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

Description

Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Hydraulic Excavator Shop Manual UENBM00504 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Hydraulic Excavator Shop Manual UENBM00504 – PDF DOWNLOAD 

Language : English
Pages : 3170
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Hydraulic Excavator Shop Manual UENBM00504 – PDF DOWNLOAD 

SERIAL NUMBERS
PC490LC-11E0 – K75001-K75095
PC490LCD-11E0 – K75001-K75152
PC490HRD-11E0 – K75001-K75229

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
METHOD FOR CHECKING ENGINE TYPE 44
PRECAUTIONS FOR DEF 46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 46
PRECAUTIONS FOR ADDING 46
PRECAUTIONS FOR STORING 46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 46
THE OTHER PRECAUTIONS 46
STORE AdBlue/DEF 47
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 51
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 58
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 60
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 61
PRACTICAL USE OF KOMTRAX 62
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 65
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 67
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 71
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 77
HOW TO READ ELECTRICAL WIRE CODE 78
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 82
STANDARD TIGHTENING TORQUE TABLE 85
CONVERSION TABLE 92
01 SPECIFICATIONS 97
CONTENTS 98
ABBREVIATION LIST 99
SPECIFICATIONS 105
SPECIFICATION DRAWING 105
SPECIFICATION DRAWING: PC490-11E0 ,PC490LC-11E0 105
WORKING RANGE DRAWINGS 107
WORKING RANGE: PC490-11E0, PC490LC-11E0 107
SPECIFICATIONS 108
SPECIFICATIONS: PC490-11E0, PC490LC-11E0 108
WEIGHT TABLE 111
WEIGHT TABLE: PC490-11E0 ,PC490LC-11E0 111
TABLE OF FUEL, COOLANT, AND LUBRICANTS 113
SPECIFICATIONS – PC490HRD-11E0 114
SPECIFICATION DRAWING 114
SPECIFICATION DRAWING: PC490HRD-11E0 114
SPECIFICATIONS 118
SPECIFICATIONS: PC490HRD-11E0 118
WEIGHT TABLE 120
WEIGHT TABLE: PC490HRD-11E0 120
10 STRUCTURE AND FUNCTION 123
CONTENTS 124
ABBREVIATION LIST 128
UREA SCR SYSTEM 134
LAYOUT DRAWING OF UREA SCR SYSTEM 134
UREA SCR SYSTEM DIAGRAM 138
FUNCTION OF UREA SCR SYSTEM 139
FUNCTION OF AdBlue/DEF SYSTEM 139
INDUCEMENT STRATEGY 141
COMPONENT PARTS OF UREA SCR SYSTEM 160
AdBlue/DEF MIXING TUBE 160
SCR ASSEMBLY 160
AdBlue/DEF TANK 163
AdBlue/DEF PUMP 165
AdBlue/DEF INJECTOR 166
AdBlue/DEF HOSE 167
AdBlue/DEF TANK HEATING VALVE 168
BOOT-UP SYSTEM 169
LAYOUT DRAWING OF BOOT-UP SYSTEM 169
SYSTEM OPERATING LAMP SYSTEM 171
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 171
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 171
BATTERY DISCONNECT SWITCH 173
FUNCTION OF BATTERY DISCONNECT SWITCH 173
ENGINE SYSTEM 174
LAYOUT DRAWING OF ENGINE SYSTEM 174
SPECIFICATIONS OF ENGINE SYSTEM 175
FUNCTION OF ENGINE SYSTEM 176
ENGINE CONTROL SYSTEM 177
ENGINE CONTROL SYSTEM DIAGRAM 177
FUNCTION OF ENGINE CONTROL SYSTEM 178
AUTO-DECELERATION SYSTEM 180
AUTO-DECELERATION SYSTEM DIAGRAM 180
FUNCTION OF AUTO-DECELERATION SYSTEM 180
OPERATION OF AUTO-DECELERATION SYSTEM 181
ENGINE AUTOMATIC WARM-UP SYSTEM 182
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 182
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 183
OVERHEAT PREVENTION SYSTEM 184
OVERHEAT PREVENTION SYSTEM DIAGRAM 184
FUNCTION OF OVERHEAT PREVENTION SYSTEM 185
TURBOCHARGER PROTECTION SYSTEM 187
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 187
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 188
AUTOMATIC IDLE STOP SYSTEM 189
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 189
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 189
COMPONENT PARTS OF ENGINE SYSTEM 192
VGT 192
EGR SYSTEM 195
EGR VALVE 197
EGR COOLER 199
KCCV SYSTEM 200
KCCV VENTILATOR 201
KDPF 203
COOLING SYSTEM 208
LAYOUT DRAWING OF COOLING SYSTEM 208
SPECIFICATIONS OF COOLING SYSTEM 209
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 211
FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 211
FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 212
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 213
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN 213
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 214
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 216
FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN 216
FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 216
COMPONENT PARTS OF COOLING SYSTEM 217
COOLING FAN PUMP 217
COOLING FAN MOTOR 224
CONTROL SYSTEM 231
LAYOUT DRAWING OF CONTROL SYSTEM 231
MACHINE MONITOR SYSTEM 234
MACHINE MONITOR SYSTEM DIAGRAM 234
KomVision SYSTEM 235
LAYOUT DRAWING OF KOMVISION SYSTEM 235
KomVision SYSTEM DIAGRAM 237
FUNCTION OF KomVision SYSTEM 237
KOMTRAX SYSTEM 239
KOMTRAX SYSTEM DIAGRAM 239
FUNCTION OF KOMTRAX SYSTEM 239
PPC LEVERS 240
LH PPC LEVER 240
RH PPC LEVER 241
AUTOMATIC GREASE SYSTEM 242
OUTLINE OF AUTO GREASE SYSTEM 242
COMPONENT PARTS OF CONTROL SYSTEM 256
MACHINE MONITOR 256
KomVision CONTROLLER 269
KomVision CAMERA 273
KOMTRAX TERMINAL 273
PUMP CONTROLLER 276
RESISTOR FOR PC-EPC VALVE 280
CAN TERMINATING RESISTOR 280
ENGINE CONTROLLER 282
FUEL CONTROL DIAL 288
FUEL FEED PUMP 290
FUEL FEED PUMP SWITCH 291
SENSOR 292
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 292
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 292
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 292
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 293
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 293
FUNCTION OF AUTO GREASE PRESSURE SWITCH 293
STRUCTURE OF OVERLOAD CAUTION SENSOR 293
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 294
FUNCTION OF OVERLOAD CAUTION SENSOR 294
HYDRAULIC SYSTEM 295
LAYOUT DRAWING OF HYDRAULIC SYSTEM 295
CLSS 297
STRUCTURE OF CLSS 297
OPERATION OF UNLOAD VALVE AND LS PRESSURE 299
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 300
PRESSURE COMPENSATION CONTROL 313
ENGINE AND PUMP COMBINED CONTROL SYSTEM 317
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 317
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 319
PUMP AND VALVE CONTROL SYSTEM 324
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 324
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 325
COMPONENT PARTS OF HYDRAULIC SYSTEM 327
HYDRAULIC TANK 327
MAIN PUMP 329
PILOT OIL FILTER 355
CONTROL VALVE 355
HYDRAULIC SYSTEM – PC490HRD-11E0 417
LAYOUT DRAWING OF HYDRAULIC SYSTEM 417
COMPONENT PARTS OF HYDRAULIC SYSTEM 420
LAYOUT DRAWING OF VALVE CONTROL SYSTEM 420
WORK EQUIPMENT SYSTEM 440
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 440
STRUCTURE OF VALVE CONTROL 445
ONE-TOUCH POWER MAXIMIZING SYSTEM 446
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 446
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 447
MACHINE PUSH-UP SYSTEM 448
MACHINE PUSH-UP SYSTEM DIAGRAM 448
FUNCTION OF MACHINE PUSH-UP SYSTEM 449
PPC LOCK SYSTEM 450
PPC LOCK SYSTEM DIAGRAM 450
FUNCTION OF PPC LOCK SYSTEM 450
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 451
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 451
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 451
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 452
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 453
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 453
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 454
TOOL CONTROL SYSTEM 455
TOOL CONTROL SYSTEM DIAGRAM 455
FUNCTION OF TOOL CONTROL SYSTEM 456
