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KOMATSU PC490HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00740 – PDF
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KOMATSU PC490HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00740 – PDF DOWNLOAD
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PC490HRD-11E0 – K75230 and up
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KOMATSU PC490HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00740 – PDF DOWNLOAD
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KOMATSU PC490HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00740 – PDF DOWNLOAD
Language : English
Pages : 3442
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS
PC490HRD-11E0 – K75230 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC490HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00740 – PDF DOWNLOAD
00 INDEX AND FOREWORD........................................................................................................................................................ 3 INDEX.................................................................................................................................................................... 4 ABBREVIATION LIST........................................................................................................................................................ 26 FOREWORD, SAFETY, BASIC INFORMATION...................................................................................................................................... 32 HOW TO READ THE SHOP MANUAL.......................................................................................................................................... 32 SAFETY NOTICE FOR OPERATION.......................................................................................................................................... 34 PRECAUTIONS TO PREVENT FIRE.......................................................................................................................................... 42 ACTIONS IF FIRE OCCURS............................................................................................................................................... 44 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS......................................................................................................................... 45 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS........................................................................................................................ 46 METHOD FOR CHECKING ENGINE TYPE...................................................................................................................................... 47 PRECAUTIONS FOR DEF.................................................................................................................................................. 49 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING................................................................................................................... 49 PRECAUTIONS FOR ADDING........................................................................................................................................... 49 PRECAUTIONS FOR STORING.......................................................................................................................................... 49 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE.......................................................................................................................... 49 THE OTHER PRECAUTIONS............................................................................................................................................ 49 STORE AdBlue/DEF..................................................................................................................................................... 50 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT......................................................................................................................... 51 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS.............................................................................................................. 54 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT........................................................................................................................ 61 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT....................................................................................................................... 63 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT..................................................................................................................... 64 PRACTICAL USE OF KOMTRAX............................................................................................................................................. 65 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER........................................................................................................................ 66 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER............................................................................................ 66 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER............................................................................................ 67 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER............................................................................................ 68 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS........................................................................................................... 70 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR............................................................................................................ 74 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR.................................................................................................... 75 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL.................................................................................................. 77 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH.................................................................................................. 78 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE............................................................................................. 80 HOW TO READ ELECTRICAL WIRE CODE..................................................................................................................................... 81 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD........................................................................................................................ 85 STANDARD TIGHTENING TORQUE TABLE..................................................................................................................................... 88 CONVERSION TABLE..................................................................................................................................................... 95 01 SPECIFICATIONS............................................................................................................................................................ 101 CONTENTS................................................................................................................................................................. 102 ABBREVIATION LIST........................................................................................................................................................ 103 SPECIFICATIONS........................................................................................................................................................... 109 SPECIFICATION DRAWING................................................................................................................................................ 109 SPECIFICATION DRAWING: PC490-11E0 ,PC490LC-11E0.................................................................................................................. 109 WORKING RANGE DRAWINGS............................................................................................................................................... 111 WORKING RANGE: PC490-11E0, PC490LC-11E0.......................................................................................................................... 111 SPECIFICATIONS....................................................................................................................................................... 112 SPECIFICATIONS: PC490-11E0, PC490LC-11E0......................................................................................................................... 112 WEIGHT TABLE......................................................................................................................................................... 115 WEIGHT TABLE: PC490-11E0 ,PC490LC-11E0........................................................................................................................... 115 TABLE OF FUEL, COOLANT, AND LUBRICANTS............................................................................................................................... 117 SPECIFICATIONS - PC490HRD-11E0........................................................................................................................................... 118 SPECIFICATION DRAWING................................................................................................................................................ 118 SPECIFICATION DRAWING: PC490HRD-11E0............................................................................................................................. 118 SPECIFICATIONS....................................................................................................................................................... 122 SPECIFICATIONS: PC490HRD-11E0.................................................................................................................................... 122 WEIGHT TABLE......................................................................................................................................................... 124 WEIGHT TABLE: PC490HRD-11E0...................................................................................................................................... 124 SPECIFICATIONS - PC490HRD-11E0 K100...................................................................................................................................... 126 SPECIFICATION DRAWING................................................................................................................................................ 126 SPECIFICATION DRAWING: PC490HRD-11E0 K100........................................................................................................................ 126 WEIGHT TABLE......................................................................................................................................................... 130 WEIGHT TABLE: PC490HRD-11E0 K100................................................................................................................................. 130 10 STRUCTURE AND FUNCTION.................................................................................................................................................... 131 CONTENTS................................................................................................................................................................. 132 ABBREVIATION LIST........................................................................................................................................................ 137 UREA SCR SYSTEM.......................................................................................................................................................... 143 LAYOUT DRAWING OF UREA SCR SYSTEM.................................................................................................................................... 143 UREA SCR SYSTEM DIAGRAM.............................................................................................................................................. 147 FUNCTION OF UREA SCR SYSTEM.......................................................................................................................................... 148 FUNCTION OF AdBlue/DEF SYSTEM.................................................................................................................................... 148 INDUCEMENT STRATEGY.............................................................................................................................................. 150 COMPONENT PARTS OF UREA SCR SYSTEM................................................................................................................................... 169 AdBlue/DEF MIXING TUBE........................................................................................................................................... 169 SCR ASSEMBLY..................................................................................................................................................... 169 AdBlue/DEF TANK.................................................................................................................................................. 172 AdBlue/DEF PUMP.................................................................................................................................................. 174 AdBlue/DEF INJECTOR.............................................................................................................................................. 175 AdBlue/DEF HOSE.................................................................................................................................................. 176 AdBlue/DEF TANK HEATING VALVE.................................................................................................................................... 177 BOOT-UP SYSTEM........................................................................................................................................................... 178 LAYOUT DRAWING OF BOOT-UP SYSTEM..................................................................................................................................... 178 SYSTEM OPERATING LAMP SYSTEM......................................................................................................................................... 180 SYSTEM OPERATING LAMP SYSTEM DIAGRAM............................................................................................................................. 180 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM............................................................................................................................. 181 OPERATION OF SYSTEM OPERATING LAMP SYSTEM............................................................................................................................ 182 BATTERY DISCONNECT SWITCH............................................................................................................................................ 183 FUNCTION OF BATTERY DISCONNECT SWITCH............................................................................................................................ 183 ENGINE SYSTEM............................................................................................................................................................ 184 LAYOUT DRAWING OF ENGINE SYSTEM...................................................................................................................................... 184 SPECIFICATIONS OF ENGINE SYSTEM.................................................................................................................................. 185 FUNCTION OF ENGINE SYSTEM........................................................................................................................................ 186 ENGINE CONTROL SYSTEM................................................................................................................................................ 187 ENGINE CONTROL SYSTEM DIAGRAM.................................................................................................................................... 187 OPERATION OF ENGINE CONTROL SYSTEM............................................................................................................................... 188 AUTO-DECELERATION SYSTEM............................................................................................................................................. 190 AUTO-DECELERATION SYSTEM DIAGRAM................................................................................................................................. 190 FUNCTION OF AUTO-DECELERATION SYSTEM............................................................................................................................. 190 OPERATION OF AUTO-DECELERATION SYSTEM............................................................................................................................ 191 ENGINE AUTOMATIC WARM-UP SYSTEM...................................................................................................................................... 192 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM.......................................................................................................................... 192 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM...................................................................................................................... 193 OVERHEAT PREVENTION SYSTEM........................................................................................................................................... 194 OVERHEAT PREVENTION SYSTEM DIAGRAM............................................................................................................................... 194 FUNCTION OF OVERHEAT PREVENTION SYSTEM........................................................................................................................... 195 TURBOCHARGER PROTECTION SYSTEM....................................................................................................................................... 197 TURBOCHARGER PROTECTION SYSTEM DIAGRAM........................................................................................................................... 197 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM....................................................................................................................... 198 AUTOMATIC IDLE STOP SYSTEM........................................................................................................................................... 199 AUTOMATIC IDLE STOP SYSTEM DIAGRAM............................................................................................................................... 199 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM........................................................................................................................... 199 OPERATION OF AUTOMATIC IDLE STOP SYSTEM.......................................................................................................................... 199 COMPONENT PARTS OF ENGINE SYSTEM..................................................................................................................................... 202 VGT.............................................................................................................................................................. 202 EGR SYSTEM....................................................................................................................................................... 205 EGR VALVE........................................................................................................................................................ 207 EGR COOLER....................................................................................................................................................... 209 KCCV SYSTEM...................................................................................................................................................... 210 KCCV VENTILATOR.................................................................................................................................................. 211 KDPF............................................................................................................................................................. 213 COOLING SYSTEM........................................................................................................................................................... 218 LAYOUT DRAWING OF COOLING SYSTEM..................................................................................................................................... 218 SPECIFICATIONS OF COOLING SYSTEM................................................................................................................................. 219 FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN............................................................................................................................ 221 FAN SPEED CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN................................................................................................................ 221 FUNCTION OF FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN............................................................................................................ 222 ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN........................................................................................................................ 223 ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF HYDRAULIC FAN............................................................................................................ 223 FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN........................................................................................................ 224 FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN......................................................................................................................... 226 FAN REVERSE ROTATION SYSTEM DIAGRAM OF HYDRAULIC FAN............................................................................................................. 226 FUNCTION OF FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN......................................................................................................... 226 COMPONENT PARTS OF COOLING SYSTEM.................................................................................................................................... 227 COOLING FAN PUMP................................................................................................................................................. 227 COOLING FAN MOTOR................................................................................................................................................ 234 CONTROL SYSTEM........................................................................................................................................................... 241 LAYOUT DRAWING OF CONTROL SYSTEM..................................................................................................................................... 241 MACHINE MONITOR SYSTEM............................................................................................................................................... 244 MACHINE MONITOR SYSTEM DIAGRAM................................................................................................................................... 244 FUNCTION OF MACHINE MONITOR SYSTEM............................................................................................................................... 244 KomVision SYSTEM..................................................................................................................................................... 245 LAYOUT DRAWING OF KOMVISION SYSTEM............................................................................................................................... 245 KomVision SYSTEM DIAGRAM......................................................................................................................................... 247 FUNCTION OF KomVision SYSTEM..................................................................................................................................... 247 KOMTRAX SYSTEM....................................................................................................................................................... 249 KOMTRAX SYSTEM DIAGRAM........................................................................................................................................... 249 FUNCTION OF KOMTRAX SYSTEM....................................................................................................................................... 249 PPC LEVERS........................................................................................................................................................... 250 LH PPC LEVER..................................................................................................................................................... 250 RH PPC LEVER..................................................................................................................................................... 251 AUTOMATIC GREASE SYSTEM.............................................................................................................................................. 252 OUTLINE OF AUTO GREASE SYSTEM.................................................................................................................................... 252 COMPONENT PARTS OF CONTROL SYSTEM.................................................................................................................................... 266 MACHINE MONITOR.................................................................................................................................................. 266 KomVision CONTROLLER............................................................................................................................................. 279 KomVision CAMERA................................................................................................................................................. 283 GATEWAY FUNCTION CONTROLLER...................................................................................................................................... 284 COMMUNICATION TERMINAL........................................................................................................................................... 287 PUMP CONTROLLER.................................................................................................................................................. 289 RESISTOR FOR PC-EPC VALVE........................................................................................................................................ 293 CAN TERMINATING RESISTOR......................................................................................................................................... 293 ENGINE CONTROLLER................................................................................................................................................ 295 FUEL CONTROL DIAL................................................................................................................................................ 301 FUEL FEED PUMP................................................................................................................................................... 303 FUEL FEED PUMP SWITCH............................................................................................................................................ 304 SENSOR............................................................................................................................................................... 305 STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH........................................................................................................... 305 SPECIFICATIONS - QUICK COUPLER LOW PRESSURE WARNING SWITCH....................................................................................................... 305 FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH............................................................................................................ 305 STRUCTURE OF AUTO GREASE PRESSURE SWITCH......................................................................................................................... 306 SPECIFICATIONS - AUTO GREASE PRESSURE SWITCH..................................................................................................................... 306 FUNCTION OF AUTO GREASE PRESSURE SWITCH.......................................................................................................................... 306 STRUCTURE OF OVERLOAD CAUTION SENSOR............................................................................................................................. 306 SPECIFICATIONS - OVERLOAD CAUTION SENSOR......................................................................................................................... 307 FUNCTION OF OVERLOAD CAUTION SENSOR.............................................................................................................................. 307 HYDRAULIC SYSTEM......................................................................................................................................................... 308 LAYOUT DRAWING OF HYDRAULIC SYSTEM................................................................................................................................... 308 CLSS................................................................................................................................................................. 310 STRUCTURE OF CLSS................................................................................................................................................ 310 OPERATION OF UNLOAD VALVE AND LS PRESSURE........................................................................................................................ 312 PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL........................................................................................................................ 313 PRESSURE COMPENSATION CONTROL.................................................................................................................................... 326 ENGINE AND PUMP COMBINED CONTROL SYSTEM.............................................................................................................................. 330 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM.................................................................................................................. 330 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM.............................................................................................................. 332 PUMP AND VALVE CONTROL SYSTEM........................................................................................................................................ 337 PUMP AND VALVE CONTROL SYSTEM DIAGRAM............................................................................................................................ 