Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Excavator Shop Manual PDF

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Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Excavator Shop Manual UENBM00501 – PDF DOWNLOAD

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Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Excavator Shop Manual UENBM00501 – PDF DOWNLOAD 

Language : English
Pages : 3092
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Excavator Shop Manual UENBM00501 – PDF DOWNLOAD 

SERIAL NUMBERS K75001 and up

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 160
FUNCTION OF BATTERY DISCONNECT SWITCH 160
ENGINE SYSTEM 161
LAYOUT DRAWING OF ENGINE SYSTEM 161
SPECIFICATIONS OF ENGINE SYSTEM 162
FUNCTION OF ENGINE SYSTEM 163
ENGINE CONTROL SYSTEM 164
ENGINE CONTROL SYSTEM DIAGRAM 164
FUNCTION OF ENGINE CONTROL SYSTEM 165
AUTO-DECELERATION SYSTEM 167
AUTO-DECELERATION SYSTEM DIAGRAM 167
FUNCTION OF AUTO-DECELERATION SYSTEM 167
OPERATION OF AUTO-DECELERATION SYSTEM 168
ENGINE AUTOMATIC WARM-UP SYSTEM 169
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 169
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 170
OVERHEAT PREVENTION SYSTEM 171
OVERHEAT PREVENTION SYSTEM DIAGRAM 171
FUNCTION OF OVERHEAT PREVENTION SYSTEM 172
TURBOCHARGER PROTECTION SYSTEM 174
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 174
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 175
AUTOMATIC IDLE STOP SYSTEM 176
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 176
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 176
COMPONENT PARTS OF ENGINE SYSTEM 179
VGT 179
EGR SYSTEM 182
EGR VALVE 184
EGR COOLER 186
KCCV SYSTEM 187
KCCV VENTILATOR 188
KDPF 190
COOLING SYSTEM 195
LAYOUT DRAWING OF COOLING SYSTEM 195
SPECIFICATIONS OF COOLING SYSTEM 196
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 198
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 198
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 199
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 200
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 200
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 201
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 203
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 203
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 203
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 224
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 257
KomVision CAMERA 261
KOMTRAX TERMINAL 261
PUMP CONTROLLER 264
RESISTOR FOR PC-EPC VALVE 268
CAN TERMINATING RESISTOR 268
ENGINE CONTROLLER 270
FUEL CONTROL DIAL 276
FUEL FEED PUMP 278
FUEL FEED PUMP SWITCH 279
SENSOR 280
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 280
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 280
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 280
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 281
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 281
FUNCTION OF AUTO GREASE PRESSURE SWITCH 281
STRUCTURE OF OVERLOAD CAUTION SENSOR 281
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 282
FUNCTION OF OVERLOAD CAUTION SENSOR 282
HYDRAULIC SYSTEM 283
LAYOUT DRAWING OF HYDRAULIC SYSTEM 283
CLSS 285
STRUCTURE OF CLSS 285
OPERATION OF UNLOAD VALVE AND LS PRESSURE 287
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 288
PRESSURE COMPENSATION CONTROL 301
ENGINE AND PUMP COMBINED CONTROL SYSTEM 304
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 304
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 306
PUMP AND VALVE CONTROL SYSTEM 311
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 311
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 312
COMPONENT PARTS OF HYDRAULIC SYSTEM 314
HYDRAULIC TANK 314
MAIN PUMP 316
PILOT OIL FILTER 342
CONTROL VALVE 342
HYDRAULIC SYSTEM – PC490HRD-11E0 404
LAYOUT DRAWING OF HYDRAULIC SYSTEM 404
COMPONENT PARTS OF HYDRAULIC SYSTEM 407
LAYOUT DRAWING OF VALVE CONTROL SYSTEM 407
WORK EQUIPMENT SYSTEM 427
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 427
STRUCTURE OF VALVE CONTROL 432
ONE-TOUCH POWER MAXIMIZING SYSTEM 433
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 433
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 434
MACHINE PUSH-UP SYSTEM 435
MACHINE PUSH-UP SYSTEM DIAGRAM 435
FUNCTION OF MACHINE PUSH-UP SYSTEM 436
PPC LOCK SYSTEM 437
PPC LOCK SYSTEM DIAGRAM 437
FUNCTION OF PPC LOCK SYSTEM 437
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 438
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 438
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 438
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 439
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 440
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 440
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 441
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 442
WORK EQUIPMENT AND SWING PPC VALVE 442
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 447
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 689
TEST OIL PRESSURE OF CONTROL CIRCUIT 693
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 693
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 695
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 695
TEST PC-EPC VALVE OUTLET PRESSURE 696
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 697
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 699
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 699
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 700
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 701
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 702
METHOD FOR ADJUSTING LS VALVE 703
TEST OUTLET PRESSURE OF SOLENOID VALVE 704
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 704
OPERATING CONDITION OF SOLENOID VALVE 705
TEST PPC VALVE OUTLET PRESSURE 707
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 707
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 709
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 709
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 710
TEST PUMP SWASH PLATE SENSOR 712
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 712
TEST COOLING FAN SPEED 713
METHOD FOR TESTING COOLING FAN SPEED 713
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 714
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 714
TEST FAN PUMP EPC ELECTRIC CURRENT 716
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 716
