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

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Komatsu HYDRAULIC EXCAVATOR PC490 -11E0 PC490LC -11E0 PC490HRD-11E0 Shop Manual UENBM00503 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC490 -11E0 PC490LC -11E0 PC490HRD-11E0 Shop Manual UENBM00503 – PDF DOWNLOAD

Language : English
Pages :3480
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC490 -11E0 PC490LC -11E0 PC490HRD-11E0 Shop Manual UENBM00503 – PDF DOWNLOAD

SERIAL NUMBERS K75001 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 UENBM00503 – PDF DOWNLOAD

SERIAL NUMBERS K75001 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) 919
KomVision screen – Check 12 m visibility 946
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 949
HANDLE BATTERY DISCONNECT SWITCH 950
TEST DIODES 951
METHOD FOR TESTING DIODE USING DIGITAL TESTER 951
METHOD FOR TESTING DIODE USING ANALOG TESTER 951
ELECTRICAL SYSTEM – PC490HRD-11E0 952
ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM 952
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – BASE MACHINE 952
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – HIGH REACH DEMOLITION WORK EQUIPMENT 955
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT 957
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – MEDIUM REACH DEMOLITION WORK EQUIPMENT 959
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – DEMOLITION DIGGING WORK EQUIPMENT 961
RH PPC LEVER 962
LH PPC LEVER 963
WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT 964
CONSTANT LINK SPEED CIRCUIT 965
PARALLEL LINK FRONT SCREEN WIPER 966
OVERLOAD CAUTION (HIGH REACH DEMOLITION) 967
ELECTRICAL SYSTEM – PC490HRD-11E0 K100 BOOM CHANGE SYSTEM 968
SWING LOCK CIRCUIT 968
HYDRAULIC LOCK CIRCUIT 969
WORK EQUIPMENT PICKUP PROXIMITY SWITCH CIRCUIT 970
BOOM RAISE LOCK CIRCUIT 971
DEPRESSURISATION CIRCUIT 972
PRESSURE INTENSIFIER CIRCUIT 973
HYDRAULIC PIN LOCK/UNLOCK CIRCUIT 974
VALVE LOCK/UNLOCK 975
1ST BOOM AND EXTENSION BOOM CAMERA 976
1st BOOM ELECTRICAL DIAGRAM 977
EXTENSION BOOM ELECTRICAL DIAGRAM 978
HIGH REACH DEMOLITION WORK EQUIPMENT ELECTRICAL DIAGRAM 979
DEMOLITION DIGGING WORK EQUIPMENT ELECTRICAL DIAGRAM 981
HYDRAULIC PIN, S-VALVE AND PICK UP PIN SENSORS, MEASURING AND ADJUSTING HYDRAULIC PIN LOCK SENSORS 983
MEASURING AND ADJUSTING HYDRAULIC PIN UNLOCK SENSORS 985
MEASURING AND ADJUSTING PICK-UP PIN SENSOR 986
MEASURING AND ADJUSTING S-VALVE PIN UNLOCK SWITCHES 987
MEASURING AND ADJUSTING A-VALVE PROXIMITY SWITCH 988
MEASURING AND ADJUSTING SHIMS FOR REACTION BRACKET 989
K100 BOOM CHANGE CONTROL SYSTEM 990
SERVICE OPERATIONS – K100 BOOM CHANGE SYSTEM 992
K100 BOOM CHANGE CONTROL SYSTEM – UPDATING SOFTWARE 998
K100 BOOM CHANGE CONTROLLER REPLACEMENT1000
Pm CLINIC1002
Pm CLINIC SERVICE1002
Pm CLINIC CHECK SHEET1003
WORKING RANGE INDICATOR SYSTEM1016
WORKING RANGE INDICATOR SYSTEM LAYOUT1016
METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU1018
DIAGNOSTICS – WORKING RANGE INDICATOR SYSTEM1020
MONITORING SYSTEM PARAMETERS AND SENSOR STATES1020
USING THE PARAMETER CHANGE LOG1022
USING ERROR LISTS AND LOGS1023
EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM1024
IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM1025
REPLACING COMPONENTS – WORKING RANGE INDICATOR SYSTEM1027
WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT1027
WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT1032
WORKING RANGE INDICATOR SYSTEM – UDATING SOFTWARE1037
CALIBRATION – WORKING RANGE INDICATOR SYSTEM1041
WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW1041
METHOD 1 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – AUTO CALIBRATION1041
METHOD 2 – BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION1049
METHOD 2 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – MANUAL CALIBRATION1052
40 TROUBLESHOOTING1067
CONTENTS1068
ABBREVIATION LIST1081
RELATED INFORMATION ON TROUBLESHOOTING1087
GENERAL TROUBLESHOOTING POINTS1087
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM1088
SEQUENCE OF EVENTS IN TROUBLESHOOTING1100
CHECKS BEFORE TROUBLESHOOTING1102
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING1104
WALK-AROUND CHECK1104
TESTING IN ACCORDANCE WITH TESTING PROCEDURE1106
CHECK FUEL LEVEL AND TYPE1106
CHECK IMPURE INGREDIENT IN FUEL1107
CHECK FUEL PREFILTER1107
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT1107
FUEL PREFILTER CARTRIDGE – REPLACE1108
CHECK MAIN FILTER1109
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)1110
CHECK COOLANT LEVEL (RESERVOIR TANK)1112
CHECK CLOGGING OF AIR CLEANER1112
OUTER ELEMENT – CLEAN1113
ELEMENTS – REPLACE1115
CHECK HYDRAULIC OIL LEVEL1116
CHECK HYDRAULIC OIL STRAINER1116
CHECK HYDRAULIC FILTER1117
CHECK OIL LEVEL IN SWING MACHINERY CASE1118
CHECK OIL LEVEL IN DAMPER CASE1119
CHECK OIL LEVEL IN FINAL DRIVE CASE1119
BLEED AIR FROM FUEL SYSTEM1120
BLEED AIR FROM HYDRAULIC SYSTEM1120
ELECTRICAL EQUIPMENT – CHECK METHOD1120
AUTOMATIC GREASE SYSTEM1126
FINDING MALFUNCTIONS1126
MALFUNCTION FINDING PROCEDURES1130
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION1132
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM1145
PROCEDURE FOR TESTING AND TROUBLESHOOTING1155
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS1158
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE1162
CONNECTOR LIST AND LAYOUT1164
CONNECTOR CONTACT IDENTIFICATION1177
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE1217
FUSE LOCATION TABLE1223
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)1226
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])1230
FAILURE CODE TABLE1232
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1251
FAILURE CODE [879AKA]1251
FAILURE CODE [879AKB]1252
FAILURE CODE [879BKA]1253
FAILURE CODE [879BKB]1255
FAILURE CODE [879CKA]1257
FAILURE CODE [879CKB]1258
FAILURE CODE [879DKZ]1259
FAILURE CODE [879EMC]1261
FAILURE CODE [879FMC]1262
FAILURE CODE [879GKX]1263
FAILURE CODE [989L00]1265
