [CA1776] .1136
FAILURE CODE [CA1777] .1139
FAILURE CODE [CA1843] .1142
FAILURE CODE [CA1844] .1144
FAILURE CODE [CA1879] .1147
FAILURE CODE [CA1881] .1150
FAILURE CODE [CA1883] .1152
FAILURE CODE [CA1885] .1155
FAILURE CODE [CA1887] .1157
FAILURE CODE [CA1921] .1159
FAILURE CODE [CA1922] .1162
FAILURE CODE [CA1923] .1167
FAILURE CODE [CA1924] .1169
FAILURE CODE [CA1925] .1171
FAILURE CODE [CA1927] .1173
FAILURE CODE [CA1928] .1175
FAILURE CODE [CA1942] .1177
FAILURE CODE [CA1963] .1178
FAILURE CODE [CA1977] .1181
FAILURE CODE [CA1993] .1184
FAILURE CODE [CA2185] .1187
FAILURE CODE [CA2186] .1189
FAILURE CODE [CA2249] .1191
FAILURE CODE [CA2265] .1192
FAILURE CODE [CA2266] .1194
FAILURE CODE [CA2271] .1196
FAILURE CODE [CA2272] .1198
FAILURE CODE [CA2349] .1200
FAILURE CODE [CA2353] .1202
FAILURE CODE [CA2357] .1204
FAILURE CODE [CA2381] .1205
FAILURE CODE [CA2382] .1207
FAILURE CODE [CA2383] .1209
FAILURE CODE [CA2386] .1211
FAILURE CODE [CA2387] .1213
FAILURE CODE [CA2555] .1214
FAILURE CODE [CA2556] .1217
FAILURE CODE [CA2637] .1219
FAILURE CODE [CA2639] .1221
FAILURE CODE [CA2732] .1224
FAILURE CODE [CA2733] .1226
FAILURE CODE [CA2741] .1228
FAILURE CODE [CA2765] .1229
FAILURE CODE [CA2771] .1230
FAILURE CODE [CA2777] .1236
FAILURE CODE [CA2878] .1239
FAILURE CODE [CA2881] .1242
FAILURE CODE [CA2976] .1245
FAILURE CODE [CA3133] .1247
FAILURE CODE [CA3134] .1249
FAILURE CODE [CA3135] .1251
FAILURE CODE [CA3142] .1254
FAILURE CODE [CA3143] .1255
FAILURE CODE [CA3144] .1256
FAILURE CODE [CA3146] .1258
FAILURE CODE [CA3147] .1259
FAILURE CODE [CA3148] .1260
FAILURE CODE [CA3151] .1262
FAILURE CODE [CA3165] .1268
FAILURE CODE [CA3167] .1270
FAILURE CODE [CA3229] .1273
FAILURE CODE [CA3231] .1275
FAILURE CODE [CA3232] .1277
FAILURE CODE [CA3235] .1281
FAILURE CODE [CA3239] .1283
FAILURE CODE [CA3241] .1286
FAILURE CODE [CA3242] .1289
FAILURE CODE [CA3251] .1292
FAILURE CODE [CA3253] .1294
FAILURE CODE [CA3254] .1297
FAILURE CODE [CA3255] .1300
FAILURE CODE [CA3256] .1304
FAILURE CODE [CA3311] .1306
FAILURE CODE [CA3312] .1308
FAILURE CODE [CA3313] .1311
FAILURE CODE [CA3314] .1312
FAILURE CODE [CA3315] .1313
FAILURE CODE [CA3316] .1316
FAILURE CODE [CA3317] .1317
FAILURE CODE [CA3318] .1318
FAILURE CODE [CA3319] .1320
FAILURE CODE [CA3321] .1321
FAILURE CODE [CA3322] .1323
FAILURE CODE [CA3419] .1326
FAILURE CODE [CA3421] .1328
FAILURE CODE [CA3497] .1330
FAILURE CODE [CA3498] .1331
FAILURE CODE [CA3543] .1332
FAILURE CODE [CA3545] .1339
FAILURE CODE [CA3547] .1341
FAILURE CODE [CA3558] .1342
FAILURE CODE [CA3559] .1344
FAILURE CODE [CA3562] .1346
FAILURE CODE [CA3563] .1348
FAILURE CODE [CA3567] .1351
FAILURE CODE [CA3568] .1354
FAILURE CODE [CA3571] .1358
FAILURE CODE [CA3572] .1360
FAILURE CODE [CA3574] .1362
FAILURE CODE [CA3575] .1364
FAILURE CODE [CA3577] .1366
FAILURE CODE [CA3578] .1368
FAILURE CODE [CA3582] .1370
FAILURE CODE [CA3583] .1376
FAILURE CODE [CA3596] .1378
FAILURE CODE [CA3649] .1380
FAILURE CODE [CA3681] .1382
FAILURE CODE [CA3682] .1387
FAILURE CODE [CA3713] .1393
FAILURE CODE [CA3717] .1396
FAILURE CODE [CA3718] .1397
FAILURE CODE [CA3725] .1398
FAILURE CODE [CA3748] .1401
FAILURE CODE [CA3751] .1403
FAILURE CODE [CA3755] .1405
FAILURE CODE [CA3866] .1407
FAILURE CODE [CA3867] .1411
FAILURE CODE [CA3868] .1414
FAILURE CODE [CA3899] .1418
FAILURE CODE [CA3911] .1420
FAILURE CODE [CA3912] .1424
FAILURE CODE [CA3932] .1426
FAILURE CODE [CA3933] .1428
FAILURE CODE [CA3934] .1430
FAILURE CODE [CA3935] .1433
FAILURE CODE [CA3936] .1435
FAILURE CODE [CA4151] .1437
FAILURE CODE [CA4152] .1441
FAILURE CODE [CA4155] .1445
FAILURE CODE [CA4156] .1447
FAILURE CODE [CA4157] .1450
FAILURE CODE [CA4158] .1452
FAILURE CODE [CA4159] .1453
FAILURE CODE [CA4161] .1454
FAILURE CODE [CA4162] .1457
FAILURE CODE [CA4163] .1460
FAILURE CODE [CA4164] .1462
FAILURE CODE [CA4165] .1464
FAILURE CODE [CA4166] .1466
FAILURE CODE [CA4168] .1468
FAILURE CODE [CA4169] .1471
FAILURE CODE [CA4171] .1473
FAILURE CODE [CA4249] .1476
FAILURE CODE [CA4251] .1478
FAILURE CODE [CA4259] .1480
FAILURE CODE [CA4261] .1482
FAILURE CODE [CA4277] .1485
FAILURE CODE [CA4281] .1489
FAILURE CODE [CA4459] .1492
FAILURE CODE [CA4461] .1495
FAILURE CODE [CA4658] .1498
FAILURE CODE [CA4731] .1502
FAILURE CODE [CA4732] .1503
FAILURE CODE [CA4739] .1504
FAILURE CODE [CA4768] .1505
FAILURE CODE [CA4769] .1507
FAILURE CODE [CA4842] .1510
FAILURE CODE [CA4952] .1514
FAILURE CODE [CA5115] .1516
FAILURE CODE [CA5179] .1519
FAILURE CODE [CA5181] .1521
FAILURE CODE [CA5383] .1523
FAILURE CODE [D110KB] .1525
FAILURE CODE [D19JKZ] .1527
FAILURE CODE [D811MC] .1530
FAILURE CODE [D862KA] .1531
FAILURE CODE [D8ALKA] .1532
FAILURE CODE [D8ALKB] .1534
FAILURE CODE [D8AQKR] .1536
FAILURE CODE [DA20MC] .1538
FAILURE CODE [DA22KK] .1539
FAILURE CODE [DA29KQ] .1542
FAILURE CODE [DA2LKA] .1544
