Komatsu PC490-11E0, PC490LC-11E0, PC490HRD-11E0 Service Manual PDF

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Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Hydraulic Excavator Shop Manual UENBM00500 – PDF DOWNLOAD

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Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Hydraulic Excavator Shop Manual UENBM00500 – PDF DOWNLOAD 

Language : English
Pages : 3018
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Hydraulic Excavator Shop Manual UENBM00500 – PDF DOWNLOAD 

UENBM00500_FrontCover 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 23
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
PRECAUTIONS FOR DEF 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 44
THE OTHER PRECAUTIONS 44
STORE DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
01 SPECIFICATIONS 95
CONTENTS 96
ABBREVIATION LIST 97
SPECIFICATIONS 103
SPECIFICATION DRAWING 103
SPECIFICATION DRAWING: PC490-11E0 ,PC490LC-11E0 103
WORKING RANGE DRAWINGS 105
WORKING RANGE: PC490-11E0, PC490LC-11E0 105
SPECIFICATIONS 106
SPECIFICATIONS: PC490-11E0, PC490LC-11E0 106
WEIGHT TABLE 109
WEIGHT TABLE: PC490-11E0 ,PC490LC-11E0 109
TABLE OF FUEL, COOLANT, AND LUBRICANTS 111
SPECIFICATIONS – PC490HRD-11E0 112
SPECIFICATION DRAWING 112
SPECIFICATION DRAWING: PC490HRD-11E0 112
SPECIFICATIONS 116
SPECIFICATIONS: PC490HRD-11E0 116
WEIGHT TABLE 118
WEIGHT TABLE: PC490HRD-11E0 118
10 STRUCTURE AND FUNCTION 121
CONTENTS 122
ABBREVIATION LIST 126
UREA SCR SYSTEM 132
LAYOUT DRAWING OF UREA SCR SYSTEM 132
UREA SCR SYSTEM DIAGRAM 136
FUNCTION OF UREA SCR SYSTEM 137
FUNCTION OF AdBlue/DEF SYSTEM 137
INDUCEMENT STRATEGY 139
COMPONENT PARTS OF UREA SCR SYSTEM 147
AdBlue/DEF MIXING TUBE 147
SCR ASSEMBLY 147
AdBlue/DEF TANK 150
AdBlue/DEF PUMP 152
AdBlue/DEF INJECTOR 153
AdBlue/DEF HOSE 154
AdBlue/DEF TANK HEATING VALVE 155
BOOT-UP SYSTEM 156
LAYOUT DRAWING OF BOOT-UP SYSTEM 156
SYSTEM OPERATING LAMP SYSTEM 158
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 158
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 158
BATTERY DISCONNECT SWITCH 159
FUNCTION OF BATTERY DISCONNECT SWITCH 159
ENGINE SYSTEM 160
LAYOUT DRAWING OF ENGINE SYSTEM 160
SPECIFICATIONS OF ENGINE SYSTEM 161
FUNCTION OF ENGINE SYSTEM 162
ENGINE CONTROL SYSTEM 163
ENGINE CONTROL SYSTEM DIAGRAM 163
FUNCTION OF ENGINE CONTROL SYSTEM 164
AUTO-DECELERATION SYSTEM 166
AUTO-DECELERATION SYSTEM DIAGRAM 166
FUNCTION OF AUTO-DECELERATION SYSTEM 166
OPERATION OF AUTO-DECELERATION SYSTEM 167
ENGINE AUTOMATIC WARM-UP SYSTEM 168
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 168
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 169
OVERHEAT PREVENTION SYSTEM 170
OVERHEAT PREVENTION SYSTEM DIAGRAM 170
FUNCTION OF OVERHEAT PREVENTION SYSTEM 171
TURBOCHARGER PROTECTION SYSTEM 173
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 173
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 174
AUTOMATIC IDLE STOP SYSTEM 175
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 175
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 175
COMPONENT PARTS OF ENGINE SYSTEM 178
VGT 178
EGR SYSTEM 181
EGR VALVE 183
EGR COOLER 185
KCCV SYSTEM 186
KCCV VENTILATOR 187
KDPF 189
COOLING SYSTEM 194
LAYOUT DRAWING OF COOLING SYSTEM 194
SPECIFICATIONS OF COOLING SYSTEM 195
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 197
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 197
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 198
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 199
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 199
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 200
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 202
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 202
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 202
COMPONENT PARTS OF COOLING SYSTEM 204
COOLING FAN PUMP 204
COOLING FAN MOTOR 211
CONTROL SYSTEM 218
LAYOUT DRAWING OF CONTROL SYSTEM 218
MACHINE MONITOR SYSTEM 221
MACHINE MONITOR SYSTEM DIAGRAM 221
KomVision SYSTEM 222
LAYOUT DRAWING OF KOMVISION SYSTEM 222
KomVision SYSTEM DIAGRAM 223
FUNCTION OF KomVision SYSTEM 224
KOMTRAX SYSTEM 226
KOMTRAX SYSTEM DIAGRAM 226
FUNCTION OF KOMTRAX SYSTEM 226
PPC LEVERS 227
LH PPC LEVER 227
RH PPC LEVER 228
AUTOMATIC GREASE SYSTEM 229
OUTLINE OF AUTO GREASE SYSTEM 229
COMPONENT PARTS OF CONTROL SYSTEM 244
MACHINE MONITOR 244
KomVision CONTROLLER 256
KomVision CAMERA 260
KOMTRAX TERMINAL 261
PUMP CONTROLLER 263
RESISTOR FOR PC-EPC VALVE 267
CAN TERMINATING RESISTOR 268
ENGINE CONTROLLER 269
FUEL CONTROL DIAL 275
FUEL FEED PUMP 277
FUEL FEED PUMP SWITCH 278
SENSOR 279
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 279
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 279
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 279
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 280
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 280
FUNCTION OF AUTO GREASE PRESSURE SWITCH 280
STRUCTURE OF OVERLOAD CAUTION SENSOR 280
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 281
FUNCTION OF OVERLOAD CAUTION SENSOR 281
HYDRAULIC SYSTEM 282
LAYOUT DRAWING OF HYDRAULIC SYSTEM 282
CLSS 284
STRUCTURE OF CLSS 284
OPERATION OF UNLOAD VALVE AND LS PRESSURE 286
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 287
PRESSURE COMPENSATION CONTROL 300
ENGINE AND PUMP COMBINED CONTROL SYSTEM 303
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 303
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 305
PUMP AND VALVE CONTROL SYSTEM 310
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 310
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 311
COMPONENT PARTS OF HYDRAULIC SYSTEM 313
HYDRAULIC TANK 313
MAIN PUMP 315
PILOT OIL FILTER 341
CONTROL VALVE 341
HYDRAULIC SYSTEM – PC490HRD-11E0 403
LAYOUT DRAWING OF HYDRAULIC SYSTEM 403
COMPONENT PARTS OF HYDRAULIC SYSTEM 406
LAYOUT DRAWING OF VALVE CONTROL SYSTEM 406
WORK EQUIPMENT SYSTEM 426
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 426
STRUCTURE OF VALVE CONTROL 431
ONE-TOUCH POWER MAXIMIZING SYSTEM 432
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 432
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 433
MACHINE PUSH-UP SYSTEM 434
MACHINE PUSH-UP SYSTEM DIAGRAM 434
FUNCTION OF MACHINE PUSH-UP SYSTEM 435
PPC LOCK SYSTEM 436
PPC LOCK SYSTEM DIAGRAM 436
FUNCTION OF PPC LOCK SYSTEM 436
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 437
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 437
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 437
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 438
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 439
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 439
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 440
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 441
WORK EQUIPMENT AND SWING PPC VALVE 441
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 446
SOLENOID VALVE 452
VARIABLE PRESSURE COMPENSATION VALVE 454
ATTACHMENT CIRCUIT SELECTOR VALVE 455
ATT EPC VALVE ASSEMBLY 458
PILOT CIRCUIT ACCUMULATOR 459
WORK EQUIPMENT SYSTEM – PC490HRD-11E0 461
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 461
SWING SYSTEM 465
LAYOUT DRAWING OF SWING SYSTEM 465
