Komatsu HYDRAULIC EXCAVATOR PC490 -11E0 PC490LC -11E0 PC490HRD-11E0 Shop Manual PDF

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Komatsu HYDRAULIC EXCAVATOR PC490 -11E0 PC490LC -11E0 PC490HRD-11E0 Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu HYDRAULIC EXCAVATOR PC490 -11E0 PC490LC -11E0 PC490HRD-11E0 Shop Manual – PDF DOWNLOAD

Language : English
Pages :3442
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC490 -11E0 PC490LC -11E0 PC490HRD-11E0 Shop Manual – PDF DOWNLOAD

SERIAL NUMBERS
PC490LC-11E0 – K75096 and up
PC490LCD-11E0 – K75153 and up
PC490HRD-11E0 – K75230 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 diagrams.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC490 -11E0 PC490LC -11E0 PC490HRD-11E0 Shop Manual – PDF DOWNLOAD

SERIAL NUMBERS
PC490LC-11E0 – K75096 and up
PC490LCD-11E0 – K75153 and up
PC490HRD-11E0 – K75230 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 26
FOREWORD, SAFETY, BASIC INFORMATION 32
HOW TO READ THE SHOP MANUAL 32
SAFETY NOTICE FOR OPERATION 34
PRECAUTIONS TO PREVENT FIRE 42
ACTIONS IF FIRE OCCURS 44
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 45
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 46
METHOD FOR CHECKING ENGINE TYPE 47
PRECAUTIONS FOR DEF 49
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 49
PRECAUTIONS FOR ADDING 49
PRECAUTIONS FOR STORING 49
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 49
THE OTHER PRECAUTIONS 49
STORE AdBlue/DEF 50
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 51
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 54
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 61
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 63
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 64
PRACTICAL USE OF KOMTRAX 65
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 66
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 66
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 67
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 68
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 70
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 74
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 77
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 78
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 80
HOW TO READ ELECTRICAL WIRE CODE 81
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 85
STANDARD TIGHTENING TORQUE TABLE 88
CONVERSION TABLE 95
01 SPECIFICATIONS 101
CONTENTS 102
ABBREVIATION LIST 103
SPECIFICATIONS 109
SPECIFICATION DRAWING 109
SPECIFICATION DRAWING: PC490-11E0 ,PC490LC-11E0 109
WORKING RANGE DRAWINGS 111
WORKING RANGE: PC490-11E0, PC490LC-11E0 111
SPECIFICATIONS 112
SPECIFICATIONS: PC490-11E0, PC490LC-11E0 112
WEIGHT TABLE 115
WEIGHT TABLE: PC490-11E0 ,PC490LC-11E0 115
TABLE OF FUEL, COOLANT, AND LUBRICANTS 117
SPECIFICATIONS – PC490HRD-11E0 118
SPECIFICATION DRAWING 118
SPECIFICATION DRAWING: PC490HRD-11E0 118
SPECIFICATIONS 122
SPECIFICATIONS: PC490HRD-11E0 122
WEIGHT TABLE 124
WEIGHT TABLE: PC490HRD-11E0 124
SPECIFICATIONS – PC490HRD-11E0 K100 126
SPECIFICATION DRAWING 126
SPECIFICATION DRAWING: PC490HRD-11E0 K100 126
WEIGHT TABLE 130
WEIGHT TABLE: PC490HRD-11E0 K100 130
10 STRUCTURE AND FUNCTION 131
CONTENTS 132
ABBREVIATION LIST 137
UREA SCR SYSTEM 143
LAYOUT DRAWING OF UREA SCR SYSTEM 143
UREA SCR SYSTEM DIAGRAM 147
FUNCTION OF UREA SCR SYSTEM 148
FUNCTION OF AdBlue/DEF SYSTEM 148
INDUCEMENT STRATEGY 150
COMPONENT PARTS OF UREA SCR SYSTEM 169
AdBlue/DEF MIXING TUBE 169
SCR ASSEMBLY 169
AdBlue/DEF TANK 172
AdBlue/DEF PUMP 174
AdBlue/DEF INJECTOR 175
AdBlue/DEF HOSE 176
AdBlue/DEF TANK HEATING VALVE 177
BOOT-UP SYSTEM 178
LAYOUT DRAWING OF BOOT-UP SYSTEM 178
SYSTEM OPERATING LAMP SYSTEM 180
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 180
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 181
OPERATION OF SYSTEM OPERATING LAMP SYSTEM 182
BATTERY DISCONNECT SWITCH 183
FUNCTION OF BATTERY DISCONNECT SWITCH 183
ENGINE SYSTEM 184
LAYOUT DRAWING OF ENGINE SYSTEM 184
SPECIFICATIONS OF ENGINE SYSTEM 185
FUNCTION OF ENGINE SYSTEM 186
ENGINE CONTROL SYSTEM 187
ENGINE CONTROL SYSTEM DIAGRAM 187
OPERATION OF ENGINE CONTROL SYSTEM 188
AUTO-DECELERATION SYSTEM 190
AUTO-DECELERATION SYSTEM DIAGRAM 190
FUNCTION OF AUTO-DECELERATION SYSTEM 190
OPERATION OF AUTO-DECELERATION SYSTEM 191
ENGINE AUTOMATIC WARM-UP SYSTEM 192
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 192
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 193
OVERHEAT PREVENTION SYSTEM 194
OVERHEAT PREVENTION SYSTEM DIAGRAM 194
FUNCTION OF OVERHEAT PREVENTION SYSTEM 195
TURBOCHARGER PROTECTION SYSTEM 197
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 197
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 198
AUTOMATIC IDLE STOP SYSTEM 199
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 199
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 199
OPERATION OF AUTOMATIC IDLE STOP SYSTEM 199
COMPONENT PARTS OF ENGINE SYSTEM 202
VGT 202
EGR SYSTEM 205
EGR VALVE 207
EGR COOLER 209
KCCV SYSTEM 210
KCCV VENTILATOR 211
KDPF 213
COOLING SYSTEM 218
LAYOUT DRAWING OF COOLING SYSTEM 218
SPECIFICATIONS OF COOLING SYSTEM 219
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 221
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 221
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 222
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 223
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 223
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 224
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 226
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 226
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 226
COMPONENT PARTS OF COOLING SYSTEM 227
COOLING FAN PUMP 227
COOLING FAN MOTOR 234
CONTROL SYSTEM 241
LAYOUT DRAWING OF CONTROL SYSTEM 241
MACHINE MONITOR SYSTEM 244
MACHINE MONITOR SYSTEM DIAGRAM 244
FUNCTION OF MACHINE MONITOR SYSTEM 244
KomVision SYSTEM 245
LAYOUT DRAWING OF KOMVISION SYSTEM 245
KomVision SYSTEM DIAGRAM 247
FUNCTION OF KomVision SYSTEM 247
KOMTRAX SYSTEM 249
KOMTRAX SYSTEM DIAGRAM 249
FUNCTION OF KOMTRAX SYSTEM 249
PPC LEVERS 250
LH PPC LEVER 250
RH PPC LEVER 251
AUTOMATIC GREASE SYSTEM 252
OUTLINE OF AUTO GREASE SYSTEM 252
COMPONENT PARTS OF CONTROL SYSTEM 266
MACHINE MONITOR 266
KomVision CONTROLLER 279
KomVision CAMERA 283
GATEWAY FUNCTION CONTROLLER 284
COMMUNICATION TERMINAL 287
PUMP CONTROLLER 289
RESISTOR FOR PC-EPC VALVE 293
CAN TERMINATING RESISTOR 293
ENGINE CONTROLLER 295
FUEL CONTROL DIAL 301
FUEL FEED PUMP 303
FUEL FEED PUMP SWITCH 304
SENSOR 305
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 305
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 305
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 305
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 306
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 306
FUNCTION OF AUTO GREASE PRESSURE SWITCH 306
STRUCTURE OF OVERLOAD CAUTION SENSOR 306
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 307
FUNCTION OF OVERLOAD CAUTION SENSOR 307
HYDRAULIC SYSTEM 308
LAYOUT DRAWING OF HYDRAULIC SYSTEM 308
CLSS 310
STRUCTURE OF CLSS 310
OPERATION OF UNLOAD VALVE AND LS PRESSURE 312
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 313
PRESSURE COMPENSATION CONTROL 326
ENGINE AND PUMP COMBINED CONTROL SYSTEM 330
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 330
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 332
PUMP AND VALVE CONTROL SYSTEM 337
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 337
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 338
COMPONENT PARTS OF HYDRAULIC SYSTEM 340
HYDRAULIC TANK 340
MAIN PUMP 342
PILOT OIL FILTER 368
CONTROL VALVE 368
HYDRAULIC SYSTEM – PC490HRD-11E0 430
LAYOUT DRAWING OF HYDRAULIC SYSTEM 430
COMPONENT PARTS OF HYDRAULIC SYSTEM 433
LAYOUT DRAWING OF VALVE CONTROL SYSTEM 433
WORK EQUIPMENT SYSTEM 453
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 453
STRUCTURE OF VALVE CONTROL 458
ONE-TOUCH POWER MAXIMIZING SYSTEM 459
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 459
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 460
MACHINE PUSH-UP SYSTEM 461
MACHINE PUSH-UP SYSTEM DIAGRAM 461