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 717
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 717
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 719
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 719
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 719
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 720
TEST OIL LEAKAGE 721
TEST OIL LEAKAGE OF BOOM CYLINDER 721
TEST OIL LEAKAGE OF ARM CYLINDER 721
TEST OIL LEAKAGE OF BUCKET CYLINDER 722
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR 722
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 723
BLEED AIR FROM HYDRAULIC CIRCUIT 724
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 726
HYDRAULIC SYSTEM – PC490HRD-11E0 729
MEASURING AND ADJUSTING SWING SPEED REDUCTION VALVE 729
MEASURING AND ADJUSTING BOOM AND BUCKET PPC REDUCTION VALVE 730
MEASURING AND ADJUSTING LINK CYLINDER FLOW CONTROL VALVE 731
MEASURING AND ADJUSTING ARM CYLINDER FLOW CONTROL VALVE 732
CAB AND ITS ATTACHMENTS 733
TEST CAB TIPPING STOPPER 733
METHOD FOR TESTING CAB TIPPING STOPPER 733
METHOD FOR ADJUSTING MIRRORS 734
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 734
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 735
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 736
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 737
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 738
ELECTRICAL SYSTEM 740
SET AND OPERATE MACHINE MONITOR 740
OPERATOR MODE 743
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 744
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 744
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 745
CHECKING FUNCTION OF SERVICE METER 745
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 745
SERVICE MODE 748
METHOD FOR OPERATING SERVICE MODE 750
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 753
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 760
METHOD FOR CONFIRMING MAINTENANCE RECORD 776
METHOD FOR OPERATING MAINTENANCE MODE SETTING 777
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 781
METHOD FOR PERFORMING NO-INJECTION CRANKING 823
METHOD FOR DISPLAYING SERVICE MESSAGE 826
METHOD FOR STARTING UP KOMTRAX TERMINAL 828
ADJUST REARVIEW CAMERA ANGLE 833
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 833
ADJUST KomVision CAMERA ANGLE 836
Angle adjustment method for KomVision camera 837
ADJUST KomVision RELATED ITEMS 841
SETTING OF KomVision (MAIN SETTING) 841
SETTING OF KomVision (CAMERA SETTING) 843
SET KomVision (camera calibration) 843
KomVision screen – Check 12 m visibility 870
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 873
HANDLE BATTERY DISCONNECT SWITCH 874
TEST DIODES 875
METHOD FOR TESTING DIODE USING DIGITAL TESTER 875
METHOD FOR TESTING DIODE USING ANALOG TESTER 875
ELECTRICAL SYSTEM – PC490HRD-11E0 876
ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM 876
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – BASE MACHINE 876
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – HIGH REACH DEMOLITION WORK EQUIPMENT 879
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT 881
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – MEDIUM REACH DEMOLITION WORK EQUIPMENT 883
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – DEMOLITION DIGGING WORK EQUIPMENT 885
RH PPC LEVER 886
LH PPC LEVER 887
WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT 888
CONSTANT LINK SPEED CIRCUIT 889
PARALLEL LINK FRONT SCREEN WIPER 890
OVERLOAD CAUTION (HIGH REACH DEMOLITION) 891
Pm CLINIC 892
Pm CLINIC SERVICE 892
Pm CLINIC CHECK SHEET 893
WORKING RANGE INDICATOR SYSTEM 906
WORKING RANGE INDICATOR SYSTEM LAYOUT 906
METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU 908
DIAGNOSTICS – WORKING RANGE INDICATOR SYSTEM 910
MONITORING SYSTEM PARAMETERS AND SENSOR STATES 910
USING THE PARAMETER CHANGE LOG 912
USING ERROR LISTS AND LOGS 913
EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM 914
IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM 915
REPLACING COMPONENTS – WORKING RANGE INDICATOR SYSTEM 917
WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT 917
WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT 922
WORKING RANGE INDICATOR SYSTEM – UDATING SOFTWARE 927
CALIBRATION – WORKING RANGE INDICATOR SYSTEM 931
WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW 931
METHOD 1 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – AUTO CALIBRATION 931
METHOD 2 – BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION 939
METHOD 2 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – MANUAL CALIBRATION 942
40 TROUBLESHOOTING 957
CONTENTS 958
ABBREVIATION LIST 969
RELATED INFORMATION ON TROUBLESHOOTING 975
GENERAL TROUBLESHOOTING POINTS 975
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 976
SEQUENCE OF EVENTS IN TROUBLESHOOTING 988
CHECKS BEFORE TROUBLESHOOTING 990
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 992
WALK-AROUND CHECK 992
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 994
CHECK FUEL LEVEL AND TYPE 994
CHECK IMPURE INGREDIENT IN FUEL 995
CHECK FUEL PREFILTER 995
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 995
FUEL PREFILTER CARTRIDGE – REPLACE 996
CHECK MAIN FILTER 997
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 998
CHECK COOLANT LEVEL (RESERVOIR TANK) 1000
CHECK CLOGGING OF AIR CLEANER 1000
OUTER ELEMENT – CLEAN 1001
ELEMENTS – REPLACE 1003
CHECK HYDRAULIC OIL LEVEL 1004
CHECK HYDRAULIC OIL STRAINER 1004
CHECK HYDRAULIC FILTER 1005
CHECK OIL LEVEL IN SWING MACHINERY CASE 1006
CHECK OIL LEVEL IN DAMPER CASE 1007
CHECK OIL LEVEL IN FINAL DRIVE CASE 1007
BLEED AIR FROM FUEL SYSTEM 1008
BLEED AIR FROM HYDRAULIC SYSTEM 1008
ELECTRICAL EQUIPMENT – CHECK METHOD 1008
AUTOMATIC GREASE SYSTEM 1014
FINDING MALFUNCTIONS 1014
MALFUNCTION FINDING PROCEDURES 1016
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1018
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 1028
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1038
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 1041
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1045
CONNECTOR LIST AND LAYOUT 1047
CONNECTOR CONTACT IDENTIFICATION 1060
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1100
FUSE LOCATION TABLE 1106
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1109
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1113
FAILURE CODE TABLE 1115
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1134
FAILURE CODE [879AKA] 1134
FAILURE CODE [879AKB] 1135