SWING CONTROL SYSTEM DIAGRAM 471
FUNCTION OF SWING CONTROL SYSTEM 471
COMPONENT PARTS OF SWING SYSTEM 475
SWING MOTOR 475
SWING MACHINERY 486
SWING CIRCLE 488
TRAVEL SYSTEM 490
LAYOUT DRAWING OF TRAVEL SYSTEM 490
TRAVEL CONTROL SYSTEM DIAGRAM 494
FUNCTION OF TRAVEL CONTROL SYSTEM 495
COMPONENT PARTS OF TRAVEL SYSTEM 496
TRAVEL MOTOR 496
FINAL DRIVE 510
TRAVEL PPC VALVE 511
CENTER SWIVEL JOINT 516
UNDERCARRIAGE AND FRAME 518
LAYOUT DRAWING OF UNDERCARRIAGE 518
SPECIFICATIONS OF UNDERCARRIAGE 518
WORK EQUIPMENT 520
STRUCTURE OF WORK EQUIPMENT 520
FUNCTION OF WORK EQUIPMENT 521
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 522
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 522
BUCKET CLEARANCE ADJUSTMENT SHIM 523
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 523
CAB AND ITS ATTACHMENTS 524
ROPS CAB 524
STRUCTURE OF ROPS CAB 524
FUNCTION OF ROPS CAB 524
CAB MOUNT 525
STRUCTURE OF CAB MOUNT 525
FUNCTION OF CAB MOUNT 525
CAB TIPPING STOPPER 526
STRUCTURE OF CAB TIPPING STOPPER 526
FUNCTION OF CAB TIPPING STOPPER 526
TILTING CAB SYSTEM 527
STRUCTURE OF TILTING CAB SYSTEM 527
OPERATION OF TILTING CAB SYSTEM 527
20 STANDARD VALUE TABLE 529
CONTENTS 530
ABBREVIATION LIST 531
STANDARD VALUE TABLE FOR ENGINE 537
STANDARD VALUE TABLE FOR ENGINE: PC490-11E0, PC490LC-11E0 537
STANDARD VALUE TABLE FOR MACHINE 540
STANDARD VALUE TABLE FOR MACHINE: PC490-11E0, PC490LC-11E0 540
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 556
STANDARD VALUE TABLE FOR MACHINE – PC490HRD-11E0 560
STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE 560
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 567
STANDARD VALUE TABLE FOR ELECTRICAL 571
STANDARD VALUE TABLE FOR ELECTRICAL 571
30 TESTING AND ADJUSTING 581
CONTENTS 582
ABBREVIATION LIST 586
RELATED INFORMATION ON TESTING AND ADJUSTING 592
TOOLS FOR TESTING AND ADJUSTING 592
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 599
ENGINE AND COOLING SYSTEM 601
TEST ENGINE SPEED 601
METHOD FOR TESTING ENGINE SPEED 601
TEST BOOST PRESSURE 604
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 604
METHOD FOR TESTING BOOST PRESSURE 605
TEST EXHAUST GAS COLOR 606
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 606
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 607
TEST AND ADJUST VALVE CLEARANCE 608
METHOD FOR TESTING VALVE CLEARANCE 608
METHOD FOR ADJUSTING VALVE CLEARANCE 611
TEST COMPRESSION PRESSURE 612
METHOD FOR TESTING COMPRESSION PRESSURE 612
TEST BLOWBY PRESSURE 615
METHOD FOR TESTING BLOWBY PRESSURE 615
TEST ENGINE OIL PRESSURE 617
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 617
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 617
TEST EGR VALVE AND VGT OIL PRESSURE 619
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 619
TEST FUEL PRESSURE 621
METHOD FOR TESTING FUEL PRESSURE 621
TEST FUEL RETURN RATE AND LEAKAGE 623
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 623
BLEED AIR FROM FUEL SYSTEM 626
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 626
TEST FUEL CIRCUIT FOR LEAKAGE 628
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 628
HANDLE CYLINDER CUT-OUT MODE OPERATION 630
HANDLE NO-INJECTION CRANKING OPERATION 631
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 632
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 632
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 632
CLEAN FUEL DOSER 634
METHOD FOR CLEANING FUEL DOSER 634
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 636
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 636
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 642
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 642
TEST SCR RELATED FUNCTIONS 643
TEST AdBlue/DEF PUMP RAISED PRESSURE 646
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 649
TEST AdBlue/DEF LINE HEATER RELAY 1 653
TEST AdBlue/DEF LINE HEATER RELAY 2 655
TEST AdBlue/DEF PUMP HEATER RELAY 658
TEST AdBlue/DEF TANK HEATER VALVE 661
TEST DENITRATION EFFICIENCY OF SCR 664
CLEAN AdBlue/DEF TANK 668
METHOD FOR CLEANING AdBlue/DEF TANK 668
POWER TRAIN 672
TEST SWING CIRCLE BEARING CLEARANCE 672
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 672
UNDERCARRIAGE AND FRAME 673
TEST AND ADJUST TRACK TENSION 673
METHOD FOR TESTING TRACK TENSION 673
METHOD FOR ADJUSTING TRACK TENSION 673
HYDRAULIC SYSTEM 675
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 675
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 675
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 681
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 682
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 688
TEST OIL PRESSURE OF CONTROL CIRCUIT 692
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 692
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 694
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 694
TEST PC-EPC VALVE OUTLET PRESSURE 695
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 696
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 698
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 698
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 699
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 700
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 701
METHOD FOR ADJUSTING LS VALVE 702
TEST OUTLET PRESSURE OF SOLENOID VALVE 703
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 703
OPERATING CONDITION OF SOLENOID VALVE 704
TEST PPC VALVE OUTLET PRESSURE 706
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 706
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 708
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 708
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 709
TEST PUMP SWASH PLATE SENSOR 711
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 711
TEST COOLING FAN SPEED 712
METHOD FOR TESTING COOLING FAN SPEED 712
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 713
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 713
TEST FAN PUMP EPC ELECTRIC CURRENT 715
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 715
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 716
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 716
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 718
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 718
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 718
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 719
TEST OIL LEAKAGE 720
TEST OIL LEAKAGE OF BOOM CYLINDER 720
TEST OIL LEAKAGE OF ARM CYLINDER 720
TEST OIL LEAKAGE OF BUCKET CYLINDER 721
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR 721
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 721
BLEED AIR FROM HYDRAULIC CIRCUIT 723
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 725
HYDRAULIC SYSTEM – PC490HRD-11E0 728
MEASURING AND ADJUSTING SWING SPEED REDUCTION VALVE 728
MEASURING AND ADJUSTING BOOM AND BUCKET PPC REDUCTION VALVE 729
MEASURING AND ADJUSTING LINK CYLINDER FLOW CONTROL VALVE 730
MEASURING AND ADJUSTING ARM CYLINDER FLOW CONTROL VALVE 731
CAB AND ITS ATTACHMENTS 732
TEST CAB TIPPING STOPPER 732
METHOD FOR TESTING CAB TIPPING STOPPER 732
METHOD FOR ADJUSTING MIRRORS 733
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 733
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 734