337 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM........................................................................................................................ 338 COMPONENT PARTS OF HYDRAULIC SYSTEM.................................................................................................................................. 340 HYDRAULIC TANK................................................................................................................................................... 340 MAIN PUMP........................................................................................................................................................ 342 PILOT OIL FILTER................................................................................................................................................. 368 CONTROL VALVE.................................................................................................................................................... 368 HYDRAULIC SYSTEM - PC490HRD-11E0......................................................................................................................................... 430 LAYOUT DRAWING OF HYDRAULIC SYSTEM................................................................................................................................... 430 COMPONENT PARTS OF HYDRAULIC SYSTEM.................................................................................................................................. 433 LAYOUT DRAWING OF VALVE CONTROL SYSTEM........................................................................................................................... 433 WORK EQUIPMENT SYSTEM.................................................................................................................................................... 453 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM.............................................................................................................................. 453 STRUCTURE OF VALVE CONTROL........................................................................................................................................... 458 ONE-TOUCH POWER MAXIMIZING SYSTEM.................................................................................................................................... 459 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM........................................................................................................................ 459 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM.................................................................................................................... 460 MACHINE PUSH-UP SYSTEM............................................................................................................................................... 461 MACHINE PUSH-UP SYSTEM DIAGRAM................................................................................................................................... 461 FUNCTION OF MACHINE PUSH-UP SYSTEM............................................................................................................................... 462 PPC LOCK SYSTEM...................................................................................................................................................... 463 PPC LOCK SYSTEM DIAGRAM.......................................................................................................................................... 463 FUNCTION OF PPC LOCK SYSTEM...................................................................................................................................... 463 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...................................................................................................................... 464 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM.......................................................................................................... 464 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...................................................................................................... 464 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM..................................................................................................... 465 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.............................................................................................................................. 466 OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT.................................................................................................................. 466 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.............................................................................................................. 467 TOOL CONTROL SYSTEM.................................................................................................................................................. 468 TOOL CONTROL SYSTEM DIAGRAM...................................................................................................................................... 468 FUNCTION OF TOOL CONTROL SYSTEM.................................................................................................................................. 469 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM............................................................................................................................. 470 WORK EQUIPMENT AND SWING PPC VALVE............................................................................................................................... 470 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)................................................................................................................... 475 SOLENOID VALVE................................................................................................................................................... 480 VARIABLE PRESSURE COMPENSATION VALVE............................................................................................................................. 482 ATTACHMENT CIRCUIT SELECTOR VALVE................................................................................................................................ 483 1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE........................................................................................................................ 485 ATTACHMENT BYPASS SOLENOID VALVE................................................................................................................................. 488 ATT EPC VALVE ASSEMBLY........................................................................................................................................... 490 PILOT CIRCUIT ACCUMULATOR........................................................................................................................................ 492 WORK EQUIPMENT SYSTEM - PC490HRD-11E0.................................................................................................................................... 493 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM.............................................................................................................................. 493 SWING SYSTEM............................................................................................................................................................. 497 LAYOUT DRAWING OF SWING SYSTEM....................................................................................................................................... 497 SWING CONTROL SYSTEM DIAGRAM......................................................................................................................................... 503 FUNCTION OF SWING CONTROL SYSTEM................................................................................................................................. 503 COMPONENT PARTS OF SWING SYSTEM...................................................................................................................................... 507 SWING MOTOR...................................................................................................................................................... 507 SWING MACHINERY.................................................................................................................................................. 518 SWING CIRCLE..................................................................................................................................................... 520 TRAVEL SYSTEM............................................................................................................................................................ 522 LAYOUT DRAWING OF TRAVEL SYSTEM...................................................................................................................................... 522 TRAVEL CONTROL SYSTEM DIAGRAM........................................................................................................................................ 526 FUNCTION OF TRAVEL CONTROL SYSTEM................................................................................................................................ 527 COMPONENT PARTS OF TRAVEL SYSTEM..................................................................................................................................... 528 TRAVEL MOTOR..................................................................................................................................................... 528 FINAL DRIVE...................................................................................................................................................... 542 TRAVEL PPC VALVE................................................................................................................................................. 543 CENTER SWIVEL JOINT.............................................................................................................................................. 548 UNDERCARRIAGE AND FRAME.................................................................................................................................................. 550 LAYOUT DRAWING OF UNDERCARRIAGE...................................................................................................................................... 550 SPECIFICATIONS OF UNDERCARRIAGE.................................................................................................................................. 550 WORK EQUIPMENT........................................................................................................................................................... 552 STRUCTURE OF WORK EQUIPMENT.......................................................................................................................................... 552 FUNCTION OF WORK EQUIPMENT........................................................................................................................................... 553 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................................................................................. 554 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................................................................. 554 BUCKET CLEARANCE ADJUSTMENT SHIM..................................................................................................................................... 555 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM..................................................................................................................... 555 CAB AND ITS ATTACHMENTS.................................................................................................................................................. 556 ROPS CAB............................................................................................................................................................. 556 STRUCTURE OF ROPS CAB............................................................................................................................................ 556 FUNCTION OF ROPS CAB............................................................................................................................................. 556 CAB MOUNT............................................................................................................................................................ 557 STRUCTURE OF CAB MOUNT........................................................................................................................................... 557 FUNCTION OF CAB MOUNT............................................................................................................................................ 557 CAB TIPPING STOPPER.................................................................................................................................................. 558 STRUCTURE OF CAB TIPPING STOPPER................................................................................................................................. 558 FUNCTION OF CAB TIPPING STOPPER.................................................................................................................................. 558 TILTING CAB SYSTEM................................................................................................................................................... 559 STRUCTURE OF TILTING CAB SYSTEM.................................................................................................................................. 559 OPERATION OF TILTING CAB SYSTEM.................................................................................................................................. 559 CONTROL SYSTEM........................................................................................................................................................... 561 K100 CONTROL SYSTEM.................................................................................................................................................. 561 STRUCTURE OF K100 CONTROL SYSTEM..................................................................................................................................... 562 HYDRAULIC SYSTEM - PC490HRD-11E0 K100.................................................................................................................................... 564 LAYOUT DRAWING OF HYDRAULIC SYSTEM................................................................................................................................... 564 LS OVERRIDE VALVE........................................................................................................................................................ 565 STRUCTURE OF LS OVERRIDE VALVE....................................................................................................................................... 565 OPERATION OF LS OVERRIDE VALVE....................................................................................................................................... 566 HYDRAULIC LOCK VALVE..................................................................................................................................................... 567 STRUCTURE OF HYDRAULIC LOCK VALVE.................................................................................................................................... 567 OPERATION OF HYDRAULIC LOCK VALVE.................................................................................................................................... 568 SWING LOCK VALVE......................................................................................................................................................... 569 STRUCTURE OF SWING LOCK VALVE........................................................................................................................................ 569 OPERATION OF SWING LOCK VALVE........................................................................................................................................ 570 BOOM RAISE LOCK VALVE.................................................................................................................................................... 571 STRUCTURE OF BOOM RAISE LOCK VALVE................................................................................................................................... 571 OPERATION OF BOOM RAISE LOCK VALVE................................................................................................................................... 572 DEPRESSURISATION VALVE................................................................................................................................................... 573 STRUCTURE OF DEPRESSURISATION AND PIN LOCK/UNLOCK VALVE.............................................................................................................. 573 OPERATION OF DEPRESSURISATION VALVE.................................................................................................................................. 575 MECHANICAL PIN LOCK/UNLOCK VALVE......................................................................................................................................... 578 STRUCTURE OF MECHANICAL PIN LOCK/UNLOCK VALVE........................................................................................................................ 578 OPERATION OF MECHANICAL PIN LOCK/UNLOCK VALVE........................................................................................................................ 579 PRESSURE INTENSIFIER SYSTEM.............................................................................................................................................. 580 STRUCTURE OF PRESSURE INTENSIFIER SYSTEM............................................................................................................................. 580 OPERATION OF PRESSURE INTENSIFIER SYSTEM............................................................................................................................. 581 20 STANDARD VALUE TABLE...................................................................................................................................................... 583 CONTENTS................................................................................................................................................................. 584 ABBREVIATION LIST........................................................................................................................................................ 585 STANDARD VALUE TABLE FOR ENGINE.......................................................................................................................................... 591 STANDARD VALUE TABLE FOR ENGINE: PC490-11E0, PC490LC-11E0............................................................................................................ 591 STANDARD VALUE TABLE FOR MACHINE......................................................................................................................................... 594 STANDARD VALUE TABLE FOR MACHINE: PC490-11E0, PC490LC-11E0........................................................................................................... 594 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE.............................................................................................................. 610 STANDARD VALUE TABLE FOR MACHINE - PC490HRD-11E0......................................................................................................................... 614 STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE............................................................................................................. 614 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE.............................................................................................................. 621 STANDARD VALUE TABLE FOR MACHINE - PC490HRD-11E0 K100.................................................................................................................... 625 STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE............................................................................................................. 625 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE.............................................................................................................. 633 STANDARD VALUE TABLE FOR ELECTRICAL...................................................................................................................................... 637 STANDARD VALUE TABLE FOR ELECTRICAL.................................................................................................................................. 637 30 TESTING AND ADJUSTING..................................................................................................................................................... 647 CONTENTS................................................................................................................................................................. 648 ABBREVIATION LIST........................................................................................................................................................ 653 RELATED INFORMATION ON TESTING AND ADJUSTING............................................................................................................................. 659 TOOLS FOR TESTING AND ADJUSTING...................................................................................................................................... 659 SKETCH OF TOOLS FOR TESTING AND ADJUSTING............................................................................................................................ 666 ENGINE AND COOLING SYSTEM................................................................................................................................................ 668 TEST ENGINE SPEED.................................................................................................................................................... 668 METHOD FOR TESTING ENGINE SPEED.................................................................................................................................. 668 TEST BOOST PRESSURE.................................................................................................................................................. 671 METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR............................................................................................................. 671 METHOD FOR TESTING BOOST PRESSURE................................................................................................................................ 672 TEST EXHAUST GAS COLOR............................................................................................................................................... 673 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...................................................................................................... 673 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER.............................................................................................................. 674 TEST AND ADJUST VALVE CLEARANCE...................................................................................................................................... 675 METHOD FOR TESTING VALVE CLEARANCE............................................................................................................................... 675 METHOD FOR ADJUSTING VALVE CLEARANCE............................................................................................................................. 678 TEST COMPRESSION PRESSURE............................................................................................................................................ 679 METHOD FOR TESTING COMPRESSION PRESSURE.......................................................................................................................... 679 TEST BLOWBY PRESSURE................................................................................................................................................. 682 METHOD FOR TESTING BLOWBY PRESSURE............................................................................................................................... 682 TEST ENGINE OIL PRESSURE............................................................................................................................................. 684 METHOD FOR TESTING ENGINE OIL PRESSURE BY MACHINE MONITOR........................................................................................................ 684 METHOD FOR TESTING ENGINE OIL PRESSURE BY TESTING TOOL........................................................................................................... 684 TEST EGR VALVE AND VGT OIL PRESSURE.................................................................................................................................. 686 METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE................................................................................................................ 686 TEST FUEL PRESSURE................................................................................................................................................... 688 METHOD FOR TESTING FUEL PRESSURE................................................................................................................................. 688 TEST FUEL RETURN RATE AND LEAKAGE.................................................................................................................................... 690 METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE.................................................................................................................. 690 BLEED AIR FROM FUEL SYSTEM........................................................................................................................................... 693 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM......................................................................................................................... 693 TEST FUEL CIRCUIT FOR LEAKAGE........................................................................................................................................ 695 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...................................................................................................................... 695 HANDLE CYLINDER CUT-OUT MODE OPERATION............................................................................................................................... 697 HANDLE NO-INJECTION CRANKING OPERATION............................................................................................................................... 698 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION.............................................................................................................. 699 METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION....................................................................................................... 699 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..................................................................................................... 699 CLEAN FUEL DOSER..................................................................................................................................................... 701 METHOD FOR CLEANING FUEL DOSER................................................................................................................................... 701 WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER............................................................................................................... 703 METHOD FOR WRITING INJECTOR COMPENSATION VALUE................................................................................................................... 703 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER....................................................................................................... 709 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...................................................................................... 709 TEST SCR RELATED FUNCTIONS........................................................................................................................................... 710 TEST AdBlue/DEF PUMP RAISED PRESSURE............................................................................................................................. 713 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR................................................................................................................... 716 TEST AdBlue/DEF LINE HEATER RELAY 1.............................................................................................................................. 720 TEST AdBlue/DEF LINE HEATER RELAY 2.............................................................................................................................. 722 TEST AdBlue/DEF PUMP HEATER RELAY................................................................................................................................ 725 TEST AdBlue/DEF TANK HEATER VALVE................................................................................................................................ 728 TEST DENITRATION EFFICIENCY OF SCR............................................................................................................................... 731 CLEAN AdBlue/DEF TANK................................................................................................................................................ 735 METHOD FOR CLEANING AdBlue/DEF TANK.............................................................................................................................. 735 POWER TRAIN.............................................................................................................................................................. 739 TEST SWING CIRCLE BEARING CLEARANCE.................................................................................................................................. 739 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE................................................................................................................ 739 UNDERCARRIAGE AND FRAME.................................................................................................................................................. 740 TEST AND ADJUST TRACK TENSION........................................................................................................................................ 740 METHOD FOR TESTING TRACK TENSION................................................................................................................................. 740 METHOD FOR ADJUSTING TRACK TENSION............................................................................................................................... 740 HYDRAULIC SYSTEM......................................................................................................................................................... 