FAILURE CODE [879BKA] 1136
FAILURE CODE [879BKB] 1138
FAILURE CODE [879CKA] 1140
FAILURE CODE [879CKB] 1141
FAILURE CODE [879DKZ] 1142
FAILURE CODE [879EMC] 1144
FAILURE CODE [879FMC] 1145
FAILURE CODE [879GKX] 1146
FAILURE CODE [989L00] 1148
FAILURE CODE [989M00] 1149
FAILURE CODE [989N00] 1150
FAILURE CODE [A1U0N3] 1151
FAILURE CODE [A1U0N4] 1153
FAILURE CODE [A900FR] 1155
FAILURE CODE [A900N6] 1156
FAILURE CODE [A900NY] 1157
FAILURE CODE [AA10NX] 1158
FAILURE CODE [AB00KE] 1160
FAILURE CODE [AQ10N3] 1163
FAILURE CODE [AS00N3] 1165
FAILURE CODE [AS00R2] 1167
FAILURE CODE [AS00R3] 1168
FAILURE CODE [AS00R4] 1169
FAILURE CODE [AS00R5] 1170
FAILURE CODE [AS00R6] 1171
FAILURE CODE [AS00ZK] 1172
FAILURE CODE [AS10KM] 1173
FAILURE CODE [AS10NR] 1174
FAILURE CODE [AS10NT] 1175
FAILURE CODE [B@BAZG] 1176
FAILURE CODE [B@BAZK] 1177
FAILURE CODE [B@BCNS] 1179
FAILURE CODE [B@BCQA] 1180
FAILURE CODE [B@BCZK] 1182
FAILURE CODE [B@HANS] 1184
FAILURE CODE [CA115] 1185
FAILURE CODE [CA122] 1186
FAILURE CODE [CA123] 1188
FAILURE CODE [CA131] 1190
FAILURE CODE [CA132] 1192
FAILURE CODE [CA135] 1194
FAILURE CODE [CA141] 1196
FAILURE CODE [CA144] 1198
FAILURE CODE [CA145] 1200
FAILURE CODE [CA153] 1202
FAILURE CODE [CA154] 1205
FAILURE CODE [CA187] 1208
FAILURE CODE [CA221] 1210
FAILURE CODE [CA222] 1212
FAILURE CODE [CA227] 1214
FAILURE CODE [CA234] 1215
FAILURE CODE [CA238] 1216
FAILURE CODE [CA239] 1218
FAILURE CODE [CA249] 1220
FAILURE CODE [CA256] 1222
FAILURE CODE [CA271] 1224
FAILURE CODE [CA272] 1226
FAILURE CODE [CA273] 1227
FAILURE CODE [CA274] 1229
FAILURE CODE [CA322] 1230
FAILURE CODE [CA323] 1232
FAILURE CODE [CA324] 1234
FAILURE CODE [CA325] 1236
FAILURE CODE [CA331] 1238
FAILURE CODE [CA332] 1240
FAILURE CODE [CA343] 1242
FAILURE CODE [CA351] 1243
FAILURE CODE [CA352] 1244
FAILURE CODE [CA356] 1247
FAILURE CODE [CA357] 1249
FAILURE CODE [CA386] 1251
FAILURE CODE [CA441] 1252
FAILURE CODE [CA442] 1254
FAILURE CODE [CA449] 1255
FAILURE CODE [CA451] 1256
FAILURE CODE [CA452] 1258
FAILURE CODE [CA515] 1260
FAILURE CODE [CA516] 1262
FAILURE CODE [CA553] 1264
FAILURE CODE [CA555] 1265
FAILURE CODE [CA556] 1266
FAILURE CODE [CA559] 1267
FAILURE CODE [CA595] 1272
FAILURE CODE [CA687] 1273
FAILURE CODE [CA689] 1275
FAILURE CODE [CA691] 1277
FAILURE CODE [CA692] 1279
FAILURE CODE [CA697] 1281
FAILURE CODE [CA698] 1282
FAILURE CODE [CA731] 1283
FAILURE CODE [CA778] 1284
FAILURE CODE [CA1117] 1287
FAILURE CODE [CA1664] 1288
FAILURE CODE [CA1669] 1291
FAILURE CODE [CA1673] 1292
FAILURE CODE [CA1677] 1293
FAILURE CODE [CA1678] 1294
FAILURE CODE [CA1682] 1295
FAILURE CODE [CA1683] 1297
FAILURE CODE [CA1684] 1299
FAILURE CODE [CA1686] 1301
FAILURE CODE [CA1691] 1302
FAILURE CODE [CA1694] 1305
FAILURE CODE [CA1695] 1307
FAILURE CODE [CA1696] 1308
FAILURE CODE [CA1712] 1310
FAILURE CODE [CA1713] 1313
FAILURE CODE [CA1714] 1315
FAILURE CODE [CA1715] 1316
FAILURE CODE [CA1776] 1317
FAILURE CODE [CA1777] 1320
FAILURE CODE [CA1843] 1323
FAILURE CODE [CA1844] 1325
FAILURE CODE [CA1879] 1328
FAILURE CODE [CA1881] 1331
FAILURE CODE [CA1883] 1333
FAILURE CODE [CA1885] 1336
FAILURE CODE [CA1887] 1338
FAILURE CODE [CA1921] 1340
FAILURE CODE [CA1922] 1343
FAILURE CODE [CA1923] 1348
FAILURE CODE [CA1924] 1350
FAILURE CODE [CA1925] 1352
FAILURE CODE [CA1927] 1354
FAILURE CODE [CA1928] 1356
FAILURE CODE [CA1942] 1358
FAILURE CODE [CA1963] 1359
FAILURE CODE [CA1977] 1362
FAILURE CODE [CA1993] 1365
FAILURE CODE [CA2185] 1368
FAILURE CODE [CA2186] 1370
FAILURE CODE [CA2249] 1372
FAILURE CODE [CA2265] 1373
FAILURE CODE [CA2266] 1375
FAILURE CODE [CA2271] 1377
FAILURE CODE [CA2272] 1379
FAILURE CODE [CA2349] 1381
FAILURE CODE [CA2353] 1383
FAILURE CODE [CA2357] 1385
FAILURE CODE [CA2381] 1386
FAILURE CODE [CA2382] 1388
FAILURE CODE [CA2383] 1390
FAILURE CODE [CA2386] 1392
FAILURE CODE [CA2387] 1394
FAILURE CODE [CA2555] 1395
FAILURE CODE [CA2556] 1398
FAILURE CODE [CA2637] 1400
FAILURE CODE [CA2639] 1402
FAILURE CODE [CA2732] 1405
FAILURE CODE [CA2733] 1407
FAILURE CODE [CA2741] 1409
FAILURE CODE [CA2765] 1410
FAILURE CODE [CA2771] 1411
FAILURE CODE [CA2777] 1417
FAILURE CODE [CA2878] 1420
FAILURE CODE [CA2881] 1423
FAILURE CODE [CA2976] 1426
FAILURE CODE [CA3133] 1428
FAILURE CODE [CA3134] 1430
FAILURE CODE [CA3135] 1432
FAILURE CODE [CA3142] 1435
FAILURE CODE [CA3143] 1436
FAILURE CODE [CA3144] 1437
FAILURE CODE [CA3146] 1439
FAILURE CODE [CA3147] 1440
FAILURE CODE [CA3148] 1441
FAILURE CODE [CA3151] 1443
FAILURE CODE [CA3165] 1449
FAILURE CODE [CA3167] 1451
FAILURE CODE [CA3229] 1454
FAILURE CODE [CA3231] 1456
FAILURE CODE [CA3232] 1458
FAILURE CODE [CA3235] 1462
FAILURE CODE [CA3239] 1464
FAILURE CODE [CA3241] 1467
FAILURE CODE [CA3242] 1470
FAILURE CODE [CA3251] 1473
FAILURE CODE [CA3253] 1475
FAILURE CODE [CA3254] 1478
FAILURE CODE [CA3255] 1481
FAILURE CODE [CA3256] 1485
FAILURE CODE [CA3311] 1487
FAILURE CODE [CA3312] 1489
FAILURE CODE [CA3313] 1492
FAILURE CODE [CA3314] 1493
FAILURE CODE [CA3315] 1494
FAILURE CODE [CA3316] 1497
FAILURE CODE [CA3317] 1498
FAILURE CODE [CA3318] 1499
FAILURE CODE [CA3319] 1501
FAILURE CODE [CA3321] 1502
FAILURE CODE [CA3322] 1504
FAILURE CODE [CA3419] 1507
FAILURE CODE [CA3421] 1509
FAILURE CODE [CA3497] 1511
FAILURE CODE [CA3498] 1512
FAILURE CODE [CA3543] 1513
FAILURE CODE [CA3545] 1520
FAILURE CODE [CA3547] 1522
FAILURE CODE [CA3558] 1523
FAILURE CODE [CA3559] 1525
FAILURE CODE [CA3562] 1527
FAILURE CODE [CA3563] 1529
FAILURE CODE [CA3567] 1532
FAILURE CODE [CA3568] 1535
FAILURE CODE [CA3571] 1539
FAILURE CODE [CA3572] 1541
FAILURE CODE [CA3574] 1543
FAILURE CODE [CA3575] 1545
FAILURE CODE [CA3577] 1547
FAILURE CODE [CA3578] 1549
FAILURE CODE [CA3582] 1551
FAILURE CODE [CA3583] 1557
FAILURE CODE [CA3596] 1559
FAILURE CODE [CA3649] 1561
FAILURE CODE [CA3681] 1563
FAILURE CODE [CA3682] 1568
FAILURE CODE [CA3713] 1574
FAILURE CODE [CA3717] 1577
FAILURE CODE [CA3718] 1578
FAILURE CODE [CA3725] 1579
FAILURE CODE [CA3748] 1582
FAILURE CODE [CA3751] 1584
FAILURE CODE [CA3755] 1586
FAILURE CODE [CA3866] 1588
FAILURE CODE [CA3867] 1592
FAILURE CODE [CA3868] 1595
FAILURE CODE [CA3899] 1599
FAILURE CODE [CA3911] 1601
FAILURE CODE [CA3912] 1605
FAILURE CODE [CA3932] 1607
FAILURE CODE [CA3933] 1609
FAILURE CODE [CA3934] 1611
FAILURE CODE [CA3935] 1614
FAILURE CODE [CA3936] 1616
FAILURE CODE [CA4151] 1618
FAILURE CODE [CA4152] 1622
FAILURE CODE [CA4155] 1626
FAILURE CODE [CA4156] 1628
FAILURE CODE [CA4157] 1631
FAILURE CODE [CA4158] 1633