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 735
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 736
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 737
ELECTRICAL SYSTEM 739
SETTING AND OPERATION OF MACHINE MONITOR 739
OPERATOR MODE 742
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 743
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 743
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 744
CHECKING FUNCTION OF SERVICE METER 744
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 744
SERVICE MODE 747
METHOD FOR OPERATING SERVICE MODE 747
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 749
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 756
767
METHOD FOR CONFIRMING MAINTENANCE RECORD 772
METHOD FOR OPERATING MAINTENANCE MODE SETTING 773
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 777
778
786
795
METHOD FOR PERFORMING NO-INJECTION CRANKING 817
818
METHOD FOR DISPLAYING SERVICE MESSAGE 821
METHOD FOR STARTING UP KOMTRAX TERMINAL 822
ADJUST REARVIEW CAMERA ANGLE 827
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 827
ADJUST KomVision CAMERA ANGLE 830
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 831
ADJUST KomVision RELATED ITEMS 835
SETTING OF KomVision (MAIN SETTING) 835
SETTING OF KomVision (CAMERA SETTING) 837
SETTING OF KomVision (CAMERA CALIBRATION) 838
KomVision screen – Check 12 m visibility 851
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 854
HANDLE BATTERY DISCONNECT SWITCH 855
TEST DIODES 856
METHOD FOR TESTING DIODE USING DIGITAL TESTER 856
METHOD FOR TESTING DIODE USING ANALOG TESTER 856
ELECTRICAL SYSTEM – PC490HRD-11E0 857
ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM 857
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – BASE MACHINE 857
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – HIGH REACH DEMOLITION WORK EQUIPMENT 860
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT 862
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – MEDIUM REACH DEMOLITION WORK EQUIPMENT 864
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – DEMOLITION DIGGING WORK EQUIPMENT 866
RH PPC LEVER 867
LH PPC LEVER 868
WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT 869
CONSTANT LINK SPEED CIRCUIT 870
PARALLEL LINK FRONT SCREEN WIPER 871
OVERLOAD CAUTION (HIGH REACH DEMOLITION) 872
Pm CLINIC 873
Pm CLINIC SERVICE 873
Pm CLINIC CHECK SHEET 874
WORKING RANGE INDICATOR SYSTEM 887
WORKING RANGE INDICATOR SYSTEM LAYOUT 887
METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU 889
DIAGNOSTICS – WORKING RANGE INDICATOR SYSTEM 891
MONITORING SYSTEM PARAMETERS AND SENSOR STATES 891
USING THE PARAMETER CHANGE LOG 893
USING ERROR LISTS AND LOGS 894
EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM 895
IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM 896
REPLACING COMPONENTS – WORKING RANGE INDICATOR SYSTEM 898
WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT 898
WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT 903
WORKING RANGE INDICATOR SYSTEM – UDATING SOFTWARE 908
CALIBRATION – WORKING RANGE INDICATOR SYSTEM 912
WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW 912
METHOD 1 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – AUTO CALIBRATION 912
METHOD 2 – BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION 920
METHOD 2 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – MANUAL CALIBRATION 923
40 TROUBLESHOOTING 939
CONTENTS 940
ABBREVIATION LIST 951
RELATED INFORMATION ON TROUBLESHOOTING 957
GENERAL TROUBLESHOOTING POINTS 957
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 959
SEQUENCE OF EVENTS IN TROUBLESHOOTING 971
CHECKS BEFORE TROUBLESHOOTING 973
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 975
WALK-AROUND CHECK 975
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 977
CHECK FUEL LEVEL AND TYPE 977
CHECK IMPURE INGREDIENT IN FUEL 978
CHECK FUEL PREFILTER 978
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 978
FUEL PREFILTER CARTRIDGE – REPLACE 979
CHECK MAIN FILTER 980
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 981
CHECK COOLANT LEVEL (RESERVOIR TANK) 983
CHECK CLOGGING OF AIR CLEANER 983
OUTER ELEMENT – CLEAN 984
ELEMENTS – REPLACE 986
CHECK HYDRAULIC OIL LEVEL 987
CHECK HYDRAULIC OIL STRAINER 987
CHECK HYDRAULIC FILTER 988
CHECK OIL LEVEL IN SWING MACHINERY CASE 989
CHECK OIL LEVEL IN DAMPER CASE 990
CHECK OIL LEVEL IN FINAL DRIVE CASE 990
BLEED AIR FROM FUEL SYSTEM 991
BLEED AIR FROM HYDRAULIC SYSTEM 991
ELECTRICAL EQUIPMENT – CHECK METHOD 991
AUTOMATIC GREASE SYSTEM 997
FINDING MALFUNCTIONS 997
MALFUNCTION FINDING PROCEDURES 999
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1001
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1011
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 1014
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1018
CONNECTOR LIST AND LAYOUT 1020
CONNECTOR CONTACT IDENTIFICATION 1033
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1073
FUSE LOCATION TABLE 1079
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1081
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1085
FAILURE CODES TABLE 1087
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1105
FAILURE CODE [879AKA] 1105
FAILURE CODE [879AKB] 1106
FAILURE CODE [879BKA] 1107
FAILURE CODE [879BKB] 1109
FAILURE CODE [879CKA] 1111
FAILURE CODE [879CKB] 1112
FAILURE CODE [879DKZ] 1113
FAILURE CODE [879EMC] 1115
FAILURE CODE [879FMC] 1116
FAILURE CODE [879GKX] 1117
FAILURE CODE [989L00] 1119
FAILURE CODE [989M00] 1120
FAILURE CODE [989N00] 1121
FAILURE CODE [A1U0N3] 1122
FAILURE CODE [A1U0N4] 1124
FAILURE CODE [A900FR] 1126
FAILURE CODE [A900N6] 1127
FAILURE CODE [A900NY] 1128
FAILURE CODE [AA10NX] 1129
FAILURE CODE [AB00KE] 1131
FAILURE CODE [AQ10N3] 1134
FAILURE CODE [AS00N3] 1136
FAILURE CODE [AS00R2] 1138
FAILURE CODE [AS00R3] 1139
FAILURE CODE [AS00R4] 1140
FAILURE CODE [AS00R5] 1141
FAILURE CODE [AS00R6] 1142
FAILURE CODE [AS00ZK] 1143
FAILURE CODE [AS10KM] 1144
FAILURE CODE [AS10NR] 1145
FAILURE CODE [AS10NT] 1146
FAILURE CODE [B@BAZG] 1147
FAILURE CODE [B@BAZK] 1148
FAILURE CODE [B@BCNS] 1150
FAILURE CODE [B@BCQA] 1151
FAILURE CODE [B@BCZK] 1153
FAILURE CODE [B@HANS] 1155
FAILURE CODE [CA115] 1156
FAILURE CODE [CA122] 1157
FAILURE CODE [CA123] 1159
FAILURE CODE [CA131] 1161
FAILURE CODE [CA132] 1163
FAILURE CODE [CA135] 1165
FAILURE CODE [CA141] 1167
FAILURE CODE [CA144] 1169
FAILURE CODE [CA145] 1171
FAILURE CODE [CA153] 1173
FAILURE CODE [CA154] 1176
FAILURE CODE [CA187] 1179
FAILURE CODE [CA221] 1181
FAILURE CODE [CA222] 1183
FAILURE CODE [CA227] 1185
FAILURE CODE [CA234] 1186
FAILURE CODE [CA238] 1187
FAILURE CODE [CA239] 1189
FAILURE CODE [CA249] 1191
FAILURE CODE [CA256] 1193
FAILURE CODE [CA271] 1195
FAILURE CODE [CA272] 1197
FAILURE CODE [CA273] 1198
FAILURE CODE [CA274] 1200
FAILURE CODE [CA322] 1201
FAILURE CODE [CA323] 1203
FAILURE CODE [CA324] 1205
FAILURE CODE [CA325] 1207
FAILURE CODE [CA331] 1209
FAILURE CODE [CA332] 1211
FAILURE CODE [CA343] 1213
FAILURE CODE [CA351] 1214
FAILURE CODE [CA352] 1215
FAILURE CODE [CA356] 1218
FAILURE CODE [CA357] 1220
FAILURE CODE [CA386] 1222
FAILURE CODE [CA441] 1223
FAILURE CODE [CA442] 1225
FAILURE CODE [CA449] 1226
FAILURE CODE [CA451] 1227
FAILURE CODE [CA452] 1229