742 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM..................................................................................................................... 742 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK...................................................................................................... 742 METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT............................................................................................ 742 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS........................................................................................... 748 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.................................................................................... 749 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.................................................................................. 756 TEST OIL PRESSURE OF CONTROL CIRCUIT................................................................................................................................. 760 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT............................................................................................................... 760 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.............................................................................................................. 762 TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)...................................................................................................... 762 TEST PC-EPC VALVE OUTLET PRESSURE................................................................................................................................ 763 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT..................................................................................................... 764 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.............................................................................................................. 766 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR................................................................................................... 766 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE...................................................................................................................... 767 METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)........................................................................................ 768 METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE.................................................................................................................. 769 METHOD FOR ADJUSTING LS VALVE.................................................................................................................................... 770 TEST OUTLET PRESSURE OF SOLENOID VALVE............................................................................................................................... 771 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE............................................................................................................. 771 OPERATING CONDITION OF SOLENOID VALVE............................................................................................................................ 772 TEST PPC VALVE OUTLET PRESSURE....................................................................................................................................... 774 METHOD FOR TESTING PPC VALVE OUTLET PRESSURE..................................................................................................................... 774 ADJUST WORK EQUIPMENT AND SWING PPC VALVES........................................................................................................................... 776 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES................................................................................................. 776 MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE.................................................................................................. 777 TEST PUMP SWASH PLATE SENSOR......................................................................................................................................... 779 METHOD FOR TESTING PUMP SWASH PLATE SENSOR....................................................................................................................... 779 TEST COOLING FAN SPEED............................................................................................................................................... 780 METHOD FOR TESTING COOLING FAN SPEED............................................................................................................................. 780 TEST OIL PRESSURE IN FAN PUMP CIRCUIT................................................................................................................................ 781 METHOD FOR TESTING OIL PRESSURE IN FAN PUMP CIRCUIT.............................................................................................................. 781 TEST FAN PUMP EPC ELECTRIC CURRENT................................................................................................................................... 783 METHOD FOR TESTING FAN PUMP EPC ELECTRIC CURRENT................................................................................................................. 783 TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE..................................................................................................................... 784 METHOD FOR TESTING FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE................................................................................................... 784 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT............................................................................................................. 786 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER........................................................................ 786 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER............................................................................................. 786 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE................................................................................................ 787 TEST OIL LEAKAGE..................................................................................................................................................... 788 TEST OIL LEAKAGE OF BOOM CYLINDER................................................................................................................................ 788 TEST OIL LEAKAGE OF ARM CYLINDER................................................................................................................................. 788 TEST OIL LEAKAGE OF BUCKET CYLINDER.............................................................................................................................. 789 METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR.................................................................................................................... 789 METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR................................................................................................................... 790 BLEED AIR FROM HYDRAULIC CIRCUIT..................................................................................................................................... 791 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT................................................................................................................... 793 HYDRAULIC SYSTEM - PC490HRD-11E0......................................................................................................................................... 796 MEASURING AND ADJUSTING SWING SPEED REDUCTION VALVE.................................................................................................................. 796 MEASURING AND ADJUSTING BOOM AND BUCKET PPC REDUCTION VALVE.......................................................................................................... 797 MEASURING AND ADJUSTING LINK CYLINDER FLOW CONTROL VALVE............................................................................................................. 798 MEASURING AND ADJUSTING ARM CYLINDER FLOW CONTROL VALVE.............................................................................................................. 799 HYDRAULIC SYSTEM - PC490HRD-11E0 K100 BOOM CHANGE SYSTEM................................................................................................................. 800 MEASURING AND ADJUSTING DEPRESSURISATION VALVE....................................................................................................................... 800 MEASURING AND ADJUSTING PIN LOCK/UNLOCK VALVE........................................................................................................................ 802 CAB AND ITS ATTACHMENTS.................................................................................................................................................. 805 TEST CAB TIPPING STOPPER............................................................................................................................................. 805 METHOD FOR TESTING CAB TIPPING STOPPER........................................................................................................................... 805 METHOD FOR ADJUSTING MIRRORS......................................................................................................................................... 806 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)............................................................................................................ 806 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)........................................................................................ 807 PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)........................................................................................................... 808 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)....................................................................................... 809 PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)............................................................................................................ 810 ELECTRICAL SYSTEM........................................................................................................................................................ 812 SET AND OPERATE MACHINE MONITOR...................................................................................................................................... 812 OPERATOR MODE.................................................................................................................................................... 815 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...................................................................................................... 816 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN......................................................................................................... 816 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)................................................................................................................ 817 CHECKING FUNCTION OF SERVICE METER............................................................................................................................... 817 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD........................................................................................................ 817 SERVICE MODE..................................................................................................................................................... 820 METHOD FOR OPERATING SERVICE MODE................................................................................................................................ 822 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION........................................................................................................... 825 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION........................................................................................................... 832 METHOD FOR CONFIRMING MAINTENANCE RECORD......................................................................................................................... 848 METHOD FOR OPERATING MAINTENANCE MODE SETTING.................................................................................................................... 849 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING.................................................................................................................. 853 METHOD FOR PERFORMING NO-INJECTION CRANKING...................................................................................................................... 898 METHOD FOR DISPLAYING SERVICE MESSAGE............................................................................................................................ 901 METHOD FOR STARTING UP KOMTRAX SYSTEM................................................................................................................................ 903 ADJUST REARVIEW CAMERA ANGLE......................................................................................................................................... 909 METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE....................................................................................................................... 909 ADJUST KomVision CAMERA ANGLE........................................................................................................................................ 912 Angle adjustment method for KomVision camera..................................................................................................................... 913 ADJUST KomVision RELATED ITEMS....................................................................................................................................... 917 SETTING OF KomVision (MAIN SETTING).............................................................................................................................. 917 SETTING OF KomVision (CAMERA SETTING)............................................................................................................................ 919 SET KomVision (camera calibration)............................................................................................................................... 921 KomVision screen - Check 12 m visibility......................................................................................................................... 947 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER.......................................................................................................................... 950 HANDLE BATTERY DISCONNECT SWITCH..................................................................................................................................... 951 TEST DIODES.......................................................................................................................................................... 952 METHOD FOR TESTING DIODE USING DIGITAL TESTER.................................................................................................................... 952 METHOD FOR TESTING DIODE USING ANALOG TESTER..................................................................................................................... 952 ELECTRICAL SYSTEM - PC490HRD-11E0........................................................................................................................................ 953 ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM................................................................................................................. 953 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - BASE MACHINE.......................................................................................................... 953 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - HIGH REACH DEMOLITION WORK EQUIPMENT.................................................................................. 956 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT......................................................................... 958 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - MEDIUM REACH DEMOLITION WORK EQUIPMENT................................................................................ 960 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - DEMOLITION DIGGING WORK EQUIPMENT..................................................................................... 962 RH PPC LEVER..................................................................................................................................................... 963 LH PPC LEVER..................................................................................................................................................... 964 WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT................................................................................................................... 965 CONSTANT LINK SPEED CIRCUIT...................................................................................................................................... 966 PARALLEL LINK FRONT SCREEN WIPER................................................................................................................................. 967 OVERLOAD CAUTION (HIGH REACH DEMOLITION)......................................................................................................................... 968 ELECTRICAL SYSTEM - PC490HRD-11E0 K100 BOOM CHANGE SYSTEM................................................................................................................ 969 SWING LOCK CIRCUIT................................................................................................................................................... 969 HYDRAULIC LOCK CIRCUIT............................................................................................................................................... 970 WORK EQUIPMENT PICKUP PROXIMITY SWITCH CIRCUIT....................................................................................................................... 971 BOOM RAISE LOCK CIRCUIT.............................................................................................................................................. 972 DEPRESSURISATION CIRCUIT............................................................................................................................................. 973 PRESSURE INTENSIFIER CIRCUIT......................................................................................................................................... 974 HYDRAULIC PIN LOCK/UNLOCK CIRCUIT.................................................................................................................................... 975 VALVE LOCK/UNLOCK.................................................................................................................................................... 976 1ST BOOM AND EXTENSION BOOM CAMERA................................................................................................................................... 977 1st BOOM ELECTRICAL DIAGRAM.......................................................................................................................................... 978 EXTENSION BOOM ELECTRICAL DIAGRAM.................................................................................................................................... 979 HIGH REACH DEMOLITION WORK EQUIPMENT ELECTRICAL DIAGRAM.............................................................................................................. 980 DEMOLITION DIGGING WORK EQUIPMENT ELECTRICAL DIAGRAM................................................................................................................. 982 HYDRAULIC PIN, S-VALVE AND PICK UP PIN SENSORS, MEASURING AND ADJUSTING HYDRAULIC PIN LOCK SENSORS................................................................... 984 MEASURING AND ADJUSTING HYDRAULIC PIN UNLOCK SENSORS................................................................................................................. 986 MEASURING AND ADJUSTING PICK-UP PIN SENSOR........................................................................................................................... 987 MEASURING AND ADJUSTING S-VALVE PIN UNLOCK SWITCHES.................................................................................................................. 988 MEASURING AND ADJUSTING A-VALVE PROXIMITY SWITCH..................................................................................................................... 989 MEASURING AND ADJUSTING SHIMS FOR REACTION BRACKET................................................................................................................... 990 K100 BOOM CHANGE CONTROL SYSTEM...................................................................................................................................... 991 SERVICE OPERATIONS - K100 BOOM CHANGE SYSTEM......................................................................................................................... 993 K100 BOOM CHANGE CONTROL SYSTEM - UPDATING SOFTWARE.................................................................................................................. 999 K100 BOOM CHANGE CONTROLLER REPLACEMENT..............................................................................................................................1001 Pm CLINIC................................................................................................................................................................1003 Pm CLINIC SERVICE....................................................................................................................................................1003 Pm CLINIC CHECK SHEET............................................................................................................................................1004 WORKING RANGE INDICATOR SYSTEM...........................................................................................................................................1017 WORKING RANGE INDICATOR SYSTEM LAYOUT................................................................................................................................1017 METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU....................................................................................................1019 DIAGNOSTICS - WORKING RANGE INDICATOR SYSTEM.........................................................................................................................1021 MONITORING SYSTEM PARAMETERS AND SENSOR STATES...................................................................................................................1021 USING THE PARAMETER CHANGE LOG...................................................................................................................................1023 USING ERROR LISTS AND LOGS.......................................................................................................................................1024 EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM..................................................................................................................1025 IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM....................................................................................................................1026 REPLACING COMPONENTS - WORKING RANGE INDICATOR SYSTEM................................................................................................................1028 WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT..........................................................................................................1028 WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT...............................................................................................................1033 WORKING RANGE INDICATOR SYSTEM - UDATING SOFTWARE................................................................................................................1038 CALIBRATION - WORKING RANGE INDICATOR SYSTEM.........................................................................................................................1042 WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW..............................................................................................................1042 METHOD 1 - CALIBRATING AND CONFIRMING CALIBRATION ACCURACY - AUTO CALIBRATION....................................................................................1042 METHOD 2 - BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION......................................................................................1050 METHOD 2 - CALIBRATING AND CONFIRMING CALIBRATION ACCURACY - MANUAL CALIBRATION..................................................................................1053 40 TROUBLESHOOTING...........................................................................................................................................................1069 CONTENTS.................................................................................................................................................................1070 ABBREVIATION LIST........................................................................................................................................................1083 RELATED INFORMATION ON TROUBLESHOOTING...................................................................................................................................1089 GENERAL TROUBLESHOOTING POINTS.......................................................................................................................................1089 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...........................................................................................................................1090 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................................................1102 CHECKS BEFORE TROUBLESHOOTING........................................................................................................................................1104 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..........................................................................................................................1106 WALK-AROUND CHECK................................................................................................................................................1106 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.........................................................................................................................1108 CHECK FUEL LEVEL AND TYPE........................................................................................................................................1108 CHECK IMPURE INGREDIENT IN FUEL..................................................................................................................................1109 CHECK FUEL PREFILTER.............................................................................................................................................1109 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT...............................................................................................................1109 FUEL PREFILTER CARTRIDGE - REPLACE...............................................................................................................................1110 CHECK MAIN FILTER................................................................................................................................................1111 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)...................................................................................................................1112 CHECK COOLANT LEVEL (RESERVOIR TANK).............................................................................................................................1114 CHECK CLOGGING OF AIR CLEANER....................................................................................................................................1114 OUTER ELEMENT - CLEAN............................................................................................................................................1115 ELEMENTS - REPLACE...............................................................................................................................................1117 CHECK HYDRAULIC OIL LEVEL........................................................................................................................................1118 CHECK HYDRAULIC OIL STRAINER.....................................................................................................................................1118 CHECK HYDRAULIC FILTER...........................................................................................................................................1119 CHECK OIL LEVEL IN SWING MACHINERY CASE..........................................................................................................................1120 CHECK OIL LEVEL IN DAMPER CASE...................................................................................................................................1121 CHECK OIL LEVEL IN FINAL DRIVE CASE..............................................................................................................................1121 BLEED AIR FROM FUEL SYSTEM.......................................................................................................................................1122 BLEED AIR FROM HYDRAULIC SYSTEM..................................................................................................................................1122 ELECTRICAL EQUIPMENT - CHECK METHOD..............................................................................................................................1122 AUTOMATIC GREASE SYSTEM..............................................................................................................................................1128 FINDING MALFUNCTIONS.............................................................................................................................................1128 MALFUNCTION FINDING PROCEDURES...................................................................................................................................1132 ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION......................................................................................................................1134 PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM........................................................................................................................1147 PROCEDURE FOR TESTING AND TROUBLESHOOTING............................................................................................................................1157 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS......................................................................................................................1160 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.......................................................................................................................1164 CONNECTOR LIST AND LAYOUT............................................................................................................................................1166 