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 457
WORK EQUIPMENT AND SWING PPC VALVE 457
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 462
SOLENOID VALVE 467
VARIABLE PRESSURE COMPENSATION VALVE 469
ATTACHMENT CIRCUIT SELECTOR VALVE 470
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 472
ATTACHMENT BYPASS SOLENOID VALVE 475
ATT EPC VALVE ASSEMBLY 477
PILOT CIRCUIT ACCUMULATOR 479
WORK EQUIPMENT SYSTEM – PC490HRD-11E0 480
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 480
SWING SYSTEM 484
LAYOUT DRAWING OF SWING SYSTEM 484
SWING CONTROL SYSTEM DIAGRAM 490
FUNCTION OF SWING CONTROL SYSTEM 490
COMPONENT PARTS OF SWING SYSTEM 494
SWING MOTOR 494
SWING MACHINERY 505
SWING CIRCLE 507
TRAVEL SYSTEM 509
LAYOUT DRAWING OF TRAVEL SYSTEM 509
TRAVEL CONTROL SYSTEM DIAGRAM 513
FUNCTION OF TRAVEL CONTROL SYSTEM 514
COMPONENT PARTS OF TRAVEL SYSTEM 515
TRAVEL MOTOR 515
FINAL DRIVE 529
TRAVEL PPC VALVE 530
CENTER SWIVEL JOINT 535
UNDERCARRIAGE AND FRAME 537
LAYOUT DRAWING OF UNDERCARRIAGE 537
SPECIFICATIONS OF UNDERCARRIAGE 537
WORK EQUIPMENT 539
STRUCTURE OF WORK EQUIPMENT 539
FUNCTION OF WORK EQUIPMENT 540
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 541
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 541
BUCKET CLEARANCE ADJUSTMENT SHIM 542
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 542
CAB AND ITS ATTACHMENTS 543
ROPS CAB 543
STRUCTURE OF ROPS CAB 543
FUNCTION OF ROPS CAB 543
CAB MOUNT 544
STRUCTURE OF CAB MOUNT 544
FUNCTION OF CAB MOUNT 544
CAB TIPPING STOPPER 545
STRUCTURE OF CAB TIPPING STOPPER 545
FUNCTION OF CAB TIPPING STOPPER 545
TILTING CAB SYSTEM 546
STRUCTURE OF TILTING CAB SYSTEM 546
OPERATION OF TILTING CAB SYSTEM 546
20 STANDARD VALUE TABLE 549
CONTENTS 550
ABBREVIATION LIST 551
STANDARD VALUE TABLE FOR ENGINE 557
STANDARD VALUE TABLE FOR ENGINE: PC490-11E0, PC490LC-11E0 557
STANDARD VALUE TABLE FOR MACHINE 560
STANDARD VALUE TABLE FOR MACHINE: PC490-11E0, PC490LC-11E0 560
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 576
STANDARD VALUE TABLE FOR MACHINE – PC490HRD-11E0 580
STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE 580
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 587
STANDARD VALUE TABLE FOR ELECTRICAL 591
STANDARD VALUE TABLE FOR ELECTRICAL 591
30 TESTING AND ADJUSTING 601
CONTENTS 602
ABBREVIATION LIST 606
RELATED INFORMATION ON TESTING AND ADJUSTING 612
TOOLS FOR TESTING AND ADJUSTING 612
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 619
ENGINE AND COOLING SYSTEM 621
TEST ENGINE SPEED 621
METHOD FOR TESTING ENGINE SPEED 621
TEST BOOST PRESSURE 624
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 624
METHOD FOR TESTING BOOST PRESSURE 625
TEST EXHAUST GAS COLOR 626
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 626
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 627
TEST AND ADJUST VALVE CLEARANCE 628
METHOD FOR TESTING VALVE CLEARANCE 628
METHOD FOR ADJUSTING VALVE CLEARANCE 631
TEST COMPRESSION PRESSURE 632
METHOD FOR TESTING COMPRESSION PRESSURE 632
TEST BLOWBY PRESSURE 635
METHOD FOR TESTING BLOWBY PRESSURE 635
TEST ENGINE OIL PRESSURE 637
METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR 637
METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL 637
TEST EGR VALVE AND VGT OIL PRESSURE 639
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 639
TEST FUEL PRESSURE 641
METHOD FOR TESTING FUEL PRESSURE 641
TEST FUEL RETURN RATE AND LEAKAGE 643
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE 643
BLEED AIR FROM FUEL SYSTEM 646
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 646
TEST FUEL CIRCUIT FOR LEAKAGE 648
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 648
HANDLE CYLINDER CUT-OUT MODE OPERATION 650
HANDLE NO-INJECTION CRANKING OPERATION 651
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 652
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 652
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 652
CLEAN FUEL DOSER 654
METHOD FOR CLEANING FUEL DOSER 654
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 656
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 656
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 662
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 662
TEST SCR RELATED FUNCTIONS 663
TEST AdBlue/DEF PUMP RAISED PRESSURE 666
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 669
TEST AdBlue/DEF LINE HEATER RELAY 1 673
TEST AdBlue/DEF LINE HEATER RELAY 2 675
TEST AdBlue/DEF PUMP HEATER RELAY 678
TEST AdBlue/DEF TANK HEATER VALVE 681
TEST DENITRATION EFFICIENCY OF SCR 684
CLEAN AdBlue/DEF TANK 688
METHOD FOR CLEANING AdBlue/DEF TANK 688
POWER TRAIN 692
TEST SWING CIRCLE BEARING CLEARANCE 692
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 692
UNDERCARRIAGE AND FRAME 693
TEST AND ADJUST TRACK TENSION 693
METHOD FOR TESTING TRACK TENSION 693
METHOD FOR ADJUSTING TRACK TENSION 693
HYDRAULIC SYSTEM 695
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 695
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 695
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 695
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 701
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 702
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 709
TEST OIL PRESSURE OF CONTROL CIRCUIT 713
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 713
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 715
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 715
TEST PC-EPC VALVE OUTLET PRESSURE 716
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 717
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 719
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 719
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 720
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 721
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 722
METHOD FOR ADJUSTING LS VALVE 723
TEST OUTLET PRESSURE OF SOLENOID VALVE 724
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 724
OPERATING CONDITION OF SOLENOID VALVE 725
TEST PPC VALVE OUTLET PRESSURE 727
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 727
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 729
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 729
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 730
TEST PUMP SWASH PLATE SENSOR 732
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 732
TEST COOLING FAN SPEED 733
METHOD FOR TESTING COOLING FAN SPEED 733
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 734
METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT 734
TEST FAN PUMP EPC ELECTRIC CURRENT 736
METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT 736
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 737
METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 737
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 739
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 739
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 739
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 740
TEST OIL LEAKAGE 741
TEST OIL LEAKAGE OF BOOM CYLINDER 741
TEST OIL LEAKAGE OF ARM CYLINDER 741
TEST OIL LEAKAGE OF BUCKET CYLINDER 742
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR 742
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 743
BLEED AIR FROM HYDRAULIC CIRCUIT 744
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 746
HYDRAULIC SYSTEM – PC490HRD-11E0 749
MEASURING AND ADJUSTING SWING SPEED REDUCTION VALVE 749
MEASURING AND ADJUSTING BOOM AND BUCKET PPC REDUCTION VALVE 750
MEASURING AND ADJUSTING LINK CYLINDER FLOW CONTROL VALVE 751