FAILURE CODE [CA515] 1231
FAILURE CODE [CA516] 1233
FAILURE CODE [CA553] 1235
FAILURE CODE [CA555] 1236
FAILURE CODE [CA556] 1237
FAILURE CODE [CA559] 1238
FAILURE CODE [CA595] 1243
FAILURE CODE [CA687] 1244
FAILURE CODE [CA689] 1246
FAILURE CODE [CA691] 1248
FAILURE CODE [CA692] 1250
FAILURE CODE [CA697] 1252
FAILURE CODE [CA698] 1253
FAILURE CODE [CA731] 1254
FAILURE CODE [CA778] 1255
FAILURE CODE [CA1117] 1258
FAILURE CODE [CA1664] 1259
FAILURE CODE [CA1669] 1262
FAILURE CODE [CA1673] 1263
FAILURE CODE [CA1677] 1264
FAILURE CODE [CA1678] 1265
FAILURE CODE [CA1682] 1266
FAILURE CODE [CA1683] 1268
FAILURE CODE [CA1684] 1270
FAILURE CODE [CA1686] 1272
FAILURE CODE [CA1691] 1273
FAILURE CODE [CA1694] 1276
FAILURE CODE [CA1695] 1278
FAILURE CODE [CA1696] 1279
FAILURE CODE [CA1712] 1281
FAILURE CODE [CA1713] 1284
FAILURE CODE [CA1714] 1286
FAILURE CODE [CA1715] 1287
FAILURE CODE [CA1776] 1288
FAILURE CODE [CA1777] 1291
FAILURE CODE [CA1843] 1294
FAILURE CODE [CA1844] 1296
FAILURE CODE [CA1879] 1299
FAILURE CODE [CA1881] 1302
FAILURE CODE [CA1883] 1304
FAILURE CODE [CA1885] 1307
FAILURE CODE [CA1887] 1309
FAILURE CODE [CA1921] 1311
FAILURE CODE [CA1922] 1314
FAILURE CODE [CA1923] 1319
FAILURE CODE [CA1924] 1321
FAILURE CODE [CA1925] 1323
FAILURE CODE [CA1927] 1325
FAILURE CODE [CA1928] 1327
FAILURE CODE [CA1942] 1329
FAILURE CODE [CA1963] 1330
FAILURE CODE [CA1977] 1333
FAILURE CODE [CA1993] 1336
FAILURE CODE [CA2185] 1339
FAILURE CODE [CA2186] 1341
FAILURE CODE [CA2249] 1343
FAILURE CODE [CA2265] 1344
FAILURE CODE [CA2266] 1346
FAILURE CODE [CA2271] 1348
FAILURE CODE [CA2272] 1350
FAILURE CODE [CA2349] 1352
FAILURE CODE [CA2353] 1354
FAILURE CODE [CA2357] 1356
FAILURE CODE [CA2381] 1357
FAILURE CODE [CA2382] 1359
FAILURE CODE [CA2383] 1361
FAILURE CODE [CA2386] 1363
FAILURE CODE [CA2387] 1365
FAILURE CODE [CA2555] 1366
FAILURE CODE [CA2556] 1369
FAILURE CODE [CA2637] 1371
FAILURE CODE [CA2639] 1373
FAILURE CODE [CA2732] 1376
FAILURE CODE [CA2733] 1378
FAILURE CODE [CA2741] 1380
FAILURE CODE [CA2765] 1381
FAILURE CODE [CA2771] 1382
FAILURE CODE [CA2777] 1388
FAILURE CODE [CA2878] 1391
FAILURE CODE [CA2881] 1394
FAILURE CODE [CA2976] 1397
FAILURE CODE [CA3133] 1399
FAILURE CODE [CA3134] 1401
FAILURE CODE [CA3135] 1403
FAILURE CODE [CA3142] 1406
FAILURE CODE [CA3143] 1407
FAILURE CODE [CA3144] 1408
FAILURE CODE [CA3146] 1410
FAILURE CODE [CA3147] 1411
FAILURE CODE [CA3148] 1412
FAILURE CODE [CA3151] 1414
FAILURE CODE [CA3165] 1420
FAILURE CODE [CA3167] 1422
FAILURE CODE [CA3229] 1425
FAILURE CODE [CA3231] 1427
FAILURE CODE [CA3232] 1429
FAILURE CODE [CA3235] 1433
FAILURE CODE [CA3239] 1435
FAILURE CODE [CA3241] 1438
FAILURE CODE [CA3242] 1441
FAILURE CODE [CA3251] 1444
FAILURE CODE [CA3253] 1446
FAILURE CODE [CA3254] 1449
FAILURE CODE [CA3255] 1452
FAILURE CODE [CA3256] 1456
FAILURE CODE [CA3311] 1458
FAILURE CODE [CA3312] 1460
FAILURE CODE [CA3313] 1463
FAILURE CODE [CA3314] 1464
FAILURE CODE [CA3315] 1465
FAILURE CODE [CA3316] 1468
FAILURE CODE [CA3317] 1469
FAILURE CODE [CA3318] 1470
FAILURE CODE [CA3319] 1472
FAILURE CODE [CA3321] 1473
FAILURE CODE [CA3322] 1475
FAILURE CODE [CA3419] 1478
FAILURE CODE [CA3421] 1480
FAILURE CODE [CA3497] 1482
FAILURE CODE [CA3498] 1483
FAILURE CODE [CA3543] 1484
FAILURE CODE [CA3545] 1491
FAILURE CODE [CA3547] 1493
FAILURE CODE [CA3558] 1494
FAILURE CODE [CA3559] 1496
FAILURE CODE [CA3562] 1498
FAILURE CODE [CA3563] 1500
FAILURE CODE [CA3567] 1503
FAILURE CODE [CA3568] 1506
FAILURE CODE [CA3571] 1510
FAILURE CODE [CA3572] 1512
FAILURE CODE [CA3574] 1514
FAILURE CODE [CA3575] 1516
FAILURE CODE [CA3577] 1518
FAILURE CODE [CA3578] 1520
FAILURE CODE [CA3582] 1522
FAILURE CODE [CA3583] 1528
FAILURE CODE [CA3596] 1530
FAILURE CODE [CA3649] 1532
FAILURE CODE [CA3681] 1534
FAILURE CODE [CA3682] 1539
FAILURE CODE [CA3713] 1545
FAILURE CODE [CA3717] 1548
FAILURE CODE [CA3718] 1549
FAILURE CODE [CA3725] 1550
FAILURE CODE [CA3748] 1553
FAILURE CODE [CA3751] 1555
FAILURE CODE [CA3755] 1557
FAILURE CODE [CA3866] 1559
FAILURE CODE [CA3867] 1563
FAILURE CODE [CA3868] 1566
FAILURE CODE [CA3899] 1570
FAILURE CODE [CA3911] 1572
FAILURE CODE [CA3912] 1576
FAILURE CODE [CA3932] 1578
FAILURE CODE [CA3933] 1580
FAILURE CODE [CA3934] 1582
FAILURE CODE [CA3935] 1585
FAILURE CODE [CA3936] 1587
FAILURE CODE [CA4151] 1589
FAILURE CODE [CA4152] 1593
FAILURE CODE [CA4155] 1597
FAILURE CODE [CA4156] 1599
FAILURE CODE [CA4157] 1602
FAILURE CODE [CA4158] 1604
FAILURE CODE [CA4159] 1605
FAILURE CODE [CA4161] 1606
FAILURE CODE [CA4162] 1609
FAILURE CODE [CA4163] 1612
FAILURE CODE [CA4164] 1614
FAILURE CODE [CA4165] 1616
FAILURE CODE [CA4166] 1618
FAILURE CODE [CA4168] 1620
FAILURE CODE [CA4169] 1623
FAILURE CODE [CA4171] 1625
FAILURE CODE [CA4249] 1628
FAILURE CODE [CA4251] 1630
FAILURE CODE [CA4259] 1632
FAILURE CODE [CA4261] 1634
FAILURE CODE [CA4277] 1637
FAILURE CODE [CA4281] 1641
FAILURE CODE [CA4459] 1644
FAILURE CODE [CA4461] 1647
FAILURE CODE [CA4658] 1650
FAILURE CODE [CA4731] 1654
FAILURE CODE [CA4732] 1655
FAILURE CODE [CA4739] 1656
FAILURE CODE [CA4768] 1657
FAILURE CODE [CA4769] 1659
FAILURE CODE [CA4842] 1662
FAILURE CODE [CA4952] 1666
FAILURE CODE [CA5115] 1668
FAILURE CODE [CA5179] 1671
FAILURE CODE [CA5181] 1673
FAILURE CODE [CA5383] 1675
FAILURE CODE [D110KB] 1677
FAILURE CODE [D19JKZ] 1679
FAILURE CODE [D811MC] 1682
FAILURE CODE [D862KA] 1683
FAILURE CODE [D8ALKA] 1684
FAILURE CODE [D8ALKB] 1686
FAILURE CODE [D8AQKR] 1688
FAILURE CODE [DA20MC] 1690
FAILURE CODE [DA22KK] 1691
FAILURE CODE [DA29KQ] 1694
FAILURE CODE [DA2LKA] 1696
FAILURE CODE [DA2LKB] 1698
FAILURE CODE [DA2QKR] 1700
FAILURE CODE [DA2RKR] 1703
FAILURE CODE [DAF0MB] 1704
FAILURE CODE [DAF0MC] 1705
FAILURE CODE [DAF8KB] 1706
FAILURE CODE [DAF9KQ] 1708
FAILURE CODE [DAFGMC] 1709
FAILURE CODE [DAFLKA] 1710
FAILURE CODE [DAFLKB] 1712
FAILURE CODE [DAFQKR] 1714
FAILURE CODE [DAZ9KQ] 1715
FAILURE CODE [DAZQKR] 1716
FAILURE CODE [DB2QKR] 1721
FAILURE CODE [DB2RKR] 1726
FAILURE CODE [DDNRKA] 1730
FAILURE CODE [DDNRKY] 1732
FAILURE CODE [DDNS00] 1734
FAILURE CODE [DGH2KA] 1736
FAILURE CODE [DGH2KB] 1738
FAILURE CODE [DHA4KA] 1740
FAILURE CODE [DHAAMA] 1742
FAILURE CODE [DHACMA] 1744
FAILURE CODE [DHPAMA] 1746
FAILURE CODE [DHPBMA] 1749
FAILURE CODE [DHS3MA] 1752
FAILURE CODE [DHS4MA] 1755
FAILURE CODE [DHS8MA] 1758
FAILURE CODE [DHS9MA] 1761
FAILURE CODE [DHSAMA] 1764
FAILURE CODE [DHSBMA] 1767
FAILURE CODE [DHSCMA] 1770
FAILURE CODE [DHSDMA] 1773
FAILURE CODE [DHSFMA] 1776
FAILURE CODE [DHSGMA] 1779
FAILURE CODE [DHSHMA] 1782
FAILURE CODE [DHSJMA] 1785
FAILURE CODE [DKR0MA] 1788
FAILURE CODE [DKR1MA] 1791
FAILURE CODE [DKULKA] 1794
FAILURE CODE [DKULKB] 1796
FAILURE CODE [DKULKY] 1798
FAILURE CODE [DLM3KA] 1799
FAILURE CODE [DLM3KB] 1801
FAILURE CODE [DLM3MB] 1803
FAILURE CODE [DR21KX] 1804
FAILURE CODE [DR31KX] 1806
FAILURE CODE [DV20KB] 1808
FAILURE CODE [DW43KA] 1810
FAILURE CODE [DW43KB] 1812
FAILURE CODE [DW43KY] 1814
FAILURE CODE [DW45KA] 1816
FAILURE CODE [DW45KB] 1819
FAILURE CODE [DW45KY] 1822
FAILURE CODE [DW4CKY] 1824
FAILURE CODE [DW7BKA] 1825
FAILURE CODE [DW7BKB] 1827
FAILURE CODE [DW7BKY] 1829
FAILURE CODE [DW91KA] 1830
FAILURE CODE [DW91KB] 1832
FAILURE CODE [DW91KY] 1834
FAILURE CODE [DWA2KA] 1836
FAILURE CODE [DWA2KB] 1838
FAILURE CODE [DWA2KY] 1840