FAILURE CODE [DA2LKB] .1546
FAILURE CODE [DA2QKR] .1548
FAILURE CODE [DA2RKR] .1551
FAILURE CODE [DAF0MB] .1552
FAILURE CODE [DAF0MC] .1553
FAILURE CODE [DAF8KB] .1554
FAILURE CODE [DAF9KQ] .1556
FAILURE CODE [DAFGMC] .1557
FAILURE CODE [DAFLKA] .1558
FAILURE CODE [DAFLKB] .1560
FAILURE CODE [DAFQKR] .1562
FAILURE CODE [DAZ9KQ] .1563
FAILURE CODE [DAZQKR] .1564
FAILURE CODE [DB2QKR] .1569
FAILURE CODE [DB2RKR] .1574
FAILURE CODE [DDNRKA] .1578
FAILURE CODE [DDNRKY] .1580
FAILURE CODE [DDNS00] .1582
FAILURE CODE [DGH2KA] .1584
FAILURE CODE [DGH2KB] .1586
FAILURE CODE [DHA4KA] .1588
FAILURE CODE [DHAAMA] .1590
FAILURE CODE [DHACMA] .1592
FAILURE CODE [DHPAMA] .1594
FAILURE CODE [DHPBMA] .1597
FAILURE CODE [DHS3MA] .1600
FAILURE CODE [DHS4MA] .1603
FAILURE CODE [DHS8MA] .1606
FAILURE CODE [DHS9MA] .1609
FAILURE CODE [DHSAMA] .1612
FAILURE CODE [DHSBMA] .1615
FAILURE CODE [DHSCMA] .1618
FAILURE CODE [DHSDMA] .1621
FAILURE CODE [DHSFMA] .1624
FAILURE CODE [DHSGMA] .1627
FAILURE CODE [DHSHMA] .1630
FAILURE CODE [DHSJMA] .1633
FAILURE CODE [DKR0MA] .1636
FAILURE CODE [DKR1MA] .1639
FAILURE CODE [DKULKA] .1642
FAILURE CODE [DKULKB] .1644
FAILURE CODE [DKULKY] .1646
FAILURE CODE [DLM3KA] .1647
FAILURE CODE [DLM3KB] .1649
FAILURE CODE [DLM3MB] .1651
FAILURE CODE [DR21KX] .1652
FAILURE CODE [DR31KX] .1654
FAILURE CODE [DV20KB] .1656
FAILURE CODE [DW43KA] .1658
FAILURE CODE [DW43KB] .1660
FAILURE CODE [DW43KY] .1662
FAILURE CODE [DW45KA] .1664
FAILURE CODE [DW45KB] .1667
FAILURE CODE [DW45KY] .1670
FAILURE CODE [DW4CKY] .1672
FAILURE CODE [DW7BKA] .1673
FAILURE CODE [DW7BKB] .1675
FAILURE CODE [DW7BKY] .1677
FAILURE CODE [DW91KA] .1678
FAILURE CODE [DW91KB] .1680
FAILURE CODE [DW91KY] .1682
FAILURE CODE [DWA2KA] .1684
FAILURE CODE [DWA2KB] .1686
FAILURE CODE [DWA2KY] .1688
FAILURE CODE [DWK0KA] .1690
FAILURE CODE [DWK0KB] .1692
FAILURE CODE [DWK0KY] .1694
FAILURE CODE [DWK2KA] .1696
FAILURE CODE [DWK2KB] .1698
FAILURE CODE [DWK2KY] .1700
FAILURE CODE [DWK8KA] .1702
FAILURE CODE [DWK8KB] .1704
FAILURE CODE [DWK8KY] .1706
FAILURE CODE [DX16KA] .1708
FAILURE CODE [DX16KB] .1710
FAILURE CODE [DXA8KA] .1712
FAILURE CODE [DXA8KB] .1714
FAILURE CODE [DXA9KA] .1716
FAILURE CODE [DXA9KB] .1718
FAILURE CODE [DXE0KA] .1720
FAILURE CODE [DXE0KB] .1722
FAILURE CODE [DXE4KA] .1724
FAILURE CODE [DXE4KB] .1726
FAILURE CODE [DXE4KY] .1728
FAILURE CODE [DXE5KA] .1730
FAILURE CODE [DXE5KB] .1732
FAILURE CODE [DXE6KA] .1734
FAILURE CODE [DXE6KB] .1736
FAILURE CODE [DXE7KA] .1738
FAILURE CODE [DXE7KB] .1740
FAILURE CODE [DXE7KY] .1742
FAILURE CODE [DXE8KA] .1744
FAILURE CODE [DXE8KB] .1746
FAILURE CODE [DXE8KY] .1748
FAILURE CODE [DXE9KA] .1750
FAILURE CODE [DXE9KB] .1752
FAILURE CODE [DXE9KY] .1754
FAILURE CODE [DXEAKA] .1756
FAILURE CODE [DXEAKB] .1758
FAILURE CODE [DXEAKY] .1760
FAILURE CODE [DY20KA] .1762
FAILURE CODE [DY20MA] .1764
FAILURE CODE [DY2CKB] .1766
FAILURE CODE [DY2DKB] .1769
FAILURE CODE [DY2EKB] .1771
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1773
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1773
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1779
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1782
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1784
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1786
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1789
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1790
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1791
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1792
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1793
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1794
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1795
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1796
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1797
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1798
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1799
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1801
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1802
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1803
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1804
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1806
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1807
E-23 FUNCTION SWITCH DOES NOT OPERATE .1808
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1809
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1810
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1811
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1812
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1813
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1814
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1815
E-31 ALARM BUZZER CANNOT BE CANCELED 1817
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1818