CONNECTOR CONTACT IDENTIFICATION.....................................................................................................................................1179 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE..............................................................................................................................1219 FUSE LOCATION TABLE..................................................................................................................................................1225 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..........................................................................................................1228 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])..........................................................................1232 FAILURE CODE TABLE...................................................................................................................................................1234 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)........................................................................................................................1253 FAILURE CODE [879AKA]................................................................................................................................................1253 FAILURE CODE [879AKB]................................................................................................................................................1254 FAILURE CODE [879BKA]................................................................................................................................................1255 FAILURE CODE [879BKB]................................................................................................................................................1257 FAILURE CODE [879CKA]................................................................................................................................................1259 FAILURE CODE [879CKB]................................................................................................................................................1260 FAILURE CODE [879DKZ]................................................................................................................................................1261 FAILURE CODE [879EMC]................................................................................................................................................1263 FAILURE CODE [879FMC]................................................................................................................................................1264 FAILURE CODE [879GKX]................................................................................................................................................1265 FAILURE CODE [989L00]................................................................................................................................................1267 FAILURE CODE [989M00]................................................................................................................................................1268 FAILURE CODE [989N00]................................................................................................................................................1269 FAILURE CODE [A1U0N3]................................................................................................................................................1270 FAILURE CODE [A1U0N4]................................................................................................................................................1272 FAILURE CODE [A900FR]................................................................................................................................................1274 FAILURE CODE [A900N6]................................................................................................................................................1275 FAILURE CODE [A900NY]................................................................................................................................................1276 FAILURE CODE [AA10NX]................................................................................................................................................1277 FAILURE CODE [AB00KE]................................................................................................................................................1279 FAILURE CODE [AQ10N3]................................................................................................................................................1282 FAILURE CODE [AS00N3]................................................................................................................................................1284 FAILURE CODE [AS00R2]................................................................................................................................................1286 FAILURE CODE [AS00R3]................................................................................................................................................1287 FAILURE CODE [AS00R4]................................................................................................................................................1288 FAILURE CODE [AS00R5]................................................................................................................................................1289 FAILURE CODE [AS00R6]................................................................................................................................................1290 FAILURE CODE [AS00ZK]................................................................................................................................................1291 FAILURE CODE [AS10KM]................................................................................................................................................1292 FAILURE CODE [AS10NR]................................................................................................................................................1293 FAILURE CODE [AS10NT]................................................................................................................................................1294 FAILURE CODE [B@BAZG]................................................................................................................................................1295 FAILURE CODE [B@BAZK]................................................................................................................................................1296 FAILURE CODE [B@BCNS]................................................................................................................................................1298 FAILURE CODE [B@BCQA]................................................................................................................................................1299 FAILURE CODE [B@BCZK]................................................................................................................................................1301 FAILURE CODE [B@HANS]................................................................................................................................................1303 FAILURE CODE [CA115].................................................................................................................................................1304 FAILURE CODE [CA122].................................................................................................................................................1305 FAILURE CODE [CA123].................................................................................................................................................1307 FAILURE CODE [CA131].................................................................................................................................................1309 FAILURE CODE [CA132].................................................................................................................................................1311 FAILURE CODE [CA135].................................................................................................................................................1313 FAILURE CODE [CA141].................................................................................................................................................1315 FAILURE CODE [CA144].................................................................................................................................................1317 FAILURE CODE [CA145].................................................................................................................................................1319 FAILURE CODE [CA153].................................................................................................................................................1321 FAILURE CODE [CA154].................................................................................................................................................1324 FAILURE CODE [CA187].................................................................................................................................................1327 FAILURE CODE [CA221].................................................................................................................................................1329 FAILURE CODE [CA222].................................................................................................................................................1331 FAILURE CODE [CA227].................................................................................................................................................1333 FAILURE CODE [CA234].................................................................................................................................................1334 FAILURE CODE [CA238].................................................................................................................................................1335 FAILURE CODE [CA239].................................................................................................................................................1337 FAILURE CODE [CA249].................................................................................................................................................1339 FAILURE CODE [CA256].................................................................................................................................................1341 FAILURE CODE [CA271].................................................................................................................................................1343 FAILURE CODE [CA272].................................................................................................................................................1345 FAILURE CODE [CA273].................................................................................................................................................1346 FAILURE CODE [CA274].................................................................................................................................................1348 FAILURE CODE [CA322].................................................................................................................................................1349 FAILURE CODE [CA323].................................................................................................................................................1351 FAILURE CODE [CA324].................................................................................................................................................1353 FAILURE CODE [CA325].................................................................................................................................................1355 FAILURE CODE [CA331].................................................................................................................................................1357 FAILURE CODE [CA332].................................................................................................................................................1359 FAILURE CODE [CA343].................................................................................................................................................1361 FAILURE CODE [CA351].................................................................................................................................................1362 FAILURE CODE [CA352].................................................................................................................................................1363 FAILURE CODE [CA356].................................................................................................................................................1366 FAILURE CODE [CA357].................................................................................................................................................1368 FAILURE CODE [CA386].................................................................................................................................................1370 FAILURE CODE [CA441].................................................................................................................................................1371 FAILURE CODE [CA442].................................................................................................................................................1373 FAILURE CODE [CA449].................................................................................................................................................1374 FAILURE CODE [CA451].................................................................................................................................................1375 FAILURE CODE [CA452].................................................................................................................................................1377 FAILURE CODE [CA515].................................................................................................................................................1379 FAILURE CODE [CA516].................................................................................................................................................1381 FAILURE CODE [CA553].................................................................................................................................................1383 FAILURE CODE [CA555].................................................................................................................................................1384 FAILURE CODE [CA556].................................................................................................................................................1385 FAILURE CODE [CA559].................................................................................................................................................1386 FAILURE CODE [CA595].................................................................................................................................................1391 FAILURE CODE [CA687].................................................................................................................................................1392 FAILURE CODE [CA689].................................................................................................................................................1394 FAILURE CODE [CA691].................................................................................................................................................1396 FAILURE CODE [CA692].................................................................................................................................................1398 FAILURE CODE [CA697].................................................................................................................................................1400 FAILURE CODE [CA698].................................................................................................................................................1401 FAILURE CODE [CA731].................................................................................................................................................1402 FAILURE CODE [CA778].................................................................................................................................................1403 FAILURE CODE [CA1117]................................................................................................................................................1406 FAILURE CODE [CA1664]................................................................................................................................................1407 FAILURE CODE [CA1669]................................................................................................................................................1410 FAILURE CODE [CA1673]................................................................................................................................................1411 FAILURE CODE [CA1677]................................................................................................................................................1412 FAILURE CODE [CA1678]................................................................................................................................................1413 FAILURE CODE [CA1682]................................................................................................................................................1414 FAILURE CODE [CA1683]................................................................................................................................................1416 FAILURE CODE [CA1684]................................................................................................................................................1418 FAILURE CODE [CA1686]................................................................................................................................................1420 FAILURE CODE [CA1691]................................................................................................................................................1421 FAILURE CODE [CA1694]................................................................................................................................................1424 FAILURE CODE [CA1695]................................................................................................................................................1426 FAILURE CODE [CA1696]................................................................................................................................................1427 FAILURE CODE [CA1712]................................................................................................................................................1429 FAILURE CODE [CA1713]................................................................................................................................................1432 FAILURE CODE [CA1714]................................................................................................................................................1434 FAILURE CODE [CA1715]................................................................................................................................................1435 FAILURE CODE [CA1776]................................................................................................................................................1436 FAILURE CODE [CA1777]................................................................................................................................................1439 FAILURE CODE [CA1843]................................................................................................................................................1442 FAILURE CODE [CA1844]................................................................................................................................................1444 FAILURE CODE [CA1879]................................................................................................................................................1447 FAILURE CODE [CA1881]................................................................................................................................................1450 FAILURE CODE [CA1883]................................................................................................................................................1452 FAILURE CODE [CA1885]................................................................................................................................................1455 FAILURE CODE [CA1887]................................................................................................................................................1457 FAILURE CODE [CA1921]................................................................................................................................................1459 FAILURE CODE [CA1922]................................................................................................................................................1462 FAILURE CODE [CA1923]................................................................................................................................................1467 FAILURE CODE [CA1924]................................................................................................................................................1469 FAILURE CODE [CA1925]................................................................................................................................................1471 FAILURE CODE [CA1927]................................................................................................................................................1473 FAILURE CODE [CA1928]................................................................................................................................................1475 FAILURE CODE [CA1942]................................................................................................................................................1477 FAILURE CODE [CA1963]................................................................................................................................................1478 FAILURE CODE [CA1977]................................................................................................................................................1481 FAILURE CODE [CA1993]................................................................................................................................................1484 FAILURE CODE [CA2185]................................................................................................................................................1487 FAILURE CODE [CA2186]................................................................................................................................................1489 FAILURE CODE [CA2249]................................................................................................................................................1491 FAILURE CODE [CA2265]................................................................................................................................................1492 FAILURE CODE [CA2266]................................................................................................................................................1494 FAILURE CODE [CA2271]................................................................................................................................................1496 FAILURE CODE [CA2272]................................................................................................................................................1498 FAILURE CODE [CA2349]................................................................................................................................................1500 FAILURE CODE [CA2353]................................................................................................................................................1502 FAILURE CODE [CA2357]................................................................................................................................................1504 FAILURE CODE [CA2381]................................................................................................................................................1505 FAILURE CODE [CA2382]................................................................................................................................................1507 FAILURE CODE [CA2383]................................................................................................................................................1509 FAILURE CODE [CA2386]................................................................................................................................................1511 FAILURE CODE [CA2387]................................................................................................................................................1513 FAILURE CODE [CA2555]................................................................................................................................................1514 FAILURE CODE [CA2556]................................................................................................................................................1517 FAILURE CODE [CA2637]................................................................................................................................................1519 FAILURE CODE [CA2639]................................................................................................................................................1521 FAILURE CODE [CA2732]................................................................................................................................................1524 FAILURE CODE [CA2733]................................................................................................................................................1526 FAILURE CODE [CA2741]................................................................................................................................................1528 FAILURE CODE [CA2765]................................................................................................................................................1529 FAILURE CODE [CA2771]................................................................................................................................................1530 FAILURE CODE [CA2777]................................................................................................................................................1536 FAILURE CODE [CA2878]................................................................................................................................................1539 FAILURE CODE [CA2881]................................................................................................................................................1542 FAILURE CODE [CA2976]................................................................................................................................................1545 FAILURE CODE [CA3133]................................................................................................................................................1547 FAILURE CODE [CA3134]................................................................................................................................................1549 FAILURE CODE [CA3135]................................................................................................................................................1551 FAILURE CODE [CA3142]................................................................................................................................................1554 FAILURE CODE [CA3143]................................................................................................................................................1555 FAILURE CODE [CA3144]................................................................................................................................................1556 FAILURE CODE [CA3146]................................................................................................................................................1558 FAILURE CODE [CA3147]................................................................................................................................................1559 FAILURE CODE [CA3148]................................................................................................................................................1560 FAILURE CODE [CA3151]................................................................................................................................................1562 FAILURE CODE [CA3165]................................................................................................................................................1568 FAILURE CODE [CA3167]................................................................................................................................................1570 FAILURE CODE [CA3229]................................................................................................................................................1573 FAILURE CODE [CA3231]................................................................................................................................................1575 FAILURE CODE [CA3232]................................................................................................................................................1577 FAILURE CODE [CA3235]................................................................................................................................................1581 FAILURE CODE [CA3239]................................................................................................................................................1583 FAILURE CODE [CA3241]................................................................................................................................................1586 FAILURE CODE [CA3242]................................................................................................................................................1589 FAILURE CODE [CA3251]................................................................................................................................................1592 FAILURE CODE [CA3253]................................................................................................................................................1594 FAILURE CODE [CA3254]................................................................................................................................................1597 FAILURE CODE [CA3255]................................................................................................................................................1600 FAILURE CODE [CA3256]................................................................................................................................................1604 FAILURE CODE [CA3311]................................................................................................................................................1606 