FAILURE CODE [989M00]1266
FAILURE CODE [989N00]1267
FAILURE CODE [A1U0N3]1268
FAILURE CODE [A1U0N4]1270
FAILURE CODE [A900FR]1272
FAILURE CODE [A900N6]1273
FAILURE CODE [A900NY]1274
FAILURE CODE [AA10NX]1275
FAILURE CODE [AB00KE]1277
FAILURE CODE [AQ10N3]1280
FAILURE CODE [AS00N3]1282
FAILURE CODE [AS00R2]1284
FAILURE CODE [AS00R3]1285
FAILURE CODE [AS00R4]1286
FAILURE CODE [AS00R5]1287
FAILURE CODE [AS00R6]1288
FAILURE CODE [AS00ZK]1289
FAILURE CODE [AS10KM]1290
FAILURE CODE [AS10NR]1291
FAILURE CODE [AS10NT]1292
FAILURE CODE [B@BAZG]1293
FAILURE CODE [B@BAZK]1294
FAILURE CODE [B@BCNS]1296
FAILURE CODE [B@BCQA]1297
FAILURE CODE [B@BCZK]1299
FAILURE CODE [B@HANS]1301
FAILURE CODE [CA115]1302
FAILURE CODE [CA122]1303
FAILURE CODE [CA123]1305
FAILURE CODE [CA131]1307
FAILURE CODE [CA132]1309
FAILURE CODE [CA135]1311
FAILURE CODE [CA141]1313
FAILURE CODE [CA144]1315
FAILURE CODE [CA145]1317
FAILURE CODE [CA153]1319
FAILURE CODE [CA154]1322
FAILURE CODE [CA187]1325
FAILURE CODE [CA221]1327
FAILURE CODE [CA222]1329
FAILURE CODE [CA227]1331
FAILURE CODE [CA234]1332
FAILURE CODE [CA238]1333
FAILURE CODE [CA239]1335
FAILURE CODE [CA249]1337
FAILURE CODE [CA256]1339
FAILURE CODE [CA271]1341
FAILURE CODE [CA272]1343
FAILURE CODE [CA273]1344
FAILURE CODE [CA274]1346
FAILURE CODE [CA322]1347
FAILURE CODE [CA323]1349
FAILURE CODE [CA324]1351
FAILURE CODE [CA325]1353
FAILURE CODE [CA331]1355
FAILURE CODE [CA332]1357
FAILURE CODE [CA343]1359
FAILURE CODE [CA351]1360
FAILURE CODE [CA352]1361
FAILURE CODE [CA356]1364
FAILURE CODE [CA357]1366
FAILURE CODE [CA386]1368
FAILURE CODE [CA441]1369
FAILURE CODE [CA442]1371
FAILURE CODE [CA449]1372
FAILURE CODE [CA451]1373
FAILURE CODE [CA452]1375
FAILURE CODE [CA515]1377
FAILURE CODE [CA516]1379
FAILURE CODE [CA553]1381
FAILURE CODE [CA555]1382
FAILURE CODE [CA556]1383
FAILURE CODE [CA559]1384
FAILURE CODE [CA595]1389
FAILURE CODE [CA687]1390
FAILURE CODE [CA689]1392
FAILURE CODE [CA691]1394
FAILURE CODE [CA692]1396
FAILURE CODE [CA697]1398
FAILURE CODE [CA698]1399
FAILURE CODE [CA731]1400
FAILURE CODE [CA778]1401
FAILURE CODE [CA1117]1404
FAILURE CODE [CA1664]1405
FAILURE CODE [CA1669]1408
FAILURE CODE [CA1673]1409
FAILURE CODE [CA1677]1410
FAILURE CODE [CA1678]1411
FAILURE CODE [CA1682]1412
FAILURE CODE [CA1683]1414
FAILURE CODE [CA1684]1416
FAILURE CODE [CA1686]1418
FAILURE CODE [CA1691]1419
FAILURE CODE [CA1694]1422
FAILURE CODE [CA1695]1424
FAILURE CODE [CA1696]1425
FAILURE CODE [CA1712]1427
FAILURE CODE [CA1713]1430
FAILURE CODE [CA1714]1432
FAILURE CODE [CA1715]1433
FAILURE CODE [CA1776]1434
FAILURE CODE [CA1777]1437
FAILURE CODE [CA1843]1440
FAILURE CODE [CA1844]1442
FAILURE CODE [CA1879]1445
FAILURE CODE [CA1881]1448
FAILURE CODE [CA1883]1450
FAILURE CODE [CA1885]1453
FAILURE CODE [CA1887]1455
FAILURE CODE [CA1921]1457
FAILURE CODE [CA1922]1460
FAILURE CODE [CA1923]1465
FAILURE CODE [CA1924]1467
FAILURE CODE [CA1925]1469
FAILURE CODE [CA1927]1471
FAILURE CODE [CA1928]1473
FAILURE CODE [CA1942]1475
FAILURE CODE [CA1963]1476
FAILURE CODE [CA1977]1479
FAILURE CODE [CA1993]1482
FAILURE CODE [CA2185]1485
FAILURE CODE [CA2186]1487
FAILURE CODE [CA2249]1489
FAILURE CODE [CA2265]1490
FAILURE CODE [CA2266]1492
FAILURE CODE [CA2271]1494
FAILURE CODE [CA2272]1496
FAILURE CODE [CA2349]1498
FAILURE CODE [CA2353]1500
FAILURE CODE [CA2357]1502
FAILURE CODE [CA2381]1503
FAILURE CODE [CA2382]1505
FAILURE CODE [CA2383]1507
FAILURE CODE [CA2386]1509
FAILURE CODE [CA2387]1511
FAILURE CODE [CA2555]1512
FAILURE CODE [CA2556]1515
FAILURE CODE [CA2637]1517
FAILURE CODE [CA2639]1519
FAILURE CODE [CA2732]1522
FAILURE CODE [CA2733]1524
FAILURE CODE [CA2741]1526
FAILURE CODE [CA2765]1527
FAILURE CODE [CA2771]1528
FAILURE CODE [CA2777]1534
FAILURE CODE [CA2878]1537
FAILURE CODE [CA2881]1540
FAILURE CODE [CA2976]1543
FAILURE CODE [CA3133]1545
FAILURE CODE [CA3134]1547
FAILURE CODE [CA3135]1549
FAILURE CODE [CA3142]1552
FAILURE CODE [CA3143]1553
FAILURE CODE [CA3144]1554
FAILURE CODE [CA3146]1556
FAILURE CODE [CA3147]1557
FAILURE CODE [CA3148]1558
FAILURE CODE [CA3151]1560
FAILURE CODE [CA3165]1566
FAILURE CODE [CA3167]1568
FAILURE CODE [CA3229]1571
FAILURE CODE [CA3231]1573
FAILURE CODE [CA3232]1575
FAILURE CODE [CA3235]1579
FAILURE CODE [CA3239]1581
FAILURE CODE [CA3241]1584
FAILURE CODE [CA3242]1587
FAILURE CODE [CA3251]1590
FAILURE CODE [CA3253]1592
FAILURE CODE [CA3254]1595
FAILURE CODE [CA3255]1598
FAILURE CODE [CA3256]1602
FAILURE CODE [CA3311]1604
FAILURE CODE [CA3312]1606
FAILURE CODE [CA3313]1609
FAILURE CODE [CA3314]1610
FAILURE CODE [CA3315]1611
FAILURE CODE [CA3316]1614
FAILURE CODE [CA3317]1615
FAILURE CODE [CA3318]1616
FAILURE CODE [CA3319]1618
FAILURE CODE [CA3321]1619
FAILURE CODE [CA3322]1621
FAILURE CODE [CA3419]1624
FAILURE CODE [CA3421]1626
FAILURE CODE [CA3497]1628
FAILURE CODE [CA3498]1629
FAILURE CODE [CA3543]1630
FAILURE CODE [CA3545]1637
FAILURE CODE [CA3547]1639
FAILURE CODE [CA3558]1640
FAILURE CODE [CA3559]1642
FAILURE CODE [CA3562]1644
FAILURE CODE [CA3563]1646
FAILURE CODE [CA3567]1649
FAILURE CODE [CA3568]1652
FAILURE CODE [CA3571]1656
FAILURE CODE [CA3572]1658
FAILURE CODE [CA3574]1660
FAILURE CODE [CA3575]1662
FAILURE CODE [CA3577]1664
FAILURE CODE [CA3578]1666
FAILURE CODE [CA3582]1668
FAILURE CODE [CA3583]1674
FAILURE CODE [CA3596]1676
FAILURE CODE [CA3649]1678
FAILURE CODE [CA3681]1680
FAILURE CODE [CA3682]1685
FAILURE CODE [CA3713]1691
FAILURE CODE [CA3717]1694
FAILURE CODE [CA3718]1695
FAILURE CODE [CA3725]1696
FAILURE CODE [CA3748]1699
FAILURE CODE [CA3751]1701
FAILURE CODE [CA3755]1703
FAILURE CODE [CA3866]1705
FAILURE CODE [CA3867]1709
FAILURE CODE [CA3868]1712
FAILURE CODE [CA3899]1716
FAILURE CODE [CA3911]1718
FAILURE CODE [CA3912]1722
FAILURE CODE [CA3932]1724
FAILURE CODE [CA3933]1726
FAILURE CODE [CA3934]1728
FAILURE CODE [CA3935]1731
FAILURE CODE [CA3936]1733
FAILURE CODE [CA4151]1735
FAILURE CODE [CA4152]1739
FAILURE CODE [CA4155]1743
FAILURE CODE [CA4156]1745
FAILURE CODE [CA4157]1748