E-33 SERVICE MODE CANNOT BE SELECTED 1819
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1820
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1822
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1823
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1826
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1828
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1830
E-40 ALARM DOES NOT SOUND DURING TRAVEL .1831
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1833
E-42 HORN DOES NOT SOUND 1834
E-43 HORN DOES NOT STOP SOUNDING 1838
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1840
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1841
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1843
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1844
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1845
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1846
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1847
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1848
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1849
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1850
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1851
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1852
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1854
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1855
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1856
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1858
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1859
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1859
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1860
FAILURE MODE AND CAUSE TABLE 1862
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1870
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1871
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1873
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1874
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1875
H-6 SPEED OR POWER OF BOOM IS LOW .1877
H-7 ARM SPEED OR POWER IS LOW .1883
H-8 BUCKET SPEED OR POWER IS LOW 1888
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1891
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1892
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1894
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1896
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1897
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1898
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1899
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1900
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1901
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1902
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1903
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1904
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1905
H-22 MACHINE DOES NOT TRAVEL STRAIGHT .1906
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1908
H-24 TRAVEL SPEED IS LOW 1911
H-25 ONE OF TRACKS DOES NOT RUN .1913
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1914
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1915
H-28 SWINGS ONLY IN ONE DIRECTION .1916
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1917
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1918
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1919
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1920
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1921
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1922
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1923
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1924
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1925
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1926
H-39 Quick coupler cylinder will not extend .1927
H-40 Quick coupler cylinder will not retract (but buzzer doesnot sound) .1929
H-41 Buzzer does not sound (but quick coupler cylinder doesretract) .1931
H-42 Quick coupler cylinder extends and retracts slowly .1933
TROUBLESHOOTING OF ENGINE (S-MODE) 1934
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1934
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1935
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1936
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1937
S-4 ENGINE STARTABILITY IS POOR .1938
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1940
S-6 ENGINE STOPS DURING OPERATION .1942
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1944
S-8 ENGINE LACKS POWER 1945
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1947
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1949
S-11 OIL BECOMES CONTAMINATED QUICKLY .1950
S-12 FUEL CONSUMPTION IS EXCESSIVE 1951
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1952
S-14 OIL PRESSURE DROPS .1953
S-15 FUEL MIXES INTO ENGINE OIL .1955