FAILURE CODE [CA3312]................................................................................................................................................1608 FAILURE CODE [CA3313]................................................................................................................................................1611 FAILURE CODE [CA3314]................................................................................................................................................1612 FAILURE CODE [CA3315]................................................................................................................................................1613 FAILURE CODE [CA3316]................................................................................................................................................1616 FAILURE CODE [CA3317]................................................................................................................................................1617 FAILURE CODE [CA3318]................................................................................................................................................1618 FAILURE CODE [CA3319]................................................................................................................................................1620 FAILURE CODE [CA3321]................................................................................................................................................1621 FAILURE CODE [CA3322]................................................................................................................................................1623 FAILURE CODE [CA3419]................................................................................................................................................1626 FAILURE CODE [CA3421]................................................................................................................................................1628 FAILURE CODE [CA3497]................................................................................................................................................1630 FAILURE CODE [CA3498]................................................................................................................................................1631 FAILURE CODE [CA3543]................................................................................................................................................1632 FAILURE CODE [CA3545]................................................................................................................................................1639 FAILURE CODE [CA3547]................................................................................................................................................1641 FAILURE CODE [CA3558]................................................................................................................................................1642 FAILURE CODE [CA3559]................................................................................................................................................1644 FAILURE CODE [CA3562]................................................................................................................................................1646 FAILURE CODE [CA3563]................................................................................................................................................1648 FAILURE CODE [CA3567]................................................................................................................................................1651 FAILURE CODE [CA3568]................................................................................................................................................1654 FAILURE CODE [CA3571]................................................................................................................................................1658 FAILURE CODE [CA3572]................................................................................................................................................1660 FAILURE CODE [CA3574]................................................................................................................................................1662 FAILURE CODE [CA3575]................................................................................................................................................1664 FAILURE CODE [CA3577]................................................................................................................................................1666 FAILURE CODE [CA3578]................................................................................................................................................1668 FAILURE CODE [CA3582]................................................................................................................................................1670 FAILURE CODE [CA3583]................................................................................................................................................1676 FAILURE CODE [CA3596]................................................................................................................................................1678 FAILURE CODE [CA3649]................................................................................................................................................1680 FAILURE CODE [CA3681]................................................................................................................................................1682 FAILURE CODE [CA3682]................................................................................................................................................1687 FAILURE CODE [CA3713]................................................................................................................................................1693 FAILURE CODE [CA3717]................................................................................................................................................1696 FAILURE CODE [CA3718]................................................................................................................................................1697 FAILURE CODE [CA3725]................................................................................................................................................1698 FAILURE CODE [CA3748]................................................................................................................................................1701 FAILURE CODE [CA3751]................................................................................................................................................1703 FAILURE CODE [CA3755]................................................................................................................................................1705 FAILURE CODE [CA3866]................................................................................................................................................1707 FAILURE CODE [CA3867]................................................................................................................................................1711 FAILURE CODE [CA3868]................................................................................................................................................1714 FAILURE CODE [CA3899]................................................................................................................................................1718 FAILURE CODE [CA3911]................................................................................................................................................1720 FAILURE CODE [CA3912]................................................................................................................................................1724 FAILURE CODE [CA3932]................................................................................................................................................1726 FAILURE CODE [CA3933]................................................................................................................................................1728 FAILURE CODE [CA3934]................................................................................................................................................1730 FAILURE CODE [CA3935]................................................................................................................................................1733 FAILURE CODE [CA3936]................................................................................................................................................1735 FAILURE CODE [CA4151]................................................................................................................................................1737 FAILURE CODE [CA4152]................................................................................................................................................1741 FAILURE CODE [CA4155]................................................................................................................................................1745 FAILURE CODE [CA4156]................................................................................................................................................1747 FAILURE CODE [CA4157]................................................................................................................................................1750 FAILURE CODE [CA4158]................................................................................................................................................1752 FAILURE CODE [CA4159]................................................................................................................................................1753 FAILURE CODE [CA4161]................................................................................................................................................1754 FAILURE CODE [CA4162]................................................................................................................................................1757 FAILURE CODE [CA4163]................................................................................................................................................1760 FAILURE CODE [CA4164]................................................................................................................................................1762 FAILURE CODE [CA4165]................................................................................................................................................1764 FAILURE CODE [CA4166]................................................................................................................................................1766 FAILURE CODE [CA4168]................................................................................................................................................1768 FAILURE CODE [CA4169]................................................................................................................................................1771 FAILURE CODE [CA4171]................................................................................................................................................1773 FAILURE CODE [CA4249]................................................................................................................................................1776 FAILURE CODE [CA4251]................................................................................................................................................1778 FAILURE CODE [CA4259]................................................................................................................................................1780 FAILURE CODE [CA4261]................................................................................................................................................1782 FAILURE CODE [CA4277]................................................................................................................................................1785 FAILURE CODE [CA4281]................................................................................................................................................1789 FAILURE CODE [CA4459]................................................................................................................................................1792 FAILURE CODE [CA4461]................................................................................................................................................1795 FAILURE CODE [CA4658]................................................................................................................................................1798 FAILURE CODE [CA4731]................................................................................................................................................1802 FAILURE CODE [CA4732]................................................................................................................................................1803 FAILURE CODE [CA4739]................................................................................................................................................1804 FAILURE CODE [CA4768]................................................................................................................................................1805 FAILURE CODE [CA4769]................................................................................................................................................1807 FAILURE CODE [CA4842]................................................................................................................................................1810 FAILURE CODE [CA4952]................................................................................................................................................1814 FAILURE CODE [CA5115]................................................................................................................................................1816 FAILURE CODE [CA5179]................................................................................................................................................1819 FAILURE CODE [CA5181]................................................................................................................................................1821 FAILURE CODE [CA5383]................................................................................................................................................1823 FAILURE CODE [D110KB]................................................................................................................................................1825 FAILURE CODE [D19JKZ]................................................................................................................................................1827 FAILURE CODE [D811MC]................................................................................................................................................1830 FAILURE CODE [D862KA]................................................................................................................................................1831 FAILURE CODE [D8ALKA]................................................................................................................................................1833 FAILURE CODE [D8ALKB]................................................................................................................................................1836 FAILURE CODE [D8AQKR]................................................................................................................................................1838 FAILURE CODE [D8G1KT]................................................................................................................................................1845 FAILURE CODE [D8G6KT]................................................................................................................................................1846 FAILURE CODE [DA20MC]................................................................................................................................................1847 FAILURE CODE [DA22KK]................................................................................................................................................1848 FAILURE CODE [DA29KQ]................................................................................................................................................1851 FAILURE CODE [DA2LKA]................................................................................................................................................1853 FAILURE CODE [DA2LKB]................................................................................................................................................1856 FAILURE CODE [DA2QKR]................................................................................................................................................1858 FAILURE CODE [DA2RKR]................................................................................................................................................1867 FAILURE CODE [DAF0KM]................................................................................................................................................1868 FAILURE CODE [DAF0MB]................................................................................................................................................1869 FAILURE CODE [DAF0MC]................................................................................................................................................1870 FAILURE CODE [DAF8KB]................................................................................................................................................1871 FAILURE CODE [DAF9KQ]................................................................................................................................................1873 FAILURE CODE [DAFGMC]................................................................................................................................................1874 FAILURE CODE [DAFLKA]................................................................................................................................................1875 FAILURE CODE [DAFLKB]................................................................................................................................................1878 FAILURE CODE [DAFQKR]................................................................................................................................................1880 FAILURE CODE [DAZ9KQ]................................................................................................................................................1888 FAILURE CODE [DAZQKR]................................................................................................................................................1889 FAILURE CODE [DB2QKR]................................................................................................................................................1896 FAILURE CODE [DB2RKR]................................................................................................................................................1904 FAILURE CODE [DBP0KM]................................................................................................................................................1908 FAILURE CODE [DBP0KT]................................................................................................................................................1909 FAILURE CODE [DBP5KB]................................................................................................................................................1910 FAILURE CODE [DBP5KY]................................................................................................................................................1913 FAILURE CODE [DBPQKR]................................................................................................................................................1916 FAILURE CODE [DDNRKA]................................................................................................................................................1924 FAILURE CODE [DDNRKY]................................................................................................................................................1926 FAILURE CODE [DDNS00]................................................................................................................................................1928 FAILURE CODE [DFB1KZ]................................................................................................................................................1930 FAILURE CODE [DFB2KZ]................................................................................................................................................1932 FAILURE CODE [DFB3L8]................................................................................................................................................1934 FAILURE CODE [DFB4L8]................................................................................................................................................1936 FAILURE CODE [DFB5KZ]................................................................................................................................................1938 FAILURE CODE [DFB6KZ]................................................................................................................................................1940 FAILURE CODE [DGH2KA]................................................................................................................................................1942 FAILURE CODE [DGH2KB]................................................................................................................................................1944 FAILURE CODE [DHA4KA]................................................................................................................................................1946 FAILURE CODE [DHAAMA]................................................................................................................................................1948 FAILURE CODE [DHACMA]................................................................................................................................................1950 FAILURE CODE [DHPAMA]................................................................................................................................................1952 FAILURE CODE [DHPBMA]................................................................................................................................................1955 FAILURE CODE [DHS3MA]................................................................................................................................................1958 FAILURE CODE [DHS4MA]................................................................................................................................................1961 FAILURE CODE [DHS8MA]................................................................................................................................................1964 FAILURE CODE [DHS9MA]................................................................................................................................................1967 FAILURE CODE [DHSAMA]................................................................................................................................................1970 FAILURE CODE [DHSBMA]................................................................................................................................................1973 FAILURE CODE [DHSCMA]................................................................................................................................................1976 FAILURE CODE [DHSDMA]................................................................................................................................................1979 FAILURE CODE [DHSFMA]................................................................................................................................................1982 FAILURE CODE [DHSGMA]................................................................................................................................................1985 FAILURE CODE [DHSHMA]................................................................................................................................................1988 FAILURE CODE [DHSJMA]................................................................................................................................................1991 FAILURE CODE [DHZAMA]................................................................................................................................................1994 FAILURE CODE [DHZCL8]................................................................................................................................................1998 FAILURE CODE [DKR0MA]................................................................................................................................................1999 FAILURE CODE [DKR1MA]................................................................................................................................................2002 FAILURE CODE [DKULKA]................................................................................................................................................2005 FAILURE CODE [DKULKB]................................................................................................................................................2007 FAILURE CODE [DKULKY]................................................................................................................................................2009 FAILURE CODE [DLM3KA]................................................................................................................................................2011 FAILURE CODE [DLM3KB]................................................................................................................................................2013 FAILURE CODE [DLM3MB]................................................................................................................................................2015 FAILURE CODE [DR10KA]................................................................................................................................................2016 FAILURE CODE [DR12KA]................................................................................................................................................2019 FAILURE CODE [DR20KA]................................................................................................................................................2021 FAILURE CODE [DR21KX]................................................................................................................................................2023 FAILURE CODE [DR30KA]................................................................................................................................................2025 FAILURE CODE [DR31KX]................................................................................................................................................2027 FAILURE CODE [DR40KA]................................................................................................................................................2029 FAILURE CODE [DUMBKA]................................................................................................................................................2031 FAILURE CODE [DUMBKB]................................................................................................................................................2034 FAILURE CODE [DV00KA]................................................................................................................................................2036 FAILURE CODE [DV00KB]................................................................................................................................................2037 FAILURE CODE [DV20KB]................................................................................................................................................2038 FAILURE CODE [DW43KA]................................................................................................................................................2040 FAILURE CODE [DW43KB]................................................................................................................................................2042 FAILURE CODE [DW43KY]................................................................................................................................................2044 FAILURE CODE [DW45KA]................................................................................................................................................2046 FAILURE CODE [DW45KB]................................................................................................................................................2049 FAILURE CODE [DW45KY]................................................................................................................................................2052 FAILURE CODE [DW4CKY]................................................................................................................................................2054 FAILURE CODE [DW7BKA]................................................................................................................................................2055 FAILURE CODE [DW7BKB]................................................................................................................................................2057 FAILURE CODE [DW7BKY]................................................................................................................................................2059 FAILURE CODE [DW91KA]................................................................................................................................................2060 FAILURE CODE [DW91KB]................................................................................................................................................2062 FAILURE CODE [DW91KY]................................................................................................................................................2064 FAILURE CODE [DWA2KA]................................................................................................................................................2066 FAILURE CODE [DWA2KB]................................................................................................................................................2068 FAILURE CODE [DWA2KY]................................................................................................................................................2070 FAILURE CODE [DWK0KA]................................................................................................................................................2072 FAILURE CODE [DWK0KB]................................................................................................................................................2074 