FAILURE CODE [CA4158]1750
FAILURE CODE [CA4159]1751
FAILURE CODE [CA4161]1752
FAILURE CODE [CA4162]1755
FAILURE CODE [CA4163]1758
FAILURE CODE [CA4164]1760
FAILURE CODE [CA4165]1762
FAILURE CODE [CA4166]1764
FAILURE CODE [CA4168]1766
FAILURE CODE [CA4169]1769
FAILURE CODE [CA4171]1771
FAILURE CODE [CA4249]1774
FAILURE CODE [CA4251]1776
FAILURE CODE [CA4259]1778
FAILURE CODE [CA4261]1780
FAILURE CODE [CA4277]1783
FAILURE CODE [CA4281]1787
FAILURE CODE [CA4459]1790
FAILURE CODE [CA4461]1793
FAILURE CODE [CA4658]1796
FAILURE CODE [CA4731]1800
FAILURE CODE [CA4732]1801
FAILURE CODE [CA4739]1802
FAILURE CODE [CA4768]1803
FAILURE CODE [CA4769]1805
FAILURE CODE [CA4842]1808
FAILURE CODE [CA4952]1812
FAILURE CODE [CA5115]1814
FAILURE CODE [CA5179]1817
FAILURE CODE [CA5181]1819
FAILURE CODE [CA5383]1821
FAILURE CODE [D110KB]1823
FAILURE CODE [D19JKZ]1825
FAILURE CODE [D811MC]1828
FAILURE CODE [D862KA]1829
FAILURE CODE [D8ALKA]1831
FAILURE CODE [D8ALKB]1834
FAILURE CODE [D8AQKR]1836
FAILURE CODE [D8G1KT]1843
FAILURE CODE [D8G6KT]1844
FAILURE CODE [DA20MC]1845
FAILURE CODE [DA22KK]1846
FAILURE CODE [DA29KQ]1849
FAILURE CODE [DA2LKA]1851
FAILURE CODE [DA2LKB]1854
FAILURE CODE [DA2QKR]1856
FAILURE CODE [DA2RKR]1865
FAILURE CODE [DAF0KM]1866
FAILURE CODE [DAF0MB]1867
FAILURE CODE [DAF0MC]1868
FAILURE CODE [DAF8KB]1869
FAILURE CODE [DAF9KQ]1871
FAILURE CODE [DAFGMC]1872
FAILURE CODE [DAFLKA]1873
FAILURE CODE [DAFLKB]1876
FAILURE CODE [DAFQKR]1878
FAILURE CODE [DAZ9KQ]1886
FAILURE CODE [DAZQKR]1887
FAILURE CODE [DB2QKR]1894
FAILURE CODE [DB2RKR]1902
FAILURE CODE [DBP0KM]1906
FAILURE CODE [DBP0KT]1907
FAILURE CODE [DBP5KB]1908
FAILURE CODE [DBP5KY]1911
FAILURE CODE [DBPQKR]1914
FAILURE CODE [DDNRKA]1922
FAILURE CODE [DDNRKY]1924
FAILURE CODE [DDNS00]1926
FAILURE CODE [DFB1KZ]1928
FAILURE CODE [DFB2KZ]1930
FAILURE CODE [DFB3L8]1932
FAILURE CODE [DFB4L8]1934
FAILURE CODE [DFB5KZ]1936
FAILURE CODE [DFB6KZ]1938
FAILURE CODE [DGH2KA]1940
FAILURE CODE [DGH2KB]1942
FAILURE CODE [DHA4KA]1944
FAILURE CODE [DHAAMA]1946
FAILURE CODE [DHACMA]1948
FAILURE CODE [DHPAMA]1950
FAILURE CODE [DHPBMA]1953
FAILURE CODE [DHS3MA]1956
FAILURE CODE [DHS4MA]1959
FAILURE CODE [DHS8MA]1962
FAILURE CODE [DHS9MA]1965
FAILURE CODE [DHSAMA]1968
FAILURE CODE [DHSBMA]1971
FAILURE CODE [DHSCMA]1974
FAILURE CODE [DHSDMA]1977
FAILURE CODE [DHSFMA]1980
FAILURE CODE [DHSGMA]1983
FAILURE CODE [DHSHMA]1986
FAILURE CODE [DHSJMA]1989
FAILURE CODE [DHZAMA]1992
FAILURE CODE [DHZCL8]1996
FAILURE CODE [DKR0MA]1997
FAILURE CODE [DKR1MA]2000
FAILURE CODE [DKULKA]2003
FAILURE CODE [DKULKB]2005
FAILURE CODE [DKULKY]2007
FAILURE CODE [DLM3KA]2009
FAILURE CODE [DLM3KB]2011
FAILURE CODE [DLM3MB]2013
FAILURE CODE [DR10KA]2014
FAILURE CODE [DR12KA]2017
FAILURE CODE [DR20KA]2019
FAILURE CODE [DR21KX]2021
FAILURE CODE [DR30KA]2023
FAILURE CODE [DR31KX]2025
FAILURE CODE [DR40KA]2027
FAILURE CODE [DUMBKA]2029
FAILURE CODE [DUMBKB]2032
FAILURE CODE [DV00KA]2034
FAILURE CODE [DV00KB]2035
FAILURE CODE [DV20KB]2036
FAILURE CODE [DW43KA]2038
FAILURE CODE [DW43KB]2040
FAILURE CODE [DW43KY]2042
FAILURE CODE [DW45KA]2044
FAILURE CODE [DW45KB]2047
FAILURE CODE [DW45KY]2050
FAILURE CODE [DW4CKY]2052
FAILURE CODE [DW7BKA]2053
FAILURE CODE [DW7BKB]2055
FAILURE CODE [DW7BKY]2057
FAILURE CODE [DW91KA]2058
FAILURE CODE [DW91KB]2060
FAILURE CODE [DW91KY]2062
FAILURE CODE [DWA2KA]2064
FAILURE CODE [DWA2KB]2066
FAILURE CODE [DWA2KY]2068
FAILURE CODE [DWK0KA]2070
FAILURE CODE [DWK0KB]2072
FAILURE CODE [DWK0KY]2074
FAILURE CODE [DWK2KA]2076
FAILURE CODE [DWK2KB]2078
FAILURE CODE [DWK2KY]2080
FAILURE CODE [DWK8KA]2082
FAILURE CODE [DWK8KB]2084
FAILURE CODE [DWK8KY]2086
FAILURE CODE [DWPUKA]2088
FAILURE CODE [DWPUKB]2090
FAILURE CODE [DWPUKY]2092
FAILURE CODE [DX16KA]2094
FAILURE CODE [DX16KB]2096
FAILURE CODE [DXA8KA]2098
FAILURE CODE [DXA8KB]2100
FAILURE CODE [DXA9KA]2102
FAILURE CODE [DXA9KB]2104
FAILURE CODE [DXE0KA]2106
FAILURE CODE [DXE0KB]2108
FAILURE CODE [DXE4KA]2110
FAILURE CODE [DXE4KB]2112
FAILURE CODE [DXE4KY]2114
FAILURE CODE [DXE5KA]2116
FAILURE CODE [DXE5KB]2118
FAILURE CODE [DXE6KA]2120
FAILURE CODE [DXE6KB]2122
FAILURE CODE [DXE7KA]2124
FAILURE CODE [DXE7KB]2126
FAILURE CODE [DXE7KY]2128
FAILURE CODE [DXE8KA]2130
FAILURE CODE [DXE8KB]2132
FAILURE CODE [DXE8KY]2134
FAILURE CODE [DXE9KA]2136
FAILURE CODE [DXE9KB]2138
FAILURE CODE [DXE9KY]2140
FAILURE CODE [DXEAKA]2142
FAILURE CODE [DXEAKB]2144
FAILURE CODE [DXEAKY]2146
FAILURE CODE [DXEKKA]2148
FAILURE CODE [DXEKKB]2150
FAILURE CODE [DXEKKY]2152
FAILURE CODE [DXELKA]2154
FAILURE CODE [DXELKB]2156
FAILURE CODE [DXELKY]2158
FAILURE CODE [DY20KA]2160
FAILURE CODE [DY20MA]2162
FAILURE CODE [DY2CKB]2164
FAILURE CODE [DY2DKB]2167
FAILURE CODE [DY2EKB]2169
FAILURE CODE [F313KA]2171
FAILURE CODE [F313KB]2173
FAILURE CODE [F318KB]2176
FAILURE CODE [F318KY]2179
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)2181
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)2181
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK2187
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK2190
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP2192
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING2194
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW2197
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW2198
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING2199
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING2200
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING2201
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2202
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2203
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2204
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2205
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING2206
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2207
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL2209
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2210