FUNCTION OF MACHINE PUSH-UP SYSTEM 462
PPC LOCK SYSTEM 463
PPC LOCK SYSTEM DIAGRAM 463
FUNCTION OF PPC LOCK SYSTEM 463
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 464
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 464
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 464
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 465
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 466
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 466
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 467
TOOL CONTROL SYSTEM 468
TOOL CONTROL SYSTEM DIAGRAM 468
FUNCTION OF TOOL CONTROL SYSTEM 469
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 470
WORK EQUIPMENT AND SWING PPC VALVE 470
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 475
SOLENOID VALVE 480
VARIABLE PRESSURE COMPENSATION VALVE 482
ATTACHMENT CIRCUIT SELECTOR VALVE 483
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 485
ATTACHMENT BYPASS SOLENOID VALVE 488
ATT EPC VALVE ASSEMBLY 490
PILOT CIRCUIT ACCUMULATOR 492
WORK EQUIPMENT SYSTEM – PC490HRD-11E0 493
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 493
SWING SYSTEM 497
LAYOUT DRAWING OF SWING SYSTEM 497
SWING CONTROL SYSTEM DIAGRAM 503
FUNCTION OF SWING CONTROL SYSTEM 503
COMPONENT PARTS OF SWING SYSTEM 507
SWING MOTOR 507
SWING MACHINERY 518
SWING CIRCLE 520
TRAVEL SYSTEM 522
LAYOUT DRAWING OF TRAVEL SYSTEM 522
TRAVEL CONTROL SYSTEM DIAGRAM 526
FUNCTION OF TRAVEL CONTROL SYSTEM 527
COMPONENT PARTS OF TRAVEL SYSTEM 528
TRAVEL MOTOR 528
FINAL DRIVE 542
TRAVEL PPC VALVE 543
CENTER SWIVEL JOINT 548
UNDERCARRIAGE AND FRAME 550
LAYOUT DRAWING OF UNDERCARRIAGE 550
SPECIFICATIONS OF UNDERCARRIAGE 550
WORK EQUIPMENT 552
STRUCTURE OF WORK EQUIPMENT 552
FUNCTION OF WORK EQUIPMENT 553
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 554
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 554
BUCKET CLEARANCE ADJUSTMENT SHIM 555
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 555
CAB AND ITS ATTACHMENTS 556
ROPS CAB 556
STRUCTURE OF ROPS CAB 556
FUNCTION OF ROPS CAB 556
CAB MOUNT 557
STRUCTURE OF CAB MOUNT 557
FUNCTION OF CAB MOUNT 557
CAB TIPPING STOPPER 558
STRUCTURE OF CAB TIPPING STOPPER 558
FUNCTION OF CAB TIPPING STOPPER 558
TILTING CAB SYSTEM 559
STRUCTURE OF TILTING CAB SYSTEM 559
OPERATION OF TILTING CAB SYSTEM 559
CONTROL SYSTEM 561
K100 CONTROL SYSTEM 561
STRUCTURE OF K100 CONTROL SYSTEM 562
HYDRAULIC SYSTEM – PC490HRD-11E0 K100 564
LAYOUT DRAWING OF HYDRAULIC SYSTEM 564
LS OVERRIDE VALVE 565
STRUCTURE OF LS OVERRIDE VALVE 565
OPERATION OF LS OVERRIDE VALVE 566
HYDRAULIC LOCK VALVE 567
STRUCTURE OF HYDRAULIC LOCK VALVE 567
OPERATION OF HYDRAULIC LOCK VALVE 568
SWING LOCK VALVE 569
STRUCTURE OF SWING LOCK VALVE 569
OPERATION OF SWING LOCK VALVE 570
BOOM RAISE LOCK VALVE 571
STRUCTURE OF BOOM RAISE LOCK VALVE 571
OPERATION OF BOOM RAISE LOCK VALVE 572
DEPRESSURISATION VALVE 573
STRUCTURE OF DEPRESSURISATION AND PIN LOCK/UNLOCK VALVE 573
OPERATION OF DEPRESSURISATION VALVE 575
MECHANICAL PIN LOCK/UNLOCK VALVE 578
STRUCTURE OF MECHANICAL PIN LOCK/UNLOCK VALVE 578
OPERATION OF MECHANICAL PIN LOCK/UNLOCK VALVE 579
PRESSURE INTENSIFIER SYSTEM 580
STRUCTURE OF PRESSURE INTENSIFIER SYSTEM 580
OPERATION OF PRESSURE INTENSIFIER SYSTEM 581
20 STANDARD VALUE TABLE 583
CONTENTS 584
ABBREVIATION LIST 585
STANDARD VALUE TABLE FOR ENGINE 591
STANDARD VALUE TABLE FOR ENGINE: PC490-11E0, PC490LC-11E0 591
STANDARD VALUE TABLE FOR MACHINE 594
STANDARD VALUE TABLE FOR MACHINE: PC490-11E0, PC490LC-11E0 594
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 610
STANDARD VALUE TABLE FOR MACHINE – PC490HRD-11E0 614
STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE 614
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 621
STANDARD VALUE TABLE FOR MACHINE – PC490HRD-11E0 K100 625
STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE 625
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 633
STANDARD VALUE TABLE FOR ELECTRICAL 637
STANDARD VALUE TABLE FOR ELECTRICAL 637
30 TESTING AND ADJUSTING 647
CONTENTS 648
ABBREVIATION LIST 653
RELATED INFORMATION ON TESTING AND ADJUSTING 659
TOOLS FOR TESTING AND ADJUSTING 659
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 666
ENGINE AND COOLING SYSTEM 668
TEST ENGINE SPEED 668
METHOD FOR TESTING ENGINE SPEED 668
TEST BOOST PRESSURE 671
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 671
METHOD FOR TESTING BOOST PRESSURE 672
TEST EXHAUST GAS COLOR 673
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 673
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 674
TEST AND ADJUST VALVE CLEARANCE 675
METHOD FOR TESTING VALVE CLEARANCE 675
METHOD FOR ADJUSTING VALVE CLEARANCE 678
TEST COMPRESSION PRESSURE 679
METHOD FOR TESTING COMPRESSION PRESSURE 679
TEST BLOWBY PRESSURE 682
METHOD FOR TESTING BLOWBY PRESSURE 682
TEST ENGINE OIL PRESSURE 684
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 684
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 684
TEST EGR VALVE AND VGT OIL PRESSURE 686
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 686
TEST FUEL PRESSURE 688
METHOD FOR TESTING FUEL PRESSURE 688
TEST FUEL RETURN RATE AND LEAKAGE 690
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 690
BLEED AIR FROM FUEL SYSTEM 693
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 693
TEST FUEL CIRCUIT FOR LEAKAGE 695
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 695
HANDLE CYLINDER CUT-OUT MODE OPERATION 697
HANDLE NO-INJECTION CRANKING OPERATION 698
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 699
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 699
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 699
CLEAN FUEL DOSER 701
METHOD FOR CLEANING FUEL DOSER 701
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 703
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 703
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 709
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 709
TEST SCR RELATED FUNCTIONS 710
TEST AdBlue/DEF PUMP RAISED PRESSURE 713
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 716
TEST AdBlue/DEF LINE HEATER RELAY 1 720
TEST AdBlue/DEF LINE HEATER RELAY 2 722
TEST AdBlue/DEF PUMP HEATER RELAY 725
TEST AdBlue/DEF TANK HEATER VALVE 728
TEST DENITRATION EFFICIENCY OF SCR 731
CLEAN AdBlue/DEF TANK 735
METHOD FOR CLEANING AdBlue/DEF TANK 735
POWER TRAIN 739
TEST SWING CIRCLE BEARING CLEARANCE 739
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 739
UNDERCARRIAGE AND FRAME 740
TEST AND ADJUST TRACK TENSION 740
METHOD FOR TESTING TRACK TENSION 740
METHOD FOR ADJUSTING TRACK TENSION 740
HYDRAULIC SYSTEM 742
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 742
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 742
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 742
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 748
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 749
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 756
TEST OIL PRESSURE OF CONTROL CIRCUIT 760
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 760
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 762
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 762
TEST PC-EPC VALVE OUTLET PRESSURE 763
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 764
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 766
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 766
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 767
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 768
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 769
METHOD FOR ADJUSTING LS VALVE 770
TEST OUTLET PRESSURE OF SOLENOID VALVE 771
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 771
OPERATING CONDITION OF SOLENOID VALVE 772
TEST PPC VALVE OUTLET PRESSURE 774
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 774
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 776
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 776
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 777
TEST PUMP SWASH PLATE SENSOR 779
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 779
TEST COOLING FAN SPEED 780
METHOD FOR TESTING COOLING FAN SPEED 780
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 781