FAILURE CODE [CA4159] 1634
FAILURE CODE [CA4161] 1635
FAILURE CODE [CA4162] 1638
FAILURE CODE [CA4163] 1641
FAILURE CODE [CA4164] 1643
FAILURE CODE [CA4165] 1645
FAILURE CODE [CA4166] 1647
FAILURE CODE [CA4168] 1649
FAILURE CODE [CA4169] 1652
FAILURE CODE [CA4171] 1654
FAILURE CODE [CA4249] 1657
FAILURE CODE [CA4251] 1659
FAILURE CODE [CA4259] 1661
FAILURE CODE [CA4261] 1663
FAILURE CODE [CA4277] 1666
FAILURE CODE [CA4281] 1670
FAILURE CODE [CA4459] 1673
FAILURE CODE [CA4461] 1676
FAILURE CODE [CA4658] 1679
FAILURE CODE [CA4731] 1683
FAILURE CODE [CA4732] 1684
FAILURE CODE [CA4739] 1685
FAILURE CODE [CA4768] 1686
FAILURE CODE [CA4769] 1688
FAILURE CODE [CA4842] 1691
FAILURE CODE [CA4952] 1695
FAILURE CODE [CA5115] 1697
FAILURE CODE [CA5179] 1700
FAILURE CODE [CA5181] 1702
FAILURE CODE [CA5383] 1704
FAILURE CODE [D110KB] 1706
FAILURE CODE [D19JKZ] 1708
FAILURE CODE [D811MC] 1711
FAILURE CODE [D862KA] 1712
FAILURE CODE [D8ALKA] 1713
FAILURE CODE [D8ALKB] 1715
FAILURE CODE [D8AQKR] 1717
FAILURE CODE [DA20MC] 1719
FAILURE CODE [DA22KK] 1720
FAILURE CODE [DA29KQ] 1723
FAILURE CODE [DA2LKA] 1725
FAILURE CODE [DA2LKB] 1727
FAILURE CODE [DA2QKR] 1729
FAILURE CODE [DA2RKR] 1732
FAILURE CODE [DAF0KM] 1733
FAILURE CODE [DAF0MB] 1734
FAILURE CODE [DAF0MC] 1735
FAILURE CODE [DAF8KB] 1736
FAILURE CODE [DAF9KQ] 1738
FAILURE CODE [DAFGMC] 1739
FAILURE CODE [DAFLKA] 1740
FAILURE CODE [DAFLKB] 1742
FAILURE CODE [DAFQKR] 1744
FAILURE CODE [DAZ9KQ] 1745
FAILURE CODE [DAZQKR] 1746
FAILURE CODE [DB2QKR] 1751
FAILURE CODE [DB2RKR] 1756
FAILURE CODE [DBP0KM] 1760
FAILURE CODE [DBP0KT] 1761
FAILURE CODE [DBP5KB] 1762
FAILURE CODE [DBP5KY] 1765
FAILURE CODE [DBPQKR] 1768
FAILURE CODE [DDNRKA] 1773
FAILURE CODE [DDNRKY] 1775
FAILURE CODE [DDNS00] 1777
FAILURE CODE [DFB1KZ] 1779
FAILURE CODE [DFB2KZ] 1781
FAILURE CODE [DFB3L8] 1783
FAILURE CODE [DFB4L8] 1785
FAILURE CODE [DFB5KZ] 1787
FAILURE CODE [DFB6KZ] 1789
FAILURE CODE [DGH2KA] 1791
FAILURE CODE [DGH2KB] 1793
FAILURE CODE [DHA4KA] 1795
FAILURE CODE [DHAAMA] 1797
FAILURE CODE [DHACMA] 1799
FAILURE CODE [DHPAMA] 1801
FAILURE CODE [DHPBMA] 1804
FAILURE CODE [DHS3MA] 1807
FAILURE CODE [DHS4MA] 1810
FAILURE CODE [DHS8MA] 1813
FAILURE CODE [DHS9MA] 1816
FAILURE CODE [DHSAMA] 1819
FAILURE CODE [DHSBMA] 1822
FAILURE CODE [DHSCMA] 1825
FAILURE CODE [DHSDMA] 1828
FAILURE CODE [DHSFMA] 1831
FAILURE CODE [DHSGMA] 1834
FAILURE CODE [DHSHMA] 1837
FAILURE CODE [DHSJMA] 1840
FAILURE CODE [DKR0MA] 1843
FAILURE CODE [DKR1MA] 1846
FAILURE CODE [DKULKA] 1849
FAILURE CODE [DKULKB] 1851
FAILURE CODE [DKULKY] 1853
FAILURE CODE [DLM3KA] 1855
FAILURE CODE [DLM3KB] 1857
FAILURE CODE [DLM3MB] 1859
FAILURE CODE [DR10KA] 1860
FAILURE CODE [DR12KA] 1863
FAILURE CODE [DR20KA] 1865
FAILURE CODE [DR21KX] 1867
FAILURE CODE [DR30KA] 1869
FAILURE CODE [DR31KX] 1871
FAILURE CODE [DR40KA] 1873
FAILURE CODE [DUMBKA] 1875
FAILURE CODE [DUMBKB] 1877
FAILURE CODE [DV20KB] 1879
FAILURE CODE [DW43KA] 1881
FAILURE CODE [DW43KB] 1883
FAILURE CODE [DW43KY] 1885
FAILURE CODE [DW45KA] 1887
FAILURE CODE [DW45KB] 1890
FAILURE CODE [DW45KY] 1893
FAILURE CODE [DW4CKY] 1895
FAILURE CODE [DW7BKA] 1896
FAILURE CODE [DW7BKB] 1898
FAILURE CODE [DW7BKY] 1900
FAILURE CODE [DW91KA] 1901
FAILURE CODE [DW91KB] 1903
FAILURE CODE [DW91KY] 1905
FAILURE CODE [DWA2KA] 1907
FAILURE CODE [DWA2KB] 1909
FAILURE CODE [DWA2KY] 1911
FAILURE CODE [DWK0KA] 1913
FAILURE CODE [DWK0KB] 1915
FAILURE CODE [DWK0KY] 1917
FAILURE CODE [DWK2KA] 1919
FAILURE CODE [DWK2KB] 1921
FAILURE CODE [DWK2KY] 1923
FAILURE CODE [DWK8KA] 1925
FAILURE CODE [DWK8KB] 1927
FAILURE CODE [DWK8KY] 1929
FAILURE CODE [DX16KA] 1931
FAILURE CODE [DX16KB] 1933
FAILURE CODE [DXA8KA] 1935
FAILURE CODE [DXA8KB] 1937
FAILURE CODE [DXA9KA] 1939
FAILURE CODE [DXA9KB] 1941
FAILURE CODE [DXE0KA] 1943
FAILURE CODE [DXE0KB] 1945
FAILURE CODE [DXE4KA] 1947
FAILURE CODE [DXE4KB] 1949
FAILURE CODE [DXE4KY] 1951
FAILURE CODE [DXE5KA] 1953
FAILURE CODE [DXE5KB] 1955
FAILURE CODE [DXE6KA] 1957
FAILURE CODE [DXE6KB] 1959
FAILURE CODE [DXE7KA] 1961
FAILURE CODE [DXE7KB] 1963
FAILURE CODE [DXE7KY] 1965
FAILURE CODE [DXE8KA] 1967
FAILURE CODE [DXE8KB] 1969
FAILURE CODE [DXE8KY] 1971
FAILURE CODE [DXE9KA] 1973
FAILURE CODE [DXE9KB] 1975
FAILURE CODE [DXE9KY] 1977
FAILURE CODE [DXEAKA] 1979
FAILURE CODE [DXEAKB] 1981
FAILURE CODE [DXEAKY] 1983
FAILURE CODE [DY20KA] 1985
FAILURE CODE [DY20MA] 1987
FAILURE CODE [DY2CKB] 1989
FAILURE CODE [DY2DKB] 1992
FAILURE CODE [DY2EKB] 1994
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1996
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1996
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2002
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2005
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2007
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2009
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2012
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2013
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2014
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2015
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2016
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2017
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2018
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2019
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2020
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2021
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2022
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 2024
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2025
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2026
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2027
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 2029
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2030
E-23 FUNCTION SWITCH DOES NOT OPERATE 2031
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 2032
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2033
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2034
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 2035
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2036
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 2037
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2038
E-31 ALARM BUZZER CANNOT BE CANCELED 2040
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2041
E-33 SERVICE MODE CANNOT BE SELECTED 2042
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2043
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 2045