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE2211
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM2212
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE2214
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED2215
E-23 FUNCTION SWITCH DOES NOT OPERATE2216
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)2217
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF2218
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER2219
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED2220
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED2221
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE2222
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE2223
E-31 ALARM BUZZER CANNOT BE CANCELED2225
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION2226
E-33 SERVICE MODE CANNOT BE SELECTED2227
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE2228
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK2230
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING2231
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE2234
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR2236
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED2238
E-40 ALARM DOES NOT SOUND DURING TRAVEL2239
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED2241
E-42 HORN DOES NOT SOUND2242
E-43 HORN DOES NOT STOP SOUNDING2246
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF2248
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE2249
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE2251
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2252
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2253
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2254
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2255
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2256
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2257
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2258
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2259
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION2260
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED2262
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY2263
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED2264
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE2266
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)2267
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)2267
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS2268
FAILURE MODE AND CAUSE TABLE2270
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK2278
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER2279
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR2281
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP2282
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS2283
H-6 SPEED OR POWER OF BOOM IS LOW2285
H-7 ARM SPEED OR POWER IS LOW2291
H-8 BUCKET SPEED OR POWER IS LOW2296
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION2299
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE2300
H-11 HYDRAULIC DRIFT OF ARM IS LARGE2302
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE2304
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES2305
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE2306
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE2307
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE2308
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED2309
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED2310
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER2311
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY2312
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW2313
H-22 MACHINE DOES NOT TRAVEL STRAIGHT2314
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW2316
H-24 TRAVEL SPEED IS LOW2319
H-25 ONE OF TRACKS DOES NOT RUN2321
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST2322
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT2323
H-28 SWINGS ONLY IN ONE DIRECTION2324
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)2325
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION2326
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)2327
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)2328
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING2329
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING2330
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)2331
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)2332
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)2333
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN2334
H-39 Quick coupler cylinder will not extend2335
H-40 Quick coupler cylinder will not retract (but buzzer doesnot sound)2337
H-41 Buzzer does not sound (but quick coupler cylinder doesretract)2339
H-42 Quick coupler cylinder extends and retracts slowly2341
TROUBLESHOOTING OF ENGINE (S-MODE)2342
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)2342
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION2343
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT2344
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)2345
S-4 ENGINE STARTABILITY IS POOR2346
S-5 ENGINE DOES NOT PICK UP SMOOTHLY2348
S-6 ENGINE STOPS DURING OPERATION2350
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2352
S-8 ENGINE LACKS POWER2353
S-9 KDPF GETS CLOGGED IN A SHORT TIME2355
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2357
S-11 OIL BECOMES CONTAMINATED QUICKLY2358
S-12 FUEL CONSUMPTION IS EXCESSIVE2359
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2360
S-14 OIL PRESSURE DROPS2361
S-15 FUEL MIXES INTO ENGINE OIL2363
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2364
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2365
S-18 UNUSUAL NOISE IS HEARD2366
S-19 VIBRATION IS EXCESSIVE2367
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT2368
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2369
S-22 ACTIVE REGENERATION TAKES TIME2371