FAILURE CODE [DWK0KA] 1842
FAILURE CODE [DWK0KB] 1844
FAILURE CODE [DWK0KY] 1846
FAILURE CODE [DWK2KA] 1848
FAILURE CODE [DWK2KB] 1850
FAILURE CODE [DWK2KY] 1852
FAILURE CODE [DWK8KA] 1854
FAILURE CODE [DWK8KB] 1856
FAILURE CODE [DWK8KY] 1858
FAILURE CODE [DX16KA] 1860
FAILURE CODE [DX16KB] 1862
FAILURE CODE [DXA8KA] 1864
FAILURE CODE [DXA8KB] 1866
FAILURE CODE [DXA9KA] 1868
FAILURE CODE [DXA9KB] 1870
FAILURE CODE [DXE0KA] 1872
FAILURE CODE [DXE0KB] 1874
FAILURE CODE [DXE4KA] 1876
FAILURE CODE [DXE4KB] 1878
FAILURE CODE [DXE4KY] 1880
FAILURE CODE [DXE5KA] 1882
FAILURE CODE [DXE5KB] 1884
FAILURE CODE [DXE6KA] 1886
FAILURE CODE [DXE6KB] 1888
FAILURE CODE [DXE7KA] 1890
FAILURE CODE [DXE7KB] 1892
FAILURE CODE [DXE7KY] 1894
FAILURE CODE [DXE8KA] 1896
FAILURE CODE [DXE8KB] 1898
FAILURE CODE [DXE8KY] 1900
FAILURE CODE [DXE9KA] 1902
FAILURE CODE [DXE9KB] 1904
FAILURE CODE [DXE9KY] 1906
FAILURE CODE [DXEAKA] 1908
FAILURE CODE [DXEAKB] 1910
FAILURE CODE [DXEAKY] 1912
FAILURE CODE [DY20KA] 1914
FAILURE CODE [DY20MA] 1916
FAILURE CODE [DY2CKB] 1918
FAILURE CODE [DY2DKB] 1921
FAILURE CODE [DY2EKB] 1923
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1925
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1925
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1931
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1934
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1936
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1938
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1941
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1942
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1943
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1944
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1945
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1946
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1947
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1948
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1949
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1950
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1951
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1953
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1954
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1955
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1956
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1958
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1959
E-23 FUNCTION SWITCH DOES NOT OPERATE 1960
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1961
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1962
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1963
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1964
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1965
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1966
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1967
E-31 ALARM BUZZER CANNOT BE CANCELED 1969
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1970
E-33 SERVICE MODE CANNOT BE SELECTED 1971
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1972
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1974
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1975
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1978
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 1980
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 1982
E-40 ALARM DOES NOT SOUND DURING TRAVEL 1983
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1985
E-42 HORN DOES NOT SOUND 1986
E-43 HORN DOES NOT STOP SOUNDING 1990
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 1992
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 1993
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1995
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1996
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1997
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1998
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1999
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2000
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2001
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2002
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2003
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2004
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 2006
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2007
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 2008
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2010
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2011
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2011
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2012
FAILURE MODE AND CAUSE TABLE 2014
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2022
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2023
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2025
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2026
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2027
H-6 SPEED OR POWER OF BOOM IS LOW 2029
H-7 ARM SPEED OR POWER IS LOW 2035
H-8 BUCKET SPEED OR POWER IS LOW 2040
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2043
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 2044
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2046
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 2048
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2049
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2050
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 2051
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2052
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 2053
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 2054
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2055
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2056
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2057
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 2058
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 2060
H-24 TRAVEL SPEED IS LOW 2063
H-25 ONE OF TRACKS DOES NOT RUN 2065
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2066
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2067
H-28 SWINGS ONLY IN ONE DIRECTION 2068
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2069
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2070
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2071
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2072
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2073
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2074
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 2075
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2076
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2077
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2078
H-39 Quick coupler cylinder will not extend 2079
H-40 Quick coupler cylinder will not retract (but buzzer doesnot sound) 2081
H-41 Buzzer does not sound (but quick coupler cylinder doesretract) 2083
H-42 Quick coupler cylinder extends and retracts slowly 2085
TROUBLESHOOTING OF ENGINE (S-MODE) 2086
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2086
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2087
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2088