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 2046
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 2049
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 2051
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 2053
E-40 ALARM DOES NOT SOUND DURING TRAVEL 2054
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2056
E-42 HORN DOES NOT SOUND 2057
E-43 HORN DOES NOT STOP SOUNDING 2061
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 2063
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 2064
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2066
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2067
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2068
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2069
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2070
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2071
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2072
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2073
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2074
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2075
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 2077
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2078
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 2079
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2081
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2082
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2082
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2083
FAILURE MODE AND CAUSE TABLE 2085
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2093
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2094
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2096
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2097
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2098
H-6 SPEED OR POWER OF BOOM IS LOW 2100
H-7 ARM SPEED OR POWER IS LOW 2106
H-8 BUCKET SPEED OR POWER IS LOW 2111
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2114
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 2115
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2117
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 2119
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2120
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2121
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 2122
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2123
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 2124
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 2125
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2126
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2127
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2128
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 2129
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 2131
H-24 TRAVEL SPEED IS LOW 2134
H-25 ONE OF TRACKS DOES NOT RUN 2136
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2137
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2138
H-28 SWINGS ONLY IN ONE DIRECTION 2139
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2140
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2141
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2142
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2143
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2144
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2145
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 2146
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2147
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2148
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2149
H-39 Quick coupler cylinder will not extend 2150
H-40 Quick coupler cylinder will not retract (but buzzer doesnot sound) 2152
H-41 Buzzer does not sound (but quick coupler cylinder doesretract) 2154
H-42 Quick coupler cylinder extends and retracts slowly 2156
TROUBLESHOOTING OF ENGINE (S-MODE) 2157
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2157
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2158
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2159
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2160
S-4 ENGINE STARTABILITY IS POOR 2161
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2163
S-6 ENGINE STOPS DURING OPERATION 2165
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2167
S-8 ENGINE LACKS POWER 2168
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2170
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2172
S-11 OIL BECOMES CONTAMINATED QUICKLY 2173
S-12 FUEL CONSUMPTION IS EXCESSIVE 2174
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2175
S-14 OIL PRESSURE DROPS 2176
S-15 FUEL MIXES INTO ENGINE OIL 2178
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2179
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2180
S-18 UNUSUAL NOISE IS HEARD 2181
S-19 VIBRATION IS EXCESSIVE 2182
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2183
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2184
S-22 ACTIVE REGENERATION TAKES TIME 2186
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2188
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2189
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2191
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2192
TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED) 2193
20 SUPPLY VOLTAGE > 32VDC 2193
21 SUPPLY VOLTAGE < 12VDC 2194
25 FILE ERROR FACTORY SETTINGS 2195
26 FILE ERROR USER SETTINGS 2196
27 FILE ERROR INPUT DATA 2197
30 PROXIMITY SWITCHES DIFFERENCE 2198
86 ANGLE SENSOR A2 TIMEOUT 2199
96 ANGLE SENSOR A3/A5 TIMEOUT 2200
106 ANGLE SENSOR A4/A6 TIMEOUT 2201
116 ANGLE SENSOR PITCH TIMEOUT 2202
126 ANGLE SENSOR ROLL TIMEOUT 2203
50 DISASSEMBLY AND ASSEMBLY 2205
CONTENTS 2206
ABBREVIATION LIST 2211
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2217
HOW TO READ THIS MANUAL 2217
COATING MATERIALS LIST 2219
SPECIAL TOOLS LIST 2223
SKETCHES OF SPECIAL TOOLS 2235
ENGINE AND COOLING SYSTEM 2241
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2241
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2241
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2247
REMOVE AND INSTALL INJECTOR ASSEMBLY 2256
METHOD FOR REMOVING INJECTOR ASSEMBLY 2256
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2262
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2272
METHOD FOR REMOVING FUEL DOSER 2272
METHOD FOR INSTALLING FUEL DOSER 2273