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1956
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1957
S-18 UNUSUAL NOISE IS HEARD .1959
S-19 VIBRATION IS EXCESSIVE .1960
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1961
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1962
S-22 ACTIVE REGENERATION TAKES TIME .1964
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1966
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1967
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1969
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1970
50 DISASSEMBLY AND ASSEMBLY .1971
CONTENTS 1972
ABBREVIATION LIST .1977
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1983
HOW TO READ THIS MANUAL .1983
COATING MATERIALS LIST 1985
SPECIAL TOOLS LIST 1989
SKETCHES OF SPECIAL TOOLS .2001
ENGINE AND COOLING SYSTEM .2007
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2007
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2007
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2013
REMOVE AND INSTALL INJECTOR ASSEMBLY 2022
METHOD FOR REMOVING INJECTOR ASSEMBLY .2022
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2028
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2038
METHOD FOR REMOVING FUEL DOSER 2038
METHOD FOR INSTALLING FUEL DOSER 2039
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2041
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2042
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2050
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2064
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2064
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2066
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2068
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2068
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2072
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2077
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY .2077
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY .2078
REMOVE AND INSTALL ALTERNATOR BELT 2080
METHOD FOR REMOVING ALTERNATOR BELT .2080
METHOD FOR INSTALLING ALTERNATOR BELT .2083
REMOVE AND INSTALL RADIATOR ASSEMBLY 2088
METHOD FOR REMOVING RADIATOR ASSEMBLY .2088
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2090
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY .2093
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2093
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2097
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2102
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2102
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2104
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2106
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2106
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2108
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2112
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2113
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2131
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2150
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2151
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2153
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2157
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2158
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2161
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2167
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2167
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2175
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2184
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2184
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2188
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2192
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2192
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2198
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2203
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2203
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2210
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2215
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2215
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2217
REMOVE AND INSTALL KDPF ASSEMBLY 2220
METHOD FOR REMOVING KDPF ASSEMBLY .2220
METHOD FOR INSTALLING KDPF ASSEMBLY .2224
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2229
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2230
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2235
REMOVE AND INSTALL SCR ASSEMBLY .2242
METHOD FOR REMOVING SCR ASSEMBLY 2242
METHOD FOR INSTALLING SCR ASSEMBLY 2245
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2249
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2249
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2254
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2259