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2089
S-4 ENGINE STARTABILITY IS POOR 2090
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2092
S-6 ENGINE STOPS DURING OPERATION 2094
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2096
S-8 ENGINE LACKS POWER 2097
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2099
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2101
S-11 OIL BECOMES CONTAMINATED QUICKLY 2102
S-12 FUEL CONSUMPTION IS EXCESSIVE 2103
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2104
S-14 OIL PRESSURE DROPS 2105
S-15 FUEL MIXES INTO ENGINE OIL 2107
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2108
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2109
S-18 UNUSUAL NOISE IS HEARD 2111
S-19 VIBRATION IS EXCESSIVE 2112
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2113
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2114
S-22 ACTIVE REGENERATION TAKES TIME 2116
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2118
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2119
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2121
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2122
TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED) 2123
20 SUPPLY VOLTAGE > 32VDC 2123
21 SUPPLY VOLTAGE < 12VDC 2124
25 FILE ERROR FACTORY SETTINGS 2125
26 FILE ERROR USER SETTINGS 2126
27 FILE ERROR INPUT DATA 2127
30 PROXIMITY SWITCHES DIFFERENCE 2128
86 ANGLE SENSOR A2 TIMEOUT 2129
96 ANGLE SENSOR A3/A5 TIMEOUT 2130
106 ANGLE SENSOR A4/A6 TIMEOUT 2131
116 ANGLE SENSOR PITCH TIMEOUT 2132
126 ANGLE SENSOR ROLL TIMEOUT 2133
50 DISASSEMBLY AND ASSEMBLY 2135
CONTENTS 2136
ABBREVIATION LIST 2141
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2147
HOW TO READ THIS MANUAL 2147
COATING MATERIALS LIST 2149
SPECIAL TOOLS LIST 2153
SKETCHES OF SPECIAL TOOLS 2165
ENGINE AND COOLING SYSTEM 2171
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2171
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2171
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2177
REMOVE AND INSTALL INJECTOR ASSEMBLY 2186
METHOD FOR REMOVING INJECTOR ASSEMBLY 2186
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2192
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2202
METHOD FOR REMOVING FUEL DOSER 2202
METHOD FOR INSTALLING FUEL DOSER 2203
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2205
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2206
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2214
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2228
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2228
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2230
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2232
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2232
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2236
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2241
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2241
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2242
REMOVE AND INSTALL ALTERNATOR BELT 2244
METHOD FOR REMOVING ALTERNATOR BELT 2244
METHOD FOR INSTALLING ALTERNATOR BELT 2247
REMOVE AND INSTALL RADIATOR ASSEMBLY 2252
METHOD FOR REMOVING RADIATOR ASSEMBLY 2252
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2254
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2257
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2257
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2261
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2266
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2266
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2268
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2270
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2270
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2272
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2276
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 2277
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 2295
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2314
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2315
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2317
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2321
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2322
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2325
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2331
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2331
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2339
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2350
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2350
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2354
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2358
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2358
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2364
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2369
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2369
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2376
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2381
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2381
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2383
REMOVE AND INSTALL KDPF ASSEMBLY 2386
METHOD FOR REMOVING KDPF ASSEMBLY 2386
METHOD FOR INSTALLING KDPF ASSEMBLY 2390
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2395
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2396
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2401
REMOVE AND INSTALL SCR ASSEMBLY 2408
METHOD FOR REMOVING SCR ASSEMBLY 2408
METHOD FOR INSTALLING SCR ASSEMBLY 2411
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2415
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2415
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2420
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 2425
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2425
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2429
REMOVE AND INSTALL KCCV ASSEMBLY 2439
METHOD FOR REMOVING KCCV ASSEMBLY 2439
METHOD FOR INSTALLING KCCV ASSEMBLY 2440
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2444
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2444
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2449
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2455
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2455
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2459
REMOVE AND INSTALL AdBlue/DEF PUMP 2464
METHOD FOR REMOVING AdBlue/DEF PUMP 2464
METHOD FOR INSTALLING AdBlue/DEF PUMP 2466
REMOVE AND INSTALL AdBlue/DEF HOSE 2467
METHOD FOR REMOVING AdBlue/DEF HOSE 2467
METHOD FOR INSTALLING AdBlue/DEF HOSE 2472
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2481
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2481
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2482
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2485
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2485
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2488
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2492
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2492
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2493
POWER TRAIN 2495
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2495