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2275
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2276
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2284
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2298
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2298
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2300
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2302
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2302
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2306
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2311
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2311
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2312
REMOVE AND INSTALL ALTERNATOR BELT 2314
METHOD FOR REMOVING ALTERNATOR BELT 2314
METHOD FOR INSTALLING ALTERNATOR BELT 2317
REMOVE AND INSTALL RADIATOR ASSEMBLY 2322
METHOD FOR REMOVING RADIATOR ASSEMBLY 2322
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2324
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2327
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2327
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2331
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2336
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2336
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2338
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2340
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2340
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2342
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2346
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 2347
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 2365
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2384
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2385
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2387
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2391
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2392
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2395
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2401
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2401
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2409
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2420
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2420
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2424
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2428
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2428
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2434
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2439
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2439
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2446
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2452
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2452
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2454
REMOVE AND INSTALL KDPF ASSEMBLY 2457
METHOD FOR REMOVING KDPF ASSEMBLY 2457
METHOD FOR INSTALLING KDPF ASSEMBLY 2461
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2466
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2467
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2472
REMOVE AND INSTALL SCR ASSEMBLY 2479
METHOD FOR REMOVING SCR ASSEMBLY 2479
METHOD FOR INSTALLING SCR ASSEMBLY 2482
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2486
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2486
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2491
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 2496
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2496
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2500
REMOVE AND INSTALL KCCV ASSEMBLY 2510
METHOD FOR REMOVING KCCV ASSEMBLY 2510
METHOD FOR INSTALLING KCCV ASSEMBLY 2511
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2515
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2515
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2520
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2526
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2526
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2530
REMOVE AND INSTALL AdBlue/DEF PUMP 2535
METHOD FOR REMOVING AdBlue/DEF PUMP 2535
METHOD FOR INSTALLING AdBlue/DEF PUMP 2537
REMOVE AND INSTALL AdBlue/DEF HOSE 2538
METHOD FOR REMOVING AdBlue/DEF HOSE 2538
METHOD FOR INSTALLING AdBlue/DEF HOSE 2543
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2552
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2552
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2553
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2556
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2556
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2559
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2563
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2563
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2564
POWER TRAIN 2566
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2566
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2566
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2567
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2568
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2568
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2573
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2579
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2579
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2580
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2582
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2582
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2586
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2592
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2592
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2592
UNDERCARRIAGE AND FRAME 2594
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2594
METHOD FOR SEPARATING TRACK ASSEMBLY 2594
METHOD FOR INSTALLING TRACK ASSEMBLY 2596
REMOVE AND INSTALL SPROCKET 2599
METHOD FOR REMOVING SPROCKET 2599
METHOD FOR INSTALLING SPROCKET 2599
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2601
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2601
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2602
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2604
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2604
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2606
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2611
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2612