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2259
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2263
REMOVE AND INSTALL KCCV ASSEMBLY 2273
METHOD FOR REMOVING KCCV ASSEMBLY .2273
METHOD FOR INSTALLING KCCV ASSEMBLY .2274
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2278
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2278
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2283
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2289
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2289
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2293
REMOVE AND INSTALL AdBlue/DEF PUMP 2298
METHOD FOR REMOVING AdBlue/DEF PUMP .2298
METHOD FOR INSTALLING AdBlue/DEF PUMP .2300
REMOVE AND INSTALL AdBlue/DEF HOSE 2301
METHOD FOR REMOVING AdBlue/DEF HOSE .2301
METHOD FOR INSTALLING AdBlue/DEF HOSE .2306
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2315
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2315
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2316
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2319
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2319
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2322
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2326
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2326
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2327
POWER TRAIN .2329
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2329
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2329
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2330
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2331
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2331
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2336
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2342
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2342
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2343
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2345
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2346
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2349
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2355
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2355
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2355
UNDERCARRIAGE AND FRAME .2357
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2357
METHOD FOR SEPARATING TRACK ASSEMBLY 2357
METHOD FOR INSTALLING TRACK ASSEMBLY 2359
REMOVE AND INSTALL SPROCKET .2362
METHOD FOR REMOVING SPROCKET 2362
METHOD FOR INSTALLING SPROCKET 2362
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2364
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2364
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2365
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2367
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2367
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2369
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2374
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2375
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2377
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2380
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2381
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2382
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2386
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2386
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2388
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2391
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2391
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2393
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2396
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2396
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2397
HYDRAULIC SYSTEM 2399
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2399
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2399
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2401
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2403
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2404
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2405
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2406
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2406
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2411
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2417
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2417
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2421
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2427
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2427
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2432
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2438
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2439
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2440