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 781
TEST FAN PUMP EPC ELECTRIC CURRENT 783
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 783
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 784
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 784
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 786
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 786
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 786
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 787
TEST OIL LEAKAGE 788
TEST OIL LEAKAGE OF BOOM CYLINDER 788
TEST OIL LEAKAGE OF ARM CYLINDER 788
TEST OIL LEAKAGE OF BUCKET CYLINDER 789
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR 789
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 790
BLEED AIR FROM HYDRAULIC CIRCUIT 791
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 793
HYDRAULIC SYSTEM – PC490HRD-11E0 796
MEASURING AND ADJUSTING SWING SPEED REDUCTION VALVE 796
MEASURING AND ADJUSTING BOOM AND BUCKET PPC REDUCTION VALVE 797
MEASURING AND ADJUSTING LINK CYLINDER FLOW CONTROL VALVE 798
MEASURING AND ADJUSTING ARM CYLINDER FLOW CONTROL VALVE 799
HYDRAULIC SYSTEM – PC490HRD-11E0 K100 BOOM CHANGE SYSTEM 800
MEASURING AND ADJUSTING DEPRESSURISATION VALVE 800
MEASURING AND ADJUSTING PIN LOCK/UNLOCK VALVE 802
CAB AND ITS ATTACHMENTS 805
TEST CAB TIPPING STOPPER 805
METHOD FOR TESTING CAB TIPPING STOPPER 805
METHOD FOR ADJUSTING MIRRORS 806
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 806
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 807
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 808
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 809
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 810
ELECTRICAL SYSTEM 812
SET AND OPERATE MACHINE MONITOR 812
OPERATOR MODE 815
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 816
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 816
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 817
CHECKING FUNCTION OF SERVICE METER 817
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 817
SERVICE MODE 820
METHOD FOR OPERATING SERVICE MODE 822
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 825
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 832
METHOD FOR CONFIRMING MAINTENANCE RECORD 848
METHOD FOR OPERATING MAINTENANCE MODE SETTING 849
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 853
METHOD FOR PERFORMING NO-INJECTION CRANKING 898
METHOD FOR DISPLAYING SERVICE MESSAGE 901
METHOD FOR STARTING UP KOMTRAX SYSTEM 903
ADJUST REARVIEW CAMERA ANGLE 909
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 909
ADJUST KomVision CAMERA ANGLE 912
Angle adjustment method for KomVision camera 913
ADJUST KomVision RELATED ITEMS 917
SETTING OF KomVision (MAIN SETTING) 917
SETTING OF KomVision (CAMERA SETTING) 919
SET KomVision (camera calibration) 921
KomVision screen – Check 12 m visibility 947
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 950
HANDLE BATTERY DISCONNECT SWITCH 951
TEST DIODES 952
METHOD FOR TESTING DIODE USING DIGITAL TESTER 952
METHOD FOR TESTING DIODE USING ANALOG TESTER 952
ELECTRICAL SYSTEM – PC490HRD-11E0 953
ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM 953
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – BASE MACHINE 953
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – HIGH REACH DEMOLITION WORK EQUIPMENT 956
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT 958
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – MEDIUM REACH DEMOLITION WORK EQUIPMENT 960
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – DEMOLITION DIGGING WORK EQUIPMENT 962
RH PPC LEVER 963
LH PPC LEVER 964
WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT 965
CONSTANT LINK SPEED CIRCUIT 966
PARALLEL LINK FRONT SCREEN WIPER 967
OVERLOAD CAUTION (HIGH REACH DEMOLITION) 968
ELECTRICAL SYSTEM – PC490HRD-11E0 K100 BOOM CHANGE SYSTEM 969
SWING LOCK CIRCUIT 969
HYDRAULIC LOCK CIRCUIT 970
WORK EQUIPMENT PICKUP PROXIMITY SWITCH CIRCUIT 971
BOOM RAISE LOCK CIRCUIT 972
DEPRESSURISATION CIRCUIT 973
PRESSURE INTENSIFIER CIRCUIT 974
HYDRAULIC PIN LOCK/UNLOCK CIRCUIT 975
VALVE LOCK/UNLOCK 976
1ST BOOM AND EXTENSION BOOM CAMERA 977
1st BOOM ELECTRICAL DIAGRAM 978
EXTENSION BOOM ELECTRICAL DIAGRAM 979
HIGH REACH DEMOLITION WORK EQUIPMENT ELECTRICAL DIAGRAM 980
DEMOLITION DIGGING WORK EQUIPMENT ELECTRICAL DIAGRAM 982
HYDRAULIC PIN, S-VALVE AND PICK UP PIN SENSORS, MEASURING AND ADJUSTING HYDRAULIC PIN LOCK SENSORS 984
MEASURING AND ADJUSTING HYDRAULIC PIN UNLOCK SENSORS 986
MEASURING AND ADJUSTING PICK-UP PIN SENSOR 987
MEASURING AND ADJUSTING S-VALVE PIN UNLOCK SWITCHES 988
MEASURING AND ADJUSTING A-VALVE PROXIMITY SWITCH 989
MEASURING AND ADJUSTING SHIMS FOR REACTION BRACKET 990
K100 BOOM CHANGE CONTROL SYSTEM 991
SERVICE OPERATIONS – K100 BOOM CHANGE SYSTEM 993
K100 BOOM CHANGE CONTROL SYSTEM – UPDATING SOFTWARE 999
K100 BOOM CHANGE CONTROLLER REPLACEMENT1001
Pm CLINIC1003
Pm CLINIC SERVICE1003
Pm CLINIC CHECK SHEET1004
WORKING RANGE INDICATOR SYSTEM1017
WORKING RANGE INDICATOR SYSTEM LAYOUT1017
METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU1019
DIAGNOSTICS – WORKING RANGE INDICATOR SYSTEM1021
MONITORING SYSTEM PARAMETERS AND SENSOR STATES1021
USING THE PARAMETER CHANGE LOG1023
USING ERROR LISTS AND LOGS1024
EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM1025
IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM1026
REPLACING COMPONENTS – WORKING RANGE INDICATOR SYSTEM1028
WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT1028
WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT1033
WORKING RANGE INDICATOR SYSTEM – UDATING SOFTWARE1038
CALIBRATION – WORKING RANGE INDICATOR SYSTEM1042
WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW1042
METHOD 1 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – AUTO CALIBRATION1042
METHOD 2 – BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION1050
METHOD 2 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – MANUAL CALIBRATION1053
40 TROUBLESHOOTING1069
CONTENTS1070
ABBREVIATION LIST1083
RELATED INFORMATION ON TROUBLESHOOTING1089
GENERAL TROUBLESHOOTING POINTS1089
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM1090
SEQUENCE OF EVENTS IN TROUBLESHOOTING1102
CHECKS BEFORE TROUBLESHOOTING1104
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING1106
WALK-AROUND CHECK1106
TESTING IN ACCORDANCE WITH TESTING PROCEDURE1108
CHECK FUEL LEVEL AND TYPE1108
CHECK IMPURE INGREDIENT IN FUEL1109
CHECK FUEL PREFILTER1109
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT1109
FUEL PREFILTER CARTRIDGE – REPLACE1110
CHECK MAIN FILTER1111
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)1112
CHECK COOLANT LEVEL (RESERVOIR TANK)1114
CHECK CLOGGING OF AIR CLEANER1114
OUTER ELEMENT – CLEAN1115
ELEMENTS – REPLACE1117
CHECK HYDRAULIC OIL LEVEL1118
CHECK HYDRAULIC OIL STRAINER1118
CHECK HYDRAULIC FILTER1119
CHECK OIL LEVEL IN SWING MACHINERY CASE1120
CHECK OIL LEVEL IN DAMPER CASE1121
CHECK OIL LEVEL IN FINAL DRIVE CASE1121
BLEED AIR FROM FUEL SYSTEM1122
BLEED AIR FROM HYDRAULIC SYSTEM1122
ELECTRICAL EQUIPMENT – CHECK METHOD1122
AUTOMATIC GREASE SYSTEM1128
FINDING MALFUNCTIONS1128
MALFUNCTION FINDING PROCEDURES1132
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION1134
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM1147
PROCEDURE FOR TESTING AND TROUBLESHOOTING1157
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS1160
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE1164
CONNECTOR LIST AND LAYOUT1166
CONNECTOR CONTACT IDENTIFICATION1179
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE1219
FUSE LOCATION TABLE1225
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1228
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])1232
FAILURE CODE TABLE1234
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1253
FAILURE CODE [879AKA]1253
FAILURE CODE [879AKB]1254
FAILURE CODE [879BKA]1255
FAILURE CODE [879BKB]1257
FAILURE CODE [879CKA]1259
FAILURE CODE [879CKB]1260
FAILURE CODE [879DKZ]1261
FAILURE CODE [879EMC]1263
FAILURE CODE [879FMC]1264
FAILURE CODE [879GKX]1265
FAILURE CODE [989L00]1267
FAILURE CODE [989M00]1268
FAILURE CODE [989N00]1269
FAILURE CODE [A1U0N3]1270
FAILURE CODE [A1U0N4]1272