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2614
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2617
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2618
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2619
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2623
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2623
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2625
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2628
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2628
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2630
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2633
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2633
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2634
HYDRAULIC SYSTEM 2637
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2637
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2637
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2639
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2641
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2642
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2642
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2644
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2644
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2649
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2655
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2655
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2659
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2665
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2665
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2670
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2676
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2677
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2678
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2683
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2683
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2684
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2686
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2686
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2687
REMOVE AND INSTALL QUICK COUPLER VALVE 2689
WORK EQUIPMENT 2691
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2691
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2692
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2695
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2699
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2699
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2702
CAB AND ITS ATTACHMENTS 2706
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2706
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2706
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2713
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2720
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2722
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2722
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2732
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2732
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2735
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2741
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2741
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2748
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2756
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2756
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2762
REMOVE AND INSTALL OPERATOR’S SEAT 2769
METHOD FOR REMOVING OPERATOR’S SEAT 2769
METHOD FOR INSTALLING OPERATOR’S SEAT 2771
REMOVE AND INSTALL SEAT BELT 2774
METHOD FOR REMOVING SEAT BELT 2774
METHOD FOR INSTALLING SEAT BELT 2775
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2776
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2776
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2781
ELECTRICAL SYSTEM 2790
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2790
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2790
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2791
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2793
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2793
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2796
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2801
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2801
METHOD FOR INSTALLING KomVision CONTROLLER 2802
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2803
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2803
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2806
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2810
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2810
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2811
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2812
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2812
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2813
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2815
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2815
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2816
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2818
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2818
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2820
REMOVE AND INSTALL KomVision CAMERA 2822
METHOD FOR REMOVING KomVision CAMERA 2822
METHOD FOR INSTALLING KomVision CAMERA 2823
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2825
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2825
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2828
60 MAINTENANCE STANDARD 2831
CONTENTS 2832
ABBREVIATION LIST 2833
ENGINE AND COOLING SYSTEM 2839
MAINTENANCE STANDARD OF ENGINE MOUNT 2839
MAINTENANCE STANDARD OF COOLING SYSTEM 2840
MAINTENANCE STANDARD OF COOLING FAN PUMP 2841
MAINTENANCE STANDARD OF SERVO VALVE 2842
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2843
POWER TRAIN 2844
MAINTENANCE STANDARD OF SWING CIRCLE 2844
MAINTENANCE STANDARD OF SWING MACHINERY 2845
MAINTENANCE STANDARD OF FINAL DRIVE 2847
MAINTENANCE STANDARD OF SPROCKET 2849
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2850
UNDERCARRIAGE AND FRAME 2852
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2852
MAINTENANCE STANDARD OF IDLER 2854
MAINTENANCE STANDARD OF TRACK ROLLER 2856
MAINTENANCE STANDARD OF CARRIER ROLLER 2858
MAINTENANCE STANDARD OF TRACK SHOE 2859
MAINTENANCE STANDARD OF TRIPLE SHOE 2862