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2445
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2445
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2446
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2448
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2448
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2449
REMOVE AND INSTALL QUICK COUPLER VALVE 2451
WORK EQUIPMENT 2453
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2453
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2454
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2457
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2461
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2461
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2464
CAB AND ITS ATTACHMENTS .2468
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2468
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2468
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2474
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) .2481
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2483
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2483
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2493
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2493
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2496
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2502
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2502
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2509
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2517
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2517
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2522
REMOVE AND INSTALL OPERATOR’S SEAT 2528
METHOD FOR REMOVING OPERATOR’S SEAT .2528
METHOD FOR INSTALLING OPERATOR’S SEAT .2530
REMOVE AND INSTALL SEAT BELT 2533
METHOD FOR REMOVING SEAT BELT .2533
METHOD FOR INSTALLING SEAT BELT .2534
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2535
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2535
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2540
ELECTRICAL SYSTEM .2549
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2549
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2549
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2550
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2552
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2552
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2555
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2560
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2560
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2563
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2567
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2567
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2568
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2569
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2569
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2570
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2572
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2572
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2573
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2575
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2575
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2577
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2579
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2579
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2582
60 MAINTENANCE STANDARD .2585
CONTENTS 2586
ABBREVIATION LIST .2587
ENGINE AND COOLING SYSTEM .2593
MAINTENANCE STANDARD OF ENGINE MOUNT 2593
MAINTENANCE STANDARD OF COOLING SYSTEM 2594
MAINTENANCE STANDARD OF COOLING FAN PUMP 2595
MAINTENANCE STANDARD OF SERVO VALVE .2596
MAINTENANCE STANDARD OF COOLING FAN MOTOR .2597
POWER TRAIN .2598
MAINTENANCE STANDARD OF SWING CIRCLE 2598
MAINTENANCE STANDARD OF SWING MACHINERY .2599
MAINTENANCE STANDARD OF FINAL DRIVE .2601
MAINTENANCE STANDARD OF SPROCKET 2603
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2604
UNDERCARRIAGE AND FRAME .2606
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2606
MAINTENANCE STANDARD OF IDLER .2608
MAINTENANCE STANDARD OF TRACK ROLLER 2610
MAINTENANCE STANDARD OF CARRIER ROLLER 2612
MAINTENANCE STANDARD OF TRACK SHOE 2613
MAINTENANCE STANDARD OF TRIPLE SHOE .2616
HYDRAULIC SYSTEM 2617
MAINTENANCE STANDARD OF MAIN PUMP .2617
MAINTENANCE STANDARD OF SWING MOTOR .2619
MAINTENANCE STANDARD OF TRAVEL MOTOR 2622
MAINTENANCE STANDARD OF CONTROL VALVE .2625
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2636
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2639
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2642
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2643
MAINTENANCE STANDARD OF SOLENOID VALVE 2645
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2646