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2373
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2374
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2376
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2377
TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED)2378
20 SUPPLY VOLTAGE > 32VDC2378
21 SUPPLY VOLTAGE < 12VDC2379
25 FILE ERROR FACTORY SETTINGS2380
26 FILE ERROR USER SETTINGS2381
27 FILE ERROR INPUT DATA2382
30 PROXIMITY SWITCHES DIFFERENCE2383
86 ANGLE SENSOR A2 TIMEOUT2384
96 ANGLE SENSOR A3/A5 TIMEOUT2385
106 ANGLE SENSOR A4/A6 TIMEOUT2386
116 ANGLE SENSOR PITCH TIMEOUT2387
126 ANGLE SENSOR ROLL TIMEOUT2388
FAILURE CODE TABLE2389
TROUBLESHOOTING FOR K100 BOOM CHANGE SYSTEM2392
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)2393
FAILURE CODE [198]2393
FAILURE CODE [199]2394
FAILURE CODE [200]2395
FAILURE CODE [201]2396
FAILURE CODE [202]2398
FAILURE CODE [203]2400
FAILURE CODE [204]2401
FAILURE CODE [205]2403
FAILURE CODE [206]2405
FAILURE CODE [207]2406
FAILURE CODE [208]2408
FAILURE CODE [209]2410
FAILURE CODE [210]2411
FAILURE CODE [211]2413
FAILURE CODE [212]2414
FAILURE CODE [213]2415
FAILURE CODE [214]2417
FAILURE CODE [215]2418
FAILURE CODE [216]2419
FAILURE CODE [217]2421
FAILURE CODE [218]2423
FAILURE CODE [219]2424
FAILURE CODE [220]2426
FAILURE CODE [221]2427
FAILURE CODE [222]2428
FAILURE CODE [223]2430
FAILURE CODE [224]2431
FAILURE CODE [225]2432
FAILURE CODE [226]2434
FAILURE CODE [227]2435
FAILURE CODE [228]2436
FAILURE CODE [229]2437
FAILURE CODE [230]2438
FAILURE CODE [231]2439
FAILURE CODE [234]2440
FAILURE CODE [235]2441
FAILURE CODE [236]2442
FAILURE CODE [237]2443
FAILURE CODE [240]2444
FAILURE CODE [241]2445
FAILURE CODE [242]2446
FAILURE CODE [250]2447
FAILURE CODE [250]2448
FAILURE CODE [250]2449
FAILURE CODE [250]2450
STATUS OF DIGITAL INPUTS WITH RESPECT TO WORK EQUIPMENT CONFIGURATIONS2451
FAILURE CODE2452
TROUBLESHOOTING FOR ERRORS ON SENSORS2453
TROUBLESHOOTING METHODS2455
JOINT 1 CAMERA IMAGE NOT DISPLAYED ON SCREEN2457
JOINT 2 CAMERA IMAGE NOT DISPLAYED ON SCREEN2458
CAMERA SCREEN DOES NOT CHANGE TO BOOM RAISE SCREEN2459
WORK EQUIPMENT IS NOT PICKED UP BY BASE MACHINE BUT SCREEN CHANGED TO BOOM RAISE SCREEN2460
CAMERA SCREEN DOES NOT APPEAR AFTER WORK EQUIPMENT IS FULLY DISENGAGED2461
SWING LOCK DOES NOT DEACTIVATE EVEN IF SWING LOCK IS RELEASED2462
LOCK LEVER IS DOWN (FREE) BUT HYDRAULIC LOCK SYMBOL APPEARS ON SCREEN2464
LOCK LEVER IS DOWN (LOCKED) BUT HYDRAULIC LOCK SYMBOL DOES NOT APPEAR ON SCREEN2465
50 DISASSEMBLY AND ASSEMBLY2467
CONTENTS2468
ABBREVIATION LIST2473
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2479
HOW TO READ THIS MANUAL2479
COATING MATERIALS LIST2481
SPECIAL TOOLS LIST2485
SKETCHES OF SPECIAL TOOLS2497
ENGINE AND COOLING SYSTEM2503
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2503
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2503
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2509
REMOVE AND INSTALL INJECTOR ASSEMBLY2518
METHOD FOR REMOVING INJECTOR ASSEMBLY2518
METHOD FOR INSTALLING INJECTOR ASSEMBLY2524
REMOVE AND INSTALL FUEL DOSER ASSEMBLY2534
METHOD FOR REMOVING FUEL DOSER2534
METHOD FOR INSTALLING FUEL DOSER2535
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2537
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2538
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2547
REMOVE AND INSTALL EGR VALVE ASSEMBLY2560
METHOD FOR REMOVING EGR VALVE ASSEMBLY2560
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2562
REMOVE AND INSTALL EGR COOLER ASSEMBLY2564
METHOD FOR REMOVING EGR COOLER ASSEMBLY2564
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2568
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY2574
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY2574
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY2575
REMOVE AND INSTALL ALTERNATOR BELT2577
METHOD FOR REMOVING ALTERNATOR BELT2577
METHOD FOR INSTALLING ALTERNATOR BELT2580
REMOVE AND INSTALL RADIATOR ASSEMBLY2585
METHOD FOR REMOVING RADIATOR ASSEMBLY2585
METHOD FOR INSTALLING RADIATOR ASSEMBLY2587
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY2590
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2590
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY2594
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2599
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2599
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2601
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2603
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2603
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2605
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2609
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2610
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2628
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2647
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2648
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2650
REMOVE AND INSTALL ENGINE REAR OIL SEAL2654
METHOD FOR REMOVING ENGINE REAR OIL SEAL2655
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2658
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2664
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2664
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2672
REMOVE AND INSTALL FUEL TANK ASSEMBLY2683
METHOD FOR REMOVING FUEL TANK ASSEMBLY2683
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2687
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2691
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2691
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2697
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2702
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2702
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2709
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2715
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2715
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2717