FAILURE CODE [DWK0KY]................................................................................................................................................2076 FAILURE CODE [DWK2KA]................................................................................................................................................2078 FAILURE CODE [DWK2KB]................................................................................................................................................2080 FAILURE CODE [DWK2KY]................................................................................................................................................2082 FAILURE CODE [DWK8KA]................................................................................................................................................2084 FAILURE CODE [DWK8KB]................................................................................................................................................2086 FAILURE CODE [DWK8KY]................................................................................................................................................2088 FAILURE CODE [DWPUKA]................................................................................................................................................2090 FAILURE CODE [DWPUKB]................................................................................................................................................2092 FAILURE CODE [DWPUKY]................................................................................................................................................2094 FAILURE CODE [DX16KA]................................................................................................................................................2096 FAILURE CODE [DX16KB]................................................................................................................................................2098 FAILURE CODE [DXA8KA]................................................................................................................................................2100 FAILURE CODE [DXA8KB]................................................................................................................................................2102 FAILURE CODE [DXA9KA]................................................................................................................................................2104 FAILURE CODE [DXA9KB]................................................................................................................................................2106 FAILURE CODE [DXE0KA]................................................................................................................................................2108 FAILURE CODE [DXE0KB]................................................................................................................................................2110 FAILURE CODE [DXE4KA]................................................................................................................................................2112 FAILURE CODE [DXE4KB]................................................................................................................................................2114 FAILURE CODE [DXE4KY]................................................................................................................................................2116 FAILURE CODE [DXE5KA]................................................................................................................................................2118 FAILURE CODE [DXE5KB]................................................................................................................................................2120 FAILURE CODE [DXE6KA]................................................................................................................................................2122 FAILURE CODE [DXE6KB]................................................................................................................................................2124 FAILURE CODE [DXE7KA]................................................................................................................................................2126 FAILURE CODE [DXE7KB]................................................................................................................................................2128 FAILURE CODE [DXE7KY]................................................................................................................................................2130 FAILURE CODE [DXE8KA]................................................................................................................................................2132 FAILURE CODE [DXE8KB]................................................................................................................................................2134 FAILURE CODE [DXE8KY]................................................................................................................................................2136 FAILURE CODE [DXE9KA]................................................................................................................................................2138 FAILURE CODE [DXE9KB]................................................................................................................................................2140 FAILURE CODE [DXE9KY]................................................................................................................................................2142 FAILURE CODE [DXEAKA]................................................................................................................................................2144 FAILURE CODE [DXEAKB]................................................................................................................................................2146 FAILURE CODE [DXEAKY]................................................................................................................................................2148 FAILURE CODE [DXEKKA]................................................................................................................................................2150 FAILURE CODE [DXEKKB]................................................................................................................................................2152 FAILURE CODE [DXEKKY]................................................................................................................................................2154 FAILURE CODE [DXELKA]................................................................................................................................................2156 FAILURE CODE [DXELKB]................................................................................................................................................2158 FAILURE CODE [DXELKY]................................................................................................................................................2160 FAILURE CODE [DY20KA]................................................................................................................................................2162 FAILURE CODE [DY20MA]................................................................................................................................................2164 FAILURE CODE [DY2CKB]................................................................................................................................................2166 FAILURE CODE [DY2DKB]................................................................................................................................................2169 FAILURE CODE [DY2EKB]................................................................................................................................................2171 FAILURE CODE [F313KA]................................................................................................................................................2173 FAILURE CODE [F313KB]................................................................................................................................................2175 FAILURE CODE [F318KB]................................................................................................................................................2178 FAILURE CODE [F318KY]................................................................................................................................................2181 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)............................................................................................................................2183 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)....................................................................................................................2183 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...........................................................................................................................2189 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK........................................................................................................................2192 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP................................................................................................2194 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING..................................................................................2196 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW...............................................2199 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW.........................................2200 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING....................................................................................2201 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING.....................................................................................2202 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING........................................................................................2203 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...................................................................................................2204 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.....................................................................................................2205 E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.....................................................................................2206 E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING............................................................................................2207 E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING......................................................................................2208 E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM........................................................................................................2209 E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL............................................................................................................2211 E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..................................................................................2212 E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE.............................................................................2213 E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................................................2214 E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE..................................................................................2216 E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED..........................................................................................................2217 E-23 FUNCTION SWITCH DOES NOT OPERATE................................................................................................................................2218 E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)........................................................................................................2219 E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF.........................................................2220 E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER.........................................................................................................2221 E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED............................................................................2222 E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED...............................................................................2223 E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE......................................................................................2224 E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE.....................................................................................2225 E-31 ALARM BUZZER CANNOT BE CANCELED.................................................................................................................................2227 E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION........................................................................................2228 E-33 SERVICE MODE CANNOT BE SELECTED.................................................................................................................................2229 E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE.................................................................................................2230 E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK..................................................................................................2232 E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING..................................................................................2233 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE..................................................................2236 E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR............................................................2238 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED............................................................................................................2240 E-40 ALARM DOES NOT SOUND DURING TRAVEL..............................................................................................................................2241 E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED...........................................................................................................2243 E-42 HORN DOES NOT SOUND.............................................................................................................................................2244 E-43 HORN DOES NOT STOP SOUNDING.....................................................................................................................................2248 E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF........................................................................................2250 E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE................................................................................................2251 E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE...........................................................................................2253 E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................................................2254 E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................................................2255 E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION............................................................................................2256 E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.............................................................................................2257 E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................................................2258 E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................................................2259 E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION..............................................................................................2260 E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.............................................................................................2261 E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION............................................................................................2262 E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED..................................................................................................................2264 E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY........................................................................................................................2265 E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED.....................................................................................................................2266 E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE.......................................................................................................................2268 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)............................................................................................................2269 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)..............................................................................................................2269 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS.....................................................................................................................2270 FAILURE MODE AND CAUSE TABLE.........................................................................................................................................2272 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK.................................................................................................................2280 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER........................................................................................................2281 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR.....................................................................................................................2283 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP................................................................................................................2284 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS.......................................................................................................................2285 H-6 SPEED OR POWER OF BOOM IS LOW....................................................................................................................................2287 H-7 ARM SPEED OR POWER IS LOW........................................................................................................................................2293 H-8 BUCKET SPEED OR POWER IS LOW.....................................................................................................................................2298 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION.................................................................................................................2301 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE................................................................................................................................2302 H-11 HYDRAULIC DRIFT OF ARM IS LARGE.................................................................................................................................2304 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE..............................................................................................................................2306 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES................................................................................2307 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE.............................................................................................................................2308 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE............................................................................................................2309 H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE.......................................................................................................................2310 H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................................................................................2311 H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED................................................................................................................2312 H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER.............................................................................2313 H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY...........................................................................................2314 H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW.........................................................................................2315 H-22 MACHINE DOES NOT TRAVEL STRAIGHT................................................................................................................................2316 H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW............................................................................................................2318 H-24 TRAVEL SPEED IS LOW.............................................................................................................................................2321 H-25 ONE OF TRACKS DOES NOT RUN......................................................................................................................................2323 H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST...............................................................................................2324 H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT.......................................................................................................2325 H-28 SWINGS ONLY IN ONE DIRECTION....................................................................................................................................2326 H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)....................................................................................2327 H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION.............................................................................2328 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)...............................................................................2329 H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)...........................................................2330 H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING..............................................................................................................2331 H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING................................................................................................2332 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)..........................................................................................2333 H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED).........................................................................................2334 H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)..........................................................................................................2335 H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN..........................................................................................................................2336 H-39 Quick coupler cylinder will not extend..........................................................................................................................2337 H-40 Quick coupler cylinder will not retract (but buzzer doesnot sound)..............................................................................................2339 H-41 Buzzer does not sound (but quick coupler cylinder doesretract)..................................................................................................2341 H-42 Quick coupler cylinder extends and retracts slowly..............................................................................................................2343 TROUBLESHOOTING OF ENGINE (S-MODE).......................................................................................................................................2344 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)..............................................................................................................2344 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...........................................................................................2345 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT.......................................................................................................................2346 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...................................................................2347 S-4 ENGINE STARTABILITY IS POOR......................................................................................................................................2348 S-5 ENGINE DOES NOT PICK UP SMOOTHLY.................................................................................................................................2350 S-6 ENGINE STOPS DURING OPERATION....................................................................................................................................2352 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE.................................................................................................................................2354 S-8 ENGINE LACKS POWER...............................................................................................................................................2355 S-9 KDPF GETS CLOGGED IN A SHORT TIME................................................................................................................................2357 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE.............................................................................................................................2359 S-11 OIL BECOMES CONTAMINATED QUICKLY................................................................................................................................2360 S-12 FUEL CONSUMPTION IS EXCESSIVE...................................................................................................................................2361 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...........................................................................................2362 S-14 OIL PRESSURE DROPS..............................................................................................................................................2363 S-15 FUEL MIXES INTO ENGINE OIL......................................................................................................................................2365 S-16 WATER MIXES INTO ENGINE OIL (MILKY).............................................................................................................................2366 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)................................................................................................................2367 S-18 UNUSUAL NOISE IS HEARD..........................................................................................................................................2368 S-19 VIBRATION IS EXCESSIVE..........................................................................................................................................2369 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT............................................................................................................................2370 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY......................................................................................................................2371 S-22 ACTIVE REGENERATION TAKES TIME..................................................................................................................................2373 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.............................................................................................................2375 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE.............................................................................................................................2376 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)........................................................................................................................2378 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).......................................................................................................2379 TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED).................................................................................................2380 20 SUPPLY VOLTAGE > 32VDC............................................................................................................................................2380 21 SUPPLY VOLTAGE < 12VDC............................................................................................................................................2381 25 FILE ERROR FACTORY SETTINGS.......................................................................................................................................2382 26 FILE ERROR USER SETTINGS..........................................................................................................................................2383 27 FILE ERROR INPUT DATA.............................................................................................................................................2384 30 PROXIMITY SWITCHES DIFFERENCE.....................................................................................................................................2385 86 ANGLE SENSOR A2 TIMEOUT...........................................................................................................................................2386 96 ANGLE SENSOR A3/A5 TIMEOUT........................................................................................................................................2387 106 ANGLE SENSOR A4/A6 TIMEOUT.......................................................................................................................................2388 116 ANGLE SENSOR PITCH TIMEOUT.......................................................................................................................................2389 126 ANGLE SENSOR ROLL TIMEOUT........................................................................................................................................2390 FAILURE CODE TABLE.......................................................................................................................................................2391 