HYDRAULIC SYSTEM 2863
MAINTENANCE STANDARD OF MAIN PUMP 2863
MAINTENANCE STANDARD OF SWING MOTOR 2865
MAINTENANCE STANDARD OF TRAVEL MOTOR 2868
MAINTENANCE STANDARD OF CONTROL VALVE 2871
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2882
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2885
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2888
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2890
MAINTENANCE STANDARD OF SOLENOID VALVE 2891
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2892
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE 2894
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2895
WORK EQUIPMENT 2896
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2896
DIMENSION OF ARM 2901
DIMENSIONS OF BUCKET 2903
MAINTENANCE STANDARD OF BOOM CYLINDER 2905
MAINTENANCE STANDARD OF ARM CYLINDER 2906
MAINTENANCE STANDARD OF BUCKET CYLINDER 2907
WORK EQUIPMENT – PC490HRD-11E0 2908
WORK EQUIPMENT – HIGH REACH DEMOLITION 2908
DIMENSION OF ARM 2908
MAINTENANCE STANDARD OF BOOM CYLINDER 2909
MAINTENANCE STANDARD OF LINK CYLINDER 2910
MAINTENANCE STANDARD OF ARM CYLINDER 2911
MAINTENANCE STANDARD OF BUCKET CYLINDER 2912
WORK EQUIPMENT – DEMOLITION DIGGING 2913
MAINTENANCE STANDARD OF ARM CYLINDER 2913
MAINTENANCE STANDARD OF BUCKET CYLINDER 2914
80 APPENDIX 2915
CONTENTS 2916
ABBREVIATION LIST 2918
AIR CONDITIONER SYSTEM 2924
PRECAUTIONS FOR REFRIGERANT 2924
AIR CONDITIONER COMPONENT 2925
SPECIFICATIONS OF AIR CONDITIONER 2927
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2928
OUTLINE OF REFRIGERATION CYCLE 2929
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2931
AIR CONDITIONER UNIT 2931
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2931
FUNCTION OF AIR CONDITIONER UNIT 2933
COMPONENT PARTS OF AIR CONDITIONER UNIT 2935
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2936
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2936
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2936
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2936
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2937
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2937
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2937
FUNCTION OF DUAL PRESSURE SWITCH 2938
AIR CONDITIONER CONTROLLER 2939
STRUCTURE OF AIR CONDITIONER CONTROLLER 2939
COMPRESSOR 2940
STRUCTURE OF COMPRESSOR 2940
SPECIFICATIONS OF COMPRESSOR 2940
FUNCTION OF COMPRESSOR 2940
CONDENSER 2941
STRUCTURE OF CONDENSER 2941
SPECIFICATIONS OF CONDENSER 2941
FUNCTION OF CONDENSER 2941
RECEIVER DRIER 2942
STRUCTURE OF RECEIVER DRIER 2942
SPECIFICATIONS OF RECEIVER DRIER 2942
FUNCTION OF RECEIVER DRIER 2942
SENSORS FOR AIR CONDITIONER SYSTEM 2943
STRUCTURE OF SUNLIGHT SENSOR 2943
FUNCTION OF SUNLIGHT SENSOR 2943
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2943
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2943
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2945
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2947
AIR CONDITIONER SYSTEM DIAGRAM 2949
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2950
FUNCTION OF AIR CONDITIONER CONTROLLER 2951
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2952
TESTING AIR LEAKAGE (DUCT) 2956
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2956
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2958
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2959
TEST VENT (MODE) CHANGEOVER 2960
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2960
TESTING FRESH/RECIRC AIR CHANGEOVER 2962
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2962
TEST SUNLIGHT SENSOR 2963
METHOD FOR TESTING SUNLIGHT SENSOR 2963
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2964
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2964
TEST RELAYS 2965
METHOD FOR TESTING RELAYS 2965
AIR CONDITIONER TROUBLESHOOTING CHART 1 2966
AIR CONDITIONER TROUBLESHOOTING CHART 2 2967
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2970
FAILURE CODE [879AKA] 2972
FAILURE CODE [879AKB] 2973
FAILURE CODE [879BKA] 2974
FAILURE CODE [879BKB] 2976
FAILURE CODE [879CKA] 2978
FAILURE CODE [879CKB] 2979
FAILURE CODE [879DKZ] 2980
FAILURE CODE [879EMC] 2982
FAILURE CODE [879FMC] 2983
FAILURE CODE [879GKX] 2984
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2986
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2987
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2988
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2989
TROUBLESHOOTING USING GAUGE PRESSURE 2990
CONNECTION OF SERVICE TOOL 2993
METHOD FOR CONNECTING SERVICE TOOL 2993
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2995
HANDLE COMPRESSOR OIL 2997
90 CIRCUIT DIAGRAMS 2999
CONTENTS 3000
ABBREVIATION LIST 3001
HYDRAULIC CIRCUIT DIAGRAM 3007
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3007
HYDRAULIC CIRCUIT DIAGRAM (1/2) 3011
HYDRAULIC CIRCUIT DIAGRAM (2/2) 3013
HYDRAULIC CIRCUIT DIAGRAM (1/4) – PC490HRD-11E0 3015
HYDRAULIC CIRCUIT DIAGRAM (2/4) – PC490HRD-11E0 3017
HYDRAULIC CIRCUIT DIAGRAM (3/4) – PC490HRD-11E0 3019
HYDRAULIC CIRCUIT DIAGRAM (4/4) – PC490HRD-11E0 3021
ELECTRICAL CIRCUIT DIAGRAM 3023
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3023
ELECTRICAL CIRCUIT DIAGRAM (1/9) 3027
ELECTRICAL CIRCUIT DIAGRAM (2/9) 3029
ELECTRICAL CIRCUIT DIAGRAM (3/9) 3031
ELECTRICAL CIRCUIT DIAGRAM (4/9) 3033
ELECTRICAL CIRCUIT DIAGRAM (5/9) 3035
ELECTRICAL CIRCUIT DIAGRAM (6/9) 3037
ELECTRICAL CIRCUIT DIAGRAM (7/9) 3039
ELECTRICAL CIRCUIT DIAGRAM (8/9) 3041
ELECTRICAL CIRCUIT DIAGRAM (9/9) 3043
ELECTRICAL CIRCUIT DIAGRAM (1/13) – PC490HRD-11E0 3045
ELECTRICAL CIRCUIT DIAGRAM (2/13) – PC490HRD-11E0 3047
ELECTRICAL CIRCUIT DIAGRAM (3/13) – PC490HRD-11E0 3049
ELECTRICAL CIRCUIT DIAGRAM (4/13) – PC490HRD-11E0 3051
ELECTRICAL CIRCUIT DIAGRAM (5/13) – PC490HRD-11E0 3053
ELECTRICAL CIRCUIT DIAGRAM (6/13) – PC490HRD-11E0 3055
ELECTRICAL CIRCUIT DIAGRAM (7/13) – PC490HRD-11E0 3057
ELECTRICAL CIRCUIT DIAGRAM (8/13) – PC490HRD-11E0 3059
ELECTRICAL CIRCUIT DIAGRAM (9/13) – PC490HRD-11E0 3061
ELECTRICAL CIRCUIT DIAGRAM (10/13) – PC490HRD-11E0 3063
ELECTRICAL CIRCUIT DIAGRAM (11/13) – PC490HRD-11E0 3065
ELECTRICAL CIRCUIT DIAGRAM (12/13) – PC490HRD-11E0 3067
ELECTRICAL CIRCUIT DIAGRAM (13/13) – PC490HRD-11E0 3069
INDEX 3071

DESCRIPTION:

Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Excavator Shop Manual UENBM00501 – 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.

IMAGES PREVIEW OF THE MANUAL:

S.V 22/12/24