FAILURE CODE [A900FR]1274
FAILURE CODE [A900N6]1275
FAILURE CODE [A900NY]1276
FAILURE CODE [AA10NX]1277
FAILURE CODE [AB00KE]1279
FAILURE CODE [AQ10N3]1282
FAILURE CODE [AS00N3]1284
FAILURE CODE [AS00R2]1286
FAILURE CODE [AS00R3]1287
FAILURE CODE [AS00R4]1288
FAILURE CODE [AS00R5]1289
FAILURE CODE [AS00R6]1290
FAILURE CODE [AS00ZK]1291
FAILURE CODE [AS10KM]1292
FAILURE CODE [AS10NR]1293
FAILURE CODE [AS10NT]1294
FAILURE CODE [B@BAZG]1295
FAILURE CODE [B@BAZK]1296
FAILURE CODE [B@BCNS]1298
FAILURE CODE [B@BCQA]1299
FAILURE CODE [B@BCZK]1301
FAILURE CODE [B@HANS]1303
FAILURE CODE [CA115]1304
FAILURE CODE [CA122]1305
FAILURE CODE [CA123]1307
FAILURE CODE [CA131]1309
FAILURE CODE [CA132]1311
FAILURE CODE [CA135]1313
FAILURE CODE [CA141]1315
FAILURE CODE [CA144]1317
FAILURE CODE [CA145]1319
FAILURE CODE [CA153]1321
FAILURE CODE [CA154]1324
FAILURE CODE [CA187]1327
FAILURE CODE [CA221]1329
FAILURE CODE [CA222]1331
FAILURE CODE [CA227]1333
FAILURE CODE [CA234]1334
FAILURE CODE [CA238]1335
FAILURE CODE [CA239]1337
FAILURE CODE [CA249]1339
FAILURE CODE [CA256]1341
FAILURE CODE [CA271]1343
FAILURE CODE [CA272]1345
FAILURE CODE [CA273]1346
FAILURE CODE [CA274]1348
FAILURE CODE [CA322]1349
FAILURE CODE [CA323]1351
FAILURE CODE [CA324]1353
FAILURE CODE [CA325]1355
FAILURE CODE [CA331]1357
FAILURE CODE [CA332]1359
FAILURE CODE [CA343]1361
FAILURE CODE [CA351]1362
FAILURE CODE [CA352]1363
FAILURE CODE [CA356]1366
FAILURE CODE [CA357]1368
FAILURE CODE [CA386]1370
FAILURE CODE [CA441]1371
FAILURE CODE [CA442]1373
FAILURE CODE [CA449]1374
FAILURE CODE [CA451]1375
FAILURE CODE [CA452]1377
FAILURE CODE [CA515]1379
FAILURE CODE [CA516]1381
FAILURE CODE [CA553]1383
FAILURE CODE [CA555]1384
FAILURE CODE [CA556]1385
FAILURE CODE [CA559]1386
FAILURE CODE [CA595]1391
FAILURE CODE [CA687]1392
FAILURE CODE [CA689]1394
FAILURE CODE [CA691]1396
FAILURE CODE [CA692]1398
FAILURE CODE [CA697]1400
FAILURE CODE [CA698]1401
FAILURE CODE [CA731]1402
FAILURE CODE [CA778]1403
FAILURE CODE [CA1117]1406
FAILURE CODE [CA1664]1407
FAILURE CODE [CA1669]1410
FAILURE CODE [CA1673]1411
FAILURE CODE [CA1677]1412
FAILURE CODE [CA1678]1413
FAILURE CODE [CA1682]1414
FAILURE CODE [CA1683]1416
FAILURE CODE [CA1684]1418
FAILURE CODE [CA1686]1420
FAILURE CODE [CA1691]1421
FAILURE CODE [CA1694]1424
FAILURE CODE [CA1695]1426
FAILURE CODE [CA1696]1427
FAILURE CODE [CA1712]1429
FAILURE CODE [CA1713]1432
FAILURE CODE [CA1714]1434
FAILURE CODE [CA1715]1435
FAILURE CODE [CA1776]1436
FAILURE CODE [CA1777]1439
FAILURE CODE [CA1843]1442
FAILURE CODE [CA1844]1444
FAILURE CODE [CA1879]1447
FAILURE CODE [CA1881]1450
FAILURE CODE [CA1883]1452
FAILURE CODE [CA1885]1455
FAILURE CODE [CA1887]1457
FAILURE CODE [CA1921]1459
FAILURE CODE [CA1922]1462
FAILURE CODE [CA1923]1467
FAILURE CODE [CA1924]1469
FAILURE CODE [CA1925]1471
FAILURE CODE [CA1927]1473
FAILURE CODE [CA1928]1475
FAILURE CODE [CA1942]1477
FAILURE CODE [CA1963]1478
FAILURE CODE [CA1977]1481
FAILURE CODE [CA1993]1484
FAILURE CODE [CA2185]1487
FAILURE CODE [CA2186]1489
FAILURE CODE [CA2249]1491
FAILURE CODE [CA2265]1492
FAILURE CODE [CA2266]1494
FAILURE CODE [CA2271]1496
FAILURE CODE [CA2272]1498
FAILURE CODE [CA2349]1500
FAILURE CODE [CA2353]1502
FAILURE CODE [CA2357]1504
FAILURE CODE [CA2381]1505
FAILURE CODE [CA2382]1507
FAILURE CODE [CA2383]1509
FAILURE CODE [CA2386]1511
FAILURE CODE [CA2387]1513
FAILURE CODE [CA2555]1514
FAILURE CODE [CA2556]1517
FAILURE CODE [CA2637]1519
FAILURE CODE [CA2639]1521
FAILURE CODE [CA2732]1524
FAILURE CODE [CA2733]1526
FAILURE CODE [CA2741]1528
FAILURE CODE [CA2765]1529
FAILURE CODE [CA2771]1530
FAILURE CODE [CA2777]1536
FAILURE CODE [CA2878]1539
FAILURE CODE [CA2881]1542
FAILURE CODE [CA2976]1545
FAILURE CODE [CA3133]1547
FAILURE CODE [CA3134]1549
FAILURE CODE [CA3135]1551
FAILURE CODE [CA3142]1554
FAILURE CODE [CA3143]1555
FAILURE CODE [CA3144]1556
FAILURE CODE [CA3146]1558
FAILURE CODE [CA3147]1559
FAILURE CODE [CA3148]1560
FAILURE CODE [CA3151]1562
FAILURE CODE [CA3165]1568
FAILURE CODE [CA3167]1570
FAILURE CODE [CA3229]1573
FAILURE CODE [CA3231]1575
FAILURE CODE [CA3232]1577
FAILURE CODE [CA3235]1581
FAILURE CODE [CA3239]1583
FAILURE CODE [CA3241]1586
FAILURE CODE [CA3242]1589
FAILURE CODE [CA3251]1592
FAILURE CODE [CA3253]1594
FAILURE CODE [CA3254]1597
FAILURE CODE [CA3255]1600
FAILURE CODE [CA3256]1604
FAILURE CODE [CA3311]1606
FAILURE CODE [CA3312]1608
FAILURE CODE [CA3313]1611
FAILURE CODE [CA3314]1612
FAILURE CODE [CA3315]1613
FAILURE CODE [CA3316]1616
FAILURE CODE [CA3317]1617
FAILURE CODE [CA3318]1618
FAILURE CODE [CA3319]1620
FAILURE CODE [CA3321]1621
FAILURE CODE [CA3322]1623
FAILURE CODE [CA3419]1626
FAILURE CODE [CA3421]1628
FAILURE CODE [CA3497]1630
FAILURE CODE [CA3498]1631
FAILURE CODE [CA3543]1632
FAILURE CODE [CA3545]1639
FAILURE CODE [CA3547]1641
FAILURE CODE [CA3558]1642
FAILURE CODE [CA3559]1644
FAILURE CODE [CA3562]1646
FAILURE CODE [CA3563]1648
FAILURE CODE [CA3567]1651
FAILURE CODE [CA3568]1654
FAILURE CODE [CA3571]1658
FAILURE CODE [CA3572]1660
FAILURE CODE [CA3574]1662
FAILURE CODE [CA3575]1664
FAILURE CODE [CA3577]1666
FAILURE CODE [CA3578]1668
FAILURE CODE [CA3582]1670
FAILURE CODE [CA3583]1676
FAILURE CODE [CA3596]1678
FAILURE CODE [CA3649]1680
FAILURE CODE [CA3681]1682
FAILURE CODE [CA3682]1687
FAILURE CODE [CA3713]1693
FAILURE CODE [CA3717]1696
FAILURE CODE [CA3718]1697
FAILURE CODE [CA3725]1698
FAILURE CODE [CA3748]1701
FAILURE CODE [CA3751]1703
FAILURE CODE [CA3755]1705
FAILURE CODE [CA3866]1707
FAILURE CODE [CA3867]1711
FAILURE CODE [CA3868]1714
FAILURE CODE [CA3899]1718
FAILURE CODE [CA3911]1720
FAILURE CODE [CA3912]1724
FAILURE CODE [CA3932]1726
FAILURE CODE [CA3933]1728
FAILURE CODE [CA3934]1730
FAILURE CODE [CA3935]1733
FAILURE CODE [CA3936]1735
FAILURE CODE [CA4151]1737
FAILURE CODE [CA4152]1741
FAILURE CODE [CA4155]1745
FAILURE CODE [CA4156]1747
FAILURE CODE [CA4157]1750
FAILURE CODE [CA4158]1752
FAILURE CODE [CA4159]1753
FAILURE CODE [CA4161]1754
FAILURE CODE [CA4162]1757
FAILURE CODE [CA4163]1760
FAILURE CODE [CA4164]1762
FAILURE CODE [CA4165]1764
FAILURE CODE [CA4166]1766
FAILURE CODE [CA4168]1768
FAILURE CODE [CA4169]1771
FAILURE CODE [CA4171]1773
FAILURE CODE [CA4249]1776
FAILURE CODE [CA4251]1778
FAILURE CODE [CA4259]1780
FAILURE CODE [CA4261]1782
FAILURE CODE [CA4277]1785
FAILURE CODE [CA4281]1789
FAILURE CODE [CA4459]1792
FAILURE CODE [CA4461]1795
FAILURE CODE [CA4658]1798
FAILURE CODE [CA4731]1802
FAILURE CODE [CA4732]1803
FAILURE CODE [CA4739]1804
FAILURE CODE [CA4768]1805
FAILURE CODE [CA4769]1807
FAILURE CODE [CA4842]1810
FAILURE CODE [CA4952]1814
FAILURE CODE [CA5115]1816
FAILURE CODE [CA5179]1819
FAILURE CODE [CA5181]1821
FAILURE CODE [CA5383]1823
FAILURE CODE [D110KB]1825
FAILURE CODE [D19JKZ]1827
FAILURE CODE [D811MC]1830
FAILURE CODE [D862KA]1831
FAILURE CODE [D8ALKA]1833
FAILURE CODE [D8ALKB]1836
FAILURE CODE [D8AQKR]1838
FAILURE CODE [D8G1KT]1845
FAILURE CODE [D8G6KT]1846
FAILURE CODE [DA20MC]1847
FAILURE CODE [DA22KK]1848
FAILURE CODE [DA29KQ]1851
FAILURE CODE [DA2LKA]1853
FAILURE CODE [DA2LKB]1856
FAILURE CODE [DA2QKR]1858
FAILURE CODE [DA2RKR]1867
FAILURE CODE [DAF0KM]1868
FAILURE CODE [DAF0MB]1869
FAILURE CODE [DAF0MC]1870
FAILURE CODE [DAF8KB]1871
FAILURE CODE [DAF9KQ]1873
FAILURE CODE [DAFGMC]1874
FAILURE CODE [DAFLKA]1875
FAILURE CODE [DAFLKB]1878
FAILURE CODE [DAFQKR]1880
FAILURE CODE [DAZ9KQ]1888
FAILURE CODE [DAZQKR]1889
FAILURE CODE [DB2QKR]1896
FAILURE CODE [DB2RKR]1904
FAILURE CODE [DBP0KM]1908
FAILURE CODE [DBP0KT]1909
FAILURE CODE [DBP5KB]1910
FAILURE CODE [DBP5KY]1913
FAILURE CODE [DBPQKR]1916
FAILURE CODE [DDNRKA]1924
FAILURE CODE [DDNRKY]1926
FAILURE CODE [DDNS00]1928
FAILURE CODE [DFB1KZ]1930
FAILURE CODE [DFB2KZ]1932
FAILURE CODE [DFB3L8]1934
FAILURE CODE [DFB4L8]1936
FAILURE CODE [DFB5KZ]1938
FAILURE CODE [DFB6KZ]1940
FAILURE CODE [DGH2KA]1942
FAILURE CODE [DGH2KB]1944
FAILURE CODE [DHA4KA]1946
FAILURE CODE [DHAAMA]1948
FAILURE CODE [DHACMA]1950
FAILURE CODE [DHPAMA]1952
FAILURE CODE [DHPBMA]1955
FAILURE CODE [DHS3MA]1958
FAILURE CODE [DHS4MA]1961
FAILURE CODE [DHS8MA]1964
FAILURE CODE [DHS9MA]1967
FAILURE CODE [DHSAMA]1970
FAILURE CODE [DHSBMA]1973
FAILURE CODE [DHSCMA]1976
FAILURE CODE [DHSDMA]1979
FAILURE CODE [DHSFMA]1982
FAILURE CODE [DHSGMA]1985