MEASURING AND ADJUSTING ARM CYLINDER FLOW CONTROL VALVE 752
CAB AND ITS ATTACHMENTS 753
TEST CAB TIPPING STOPPER 753
METHOD FOR TESTING CAB TIPPING STOPPER 753
METHOD FOR ADJUSTING MIRRORS 754
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 754
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 755
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 756
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 757
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 758
ELECTRICAL SYSTEM 760
SET AND OPERATE MACHINE MONITOR 760
OPERATOR MODE 763
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 764
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 764
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 765
CHECKING FUNCTION OF SERVICE METER 765
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 765
SERVICE MODE 768
METHOD FOR OPERATING SERVICE MODE 770
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 773
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 780
METHOD FOR CONFIRMING MAINTENANCE RECORD 796
METHOD FOR OPERATING MAINTENANCE MODE SETTING 797
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 801
METHOD FOR PERFORMING NO-INJECTION CRANKING 846
METHOD FOR DISPLAYING SERVICE MESSAGE 849
METHOD FOR STARTING UP KOMTRAX TERMINAL 851
ADJUST REARVIEW CAMERA ANGLE 856
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 856
ADJUST KomVision CAMERA ANGLE 859
Angle adjustment method for KomVision camera 860
ADJUST KomVision RELATED ITEMS 864
SETTING OF KomVision (MAIN SETTING) 864
SETTING OF KomVision (CAMERA SETTING) 866
SET KomVision (camera calibration) 868
KomVision screen – Check 12 m visibility 894
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 897
HANDLE BATTERY DISCONNECT SWITCH 898
TEST DIODES 899
METHOD FOR TESTING DIODE USING DIGITAL TESTER 899
METHOD FOR TESTING DIODE USING ANALOG TESTER 899
ELECTRICAL SYSTEM – PC490HRD-11E0 900
ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM 900
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – BASE MACHINE 900
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – HIGH REACH DEMOLITION WORK EQUIPMENT 903
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT 905
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – MEDIUM REACH DEMOLITION WORK EQUIPMENT 907
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – DEMOLITION DIGGING WORK EQUIPMENT 909
RH PPC LEVER 910
LH PPC LEVER 911
WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT 912
CONSTANT LINK SPEED CIRCUIT 913
PARALLEL LINK FRONT SCREEN WIPER 914
OVERLOAD CAUTION (HIGH REACH DEMOLITION) 915
Pm CLINIC 916
Pm CLINIC SERVICE 916
Pm CLINIC CHECK SHEET 917
WORKING RANGE INDICATOR SYSTEM 930
WORKING RANGE INDICATOR SYSTEM LAYOUT 930
METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU 932
DIAGNOSTICS – WORKING RANGE INDICATOR SYSTEM 934
MONITORING SYSTEM PARAMETERS AND SENSOR STATES 934
USING THE PARAMETER CHANGE LOG 936
USING ERROR LISTS AND LOGS 937
EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM 938
IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM 939
REPLACING COMPONENTS – WORKING RANGE INDICATOR SYSTEM 941
WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT 941
WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT 946
WORKING RANGE INDICATOR SYSTEM – UDATING SOFTWARE 951
CALIBRATION – WORKING RANGE INDICATOR SYSTEM 955
WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW 955
METHOD 1 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – AUTO CALIBRATION 955
METHOD 2 – BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION 963
METHOD 2 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – MANUAL CALIBRATION 966
40 TROUBLESHOOTING 981
CONTENTS 982
ABBREVIATION LIST 994
RELATED INFORMATION ON TROUBLESHOOTING 1000
GENERAL TROUBLESHOOTING POINTS 1000
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 1001
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1013
CHECKS BEFORE TROUBLESHOOTING 1015
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 1017
WALK-AROUND CHECK 1017
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 1019
CHECK FUEL LEVEL AND TYPE 1019
CHECK IMPURE INGREDIENT IN FUEL 1020
CHECK FUEL PREFILTER 1020
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 1020
FUEL PREFILTER CARTRIDGE – REPLACE 1021
CHECK MAIN FILTER 1022
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 1023
CHECK COOLANT LEVEL (RESERVOIR TANK) 1025
CHECK CLOGGING OF AIR CLEANER 1025
OUTER ELEMENT – CLEAN 1026
ELEMENTS – REPLACE 1028
CHECK HYDRAULIC OIL LEVEL 1029
CHECK HYDRAULIC OIL STRAINER 1029
CHECK HYDRAULIC FILTER 1030
CHECK OIL LEVEL IN SWING MACHINERY CASE 1031
CHECK OIL LEVEL IN DAMPER CASE 1032
CHECK OIL LEVEL IN FINAL DRIVE CASE 1032
BLEED AIR FROM FUEL SYSTEM 1033
BLEED AIR FROM HYDRAULIC SYSTEM 1033
ELECTRICAL EQUIPMENT – CHECK METHOD 1033
AUTOMATIC GREASE SYSTEM 1039
FINDING MALFUNCTIONS 1039
MALFUNCTION FINDING PROCEDURES 1043
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1045
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 1055
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1065
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 1068
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1072
CONNECTOR LIST AND LAYOUT 1074
CONNECTOR CONTACT IDENTIFICATION 1087
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1127
FUSE LOCATION TABLE 1133
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1136
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1140
FAILURE CODE TABLE 1142
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1161
FAILURE CODE [879AKA] 1161
FAILURE CODE [879AKB] 1162
FAILURE CODE [879BKA] 1163
FAILURE CODE [879BKB] 1165
FAILURE CODE [879CKA] 1167
FAILURE CODE [879CKB] 1168
FAILURE CODE [879DKZ] 1169
FAILURE CODE [879EMC] 1171
FAILURE CODE [879FMC] 1172
FAILURE CODE [879GKX] 1173
FAILURE CODE [989L00] 1175
FAILURE CODE [989M00] 1176
FAILURE CODE [989N00] 1177
FAILURE CODE [A1U0N3] 1178
FAILURE CODE [A1U0N4] 1180
FAILURE CODE [A900FR] 1182
FAILURE CODE [A900N6] 1183
FAILURE CODE [A900NY] 1184
FAILURE CODE [AA10NX] 1185
FAILURE CODE [AB00KE] 1187
FAILURE CODE [AQ10N3] 1190
FAILURE CODE [AS00N3] 1192
FAILURE CODE [AS00R2] 1194
FAILURE CODE [AS00R3] 1195
FAILURE CODE [AS00R4] 1196
FAILURE CODE [AS00R5] 1197
FAILURE CODE [AS00R6] 1198
FAILURE CODE [AS00ZK] 1199
FAILURE CODE [AS10KM] 1200
FAILURE CODE [AS10NR] 1201
FAILURE CODE [AS10NT] 1202
FAILURE CODE [B@BAZG] 1203
FAILURE CODE [B@BAZK] 1204
FAILURE CODE [B@BCNS] 1206
FAILURE CODE [B@BCQA] 1207
FAILURE CODE [B@BCZK] 1209
FAILURE CODE [B@HANS] 1211
FAILURE CODE [CA115] 1212
FAILURE CODE [CA122] 1213
FAILURE CODE [CA123] 1215
FAILURE CODE [CA131] 1217
FAILURE CODE [CA132] 1219
FAILURE CODE [CA135] 1221
FAILURE CODE [CA141] 1223
FAILURE CODE [CA144] 1225
FAILURE CODE [CA145] 1227
FAILURE CODE [CA153] 1229
FAILURE CODE [CA154] 1232
FAILURE CODE [CA187] 1235
FAILURE CODE [CA221] 1237
FAILURE CODE [CA222] 1239
FAILURE CODE [CA227] 1241
FAILURE CODE [CA234] 1242
FAILURE CODE [CA238] 1243
FAILURE CODE [CA239] 1245
FAILURE CODE [CA249] 1247
FAILURE CODE [CA256] 1249
FAILURE CODE [CA271] 1251
FAILURE CODE [CA272] 1253
FAILURE CODE [CA273] 1254
FAILURE CODE [CA274] 1256
FAILURE CODE [CA322] 1257
FAILURE CODE [CA323] 1259
FAILURE CODE [CA324] 1261
FAILURE CODE [CA325] 1263
FAILURE CODE [CA331] 1265
FAILURE CODE [CA332] 1267
FAILURE CODE [CA343] 1269
FAILURE CODE [CA351] 1270
FAILURE CODE [CA352] 1271
FAILURE CODE [CA356] 1274
FAILURE CODE [CA357] 1276
FAILURE CODE [CA386] 1278
FAILURE CODE [CA441] 1279
FAILURE CODE [CA442] 1281