REMOVE AND INSTALL KDPF ASSEMBLY2720
METHOD FOR REMOVING KDPF ASSEMBLY2720
METHOD FOR INSTALLING KDPF ASSEMBLY2724
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2729
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2730
METHOD FOR ASSEMBLING KDPF ASSEMBLY2735
REMOVE AND INSTALL SCR ASSEMBLY2742
METHOD FOR REMOVING SCR ASSEMBLY2742
METHOD FOR INSTALLING SCR ASSEMBLY2745
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2749
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2749
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2754
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2759
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2759
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2763
REMOVE AND INSTALL KCCV ASSEMBLY2773
METHOD FOR REMOVING KCCV ASSEMBLY2773
METHOD FOR INSTALLING KCCV ASSEMBLY2774
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2778
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2778
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2783
REMOVE AND INSTALL AdBlue/DEF INJECTOR2789
METHOD FOR REMOVING AdBlue/DEF INJECTOR2789
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2793
REMOVE AND INSTALL AdBlue/DEF PUMP2798
METHOD FOR REMOVING AdBlue/DEF PUMP2798
METHOD FOR INSTALLING AdBlue/DEF PUMP2800
REMOVE AND INSTALL AdBlue/DEF HOSE2801
METHOD FOR REMOVING AdBlue/DEF HOSE2801
METHOD FOR INSTALLING AdBlue/DEF HOSE2806
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2815
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2815
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2816
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2819
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2819
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2822
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2826
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2826
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2827
POWER TRAIN2829
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2829
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2829
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2830
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2831
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2831
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2836
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2842
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2842
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2843
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2845
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2845
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2849
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2855
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2855
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2855
UNDERCARRIAGE AND FRAME2857
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2857
METHOD FOR SEPARATING TRACK ASSEMBLY2857
METHOD FOR INSTALLING TRACK ASSEMBLY2859
REMOVE AND INSTALL SPROCKET2862
METHOD FOR REMOVING SPROCKET2862
METHOD FOR INSTALLING SPROCKET2862
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2864
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2864
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2865
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2867
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2867
METHOD FOR ASSEMBLING IDLER ASSEMBLY2869
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2874
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2875
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2877
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2880
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2881
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2882
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY2886
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2886
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2888
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2891
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2891
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2893
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2896
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2896
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2897
HYDRAULIC SYSTEM2900
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2900
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2900
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2902
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2904
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2905
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2905
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2907
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2907
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2912
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2918
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2918
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2922
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2928
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2928
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2933
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2939
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2940
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2941
REMOVE AND INSTALL ATT BYPASS SOLENOID2946
REMOVE ATT BYPASS SOLENOID2946
INSTALL ATT BYPASS SOLENOID2949
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2951
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2951
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2952
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2954
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2954
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2955
REMOVE AND INSTALL QUICK COUPLER VALVE2957
WORK EQUIPMENT2959
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2959