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE .2648
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2649
WORK EQUIPMENT 2650
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2650
DIMENSION OF ARM 2655
DIMENSIONS OF BUCKET 2657
MAINTENANCE STANDARD OF BOOM CYLINDER .2659
MAINTENANCE STANDARD OF ARM CYLINDER 2660
MAINTENANCE STANDARD OF BUCKET CYLINDER .2661
80 APPENDIX .2663
CONTENTS 2664
ABBREVIATION LIST .2666
AIR CONDITIONER SYSTEM 2672
PRECAUTIONS FOR REFRIGERANT .2672
AIR CONDITIONER COMPONENT .2673
SPECIFICATIONS OF AIR CONDITIONER .2675
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2676
OUTLINE OF REFRIGERATION CYCLE 2677
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2679
AIR CONDITIONER UNIT 2679
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2679
FUNCTION OF AIR CONDITIONER UNIT 2681
COMPONENT PARTS OF AIR CONDITIONER UNIT .2683
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2684
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2684
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2684
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2684
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2685
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2685
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2685
FUNCTION OF DUAL PRESSURE SWITCH 2686
AIR CONDITIONER CONTROLLER 2687
STRUCTURE OF AIR CONDITIONER CONTROLLER .2687
COMPRESSOR 2688
STRUCTURE OF COMPRESSOR .2688
SPECIFICATIONS OF COMPRESSOR 2688
FUNCTION OF COMPRESSOR 2688
CONDENSER .2689
STRUCTURE OF CONDENSER 2689
SPECIFICATIONS OF CONDENSER .2689
FUNCTION OF CONDENSER .2689
RECEIVER DRIER 2690
STRUCTURE OF RECEIVER DRIER .2690
SPECIFICATIONS OF RECEIVER DRIER 2690
FUNCTION OF RECEIVER DRIER 2690
SENSORS FOR AIR CONDITIONER SYSTEM 2691
STRUCTURE OF SUNLIGHT SENSOR 2691
FUNCTION OF SUNLIGHT SENSOR .2691
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2691
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2691
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2693
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2695
AIR CONDITIONER SYSTEM DIAGRAM 2697
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2698
FUNCTION OF AIR CONDITIONER CONTROLLER 2699
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2700
TESTING AIR LEAKAGE (DUCT) 2704
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2704
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2706
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2707
TEST VENT (MODE) CHANGEOVER .2708
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2708
TESTING FRESH/RECIRC AIR CHANGEOVER .2710
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2710
TEST SUNLIGHT SENSOR 2711
METHOD FOR TESTING SUNLIGHT SENSOR 2711
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2712
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2712
TEST RELAYS .2714
METHOD FOR TESTING RELAYS .2714
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2715
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2717
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2720
FAILURE CODE [879AKA] .2722
FAILURE CODE [879AKB] .2723
FAILURE CODE [879BKA] .2724
FAILURE CODE [879BKB] .2726
FAILURE CODE [879CKA] .2728
FAILURE CODE [879CKB] .2729
FAILURE CODE [879DKZ] .2730
FAILURE CODE [879EMC] .2732
FAILURE CODE [879FMC] .2733
FAILURE CODE [879GKX] .2734
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2736
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2737
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2738
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2739
TROUBLESHOOTING USING GAUGE PRESSURE 2740
CONNECTION OF SERVICE TOOL 2743
METHOD FOR CONNECTING SERVICE TOOL 2743
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2745
HANDLE COMPRESSOR OIL .2747
90 CIRCUIT DIAGRAMS .2749
CONTENTS 2750
ABBREVIATION LIST .2751
HYDRAULIC CIRCUIT DIAGRAM .2757
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2757
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2761
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2763
ELECTRICAL CIRCUIT DIAGRAM 2765
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2765
ELECTRICAL CIRCUIT DIAGRAM (1/9) 2769
ELECTRICAL CIRCUIT DIAGRAM (2/9) 2771
ELECTRICAL CIRCUIT DIAGRAM (3/9) 2773
ELECTRICAL CIRCUIT DIAGRAM (4/9) 2775
ELECTRICAL CIRCUIT DIAGRAM (5/9) 2777
ELECTRICAL CIRCUIT DIAGRAM (6/9) 2779
ELECTRICAL CIRCUIT DIAGRAM (7/9) 2781
ELECTRICAL CIRCUIT DIAGRAM (8/9) 2783
ELECTRICAL CIRCUIT DIAGRAM (9/9) 2785
INDEX 2787

DESCRIPTION:

Komatsu PC490-11,PC490LC-11 Hydraulic Excavator Shop Manual UENBM00301 –  PDF DOWNLOAD

SERIAL NUMBERS

• 85006 and up
• K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION 
HOW TO READ THE SHOP MANUAL
• 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 diagram

G.B 29/12/24