FAILURE CODE [CA449] 1282
FAILURE CODE [CA451] 1283
FAILURE CODE [CA452] 1285
FAILURE CODE [CA515] 1287
FAILURE CODE [CA516] 1289
FAILURE CODE [CA553] 1291
FAILURE CODE [CA555] 1292
FAILURE CODE [CA556] 1293
FAILURE CODE [CA559] 1294
FAILURE CODE [CA595] 1299
FAILURE CODE [CA687] 1300
FAILURE CODE [CA689] 1302
FAILURE CODE [CA691] 1304
FAILURE CODE [CA692] 1306
FAILURE CODE [CA697] 1308
FAILURE CODE [CA698] 1309
FAILURE CODE [CA731] 1310
FAILURE CODE [CA778] 1311
FAILURE CODE [CA1117] 1314
FAILURE CODE [CA1664] 1315
FAILURE CODE [CA1669] 1318
FAILURE CODE [CA1673] 1319
FAILURE CODE [CA1677] 1320
FAILURE CODE [CA1678] 1321
FAILURE CODE [CA1682] 1322
FAILURE CODE [CA1683] 1324
FAILURE CODE [CA1684] 1326
FAILURE CODE [CA1686] 1328
FAILURE CODE [CA1691] 1329
FAILURE CODE [CA1694] 1332
FAILURE CODE [CA1695] 1334
FAILURE CODE [CA1696] 1335
FAILURE CODE [CA1712] 1337
FAILURE CODE [CA1713] 1340
FAILURE CODE [CA1714] 1342
FAILURE CODE [CA1715] 1343
FAILURE CODE [CA1776] 1344
FAILURE CODE [CA1777] 1347
FAILURE CODE [CA1843] 1350
FAILURE CODE [CA1844] 1352
FAILURE CODE [CA1879] 1355
FAILURE CODE [CA1881] 1358
FAILURE CODE [CA1883] 1360
FAILURE CODE [CA1885] 1363
FAILURE CODE [CA1887] 1365
FAILURE CODE [CA1921] 1367
FAILURE CODE [CA1922] 1370
FAILURE CODE [CA1923] 1375
FAILURE CODE [CA1924] 1377
FAILURE CODE [CA1925] 1379
FAILURE CODE [CA1927] 1381
FAILURE CODE [CA1928] 1383
FAILURE CODE [CA1942] 1385
FAILURE CODE [CA1963] 1386
FAILURE CODE [CA1977] 1389
FAILURE CODE [CA1993] 1392
FAILURE CODE [CA2185] 1395
FAILURE CODE [CA2186] 1397
FAILURE CODE [CA2249] 1399
FAILURE CODE [CA2265] 1400
FAILURE CODE [CA2266] 1402
FAILURE CODE [CA2271] 1404
FAILURE CODE [CA2272] 1406
FAILURE CODE [CA2349] 1408
FAILURE CODE [CA2353] 1410
FAILURE CODE [CA2357] 1412
FAILURE CODE [CA2381] 1413
FAILURE CODE [CA2382] 1415
FAILURE CODE [CA2383] 1417
FAILURE CODE [CA2386] 1419
FAILURE CODE [CA2387] 1421
FAILURE CODE [CA2555] 1422
FAILURE CODE [CA2556] 1425
FAILURE CODE [CA2637] 1427
FAILURE CODE [CA2639] 1429
FAILURE CODE [CA2732] 1432
FAILURE CODE [CA2733] 1434
FAILURE CODE [CA2741] 1436
FAILURE CODE [CA2765] 1437
FAILURE CODE [CA2771] 1438
FAILURE CODE [CA2777] 1444
FAILURE CODE [CA2878] 1447
FAILURE CODE [CA2881] 1450
FAILURE CODE [CA2976] 1453
FAILURE CODE [CA3133] 1455
FAILURE CODE [CA3134] 1457
FAILURE CODE [CA3135] 1459
FAILURE CODE [CA3142] 1462
FAILURE CODE [CA3143] 1463
FAILURE CODE [CA3144] 1464
FAILURE CODE [CA3146] 1466
FAILURE CODE [CA3147] 1467
FAILURE CODE [CA3148] 1468
FAILURE CODE [CA3151] 1470
FAILURE CODE [CA3165] 1476
FAILURE CODE [CA3167] 1478
FAILURE CODE [CA3229] 1481
FAILURE CODE [CA3231] 1483
FAILURE CODE [CA3232] 1485
FAILURE CODE [CA3235] 1489
FAILURE CODE [CA3239] 1491
FAILURE CODE [CA3241] 1494
FAILURE CODE [CA3242] 1497
FAILURE CODE [CA3251] 1500
FAILURE CODE [CA3253] 1502
FAILURE CODE [CA3254] 1505
FAILURE CODE [CA3255] 1508
FAILURE CODE [CA3256] 1512
FAILURE CODE [CA3311] 1514
FAILURE CODE [CA3312] 1516
FAILURE CODE [CA3313] 1519
FAILURE CODE [CA3314] 1520
FAILURE CODE [CA3315] 1521
FAILURE CODE [CA3316] 1524
FAILURE CODE [CA3317] 1525
FAILURE CODE [CA3318] 1526
FAILURE CODE [CA3319] 1528
FAILURE CODE [CA3321] 1529
FAILURE CODE [CA3322] 1531
FAILURE CODE [CA3419] 1534
FAILURE CODE [CA3421] 1536
FAILURE CODE [CA3497] 1538
FAILURE CODE [CA3498] 1539
FAILURE CODE [CA3543] 1540
FAILURE CODE [CA3545] 1547
FAILURE CODE [CA3547] 1549
FAILURE CODE [CA3558] 1550
FAILURE CODE [CA3559] 1552
FAILURE CODE [CA3562] 1554
FAILURE CODE [CA3563] 1556
FAILURE CODE [CA3567] 1559
FAILURE CODE [CA3568] 1562
FAILURE CODE [CA3571] 1566
FAILURE CODE [CA3572] 1568
FAILURE CODE [CA3574] 1570
FAILURE CODE [CA3575] 1572
FAILURE CODE [CA3577] 1574
FAILURE CODE [CA3578] 1576
FAILURE CODE [CA3582] 1578
FAILURE CODE [CA3583] 1584
FAILURE CODE [CA3596] 1586
FAILURE CODE [CA3649] 1588
FAILURE CODE [CA3681] 1590
FAILURE CODE [CA3682] 1595
FAILURE CODE [CA3713] 1601
FAILURE CODE [CA3717] 1604
FAILURE CODE [CA3718] 1605
FAILURE CODE [CA3725] 1606
FAILURE CODE [CA3748] 1609
FAILURE CODE [CA3751] 1611
FAILURE CODE [CA3755] 1613
FAILURE CODE [CA3866] 1615
FAILURE CODE [CA3867] 1619
FAILURE CODE [CA3868] 1622
FAILURE CODE [CA3899] 1626
FAILURE CODE [CA3911] 1628
FAILURE CODE [CA3912] 1632
FAILURE CODE [CA3932] 1634
FAILURE CODE [CA3933] 1636
FAILURE CODE [CA3934] 1638
FAILURE CODE [CA3935] 1641
FAILURE CODE [CA3936] 1643
FAILURE CODE [CA4151] 1645
FAILURE CODE [CA4152] 1649
FAILURE CODE [CA4155] 1653
FAILURE CODE [CA4156] 1655
FAILURE CODE [CA4157] 1658
FAILURE CODE [CA4158] 1660
FAILURE CODE [CA4159] 1661
FAILURE CODE [CA4161] 1662
FAILURE CODE [CA4162] 1665
FAILURE CODE [CA4163] 1668
FAILURE CODE [CA4164] 1670
FAILURE CODE [CA4165] 1672
FAILURE CODE [CA4166] 1674
FAILURE CODE [CA4168] 1676
FAILURE CODE [CA4169] 1679
FAILURE CODE [CA4171] 1681
FAILURE CODE [CA4249] 1684
FAILURE CODE [CA4251] 1686
FAILURE CODE [CA4259] 1688
FAILURE CODE [CA4261] 1690
FAILURE CODE [CA4277] 1693
FAILURE CODE [CA4281] 1697
FAILURE CODE [CA4459] 1700
FAILURE CODE [CA4461] 1703
FAILURE CODE [CA4658] 1706
FAILURE CODE [CA4731] 1710
FAILURE CODE [CA4732] 1711
FAILURE CODE [CA4739] 1712
FAILURE CODE [CA4768] 1713
FAILURE CODE [CA4769] 1715
FAILURE CODE [CA4842] 1718
FAILURE CODE [CA4952] 1722
FAILURE CODE [CA5115] 1724
FAILURE CODE [CA5179] 1727
FAILURE CODE [CA5181] 1729
FAILURE CODE [CA5383] 1731
FAILURE CODE [D110KB] 1733
FAILURE CODE [D19JKZ] 1735
FAILURE CODE [D811MC] 1738
FAILURE CODE [D862KA] 1739
FAILURE CODE [D8ALKA] 1740
FAILURE CODE [D8ALKB] 1742
FAILURE CODE [D8AQKR] 1744
FAILURE CODE [D8G1KT] 1746
FAILURE CODE [D8G6KT] 1747
FAILURE CODE [DA20MC] 1748
FAILURE CODE [DA22KK] 1749
FAILURE CODE [DA29KQ] 1752
FAILURE CODE [DA2LKA] 1754
FAILURE CODE [DA2LKB] 1756
FAILURE CODE [DA2QKR] 1758
FAILURE CODE [DA2RKR] 1761
FAILURE CODE [DAF0KM] 1762
FAILURE CODE [DAF0MB] 1763
FAILURE CODE [DAF0MC] 1764
FAILURE CODE [DAF8KB] 1765
FAILURE CODE [DAF9KQ] 1767
FAILURE CODE [DAFGMC] 1768
FAILURE CODE [DAFLKA] 1769
FAILURE CODE [DAFLKB] 1771
FAILURE CODE [DAFQKR] 1773
FAILURE CODE [DAZ9KQ] 1774
FAILURE CODE [DAZQKR] 1775
FAILURE CODE [DB2QKR] 1780
FAILURE CODE [DB2RKR] 1785
FAILURE CODE [DBP0KM] 1789
FAILURE CODE [DBP0KT] 1790
FAILURE CODE [DBP5KB] 1791
FAILURE CODE [DBP5KY] 1794
FAILURE CODE [DBPQKR] 1797
FAILURE CODE [DDNRKA] 1802
FAILURE CODE [DDNRKY] 1804
FAILURE CODE [DDNS00] 1806
FAILURE CODE [DFB1KZ] 1808
FAILURE CODE [DFB2KZ] 1810
FAILURE CODE [DFB3L8] 1812
FAILURE CODE [DFB4L8] 1814
FAILURE CODE [DFB5KZ] 1816
FAILURE CODE [DFB6KZ] 1818
FAILURE CODE [DGH2KA] 1820
FAILURE CODE [DGH2KB] 1822
FAILURE CODE [DHA4KA] 1824
FAILURE CODE [DHAAMA] 1826
FAILURE CODE [DHACMA] 1828
FAILURE CODE [DHPAMA] 1830
FAILURE CODE [DHPBMA] 1833
FAILURE CODE [DHS3MA] 1836
FAILURE CODE [DHS4MA] 1839
FAILURE CODE [DHS8MA] 1842
FAILURE CODE [DHS9MA] 1845
FAILURE CODE [DHSAMA] 1848
FAILURE CODE [DHSBMA] 1851
FAILURE CODE [DHSCMA] 1854
FAILURE CODE [DHSDMA] 1857
FAILURE CODE [DHSFMA] 1860
FAILURE CODE [DHSGMA] 1863
FAILURE CODE [DHSHMA] 1866
FAILURE CODE [DHSJMA] 1869
FAILURE CODE [DHZCL8] 1872
FAILURE CODE [DHZAMA] 1873
FAILURE CODE [DKR0MA] 1877
FAILURE CODE [DKR1MA] 1880
FAILURE CODE [DKULKA] 1883
FAILURE CODE [DKULKB] 1885
FAILURE CODE [DKULKY] 1887
FAILURE CODE [DLM3KA] 1889
FAILURE CODE [DLM3KB] 1891
FAILURE CODE [DLM3MB] 1893
FAILURE CODE [DR10KA] 1894
FAILURE CODE [DR12KA] 1897
FAILURE CODE [DR20KA] 1899
FAILURE CODE [DR21KX] 1901
FAILURE CODE [DR30KA] 1903
FAILURE CODE [DR31KX] 1905
FAILURE CODE [DR40KA] 1907
FAILURE CODE [DUMBKA] 1909
FAILURE CODE [DUMBKB] 1911
FAILURE CODE [DV00KA] 1913