FAILURE CODE [DHSHMA]1988
FAILURE CODE [DHSJMA]1991
FAILURE CODE [DHZAMA]1994
FAILURE CODE [DHZCL8]1998
FAILURE CODE [DKR0MA]1999
FAILURE CODE [DKR1MA]2002
FAILURE CODE [DKULKA]2005
FAILURE CODE [DKULKB]2007
FAILURE CODE [DKULKY]2009
FAILURE CODE [DLM3KA]2011
FAILURE CODE [DLM3KB]2013
FAILURE CODE [DLM3MB]2015
FAILURE CODE [DR10KA]2016
FAILURE CODE [DR12KA]2019
FAILURE CODE [DR20KA]2021
FAILURE CODE [DR21KX]2023
FAILURE CODE [DR30KA]2025
FAILURE CODE [DR31KX]2027
FAILURE CODE [DR40KA]2029
FAILURE CODE [DUMBKA]2031
FAILURE CODE [DUMBKB]2034
FAILURE CODE [DV00KA]2036
FAILURE CODE [DV00KB]2037
FAILURE CODE [DV20KB]2038
FAILURE CODE [DW43KA]2040
FAILURE CODE [DW43KB]2042
FAILURE CODE [DW43KY]2044
FAILURE CODE [DW45KA]2046
FAILURE CODE [DW45KB]2049
FAILURE CODE [DW45KY]2052
FAILURE CODE [DW4CKY]2054
FAILURE CODE [DW7BKA]2055
FAILURE CODE [DW7BKB]2057
FAILURE CODE [DW7BKY]2059
FAILURE CODE [DW91KA]2060
FAILURE CODE [DW91KB]2062
FAILURE CODE [DW91KY]2064
FAILURE CODE [DWA2KA]2066
FAILURE CODE [DWA2KB]2068
FAILURE CODE [DWA2KY]2070
FAILURE CODE [DWK0KA]2072
FAILURE CODE [DWK0KB]2074
FAILURE CODE [DWK0KY]2076
FAILURE CODE [DWK2KA]2078
FAILURE CODE [DWK2KB]2080
FAILURE CODE [DWK2KY]2082
FAILURE CODE [DWK8KA]2084
FAILURE CODE [DWK8KB]2086
FAILURE CODE [DWK8KY]2088
FAILURE CODE [DWPUKA]2090
FAILURE CODE [DWPUKB]2092
FAILURE CODE [DWPUKY]2094
FAILURE CODE [DX16KA]2096
FAILURE CODE [DX16KB]2098
FAILURE CODE [DXA8KA]2100
FAILURE CODE [DXA8KB]2102
FAILURE CODE [DXA9KA]2104
FAILURE CODE [DXA9KB]2106
FAILURE CODE [DXE0KA]2108
FAILURE CODE [DXE0KB]2110
FAILURE CODE [DXE4KA]2112
FAILURE CODE [DXE4KB]2114
FAILURE CODE [DXE4KY]2116
FAILURE CODE [DXE5KA]2118
FAILURE CODE [DXE5KB]2120
FAILURE CODE [DXE6KA]2122
FAILURE CODE [DXE6KB]2124
FAILURE CODE [DXE7KA]2126
FAILURE CODE [DXE7KB]2128
FAILURE CODE [DXE7KY]2130
FAILURE CODE [DXE8KA]2132
FAILURE CODE [DXE8KB]2134
FAILURE CODE [DXE8KY]2136
FAILURE CODE [DXE9KA]2138
FAILURE CODE [DXE9KB]2140
FAILURE CODE [DXE9KY]2142
FAILURE CODE [DXEAKA]2144
FAILURE CODE [DXEAKB]2146
FAILURE CODE [DXEAKY]2148
FAILURE CODE [DXEKKA]2150
FAILURE CODE [DXEKKB]2152
FAILURE CODE [DXEKKY]2154
FAILURE CODE [DXELKA]2156
FAILURE CODE [DXELKB]2158
FAILURE CODE [DXELKY]2160
FAILURE CODE [DY20KA]2162
FAILURE CODE [DY20MA]2164
FAILURE CODE [DY2CKB]2166
FAILURE CODE [DY2DKB]2169
FAILURE CODE [DY2EKB]2171
FAILURE CODE [F313KA]2173
FAILURE CODE [F313KB]2175
FAILURE CODE [F318KB]2178
FAILURE CODE [F318KY]2181
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2183
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2183
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK2189
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK2192
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2194
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING2196
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW2199
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW2200
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING2201
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING2202
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING2203
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2204
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2205
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2206
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2207
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2208
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2209
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL2211
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2212
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE2213
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2214
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE2216
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED2217
E-23 FUNCTION SWITCH DOES NOT OPERATE2218
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)2219
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF2220
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER2221
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED2222
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED2223
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE2224
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE2225
E-31 ALARM BUZZER CANNOT BE CANCELED2227
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION2228
E-33 SERVICE MODE CANNOT BE SELECTED2229
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE2230
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK2232
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING2233
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE2236
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR2238
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED2240
E-40 ALARM DOES NOT SOUND DURING TRAVEL2241
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED2243
E-42 HORN DOES NOT SOUND2244
E-43 HORN DOES NOT STOP SOUNDING2248
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF2250
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE2251
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE2253
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2254
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2255
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2256
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2257
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2258
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2259
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2260
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2261
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2262
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED2264
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2265
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED2266
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE2268
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2269
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2269
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS2270
FAILURE MODE AND CAUSE TABLE2272
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK2280
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER2281
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR2283
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP2284
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2285
H-6 SPEED OR POWER OF BOOM IS LOW2287
H-7 ARM SPEED OR POWER IS LOW2293
H-8 BUCKET SPEED OR POWER IS LOW2298
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION2301
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE2302
H-11 HYDRAULIC DRIFT OF ARM IS LARGE2304
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE2306
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2307
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE2308
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE2309
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE2310
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED2311
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED2312
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER2313
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY2314
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW2315
H-22 MACHINE DOES NOT TRAVEL STRAIGHT2316
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW2318
H-24 TRAVEL SPEED IS LOW2321
H-25 ONE OF TRACKS DOES NOT RUN2323
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST2324
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT2325
H-28 SWINGS ONLY IN ONE DIRECTION2326
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)2327
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION2328
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)2329
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)2330
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING2331
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING2332
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)2333
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)2334
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2335
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN2336
H-39 Quick coupler cylinder will not extend2337