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2960
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2963
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2967
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2967
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2970
CAB AND ITS ATTACHMENTS2974
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2974
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2974
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2981
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS)2988
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2990
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2990
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY3000
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY3000
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY3003
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY3009
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY3009
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY3016
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY3024
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY3024
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY3030
REMOVE AND INSTALL OPERATOR’S SEAT3037
METHOD FOR REMOVING OPERATOR’S SEAT3037
METHOD FOR INSTALLING OPERATOR’S SEAT3039
REMOVE AND INSTALL SEAT BELT3042
METHOD FOR REMOVING SEAT BELT3042
METHOD FOR INSTALLING SEAT BELT3043
REMOVE AND INSTALL FRONT WIPER ASSEMBLY3044
METHOD FOR REMOVING FRONT WIPER ASSEMBLY3044
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY3049
ELECTRICAL SYSTEM3058
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY3058
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY3058
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY3059
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY3061
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY3061
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY3064
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY3069
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY3069
METHOD FOR INSTALLING KomVision CONTROLLER3070
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY3071
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY3071
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY3074
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR3078
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR3078
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR3079
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR3080
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR3080
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR3081
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR3083
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR3083
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR3084
REMOVE AND INSTALL SCR TEMPERATURE SENSOR3086
METHOD FOR REMOVING SCR TEMPERATURE SENSOR3086
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR3088
REMOVE AND INSTALL KomVision CAMERA3090
METHOD FOR REMOVING KomVision CAMERA3090
METHOD FOR INSTALLING KomVision CAMERA3091
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY3093
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY3093
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY3097
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS3103
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS3103
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS3111
REMOVE AND INSTALL COMMUNICATION TERMINAL3120
METHOD FOR REMOVING COMMUNICATION TERMINAL3120
METHOD FOR INSTALLING COMMUNICATION TERMINAL3122
60 MAINTENANCE STANDARD3125
CONTENTS3126
ABBREVIATION LIST3128
ENGINE AND COOLING SYSTEM3134
MAINTENANCE STANDARD OF ENGINE MOUNT3134
MAINTENANCE STANDARD OF COOLING SYSTEM3135
MAINTENANCE STANDARD OF COOLING FAN PUMP3136
MAINTENANCE STANDARD OF SERVO VALVE3137
MAINTENANCE STANDARD OF COOLING FAN MOTOR3138
POWER TRAIN3139
MAINTENANCE STANDARD OF SWING CIRCLE3139
MAINTENANCE STANDARD OF SWING MACHINERY3140
MAINTENANCE STANDARD OF FINAL DRIVE3142
MAINTENANCE STANDARD OF SPROCKET3144
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING3145
UNDERCARRIAGE AND FRAME3147
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION3147
MAINTENANCE STANDARD OF IDLER3149
MAINTENANCE STANDARD OF TRACK ROLLER3151
MAINTENANCE STANDARD OF CARRIER ROLLER3153
MAINTENANCE STANDARD OF TRACK SHOE3154
MAINTENANCE STANDARD OF TRIPLE SHOE3157
HYDRAULIC SYSTEM3158
MAINTENANCE STANDARD OF MAIN PUMP3158
MAINTENANCE STANDARD OF SWING MOTOR3160
MAINTENANCE STANDARD OF TRAVEL MOTOR3163
MAINTENANCE STANDARD OF CONTROL VALVE3166
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE3177
MAINTENANCE STANDARD OF TRAVEL PPC VALVE3180
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)3183
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE3185
MAINTENANCE STANDARD OF SOLENOID VALVE3186
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE3187
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE3189
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT3190
WORK EQUIPMENT3191
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE3191
DIMENSION OF ARM3196
DIMENSIONS OF BUCKET3198
MAINTENANCE STANDARD OF BOOM CYLINDER3200
MAINTENANCE STANDARD OF ARM CYLINDER3201
MAINTENANCE STANDARD OF BUCKET CYLINDER3202
WORK EQUIPMENT – PC490HRD-11E03203
WORK EQUIPMENT – HIGH REACH DEMOLITION3203
DIMENSION OF ARM3203
MAINTENANCE STANDARD OF BOOM CYLINDER3204
MAINTENANCE STANDARD OF LINK CYLINDER3205
MAINTENANCE STANDARD OF ARM CYLINDER3206
MAINTENANCE STANDARD OF BUCKET CYLINDER3207
WORK EQUIPMENT – DEMOLITION DIGGING3208
MAINTENANCE STANDARD OF ARM CYLINDER3208
MAINTENANCE STANDARD OF BUCKET CYLINDER3209
PC490HRD-11E0 K100 BOOM CHANGE SYSTEM3210
S AND A VALVES MAINTENANCE SCHEDULE3210
GREASING PROCEDURE OF S VALVE ASSEMBLY LOCKING PINS (RECOMMENDED EVERY 1000 HOURS/1 YEAR WHICH EVER OCCURS FIRST OR IF DIFFICULTY CONNECTING/DISCONNECTING OCCURS3217