FAILURE CODE [DV00KB] 1914
FAILURE CODE [DV20KB] 1915
FAILURE CODE [DW43KA] 1917
FAILURE CODE [DW43KB] 1919
FAILURE CODE [DW43KY] 1921
FAILURE CODE [DW45KA] 1923
FAILURE CODE [DW45KB] 1926
FAILURE CODE [DW45KY] 1929
FAILURE CODE [DW4CKY] 1931
FAILURE CODE [DW7BKA] 1932
FAILURE CODE [DW7BKB] 1934
FAILURE CODE [DW7BKY] 1936
FAILURE CODE [DW91KA] 1937
FAILURE CODE [DW91KB] 1939
FAILURE CODE [DW91KY] 1941
FAILURE CODE [DWA2KA] 1943
FAILURE CODE [DWA2KB] 1945
FAILURE CODE [DWA2KY] 1947
FAILURE CODE [DWK0KA] 1949
FAILURE CODE [DWK0KB] 1951
FAILURE CODE [DWK0KY] 1953
FAILURE CODE [DWK2KA] 1955
FAILURE CODE [DWK2KB] 1957
FAILURE CODE [DWK2KY] 1959
FAILURE CODE [DWK8KA] 1961
FAILURE CODE [DWK8KB] 1963
FAILURE CODE [DWK8KY] 1965
FAILURE CODE [DWPUKA] 1967
FAILURE CODE [DWPUKB] 1969
FAILURE CODE [DWPUKY] 1971
FAILURE CODE [DX16KA] 1973
FAILURE CODE [DX16KB] 1975
FAILURE CODE [DXA8KA] 1977
FAILURE CODE [DXA8KB] 1979
FAILURE CODE [DXA9KA] 1981
FAILURE CODE [DXA9KB] 1983
FAILURE CODE [DXE0KA] 1985
FAILURE CODE [DXE0KB] 1987
FAILURE CODE [DXE4KA] 1989
FAILURE CODE [DXE4KB] 1991
FAILURE CODE [DXE4KY] 1993
FAILURE CODE [DXE5KA] 1995
FAILURE CODE [DXE5KB] 1997
FAILURE CODE [DXE6KA] 1999
FAILURE CODE [DXE6KB] 2001
FAILURE CODE [DXE7KA] 2003
FAILURE CODE [DXE7KB] 2005
FAILURE CODE [DXE7KY] 2007
FAILURE CODE [DXE8KA] 2009
FAILURE CODE [DXE8KB] 2011
FAILURE CODE [DXE8KY] 2013
FAILURE CODE [DXE9KA] 2015
FAILURE CODE [DXE9KB] 2017
FAILURE CODE [DXE9KY] 2019
FAILURE CODE [DXEAKA] 2021
FAILURE CODE [DXEAKB] 2023
FAILURE CODE [DXEAKY] 2025
FAILURE CODE [DXEKKA] 2027
FAILURE CODE [DXEKKB] 2029
FAILURE CODE [DXEKKY] 2031
FAILURE CODE [DXELKA] 2033
FAILURE CODE [DXELKB] 2035
FAILURE CODE [DXELKY] 2037
FAILURE CODE [DY20KA] 2039
FAILURE CODE [DY20MA] 2041
FAILURE CODE [DY2CKB] 2043
FAILURE CODE [DY2DKB] 2046
FAILURE CODE [DY2EKB] 2048
FAILURE CODE [F313KA] 2050
FAILURE CODE [F313KB] 2052
FAILURE CODE [F318KB] 2055
FAILURE CODE [F318KY] 2058
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2060
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2060
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2066
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2069
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2071
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2073
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2076
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2077
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2078
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2079
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2080
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2081
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2082
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2083
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2084
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2085
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2086
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 2088
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2089
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2090
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2091
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 2093
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2094
E-23 FUNCTION SWITCH DOES NOT OPERATE 2095
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 2096
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2097
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2098
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 2099
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2100
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 2101
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2102
E-31 ALARM BUZZER CANNOT BE CANCELED 2104
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2105
E-33 SERVICE MODE CANNOT BE SELECTED 2106
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2107
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 2109
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 2110
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 2113
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 2115
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 2117
E-40 ALARM DOES NOT SOUND DURING TRAVEL 2118
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2120
E-42 HORN DOES NOT SOUND 2121
E-43 HORN DOES NOT STOP SOUNDING 2125
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 2127
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 2128
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2130
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2131
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2132
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2133
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2134
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2135
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2136
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2137
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2138
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2139
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 2141
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2142
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 2143
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2145
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2146
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2146
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2147
FAILURE MODE AND CAUSE TABLE 2149
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2157
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2158
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2160
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2161
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2162
H-6 SPEED OR POWER OF BOOM IS LOW 2164
H-7 ARM SPEED OR POWER IS LOW 2170
H-8 BUCKET SPEED OR POWER IS LOW 2175
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2178
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 2179
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2181
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 2183
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2184
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2185
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 2186
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2187
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 2188
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 2189
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2190
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2191
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2192
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 2193
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 2195
H-24 TRAVEL SPEED IS LOW 2198
H-25 ONE OF TRACKS DOES NOT RUN 2200
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2201
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2202
H-28 SWINGS ONLY IN ONE DIRECTION 2203
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2204
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2205
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2206
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2207
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2208
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2209
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 2210
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2211
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2212