H-40 Quick coupler cylinder will not retract (but buzzer doesnot sound)2339
H-41 Buzzer does not sound (but quick coupler cylinder doesretract)2341
H-42 Quick coupler cylinder extends and retracts slowly2343
TROUBLESHOOTING OF ENGINE (S-MODE)2344
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2344
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2345
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2346
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2347
S-4 ENGINE STARTABILITY IS POOR2348
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2350
S-6 ENGINE STOPS DURING OPERATION2352
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2354
S-8 ENGINE LACKS POWER2355
S-9 KDPF GETS CLOGGED IN A SHORT TIME2357
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2359
S-11 OIL BECOMES CONTAMINATED QUICKLY2360
S-12 FUEL CONSUMPTION IS EXCESSIVE2361
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2362
S-14 OIL PRESSURE DROPS2363
S-15 FUEL MIXES INTO ENGINE OIL2365
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2366
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2367
S-18 UNUSUAL NOISE IS HEARD2368
S-19 VIBRATION IS EXCESSIVE2369
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2370
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2371
S-22 ACTIVE REGENERATION TAKES TIME2373
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2375
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2376
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2378
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2379
TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED)2380
20 SUPPLY VOLTAGE > 32VDC2380
21 SUPPLY VOLTAGE < 12VDC2381
25 FILE ERROR FACTORY SETTINGS2382
26 FILE ERROR USER SETTINGS2383
27 FILE ERROR INPUT DATA2384
30 PROXIMITY SWITCHES DIFFERENCE2385
86 ANGLE SENSOR A2 TIMEOUT2386
96 ANGLE SENSOR A3/A5 TIMEOUT2387
106 ANGLE SENSOR A4/A6 TIMEOUT2388
116 ANGLE SENSOR PITCH TIMEOUT2389
126 ANGLE SENSOR ROLL TIMEOUT2390
FAILURE CODE TABLE2391
TROUBLESHOOTING FOR K100 BOOM CHANGE SYSTEM2394
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)2395
FAILURE CODE [198]2395
FAILURE CODE [199]2396
FAILURE CODE [200]2397
FAILURE CODE [201]2398
FAILURE CODE [202]2400
FAILURE CODE [203]2402
FAILURE CODE [204]2403
FAILURE CODE [205]2405
FAILURE CODE [206]2407
FAILURE CODE [207]2408
FAILURE CODE [208]2410
FAILURE CODE [209]2412
FAILURE CODE [210]2413
FAILURE CODE [211]2415
FAILURE CODE [212]2416
FAILURE CODE [213]2417
FAILURE CODE [214]2419
FAILURE CODE [215]2420
FAILURE CODE [216]2421
FAILURE CODE [217]2423
FAILURE CODE [218]2425
FAILURE CODE [219]2426
FAILURE CODE [220]2428
FAILURE CODE [221]2429
FAILURE CODE [222]2430
FAILURE CODE [223]2432
FAILURE CODE [224]2433
FAILURE CODE [225]2434
FAILURE CODE [226]2436
FAILURE CODE [227]2437
FAILURE CODE [228]2438
FAILURE CODE [229]2439
FAILURE CODE [230]2440
FAILURE CODE [231]2441
FAILURE CODE [234]2442
FAILURE CODE [235]2443
FAILURE CODE [236]2444
FAILURE CODE [237]2445
FAILURE CODE [240]2446
FAILURE CODE [241]2447
FAILURE CODE [242]2448
FAILURE CODE [250]2449
FAILURE CODE [250]2450
FAILURE CODE [250]2451
FAILURE CODE [250]2452
STATUS OF DIGITAL INPUTS WITH RESPECT TO WORK EQUIPMENT CONFIGURATIONS2453
FAILURE CODE2454
TROUBLESHOOTING FOR ERRORS ON SENSORS2455
TROUBLESHOOTING METHODS2457
JOINT 1 CAMERA IMAGE NOT DISPLAYED ON SCREEN2459
JOINT 2 CAMERA IMAGE NOT DISPLAYED ON SCREEN2460
CAMERA SCREEN DOES NOT CHANGE TO BOOM RAISE SCREEN2461
WORK EQUIPMENT IS NOT PICKED UP BY BASE MACHINE BUT SCREEN CHANGED TO BOOM RAISE SCREEN2462
CAMERA SCREEN DOES NOT APPEAR AFTER WORK EQUIPMENT IS FULLY DISENGAGED2463
SWING LOCK DOES NOT DEACTIVATE EVEN IF SWING LOCK IS RELEASED2464
LOCK LEVER IS DOWN (FREE) BUT HYDRAULIC LOCK SYMBOL APPEARS ON SCREEN2466
LOCK LEVER IS DOWN (LOCKED) BUT HYDRAULIC LOCK SYMBOL DOES NOT APPEAR ON SCREEN2467
50 DISASSEMBLY AND ASSEMBLY2469
CONTENTS2470
ABBREVIATION LIST2475
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2481
HOW TO READ THIS MANUAL2481
COATING MATERIALS LIST2483
SPECIAL TOOLS LIST2488
SKETCHES OF SPECIAL TOOLS2500
ENGINE AND COOLING SYSTEM2506
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2506
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2506
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2512
REMOVE AND INSTALL INJECTOR ASSEMBLY2521
METHOD FOR REMOVING INJECTOR ASSEMBLY2521
METHOD FOR INSTALLING INJECTOR ASSEMBLY2527
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2537
METHOD FOR REMOVING FUEL DOSER2537
METHOD FOR INSTALLING FUEL DOSER2538
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2540
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2541
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2550
REMOVE AND INSTALL EGR VALVE ASSEMBLY2563
METHOD FOR REMOVING EGR VALVE ASSEMBLY2563
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2565
REMOVE AND INSTALL EGR COOLER ASSEMBLY2567
METHOD FOR REMOVING EGR COOLER ASSEMBLY2567
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2571
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2577
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2577
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2578
REMOVE AND INSTALL ALTERNATOR BELT2580
METHOD FOR REMOVING ALTERNATOR BELT2580
METHOD FOR INSTALLING ALTERNATOR BELT2583
REMOVE AND INSTALL RADIATOR ASSEMBLY2588
METHOD FOR REMOVING RADIATOR ASSEMBLY2588
METHOD FOR INSTALLING RADIATOR ASSEMBLY2590
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2593
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2593
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2597
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2602
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2602
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2604
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2606
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2606
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2608
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2612
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2613
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2631
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2650
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2651
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2653
REMOVE AND INSTALL ENGINE REAR OIL SEAL2657
METHOD FOR REMOVING ENGINE REAR OIL SEAL2658
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2661
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2667
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2667
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2675
REMOVE AND INSTALL FUEL TANK ASSEMBLY2686
METHOD FOR REMOVING FUEL TANK ASSEMBLY2686
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2690
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2694
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2694
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2700
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2705
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2705
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2712
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2718
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2718
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2720
REMOVE AND INSTALL KDPF ASSEMBLY2723
METHOD FOR REMOVING KDPF ASSEMBLY2723
METHOD FOR INSTALLING KDPF ASSEMBLY2727
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2732
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2733
METHOD FOR ASSEMBLING KDPF ASSEMBLY2738
REMOVE AND INSTALL SCR ASSEMBLY2745
METHOD FOR REMOVING SCR ASSEMBLY2745
METHOD FOR INSTALLING SCR ASSEMBLY2748
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2752
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2752
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2757
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2762
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2762
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2766
REMOVE AND INSTALL KCCV ASSEMBLY2776
METHOD FOR REMOVING KCCV ASSEMBLY2776
METHOD FOR INSTALLING KCCV ASSEMBLY2777
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2781