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2495
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2496
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2497
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2497
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2502
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2508
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2508
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2509
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2511
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2512
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2515
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2521
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2521
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2521
UNDERCARRIAGE AND FRAME 2523
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2523
METHOD FOR SEPARATING TRACK ASSEMBLY 2523
METHOD FOR INSTALLING TRACK ASSEMBLY 2525
REMOVE AND INSTALL SPROCKET 2528
METHOD FOR REMOVING SPROCKET 2528
METHOD FOR INSTALLING SPROCKET 2528
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2530
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2530
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2531
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2533
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2533
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2535
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2540
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2541
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2543
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2546
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2547
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2548
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2552
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2552
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2554
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2557
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2557
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2559
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2562
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2562
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2563
HYDRAULIC SYSTEM 2565
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2565
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2565
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2567
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2569
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2570
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2571
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2572
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2572
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2577
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2583
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2583
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2587
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2593
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2593
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2598
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2604
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2605
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2606
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2611
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2611
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2612
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2614
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2614
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2615
REMOVE AND INSTALL QUICK COUPLER VALVE 2617
WORK EQUIPMENT 2619
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2619
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2620
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2623
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2627
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2627
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2630
CAB AND ITS ATTACHMENTS 2634
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2634
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2634
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2640
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2647
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2649
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2649
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2659
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2659
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2662
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2668
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2668
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2675
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2683
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2683
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2688
REMOVE AND INSTALL OPERATOR’S SEAT 2694
METHOD FOR REMOVING OPERATOR’S SEAT 2694
METHOD FOR INSTALLING OPERATOR’S SEAT 2696
REMOVE AND INSTALL SEAT BELT 2699
METHOD FOR REMOVING SEAT BELT 2699
METHOD FOR INSTALLING SEAT BELT 2700
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2701
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2701
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2706
ELECTRICAL SYSTEM 2715
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2715
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2715
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2716
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2718
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2718
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2721
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2726
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2726
METHOD FOR INSTALLING KomVision CONTROLLER 2727
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2728
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2728
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2731
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2735
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2735
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2736
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2737
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2737
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2738
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2740
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2740
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2741
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2743
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2743
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2745
REMOVE AND INSTALL KomVision CAMERA 2747
METHOD FOR REMOVING KomVision CAMERA 2747
METHOD FOR INSTALLING KomVision CAMERA 2748
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2750
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2750
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2753
60 MAINTENANCE STANDARD 2757
CONTENTS 2758
ABBREVIATION LIST 2759
ENGINE AND COOLING SYSTEM 2765