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2213
H-39 Quick coupler cylinder will not extend 2214
H-40 Quick coupler cylinder will not retract (but buzzer doesnot sound) 2216
H-41 Buzzer does not sound (but quick coupler cylinder doesretract) 2218
H-42 Quick coupler cylinder extends and retracts slowly 2220
TROUBLESHOOTING OF ENGINE (S-MODE) 2221
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2221
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2222
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2223
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2224
S-4 ENGINE STARTABILITY IS POOR 2225
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2227
S-6 ENGINE STOPS DURING OPERATION 2229
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2231
S-8 ENGINE LACKS POWER 2232
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2234
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2236
S-11 OIL BECOMES CONTAMINATED QUICKLY 2237
S-12 FUEL CONSUMPTION IS EXCESSIVE 2238
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2239
S-14 OIL PRESSURE DROPS 2240
S-15 FUEL MIXES INTO ENGINE OIL 2242
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2243
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2244
S-18 UNUSUAL NOISE IS HEARD 2245
S-19 VIBRATION IS EXCESSIVE 2246
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2247
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2248
S-22 ACTIVE REGENERATION TAKES TIME 2250
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2252
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2253
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2255
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2256
TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED) 2257
20 SUPPLY VOLTAGE > 32VDC 2257
21 SUPPLY VOLTAGE < 12VDC 2258
25 FILE ERROR FACTORY SETTINGS 2259
26 FILE ERROR USER SETTINGS 2260
27 FILE ERROR INPUT DATA 2261
30 PROXIMITY SWITCHES DIFFERENCE 2262
86 ANGLE SENSOR A2 TIMEOUT 2263
96 ANGLE SENSOR A3/A5 TIMEOUT 2264
106 ANGLE SENSOR A4/A6 TIMEOUT 2265
116 ANGLE SENSOR PITCH TIMEOUT 2266
126 ANGLE SENSOR ROLL TIMEOUT 2267
50 DISASSEMBLY AND ASSEMBLY 2269
CONTENTS 2270
ABBREVIATION LIST 2275
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2281
HOW TO READ THIS MANUAL 2281
COATING MATERIALS LIST 2283
SPECIAL TOOLS LIST 2288
SKETCHES OF SPECIAL TOOLS 2300
ENGINE AND COOLING SYSTEM 2306
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2306
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2306
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2312
REMOVE AND INSTALL INJECTOR ASSEMBLY 2321
METHOD FOR REMOVING INJECTOR ASSEMBLY 2321
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2327
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 2337
METHOD FOR REMOVING FUEL DOSER 2337
METHOD FOR INSTALLING FUEL DOSER 2338
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2340
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2341
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2350
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2363
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2363
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2365
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2367
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2367
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2371
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 2377
METHOD FOR REMOVING STARTING MOTOR ASSEMBLY 2377
METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY 2378
REMOVE AND INSTALL ALTERNATOR BELT 2380
METHOD FOR REMOVING ALTERNATOR BELT 2380
METHOD FOR INSTALLING ALTERNATOR BELT 2383
REMOVE AND INSTALL RADIATOR ASSEMBLY 2388
METHOD FOR REMOVING RADIATOR ASSEMBLY 2388
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2390
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 2393
METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2393
METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY 2397
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2402
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2402
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2404
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2406
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2406
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2408
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2412
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 2413
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 2431
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2450
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2451
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2453
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2457
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2458
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2461
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2467
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2467
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2475
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2486
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2486
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2490
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2494
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2494
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2500
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2505
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2505
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2512
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2518
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2518
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2520
REMOVE AND INSTALL KDPF ASSEMBLY 2523
METHOD FOR REMOVING KDPF ASSEMBLY 2523
METHOD FOR INSTALLING KDPF ASSEMBLY 2527
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2532
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2533
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2538
REMOVE AND INSTALL SCR ASSEMBLY 2545
METHOD FOR REMOVING SCR ASSEMBLY 2545
METHOD FOR INSTALLING SCR ASSEMBLY 2548
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2552
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2552
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2557
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 2562
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2562
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2566
REMOVE AND INSTALL KCCV ASSEMBLY 2576
METHOD FOR REMOVING KCCV ASSEMBLY 2576
METHOD FOR INSTALLING KCCV ASSEMBLY 2577
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2581
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2581
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2586
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2592
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2592
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2596
REMOVE AND INSTALL AdBlue/DEF PUMP 2601
METHOD FOR REMOVING AdBlue/DEF PUMP 2601
METHOD FOR INSTALLING AdBlue/DEF PUMP 2603
REMOVE AND INSTALL AdBlue/DEF HOSE 2604
METHOD FOR REMOVING AdBlue/DEF HOSE 2604
METHOD FOR INSTALLING AdBlue/DEF HOSE 2609
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2618
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2618
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2619
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2622
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2622