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2781
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2786
REMOVE AND INSTALL AdBlue/DEF INJECTOR2792
METHOD FOR REMOVING AdBlue/DEF INJECTOR2792
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2796
REMOVE AND INSTALL AdBlue/DEF PUMP2801
METHOD FOR REMOVING AdBlue/DEF PUMP2801
METHOD FOR INSTALLING AdBlue/DEF PUMP2803
REMOVE AND INSTALL AdBlue/DEF HOSE2804
METHOD FOR REMOVING AdBlue/DEF HOSE2804
METHOD FOR INSTALLING AdBlue/DEF HOSE2809
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2818
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2818
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2819
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2822
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2822
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2825
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2829
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2829
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2830
POWER TRAIN2832
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2832
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2832
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2833
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2834
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2834
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2839
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2845
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2845
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2846
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2848
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2848
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2852
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2858
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2858
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2858
UNDERCARRIAGE AND FRAME2860
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2860
METHOD FOR SEPARATING TRACK ASSEMBLY2860
METHOD FOR INSTALLING TRACK ASSEMBLY2862
REMOVE AND INSTALL SPROCKET2865
METHOD FOR REMOVING SPROCKET2865
METHOD FOR INSTALLING SPROCKET2865
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2867
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2867
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2868
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2870
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2870
METHOD FOR ASSEMBLING IDLER ASSEMBLY2872
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2877
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2878
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2880
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2883
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2884
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2885
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY2889
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2889
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2891
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2894
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2894
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2896
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2899
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2899
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2900
HYDRAULIC SYSTEM2903
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2903
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2903
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2905
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2907
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2908
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2908
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2910
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2910
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2915
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2921
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2921
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2925
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2931
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2931
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2936
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2942
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2943
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2944
REMOVE AND INSTALL ATT BYPASS SOLENOID2949
REMOVE ATT BYPASS SOLENOID2949
INSTALL ATT BYPASS SOLENOID2952
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2954
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2954
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2955
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2957
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2957
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2958
REMOVE AND INSTALL QUICK COUPLER VALVE2960
WORK EQUIPMENT2962
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2962
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2963
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2966
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2970
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2970
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2973
CAB AND ITS ATTACHMENTS2977
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2977
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2977
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2984
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2991
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2993
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2993
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY3003
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY3003
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY3006
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY3012
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY3012
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY3019
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY3027
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY3027
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY3033
REMOVE AND INSTALL OPERATOR’S SEAT3040
METHOD FOR REMOVING OPERATOR’S SEAT3040
METHOD FOR INSTALLING OPERATOR’S SEAT3042
REMOVE AND INSTALL SEAT BELT3045
METHOD FOR REMOVING SEAT BELT3045
METHOD FOR INSTALLING SEAT BELT3046
REMOVE AND INSTALL FRONT WIPER ASSEMBLY3047
METHOD FOR REMOVING FRONT WIPER ASSEMBLY3047
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY3052
ELECTRICAL SYSTEM3061
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY3061
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY3061
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY3062
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY3064
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY3064
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY3067
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY3072
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY3072
METHOD FOR INSTALLING KomVision CONTROLLER3073
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY3074
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY3074
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY3077
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR3081
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR3081
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR3082
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3083
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR3083
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR3084
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3086
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR3086
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR3087
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3089
METHOD FOR REMOVING SCR TEMPERATURE SENSOR3089
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR3091
REMOVE AND INSTALL KomVision CAMERA3093
METHOD FOR REMOVING KomVision CAMERA3093
METHOD FOR INSTALLING KomVision CAMERA3094
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3096
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY3096