MAINTENANCE STANDARD OF ENGINE MOUNT 2765
MAINTENANCE STANDARD OF COOLING SYSTEM 2766
MAINTENANCE STANDARD OF COOLING FAN PUMP 2767
MAINTENANCE STANDARD OF SERVO VALVE 2768
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2769
POWER TRAIN 2770
MAINTENANCE STANDARD OF SWING CIRCLE 2770
MAINTENANCE STANDARD OF SWING MACHINERY 2771
MAINTENANCE STANDARD OF FINAL DRIVE 2773
MAINTENANCE STANDARD OF SPROCKET 2775
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2776
UNDERCARRIAGE AND FRAME 2778
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2778
MAINTENANCE STANDARD OF IDLER 2780
MAINTENANCE STANDARD OF TRACK ROLLER 2782
MAINTENANCE STANDARD OF CARRIER ROLLER 2784
MAINTENANCE STANDARD OF TRACK SHOE 2785
MAINTENANCE STANDARD OF TRIPLE SHOE 2788
HYDRAULIC SYSTEM 2789
MAINTENANCE STANDARD OF MAIN PUMP 2789
MAINTENANCE STANDARD OF SWING MOTOR 2791
MAINTENANCE STANDARD OF TRAVEL MOTOR 2794
MAINTENANCE STANDARD OF CONTROL VALVE 2797
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2808
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2811
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2814
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2815
MAINTENANCE STANDARD OF SOLENOID VALVE 2817
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2818
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE 2820
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2821
WORK EQUIPMENT 2822
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2822
DIMENSION OF ARM 2827
DIMENSIONS OF BUCKET 2829
MAINTENANCE STANDARD OF BOOM CYLINDER 2831
MAINTENANCE STANDARD OF ARM CYLINDER 2832
MAINTENANCE STANDARD OF BUCKET CYLINDER 2833
WORK EQUIPMENT – PC490HRD-11E0 2834
WORK EQUIPMENT – HIGH REACH DEMOLITION 2834
DIMENSION OF ARM 2834
MAINTENANCE STANDARD OF BOOM CYLINDER 2835
MAINTENANCE STANDARD OF LINK CYLINDER 2836
MAINTENANCE STANDARD OF ARM CYLINDER 2837
MAINTENANCE STANDARD OF BUCKET CYLINDER 2838
WORK EQUIPMENT – DEMOLITION DIGGING 2839
MAINTENANCE STANDARD OF ARM CYLINDER 2839
MAINTENANCE STANDARD OF BUCKET CYLINDER 2840
80 APPENDIX 2841
CONTENTS 2842
ABBREVIATION LIST 2844
AIR CONDITIONER SYSTEM 2850
PRECAUTIONS FOR REFRIGERANT 2850
AIR CONDITIONER COMPONENT 2851
SPECIFICATIONS OF AIR CONDITIONER 2853
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2854
OUTLINE OF REFRIGERATION CYCLE 2855
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2857
AIR CONDITIONER UNIT 2857
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2857
FUNCTION OF AIR CONDITIONER UNIT 2859
COMPONENT PARTS OF AIR CONDITIONER UNIT 2861
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2862
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2862
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2862
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2862
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2863
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2863
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2863
FUNCTION OF DUAL PRESSURE SWITCH 2864
AIR CONDITIONER CONTROLLER 2865
STRUCTURE OF AIR CONDITIONER CONTROLLER 2865
COMPRESSOR 2866
STRUCTURE OF COMPRESSOR 2866
SPECIFICATIONS OF COMPRESSOR 2866
FUNCTION OF COMPRESSOR 2866
CONDENSER 2867
STRUCTURE OF CONDENSER 2867
SPECIFICATIONS OF CONDENSER 2867
FUNCTION OF CONDENSER 2867
RECEIVER DRIER 2868
STRUCTURE OF RECEIVER DRIER 2868
SPECIFICATIONS OF RECEIVER DRIER 2868
FUNCTION OF RECEIVER DRIER 2868
SENSORS FOR AIR CONDITIONER SYSTEM 2869
STRUCTURE OF SUNLIGHT SENSOR 2869
FUNCTION OF SUNLIGHT SENSOR 2869
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2869
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2869
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2871
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2873
AIR CONDITIONER SYSTEM DIAGRAM 2875
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2876
FUNCTION OF AIR CONDITIONER CONTROLLER 2877
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2878
TESTING AIR LEAKAGE (DUCT) 2882
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2882
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2884
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2885
TEST VENT (MODE) CHANGEOVER 2886
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2886
TESTING FRESH/RECIRC AIR CHANGEOVER 2888
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2888
TEST SUNLIGHT SENSOR 2889
METHOD FOR TESTING SUNLIGHT SENSOR 2889
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2890
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2890
TEST RELAYS 2892
METHOD FOR TESTING RELAYS 2892
AIR CONDITIONER TROUBLESHOOTING CHART 1 2893
AIR CONDITIONER TROUBLESHOOTING CHART 2 2895
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2898
FAILURE CODE [879AKA] 2900
FAILURE CODE [879AKB] 2901
FAILURE CODE [879BKA] 2902
FAILURE CODE [879BKB] 2904
FAILURE CODE [879CKA] 2906
FAILURE CODE [879CKB] 2907
FAILURE CODE [879DKZ] 2908
FAILURE CODE [879EMC] 2910
FAILURE CODE [879FMC] 2911
FAILURE CODE [879GKX] 2912
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2914
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2915
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2916
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2917
TROUBLESHOOTING USING GAUGE PRESSURE 2918
CONNECTION OF SERVICE TOOL 2921
METHOD FOR CONNECTING SERVICE TOOL 2921
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2923
HANDLE COMPRESSOR OIL 2925
90 CIRCUIT DIAGRAMS 2927
CONTENTS 2928
ABBREVIATION LIST 2929
HYDRAULIC CIRCUIT DIAGRAM 2935
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2935
HYDRAULIC CIRCUIT DIAGRAM (1/2) 2939
HYDRAULIC CIRCUIT DIAGRAM (2/2) 2941
HYDRAULIC CIRCUIT DIAGRAM (1/4) – PC490HRD-11E0 2943
HYDRAULIC CIRCUIT DIAGRAM (2/4) – PC490HRD-11E0 2945
HYDRAULIC CIRCUIT DIAGRAM (3/4) – PC490HRD-11E0 2947
HYDRAULIC CIRCUIT DIAGRAM (4/4) – PC490HRD-11E0 2949
ELECTRICAL CIRCUIT DIAGRAM 2951
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2951
ELECTRICAL CIRCUIT DIAGRAM (1/9) 2955
ELECTRICAL CIRCUIT DIAGRAM (2/9) 2957
ELECTRICAL CIRCUIT DIAGRAM (3/9) 2959
ELECTRICAL CIRCUIT DIAGRAM (4/9) 2961
ELECTRICAL CIRCUIT DIAGRAM (5/9) 2963
ELECTRICAL CIRCUIT DIAGRAM (6/9) 2965
ELECTRICAL CIRCUIT DIAGRAM (7/9) 2967
ELECTRICAL CIRCUIT DIAGRAM (8/9) 2969
ELECTRICAL CIRCUIT DIAGRAM (9/9) 2971
ELECTRICAL CIRCUIT DIAGRAM (1/13) – PC490HRD-11E0 2973
ELECTRICAL CIRCUIT DIAGRAM (2/13) – PC490HRD-11E0 2975
ELECTRICAL CIRCUIT DIAGRAM (3/13) – PC490HRD-11E0 2977
ELECTRICAL CIRCUIT DIAGRAM (4/13) – PC490HRD-11E0 2979
ELECTRICAL CIRCUIT DIAGRAM (5/13) – PC490HRD-11E0 2981
ELECTRICAL CIRCUIT DIAGRAM (6/13) – PC490HRD-11E0 2983
ELECTRICAL CIRCUIT DIAGRAM (7/13) – PC490HRD-11E0 2985
ELECTRICAL CIRCUIT DIAGRAM (8/13) – PC490HRD-11E0 2987
ELECTRICAL CIRCUIT DIAGRAM (9/13) – PC490HRD-11E0 2989
ELECTRICAL CIRCUIT DIAGRAM (10/13) – PC490HRD-11E0 2991
ELECTRICAL CIRCUIT DIAGRAM (11/13) – PC490HRD-11E0 2993
ELECTRICAL CIRCUIT DIAGRAM (12/13) – PC490HRD-11E0 2995
ELECTRICAL CIRCUIT DIAGRAM (13/13) – PC490HRD-11E0 2997
INDEX 2999

DESCRIPTION:

Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Hydraulic Excavator Shop Manual UENBM00500 – PDF DOWNLOAD 

SERIAL NUMBERS K75001 and up

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.

S.V 26/12/24