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2625
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2629
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2629
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2630
POWER TRAIN 2632
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2632
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2632
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2633
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2634
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2634
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2639
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2645
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2645
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2646
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2648
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2648
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2652
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2658
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2658
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2658
UNDERCARRIAGE AND FRAME 2660
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2660
METHOD FOR SEPARATING TRACK ASSEMBLY 2660
METHOD FOR INSTALLING TRACK ASSEMBLY 2662
REMOVE AND INSTALL SPROCKET 2665
METHOD FOR REMOVING SPROCKET 2665
METHOD FOR INSTALLING SPROCKET 2665
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2667
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2667
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2668
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2670
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2670
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2672
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2677
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2678
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2680
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2683
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2684
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2685
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 2689
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2689
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2691
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2694
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2694
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2696
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2699
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2699
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2700
HYDRAULIC SYSTEM 2703
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2703
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2703
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2705
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2707
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2708
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2708
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2710
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2710
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2715
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2721
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2721
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2725
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2731
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2731
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2736
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2742
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2743
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2744
REMOVE AND INSTALL ATT BYPASS SOLENOID 2749
REMOVE ATT BYPASS SOLENOID 2749
INSTALL ATT BYPASS SOLENOID 2752
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2754
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2754
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2755
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2757
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2757
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2758
REMOVE AND INSTALL QUICK COUPLER VALVE 2760
WORK EQUIPMENT 2762
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2762
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2763
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2766
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2770
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2770
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2773
CAB AND ITS ATTACHMENTS 2777
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2777
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2777
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2784
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 2791
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2793
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2793
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2803
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2803
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2806
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2812
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2812
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2819
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2827
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2827
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2833
REMOVE AND INSTALL OPERATOR’S SEAT 2840
METHOD FOR REMOVING OPERATOR’S SEAT 2840
METHOD FOR INSTALLING OPERATOR’S SEAT 2842
REMOVE AND INSTALL SEAT BELT 2845
METHOD FOR REMOVING SEAT BELT 2845
METHOD FOR INSTALLING SEAT BELT 2846
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2847
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2847
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2852
ELECTRICAL SYSTEM 2861
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2861
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2861
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2862
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2864
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2864
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2867
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2872
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2872
METHOD FOR INSTALLING KomVision CONTROLLER 2873
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2874
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2874
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2877
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2881
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2881
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2882
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2883
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2883
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2884
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2886
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2886
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2887
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2889
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2889
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2891
REMOVE AND INSTALL KomVision CAMERA 2893
METHOD FOR REMOVING KomVision CAMERA 2893
METHOD FOR INSTALLING KomVision CAMERA 2894
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2896
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2896
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2899