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY3100
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS3106
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS3106
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS3114
REMOVE AND INSTALL COMMUNICATION TERMINAL3123
METHOD FOR REMOVING COMMUNICATION TERMINAL3123
METHOD FOR INSTALLING COMMUNICATION TERMINAL3125
60 MAINTENANCE STANDARD3129
CONTENTS3130
ABBREVIATION LIST3132
ENGINE AND COOLING SYSTEM3138
MAINTENANCE STANDARD OF ENGINE MOUNT3138
MAINTENANCE STANDARD OF COOLING SYSTEM3139
MAINTENANCE STANDARD OF COOLING FAN PUMP3140
MAINTENANCE STANDARD OF SERVO VALVE3141
MAINTENANCE STANDARD OF COOLING FAN MOTOR3142
POWER TRAIN3143
MAINTENANCE STANDARD OF SWING CIRCLE3143
MAINTENANCE STANDARD OF SWING MACHINERY3144
MAINTENANCE STANDARD OF FINAL DRIVE3146
MAINTENANCE STANDARD OF SPROCKET3148
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING3149
UNDERCARRIAGE AND FRAME3151
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION3151
MAINTENANCE STANDARD OF IDLER3153
MAINTENANCE STANDARD OF TRACK ROLLER3155
MAINTENANCE STANDARD OF CARRIER ROLLER3157
MAINTENANCE STANDARD OF TRACK SHOE3158
MAINTENANCE STANDARD OF TRIPLE SHOE3161
HYDRAULIC SYSTEM3162
MAINTENANCE STANDARD OF MAIN PUMP3162
MAINTENANCE STANDARD OF SWING MOTOR3164
MAINTENANCE STANDARD OF TRAVEL MOTOR3167
MAINTENANCE STANDARD OF CONTROL VALVE3170
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE3181
MAINTENANCE STANDARD OF TRAVEL PPC VALVE3184
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)3187
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE3189
MAINTENANCE STANDARD OF SOLENOID VALVE3190
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE3191
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE3193
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT3194
WORK EQUIPMENT3195
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE3195
DIMENSION OF ARM3200
DIMENSIONS OF BUCKET3202
MAINTENANCE STANDARD OF BOOM CYLINDER3204
MAINTENANCE STANDARD OF ARM CYLINDER3205
MAINTENANCE STANDARD OF BUCKET CYLINDER3206
WORK EQUIPMENT – PC490HRD-11E03207
WORK EQUIPMENT – HIGH REACH DEMOLITION3207
DIMENSION OF ARM3207
MAINTENANCE STANDARD OF BOOM CYLINDER3208
MAINTENANCE STANDARD OF LINK CYLINDER3209
MAINTENANCE STANDARD OF ARM CYLINDER3210
MAINTENANCE STANDARD OF BUCKET CYLINDER3211
WORK EQUIPMENT – DEMOLITION DIGGING3212
MAINTENANCE STANDARD OF ARM CYLINDER3212
MAINTENANCE STANDARD OF BUCKET CYLINDER3213
PC490HRD-11E0 K100 BOOM CHANGE SYSTEM3214
S AND A VALVES MAINTENANCE SCHEDULE3214
GREASING PROCEDURE OF S VALVE ASSEMBLY LOCKING PINS (RECOMMENDED EVERY 1000 HOURS/1 YEAR WHICH EVER OCCURS FIRST OR IF DIFFICULTY CONNECTING/DISCONNECTING OCCURS3221
JACKING BOLTS FOR VALVE LOCKING CYLINDER ASSEMBLY REMOVAL3223
MAINTENANCE STANDARD OF SWING CIRCLE3226
MAINTENANCE STANDARD OF COUNTERWEIGHT BOLTS3227
MAINTENANCE STANDARD OF WORKSTAND3228
80 APPENDIX3229
CONTENTS3230
ABBREVIATION LIST3232
AIR CONDITIONER SYSTEM3238
PRECAUTIONS FOR REFRIGERANT3238
AIR CONDITIONER COMPONENT3239
SPECIFICATIONS OF AIR CONDITIONER3241
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3242
OUTLINE OF REFRIGERATION CYCLE3243
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3245
AIR CONDITIONER UNIT3245
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3245
FUNCTION OF AIR CONDITIONER UNIT3247
COMPONENT PARTS OF AIR CONDITIONER UNIT3249
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3250
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3250
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3250
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3250
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3251
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3251
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3251
FUNCTION OF DUAL PRESSURE SWITCH3252
AIR CONDITIONER CONTROLLER3253
STRUCTURE OF AIR CONDITIONER CONTROLLER3253
COMPRESSOR3254
STRUCTURE OF COMPRESSOR3254
SPECIFICATIONS OF COMPRESSOR3254
FUNCTION OF COMPRESSOR3254
CONDENSER3255
STRUCTURE OF CONDENSER3255
SPECIFICATIONS OF CONDENSER3255
FUNCTION OF CONDENSER3255
RECEIVER DRIER3256
STRUCTURE OF RECEIVER DRIER3256
SPECIFICATIONS OF RECEIVER DRIER3256
FUNCTION OF RECEIVER DRIER3256
SENSORS FOR AIR CONDITIONER SYSTEM3257
STRUCTURE OF SUNLIGHT SENSOR3257
FUNCTION OF SUNLIGHT SENSOR3257
STRUCTURE OF AMBIENT TEMPERATURE SENSOR3257
FUNCTION OF AMBIENT TEMPERATURE SENSOR3257
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3259
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3261
AIR CONDITIONER SYSTEM DIAGRAM3263
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3264
FUNCTION OF AIR CONDITIONER CONTROLLER3265
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3266
TESTING AIR LEAKAGE (DUCT)3270
METHOD FOR TESTING AIR LEAKAGE (DUCT)3270
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3272
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3273
TEST VENT (MODE) CHANGEOVER3274
METHOD FOR TESTING VENT (MODE) CHANGEOVER3274
TESTING FRESH/RECIRC AIR CHANGEOVER3276
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3276
TEST SUNLIGHT SENSOR3277
METHOD FOR TESTING SUNLIGHT SENSOR3277
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT3278
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT3278
TEST RELAYS3279
METHOD FOR TESTING RELAYS3279
AIR CONDITIONER TROUBLESHOOTING CHART 13280
AIR CONDITIONER TROUBLESHOOTING CHART 23281
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3284
FAILURE CODE [879AKA]3286
FAILURE CODE [879AKB]3287
FAILURE CODE [879BKA]3288
FAILURE CODE [879BKB]3290
FAILURE CODE [879CKA]3292
FAILURE CODE [879CKB]3293
FAILURE CODE [879DKZ]3294
FAILURE CODE [879EMC]3296
FAILURE CODE [879FMC]3297
FAILURE CODE [879GKX]3298
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3300
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3301
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3302
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3303
TROUBLESHOOTING USING GAUGE PRESSURE3304
CONNECTION OF SERVICE TOOL3307
METHOD FOR CONNECTING SERVICE TOOL3307
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3309
HANDLE COMPRESSOR OIL3311
PC490HRD-11E0 K100 BOOM CHANGE SYSTEM3313
AUXILLARY CONNECTIONS3313
WORKSTAND BRACKET3316
90 CIRCUIT DIAGRAMS3319
CONTENTS3320
ABBREVIATION LIST3321
HYDRAULIC CIRCUIT DIAGRAM (PC490)3327
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3327
HYDRAULIC CIRCUIT DIAGRAM (1/3)3331
HYDRAULIC CIRCUIT DIAGRAM (2/3)3333
HYDRAULIC CIRCUIT DIAGRAM (3/3)3335
HYDRAULIC CIRCUIT DIAGRAM (PC490HRD)3337
HYDRAULIC CIRCUIT DIAGRAM (1/2)3339
HYDRAULIC CIRCUIT DIAGRAM (2/2)3341
HYDRAULIC CIRCUIT DIAGRAM (1/8)3343
HYDRAULIC CIRCUIT DIAGRAM (2/8)3345
HYDRAULIC CIRCUIT DIAGRAM (3/8)3347
HYDRAULIC CIRCUIT DIAGRAM (4/8)3349
HYDRAULIC CIRCUIT DIAGRAM (5/8)3351
HYDRAULIC CIRCUIT DIAGRAM (6/8)3353
HYDRAULIC CIRCUIT DIAGRAM (7/8)3355
HYDRAULIC CIRCUIT DIAGRAM (8/8)3357
ELECTRICAL CIRCUIT DIAGRAM (PC490)3359
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3359
ELECTRICAL CIRCUIT DIAGRAM (1/11)3363
ELECTRICAL CIRCUIT DIAGRAM (2/11)3365
ELECTRICAL CIRCUIT DIAGRAM (3/11)3367
ELECTRICAL CIRCUIT DIAGRAM (4/11)3369
ELECTRICAL CIRCUIT DIAGRAM (5/11)3371
ELECTRICAL CIRCUIT DIAGRAM (6/11)3373
ELECTRICAL CIRCUIT DIAGRAM (7/11)3375
ELECTRICAL CIRCUIT DIAGRAM (8/11)3377
ELECTRICAL CIRCUIT DIAGRAM (9/11)3379
ELECTRICAL CIRCUIT DIAGRAM (10/11)3381
ELECTRICAL CIRCUIT DIAGRAM (11/11)3383
ELECTRICAL CIRCUIT DIAGRAM (PC490HRD)3385
ELECTRICAL CIRCUIT DIAGRAM (1/17)3387
ELECTRICAL CIRCUIT DIAGRAM (2/17)3389
ELECTRICAL CIRCUIT DIAGRAM (3/17)3391
ELECTRICAL CIRCUIT DIAGRAM (4/17)3393
ELECTRICAL CIRCUIT DIAGRAM (5/17)3395
ELECTRICAL CIRCUIT DIAGRAM (6/17)3397
ELECTRICAL CIRCUIT DIAGRAM (7/17)3399
ELECTRICAL CIRCUIT DIAGRAM (8/17)3401
ELECTRICAL CIRCUIT DIAGRAM (9/17)3403
ELECTRICAL CIRCUIT DIAGRAM (10/17)3405
ELECTRICAL CIRCUIT DIAGRAM (11/17)3407
ELECTRICAL CIRCUIT DIAGRAM (12/17)3409
ELECTRICAL CIRCUIT DIAGRAM (13/17)3411
ELECTRICAL CIRCUIT DIAGRAM (14/17)3413
ELECTRICAL CIRCUIT DIAGRAM (15/17)3415
ELECTRICAL CIRCUIT DIAGRAM (16/17)3417
ELECTRICAL CIRCUIT DIAGRAM (17/17)3419
INDEX3421

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24