TROUBLESHOOTING FOR K100 BOOM CHANGE SYSTEM..............................................................................................................................2394 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)........................................................................................................................2395 FAILURE CODE [198]...................................................................................................................................................2395 FAILURE CODE [199]...................................................................................................................................................2396 FAILURE CODE [200]...................................................................................................................................................2397 FAILURE CODE [201]...................................................................................................................................................2398 FAILURE CODE [202]...................................................................................................................................................2400 FAILURE CODE [203]...................................................................................................................................................2402 FAILURE CODE [204]...................................................................................................................................................2403 FAILURE CODE [205]...................................................................................................................................................2405 FAILURE CODE [206]...................................................................................................................................................2407 FAILURE CODE [207]...................................................................................................................................................2408 FAILURE CODE [208]...................................................................................................................................................2410 FAILURE CODE [209]...................................................................................................................................................2412 FAILURE CODE [210]...................................................................................................................................................2413 FAILURE CODE [211]...................................................................................................................................................2415 FAILURE CODE [212]...................................................................................................................................................2416 FAILURE CODE [213]...................................................................................................................................................2417 FAILURE CODE [214]...................................................................................................................................................2419 FAILURE CODE [215]...................................................................................................................................................2420 FAILURE CODE [216]...................................................................................................................................................2421 FAILURE CODE [217]...................................................................................................................................................2423 FAILURE CODE [218]...................................................................................................................................................2425 FAILURE CODE [219]...................................................................................................................................................2426 FAILURE CODE [220]...................................................................................................................................................2428 FAILURE CODE [221]...................................................................................................................................................2429 FAILURE CODE [222]...................................................................................................................................................2430 FAILURE CODE [223]...................................................................................................................................................2432 FAILURE CODE [224]...................................................................................................................................................2433 FAILURE CODE [225]...................................................................................................................................................2434 FAILURE CODE [226]...................................................................................................................................................2436 FAILURE CODE [227]...................................................................................................................................................2437 FAILURE CODE [228]...................................................................................................................................................2438 FAILURE CODE [229]...................................................................................................................................................2439 FAILURE CODE [230]...................................................................................................................................................2440 FAILURE CODE [231]...................................................................................................................................................2441 FAILURE CODE [234]...................................................................................................................................................2442 FAILURE CODE [235]...................................................................................................................................................2443 FAILURE CODE [236]...................................................................................................................................................2444 FAILURE CODE [237]...................................................................................................................................................2445 FAILURE CODE [240]...................................................................................................................................................2446 FAILURE CODE [241]...................................................................................................................................................2447 FAILURE CODE [242]...................................................................................................................................................2448 FAILURE CODE [250]...................................................................................................................................................2449 FAILURE CODE [250]...................................................................................................................................................2450 FAILURE CODE [250]...................................................................................................................................................2451 FAILURE CODE [250]...................................................................................................................................................2452 STATUS OF DIGITAL INPUTS WITH RESPECT TO WORK EQUIPMENT CONFIGURATIONS...............................................................................................2453 FAILURE CODE.........................................................................................................................................................2454 TROUBLESHOOTING FOR ERRORS ON SENSORS................................................................................................................................2455 TROUBLESHOOTING METHODS..............................................................................................................................................2457 JOINT 1 CAMERA IMAGE NOT DISPLAYED ON SCREEN.........................................................................................................................2459 JOINT 2 CAMERA IMAGE NOT DISPLAYED ON SCREEN.........................................................................................................................2460 CAMERA SCREEN DOES NOT CHANGE TO BOOM RAISE SCREEN...................................................................................................................2461 WORK EQUIPMENT IS NOT PICKED UP BY BASE MACHINE BUT SCREEN CHANGED TO BOOM RAISE SCREEN..............................................................................2462 CAMERA SCREEN DOES NOT APPEAR AFTER WORK EQUIPMENT IS FULLY DISENGAGED...............................................................................................2463 SWING LOCK DOES NOT DEACTIVATE EVEN IF SWING LOCK IS RELEASED........................................................................................................2464 LOCK LEVER IS DOWN (FREE) BUT HYDRAULIC LOCK SYMBOL APPEARS ON SCREEN................................................................................................2466 LOCK LEVER IS DOWN (LOCKED) BUT HYDRAULIC LOCK SYMBOL DOES NOT APPEAR ON SCREEN......................................................................................2467 50 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................2469 CONTENTS.................................................................................................................................................................2470 ABBREVIATION LIST........................................................................................................................................................2475 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY..........................................................................................................................2481 HOW TO READ THIS MANUAL..............................................................................................................................................2481 COATING MATERIALS LIST...............................................................................................................................................2483 SPECIAL TOOLS LIST...................................................................................................................................................2488 SKETCHES OF SPECIAL TOOLS............................................................................................................................................2500 ENGINE AND COOLING SYSTEM................................................................................................................................................2506 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY..............................................................................................................................2506 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY.........................................................................................................................2506 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY.......................................................................................................................2512 REMOVE AND INSTALL INJECTOR ASSEMBLY.................................................................................................................................2521 METHOD FOR REMOVING INJECTOR ASSEMBLY............................................................................................................................2521 METHOD FOR INSTALLING INJECTOR ASSEMBLY..........................................................................................................................2527 REMOVE AND INSTALL FUEL DOSER ASSEMBLY...............................................................................................................................2537 METHOD FOR REMOVING FUEL DOSER...................................................................................................................................2537 METHOD FOR INSTALLING FUEL DOSER.................................................................................................................................2538 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY............................................................................................................................2540 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY.......................................................................................................................2541 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY.....................................................................................................................2550 REMOVE AND INSTALL EGR VALVE ASSEMBLY................................................................................................................................2563 METHOD FOR REMOVING EGR VALVE ASSEMBLY...........................................................................................................................2563 METHOD FOR INSTALLING EGR VALVE ASSEMBLY.........................................................................................................................2565 REMOVE AND INSTALL EGR COOLER ASSEMBLY...............................................................................................................................2567 METHOD FOR REMOVING EGR COOLER ASSEMBLY..........................................................................................................................2567 METHOD FOR INSTALLING EGR COOLER ASSEMBLY........................................................................................................................2571 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...........................................................................................................................2577 METHOD FOR REMOVING STARTING MOTOR ASSEMBLY......................................................................................................................2577 METHOD FOR INSTALLING STARTING MOTOR ASSEMBLY....................................................................................................................2578 REMOVE AND INSTALL ALTERNATOR BELT...................................................................................................................................2580 METHOD FOR REMOVING ALTERNATOR BELT..............................................................................................................................2580 METHOD FOR INSTALLING ALTERNATOR BELT............................................................................................................................2583 REMOVE AND INSTALL RADIATOR ASSEMBLY.................................................................................................................................2588 METHOD FOR REMOVING RADIATOR ASSEMBLY............................................................................................................................2588 METHOD FOR INSTALLING RADIATOR ASSEMBLY..........................................................................................................................2590 REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY................................................................................................................2593 METHOD FOR REMOVING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY...................................................................................................2593 METHOD FOR INSTALLING COOLING FAN AND COOLING FAN MOTOR ASSEMBLY.................................................................................................2597 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY.....................................................................................................................2602 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY................................................................................................................2602 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY..............................................................................................................2604 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY..............................................................................................................................2606 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY.........................................................................................................................2606 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY.......................................................................................................................2608 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY.....................................................................................................................2612 METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY................................................................................................................2613 METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY..............................................................................................................2631 REMOVE AND INSTALL ENGINE FRONT OIL SEAL.............................................................................................................................2650 METHOD FOR REMOVING ENGINE FRONT OIL SEAL........................................................................................................................2651 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL......................................................................................................................2653 REMOVE AND INSTALL ENGINE REAR OIL SEAL..............................................................................................................................2657 METHOD FOR REMOVING ENGINE REAR OIL SEAL.........................................................................................................................2658 METHOD FOR INSTALLING ENGINE REAR OIL SEAL.......................................................................................................................2661 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY..............................................................................................................................2667 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY.........................................................................................................................2667 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY.......................................................................................................................2675 REMOVE AND INSTALL FUEL TANK ASSEMBLY................................................................................................................................2686 METHOD FOR REMOVING FUEL TANK ASSEMBLY...........................................................................................................................2686 METHOD FOR INSTALLING FUEL TANK ASSEMBLY.........................................................................................................................2690 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY..........................................................................................................................2694 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY.....................................................................................................................2694 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...................................................................................................................2700 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY............................................................................................................2705 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.......................................................................................................2705 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.....................................................................................................2712 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER................................................................................................................2718 METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER...........................................................................................................2718 METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER.........................................................................................................2720 REMOVE AND INSTALL KDPF ASSEMBLY.....................................................................................................................................2723 METHOD FOR REMOVING KDPF ASSEMBLY................................................................................................................................2723 METHOD FOR INSTALLING KDPF ASSEMBLY..............................................................................................................................2727 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY............................................................................................................................2732 METHOD FOR DISASSEMBLING KDPF ASSEMBLY...........................................................................................................................2733 METHOD FOR ASSEMBLING KDPF ASSEMBLY..............................................................................................................................2738 REMOVE AND INSTALL SCR ASSEMBLY......................................................................................................................................2745 METHOD FOR REMOVING SCR ASSEMBLY.................................................................................................................................2745 METHOD FOR INSTALLING SCR ASSEMBLY...............................................................................................................................2748 REMOVE AND INSTALL KDPF, SCR ASSEMBLY................................................................................................................................2752 METHOD FOR REMOVING KDPF, SCR ASSEMBLY...........................................................................................................................2752 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY.........................................................................................................................2757 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET........................................................................................................................2762 METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET...................................................................................................................2762 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET.................................................................................................................2766 REMOVE AND INSTALL KCCV ASSEMBLY.....................................................................................................................................2776 METHOD FOR REMOVING KCCV ASSEMBLY................................................................................................................................2776 METHOD FOR INSTALLING KCCV ASSEMBLY..............................................................................................................................2777 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE............................................................................................................................2781 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE.......................................................................................................................2781 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE.....................................................................................................................2786 REMOVE AND INSTALL AdBlue/DEF INJECTOR...............................................................................................................................2792 METHOD FOR REMOVING AdBlue/DEF INJECTOR..........................................................................................................................2792 METHOD FOR INSTALLING AdBlue/DEF INJECTOR........................................................................................................................2796 REMOVE AND INSTALL AdBlue/DEF PUMP...................................................................................................................................2801 METHOD FOR REMOVING AdBlue/DEF PUMP..............................................................................................................................2801 METHOD FOR INSTALLING AdBlue/DEF PUMP............................................................................................................................2803 REMOVE AND INSTALL AdBlue/DEF HOSE...................................................................................................................................2804 METHOD FOR REMOVING AdBlue/DEF HOSE..............................................................................................................................2804 METHOD FOR INSTALLING AdBlue/DEF HOSE............................................................................................................................2809 REMOVE AND INSTALL AIR CLEANER ASSEMBLY..............................................................................................................................2818 METHOD FOR REMOVING AIR CLEANER ASSEMBLY.........................................................................................................................2818 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY.......................................................................................................................2819 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...............................................................................................................2822 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................................................2822 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY........................................................................................................2825 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY................................................................................................................2829 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................................................2829 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY.........................................................................................................2830 POWER TRAIN..............................................................................................................................................................2832 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.............................................................................................................2832 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................................................2832 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY......................................................................................................2833 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY........................................................................................................................2834 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY....................................................................................................................2834 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY.......................................................................................................................2839 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY..........................................................................................................2845 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................................................................................................2845 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY...................................................................................................2846 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY....................................................................................................................2848 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY................................................................................................................2848 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY...................................................................................................................2852 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY.............................................................................................................................2858 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY........................................................................................................................2858 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY......................................................................................................................2858 UNDERCARRIAGE AND FRAME..................................................................................................................................................2860 SEPARATION AND CONNECTION OF TRACK ASSEMBLY..........................................................................................................................2860 METHOD FOR SEPARATING TRACK ASSEMBLY.............................................................................................................................2860 METHOD FOR INSTALLING TRACK ASSEMBLY.............................................................................................................................2862 REMOVE AND INSTALL SPROCKET..........................................................................................................................................2865 METHOD FOR REMOVING SPROCKET.....................................................................................................................................2865 METHOD FOR INSTALLING SPROCKET...................................................................................................................................2865 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY..................................................................................................................2867 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY.............................................................................................................2867 