60 MAINTENANCE STANDARD 2903
CONTENTS 2904
ABBREVIATION LIST 2905
ENGINE AND COOLING SYSTEM 2911
MAINTENANCE STANDARD OF ENGINE MOUNT 2911
MAINTENANCE STANDARD OF COOLING SYSTEM 2912
MAINTENANCE STANDARD OF COOLING FAN PUMP 2913
MAINTENANCE STANDARD OF SERVO VALVE 2914
MAINTENANCE STANDARD OF COOLING FAN MOTOR 2915
POWER TRAIN 2916
MAINTENANCE STANDARD OF SWING CIRCLE 2916
MAINTENANCE STANDARD OF SWING MACHINERY 2917
MAINTENANCE STANDARD OF FINAL DRIVE 2919
MAINTENANCE STANDARD OF SPROCKET 2921
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2922
UNDERCARRIAGE AND FRAME 2924
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2924
MAINTENANCE STANDARD OF IDLER 2926
MAINTENANCE STANDARD OF TRACK ROLLER 2928
MAINTENANCE STANDARD OF CARRIER ROLLER 2930
MAINTENANCE STANDARD OF TRACK SHOE 2931
MAINTENANCE STANDARD OF TRIPLE SHOE 2934
HYDRAULIC SYSTEM 2935
MAINTENANCE STANDARD OF MAIN PUMP 2935
MAINTENANCE STANDARD OF SWING MOTOR 2937
MAINTENANCE STANDARD OF TRAVEL MOTOR 2940
MAINTENANCE STANDARD OF CONTROL VALVE 2943
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2954
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2957
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2960
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2962
MAINTENANCE STANDARD OF SOLENOID VALVE 2963
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2964
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE 2966
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2967
WORK EQUIPMENT 2968
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2968
DIMENSION OF ARM 2973
DIMENSIONS OF BUCKET 2975
MAINTENANCE STANDARD OF BOOM CYLINDER 2977
MAINTENANCE STANDARD OF ARM CYLINDER 2978
MAINTENANCE STANDARD OF BUCKET CYLINDER 2979
WORK EQUIPMENT – PC490HRD-11E0 2980
WORK EQUIPMENT – HIGH REACH DEMOLITION 2980
DIMENSION OF ARM 2980
MAINTENANCE STANDARD OF BOOM CYLINDER 2981
MAINTENANCE STANDARD OF LINK CYLINDER 2982
MAINTENANCE STANDARD OF ARM CYLINDER 2983
MAINTENANCE STANDARD OF BUCKET CYLINDER 2984
WORK EQUIPMENT – DEMOLITION DIGGING 2985
MAINTENANCE STANDARD OF ARM CYLINDER 2985
MAINTENANCE STANDARD OF BUCKET CYLINDER 2986
80 APPENDIX 2987
CONTENTS 2988
ABBREVIATION LIST 2990
AIR CONDITIONER SYSTEM 2996
PRECAUTIONS FOR REFRIGERANT 2996
AIR CONDITIONER COMPONENT 2997
SPECIFICATIONS OF AIR CONDITIONER 2999
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3000
OUTLINE OF REFRIGERATION CYCLE 3001
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3003
AIR CONDITIONER UNIT 3003
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3003
FUNCTION OF AIR CONDITIONER UNIT 3005
COMPONENT PARTS OF AIR CONDITIONER UNIT 3007
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3008
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3008
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3008
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3008
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3009
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3009
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3009
FUNCTION OF DUAL PRESSURE SWITCH 3010
AIR CONDITIONER CONTROLLER 3011
STRUCTURE OF AIR CONDITIONER CONTROLLER 3011
COMPRESSOR 3012
STRUCTURE OF COMPRESSOR 3012
SPECIFICATIONS OF COMPRESSOR 3012
FUNCTION OF COMPRESSOR 3012
CONDENSER 3013
STRUCTURE OF CONDENSER 3013
SPECIFICATIONS OF CONDENSER 3013
FUNCTION OF CONDENSER 3013
RECEIVER DRIER 3014
STRUCTURE OF RECEIVER DRIER 3014
SPECIFICATIONS OF RECEIVER DRIER 3014
FUNCTION OF RECEIVER DRIER 3014
SENSORS FOR AIR CONDITIONER SYSTEM 3015
STRUCTURE OF SUNLIGHT SENSOR 3015
FUNCTION OF SUNLIGHT SENSOR 3015
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3015
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3015
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3017
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3019
AIR CONDITIONER SYSTEM DIAGRAM 3021
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3022
FUNCTION OF AIR CONDITIONER CONTROLLER 3023
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3024
TESTING AIR LEAKAGE (DUCT) 3028
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3028
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3030
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3031
TEST VENT (MODE) CHANGEOVER 3032
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3032
TESTING FRESH/RECIRC AIR CHANGEOVER 3034
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3034
TEST SUNLIGHT SENSOR 3035
METHOD FOR TESTING SUNLIGHT SENSOR 3035
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3036
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3036
TEST RELAYS 3037
METHOD FOR TESTING RELAYS 3037
AIR CONDITIONER TROUBLESHOOTING CHART 1 3038
AIR CONDITIONER TROUBLESHOOTING CHART 2 3039
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3042
FAILURE CODE [879AKA] 3044
FAILURE CODE [879AKB] 3045
FAILURE CODE [879BKA] 3046
FAILURE CODE [879BKB] 3048
FAILURE CODE [879CKA] 3050
FAILURE CODE [879CKB] 3051
FAILURE CODE [879DKZ] 3052
FAILURE CODE [879EMC] 3054
FAILURE CODE [879FMC] 3055
FAILURE CODE [879GKX] 3056
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3058
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3059
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3060
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3061
TROUBLESHOOTING USING GAUGE PRESSURE 3062
CONNECTION OF SERVICE TOOL 3065
METHOD FOR CONNECTING SERVICE TOOL 3065
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3067
HANDLE COMPRESSOR OIL 3069
90 CIRCUIT DIAGRAMS 3071
CONTENTS 3072
ABBREVIATION LIST 3073
HYDRAULIC CIRCUIT DIAGRAM 3079
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3079
HYDRAULIC CIRCUIT DIAGRAM (1/3) 3083
HYDRAULIC CIRCUIT DIAGRAM (2/3) 3085
HYDRAULIC CIRCUIT DIAGRAM (3/3) 3087
HYDRAULIC CIRCUIT DIAGRAM (1/4) – PC490HRD-11E0 3089
HYDRAULIC CIRCUIT DIAGRAM (2/4) – PC490HRD-11E0 3091
HYDRAULIC CIRCUIT DIAGRAM (3/4) – PC490HRD-11E0 3093
HYDRAULIC CIRCUIT DIAGRAM (4/4) – PC490HRD-11E0 3095
ELECTRICAL CIRCUIT DIAGRAM (PC490) 3097
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3097
ELECTRICAL CIRCUIT DIAGRAM (1/10) 3101
ELECTRICAL CIRCUIT DIAGRAM (2/10) 3103
ELECTRICAL CIRCUIT DIAGRAM (3/10) 3105
ELECTRICAL CIRCUIT DIAGRAM (4/10) 3107
ELECTRICAL CIRCUIT DIAGRAM (5/10) 3109
ELECTRICAL CIRCUIT DIAGRAM (6/10) 3111
ELECTRICAL CIRCUIT DIAGRAM (7/10) 3113
ELECTRICAL CIRCUIT DIAGRAM (8/10) 3115
ELECTRICAL CIRCUIT DIAGRAM (9/10) 3117
ELECTRICAL CIRCUIT DIAGRAM (10/10) 3119
ELECTRICAL CIRCUIT DIAGRAM (PC490HRD) 3121
ELECTRICAL CIRCUIT DIAGRAM (1/13) – PC490HRD-11E0 3123
ELECTRICAL CIRCUIT DIAGRAM (2/13) – PC490HRD-11E0 3125
ELECTRICAL CIRCUIT DIAGRAM (3/13) – PC490HRD-11E0 3127
ELECTRICAL CIRCUIT DIAGRAM (4/13) – PC490HRD-11E0 3129
ELECTRICAL CIRCUIT DIAGRAM (5/13) – PC490HRD-11E0 3131
ELECTRICAL CIRCUIT DIAGRAM (6/13) – PC490HRD-11E0 3133
ELECTRICAL CIRCUIT DIAGRAM (7/13) – PC490HRD-11E0 3135
ELECTRICAL CIRCUIT DIAGRAM (8/13) – PC490HRD-11E0 3137
ELECTRICAL CIRCUIT DIAGRAM (9/13) – PC490HRD-11E0 3139
ELECTRICAL CIRCUIT DIAGRAM (10/13) – PC490HRD-11E0 3141
ELECTRICAL CIRCUIT DIAGRAM (11/13) – PC490HRD-11E0 3143
ELECTRICAL CIRCUIT DIAGRAM (12/13) – PC490HRD-11E0 3145
ELECTRICAL CIRCUIT DIAGRAM (13/13) – PC490HRD-11E0 3147
INDEX 3149

DESCRIPTION:

Komatsu PC490-11E0 PC490LC-11E0 PC490HRD-11E0 Hydraulic Excavator Shop Manual UENBM00504 – PDF DOWNLOAD 

SERIAL NUMBERS
PC490LC-11E0 – K75001-K75095
PC490LCD-11E0 – K75001-K75152
PC490HRD-11E0 – K75001-K75229

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

S.V 31/12/24