JACKING BOLTS FOR VALVE LOCKING CYLINDER ASSEMBLY REMOVAL3219
MAINTENANCE STANDARD OF SWING CIRCLE3222
MAINTENANCE STANDARD OF COUNTERWEIGHT BOLTS3223
MAINTENANCE STANDARD OF WORKSTAND3224
80 APPENDIX3225
CONTENTS3226
ABBREVIATION LIST3228
AIR CONDITIONER SYSTEM3234
PRECAUTIONS FOR REFRIGERANT3234
AIR CONDITIONER COMPONENT3235
SPECIFICATIONS OF AIR CONDITIONER3237
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE3238
OUTLINE OF REFRIGERATION CYCLE3239
COMPONENT PARTS OF AIR CONDITIONER SYSTEM3241
AIR CONDITIONER UNIT3241
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT3241
FUNCTION OF AIR CONDITIONER UNIT3243
COMPONENT PARTS OF AIR CONDITIONER UNIT3245
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT3246
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT3246
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT3246
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT3246
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3247
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3247
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT3247
FUNCTION OF DUAL PRESSURE SWITCH3248
AIR CONDITIONER CONTROLLER3249
STRUCTURE OF AIR CONDITIONER CONTROLLER3249
COMPRESSOR3250
STRUCTURE OF COMPRESSOR3250
SPECIFICATIONS OF COMPRESSOR3250
FUNCTION OF COMPRESSOR3250
CONDENSER3251
STRUCTURE OF CONDENSER3251
SPECIFICATIONS OF CONDENSER3251
FUNCTION OF CONDENSER3251
RECEIVER DRIER3252
STRUCTURE OF RECEIVER DRIER3252
SPECIFICATIONS OF RECEIVER DRIER3252
FUNCTION OF RECEIVER DRIER3252
SENSORS FOR AIR CONDITIONER SYSTEM3253
STRUCTURE OF SUNLIGHT SENSOR3253
FUNCTION OF SUNLIGHT SENSOR3253
STRUCTURE OF AMBIENT TEMPERATURE SENSOR3253
FUNCTION OF AMBIENT TEMPERATURE SENSOR3253
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER3255
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER3257
AIR CONDITIONER SYSTEM DIAGRAM3259
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER3260
FUNCTION OF AIR CONDITIONER CONTROLLER3261
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS3262
TESTING AIR LEAKAGE (DUCT)3266
METHOD FOR TESTING AIR LEAKAGE (DUCT)3266
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION3268
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR3269
TEST VENT (MODE) CHANGEOVER3270
METHOD FOR TESTING VENT (MODE) CHANGEOVER3270
TESTING FRESH/RECIRC AIR CHANGEOVER3272
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER3272
TEST SUNLIGHT SENSOR3273
METHOD FOR TESTING SUNLIGHT SENSOR3273
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT3274
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT3274
TEST RELAYS3275
METHOD FOR TESTING RELAYS3275
AIR CONDITIONER TROUBLESHOOTING CHART 13276
AIR CONDITIONER TROUBLESHOOTING CHART 23277
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE3280
FAILURE CODE [879AKA]3282
FAILURE CODE [879AKB]3283
FAILURE CODE [879BKA]3284
FAILURE CODE [879BKB]3286
FAILURE CODE [879CKA]3288
FAILURE CODE [879CKB]3289
FAILURE CODE [879DKZ]3290
FAILURE CODE [879EMC]3292
FAILURE CODE [879FMC]3293
FAILURE CODE [879GKX]3294
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)3296
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)3297
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)3298
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER3299
TROUBLESHOOTING USING GAUGE PRESSURE3300
CONNECTION OF SERVICE TOOL3303
METHOD FOR CONNECTING SERVICE TOOL3303
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS3305
HANDLE COMPRESSOR OIL3307
PC490HRD-11E0 K100 BOOM CHANGE SYSTEM3309
AUXILLARY CONNECTIONS3309
WORKSTAND BRACKET3312
90 CIRCUIT DIAGRAMS3315
CONTENTS3316
ABBREVIATION LIST3318
HYDRAULIC CIRCUIT DIAGRAM3324
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM3324
HYDRAULIC CIRCUIT DIAGRAM (1/2)3329
HYDRAULIC CIRCUIT DIAGRAM (2/2)3331
HYDRAULIC CIRCUIT DIAGRAM (1/8)3333
HYDRAULIC CIRCUIT DIAGRAM (2/8)3335
HYDRAULIC CIRCUIT DIAGRAM (3/8)3337
HYDRAULIC CIRCUIT DIAGRAM (4/8)3339
HYDRAULIC CIRCUIT DIAGRAM (5/8)3341
HYDRAULIC CIRCUIT DIAGRAM (6/8)3343
HYDRAULIC CIRCUIT DIAGRAM (7/8)3345
HYDRAULIC CIRCUIT DIAGRAM (8/8)3347
HYDRAULIC CIRCUIT DIAGRAM GATEWAY (1/3)3349
HYDRAULIC CIRCUIT DIAGRAM (1/3)3351
HYDRAULIC CIRCUIT DIAGRAM (2/3)3353
HYDRAULIC CIRCUIT DIAGRAM (3/3)3355
ELECTRICAL CIRCUIT DIAGRAM3357
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM3357
ELECTRICAL CIRCUIT DIAGRAM (1/9)3361
ELECTRICAL CIRCUIT DIAGRAM (2/9)3363
ELECTRICAL CIRCUIT DIAGRAM (3/9)3365
ELECTRICAL CIRCUIT DIAGRAM (4/9)3367
ELECTRICAL CIRCUIT DIAGRAM (5/9)3369
ELECTRICAL CIRCUIT DIAGRAM (6/9)3371
ELECTRICAL CIRCUIT DIAGRAM (7/9)3373
ELECTRICAL CIRCUIT DIAGRAM (8/9)3375
ELECTRICAL CIRCUIT DIAGRAM (9/9)3377
ELECTRICAL CIRCUIT DIAGRAM (1/17)3379
ELECTRICAL CIRCUIT DIAGRAM (2/17)3381
ELECTRICAL CIRCUIT DIAGRAM (3/17)3383
ELECTRICAL CIRCUIT DIAGRAM (4/17)3385
ELECTRICAL CIRCUIT DIAGRAM (5/17)3387
ELECTRICAL CIRCUIT DIAGRAM (6/17)3389
ELECTRICAL CIRCUIT DIAGRAM (7/17)3391
ELECTRICAL CIRCUIT DIAGRAM (8/17)3393
ELECTRICAL CIRCUIT DIAGRAM (9/17)3395
ELECTRICAL CIRCUIT DIAGRAM (10/17)3397
ELECTRICAL CIRCUIT DIAGRAM (11/17)3399
ELECTRICAL CIRCUIT DIAGRAM (12/17)3401
ELECTRICAL CIRCUIT DIAGRAM (13/17)3403
ELECTRICAL CIRCUIT DIAGRAM (14/17)3405
ELECTRICAL CIRCUIT DIAGRAM (15/17)3407
ELECTRICAL CIRCUIT DIAGRAM (16/17)3409
ELECTRICAL CIRCUIT DIAGRAM (17/17)3411
WIRING DIAGRAM (BEFORE GATEWAY)3413
WIRING DIAGRAM (1/10)3415
WIRING DIAGRAM (2/10)3417
WIRING DIAGRAM (3/10)3419
WIRING DIAGRAM (4/10)3421
WIRING DIAGRAM (5/10)3423
WIRING DIAGRAM (6/10)3425
WIRING DIAGRAM (7/10)3427
WIRING DIAGRAM (8/10)3429
WIRING DIAGRAM (9/10)3431
WIRING DIAGRAM (10/10)3433
WIRING DIAGRAM (AFTER GATEWAY)3435
WIRING DIAGRAM (1/11)3437
WIRING DIAGRAM (2/11)3439
WIRING DIAGRAM (3/11)3441
WIRING DIAGRAM (4/11)3443
WIRING DIAGRAM (5/11)3445
WIRING DIAGRAM (6/11)3447
WIRING DIAGRAM (7/11)3449
WIRING DIAGRAM (8/11)3451
WIRING DIAGRAM (9/11)3453
WIRING DIAGRAM (10/11)3455
WIRING DIAGRAM (11/11)3457
INDEX3459

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24