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY...........................................................................................................2868 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY..............................................................................................................................2870 METHOD FOR DISASSEMBLING IDLER ASSEMBLY..........................................................................................................................2870 METHOD FOR ASSEMBLING IDLER ASSEMBLY.............................................................................................................................2872 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY...................................................................................................................2877 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY..................................................................................................................2878 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY.....................................................................................................................2880 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY.......................................................................................................................2883 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY...................................................................................................................2884 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY......................................................................................................................2885 DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY.....................................................................................................................2889 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY.................................................................................................................2889 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY....................................................................................................................2891 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY..........................................................................................................................2894 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY.....................................................................................................................2894 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY...................................................................................................................2896 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY............................................................................................................................2899 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY.......................................................................................................................2899 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY.....................................................................................................................2900 HYDRAULIC SYSTEM.........................................................................................................................................................2903 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY......................................................................................................................2903 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY.................................................................................................................2903 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY...............................................................................................................2905 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY................................................................................................................2907 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY............................................................................................................2908 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...............................................................................................................2908 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...........................................................................................................................2910 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY......................................................................................................................2910 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY....................................................................................................................2915 REMOVE AND INSTALL MAIN PUMP ASSEMBLY................................................................................................................................2921 METHOD FOR REMOVING MAIN PUMP ASSEMBLY...........................................................................................................................2921 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY.........................................................................................................................2925 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY............................................................................................................................2931 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY.......................................................................................................................2931 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY.....................................................................................................................2936 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY......................................................................................................................2942 METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING.......................................................................................................2943 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY.....................................................................................................................2944 REMOVE AND INSTALL ATT BYPASS SOLENOID...............................................................................................................................2949 REMOVE ATT BYPASS SOLENOID.......................................................................................................................................2949 INSTALL ATT BYPASS SOLENOID......................................................................................................................................2952 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...........................................................................................................2954 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.......................................................................................................2954 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..........................................................................................................2955 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY...................................................................................................................2957 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY...............................................................................................................2957 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY..................................................................................................................2958 REMOVE AND INSTALL QUICK COUPLER VALVE...............................................................................................................................2960 WORK EQUIPMENT...........................................................................................................................................................2962 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...........................................................................................................................2962 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY......................................................................................................................2963 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY....................................................................................................................2966 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY............................................................................................................2970 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY........................................................................................................2970 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...........................................................................................................2973 CAB AND ITS ATTACHMENTS..................................................................................................................................................2977 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...........................................................................................................................2977 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY......................................................................................................................2977 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY....................................................................................................................2984 REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)..............................................................................................................2991 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY......................................................................................................................2993 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY....................................................................................................................2993 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY.............................................................................................................................3003 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY........................................................................................................................3003 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY......................................................................................................................3006 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY..............................................................................................................................3012 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY.........................................................................................................................3012 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY.......................................................................................................................3019 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY.....................................................................................................................3027 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY................................................................................................................3027 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY..............................................................................................................3033 REMOVE AND INSTALL OPERATOR'S SEAT...................................................................................................................................3040 METHOD FOR REMOVING OPERATOR'S SEAT..............................................................................................................................3040 METHOD FOR INSTALLING OPERATOR'S SEAT............................................................................................................................3042 REMOVE AND INSTALL SEAT BELT.........................................................................................................................................3045 METHOD FOR REMOVING SEAT BELT....................................................................................................................................3045 METHOD FOR INSTALLING SEAT BELT..................................................................................................................................3046 REMOVE AND INSTALL FRONT WIPER ASSEMBLY..............................................................................................................................3047 METHOD FOR REMOVING FRONT WIPER ASSEMBLY.........................................................................................................................3047 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY.......................................................................................................................3052 ELECTRICAL SYSTEM........................................................................................................................................................3061 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY........................................................................................................................3061 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...................................................................................................................3061 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY.................................................................................................................3062 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY..........................................................................................................................3064 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY.....................................................................................................................3064 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY...................................................................................................................3067 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY.....................................................................................................................3072 METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY................................................................................................................3072 METHOD FOR INSTALLING KomVision CONTROLLER.......................................................................................................................3073 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY..........................................................................................................................3074 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY.....................................................................................................................3074 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...................................................................................................................3077 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR...........................................................................................................................3081 METHOD FOR REMOVING PUMP SWASH PLATE SENSOR......................................................................................................................3081 METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR....................................................................................................................3082 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR..............................................................................................................3083 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................................................3083 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR.......................................................................................................3084 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR....................................................................................................................3086 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...............................................................................................................3086 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR.............................................................................................................3087 REMOVE AND INSTALL SCR TEMPERATURE SENSOR............................................................................................................................3089 METHOD FOR REMOVING SCR TEMPERATURE SENSOR.......................................................................................................................3089 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR.....................................................................................................................3091 REMOVE AND INSTALL KomVision CAMERA..................................................................................................................................3093 METHOD FOR REMOVING KomVision CAMERA.............................................................................................................................3093 METHOD FOR INSTALLING KomVision CAMERA...........................................................................................................................3094 REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY..............................................................................................................3096 METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY.........................................................................................................3096 METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY.......................................................................................................3100 REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS.............................................................................................................3106 METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS........................................................................................................3106 METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS......................................................................................................3114 REMOVE AND INSTALL COMMUNICATION TERMINAL............................................................................................................................3123 METHOD FOR REMOVING COMMUNICATION TERMINAL.......................................................................................................................3123 METHOD FOR INSTALLING COMMUNICATION TERMINAL.....................................................................................................................3125 60 MAINTENANCE STANDARD......................................................................................................................................................3129 CONTENTS.................................................................................................................................................................3130 ABBREVIATION LIST........................................................................................................................................................3132 ENGINE AND COOLING SYSTEM................................................................................................................................................3138 MAINTENANCE STANDARD OF ENGINE MOUNT.................................................................................................................................3138 MAINTENANCE STANDARD OF COOLING SYSTEM...............................................................................................................................3139 MAINTENANCE STANDARD OF COOLING FAN PUMP.............................................................................................................................3140 MAINTENANCE STANDARD OF SERVO VALVE..............................................................................................................................3141 MAINTENANCE STANDARD OF COOLING FAN MOTOR............................................................................................................................3142 POWER TRAIN..............................................................................................................................................................3143 MAINTENANCE STANDARD OF SWING CIRCLE.................................................................................................................................3143 MAINTENANCE STANDARD OF SWING MACHINERY..............................................................................................................................3144 MAINTENANCE STANDARD OF FINAL DRIVE..................................................................................................................................3146 MAINTENANCE STANDARD OF SPROCKET.....................................................................................................................................3148 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING....................................................................................................3149 UNDERCARRIAGE AND FRAME..................................................................................................................................................3151 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION................................................................................................................3151 MAINTENANCE STANDARD OF IDLER........................................................................................................................................3153 MAINTENANCE STANDARD OF TRACK ROLLER.................................................................................................................................3155 MAINTENANCE STANDARD OF CARRIER ROLLER...............................................................................................................................3157 MAINTENANCE STANDARD OF TRACK SHOE...................................................................................................................................3158 MAINTENANCE STANDARD OF TRIPLE SHOE..................................................................................................................................3161 HYDRAULIC SYSTEM.........................................................................................................................................................3162 MAINTENANCE STANDARD OF MAIN PUMP....................................................................................................................................3162 MAINTENANCE STANDARD OF SWING MOTOR..................................................................................................................................3164 MAINTENANCE STANDARD OF TRAVEL MOTOR.................................................................................................................................3167 MAINTENANCE STANDARD OF CONTROL VALVE................................................................................................................................3170 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE...........................................................................................................3181 MAINTENANCE STANDARD OF TRAVEL PPC VALVE.............................................................................................................................3184 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...............................................................................................3187 MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE...............................................................................................3189 MAINTENANCE STANDARD OF SOLENOID VALVE...............................................................................................................................3190 MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE.............................................................................................................3191 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE............................................................................................................3193 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT..........................................................................................................................3194 WORK EQUIPMENT...........................................................................................................................................................3195 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE.......................................................................................................................3195 DIMENSION OF ARM.................................................................................................................................................3200 DIMENSIONS OF BUCKET.............................................................................................................................................3202 MAINTENANCE STANDARD OF BOOM CYLINDER................................................................................................................................3204 MAINTENANCE STANDARD OF ARM CYLINDER.................................................................................................................................3205 MAINTENANCE STANDARD OF BUCKET CYLINDER..............................................................................................................................3206 WORK EQUIPMENT - PC490HRD-11E0...........................................................................................................................................3207 WORK EQUIPMENT - HIGH REACH DEMOLITION...............................................................................................................................3207 DIMENSION OF ARM.................................................................................................................................................3207 MAINTENANCE STANDARD OF BOOM CYLINDER............................................................................................................................3208 MAINTENANCE STANDARD OF LINK CYLINDER............................................................................................................................3209 MAINTENANCE STANDARD OF ARM CYLINDER.............................................................................................................................3210 MAINTENANCE STANDARD OF BUCKET CYLINDER..........................................................................................................................3211 WORK EQUIPMENT - DEMOLITION DIGGING..................................................................................................................................3212 MAINTENANCE STANDARD OF ARM CYLINDER.............................................................................................................................3212 MAINTENANCE STANDARD OF BUCKET CYLINDER..........................................................................................................................3213 PC490HRD-11E0 K100 BOOM CHANGE SYSTEM....................................................................................................................................3214 S AND A VALVES MAINTENANCE SCHEDULE..................................................................................................................................3214 GREASING PROCEDURE OF S VALVE ASSEMBLY LOCKING PINS (RECOMMENDED EVERY 1000 HOURS/1 YEAR WHICH EVER OCCURS FIRST OR IF DIFFICULTY CONNECTING/DISCONNECTING OCCURS....3221 JACKING BOLTS FOR VALVE LOCKING CYLINDER ASSEMBLY REMOVAL............................................................................................................3223 MAINTENANCE STANDARD OF SWING CIRCLE.................................................................................................................................3226 MAINTENANCE STANDARD OF COUNTERWEIGHT BOLTS..........................................................................................................................3227 MAINTENANCE STANDARD OF WORKSTAND....................................................................................................................................3228 80 APPENDIX..................................................................................................................................................................3229 CONTENTS.................................................................................................................................................................3230 ABBREVIATION LIST........................................................................................................................................................3232 AIR CONDITIONER SYSTEM...................................................................................................................................................3238 PRECAUTIONS FOR REFRIGERANT..........................................................................................................................................3238 AIR CONDITIONER COMPONENT............................................................................................................................................3239 SPECIFICATIONS OF AIR CONDITIONER....................................................................................................................................3241 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE....................................................................................................................3242 OUTLINE OF REFRIGERATION CYCLE.......................................................................................................................................3243 COMPONENT PARTS OF AIR CONDITIONER SYSTEM................................................................................................................................3245 AIR CONDITIONER UNIT.................................................................................................................................................3245 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT....................................................................................................................3245 FUNCTION OF AIR CONDITIONER UNIT.................................................................................................................................3247 COMPONENT PARTS OF AIR CONDITIONER UNIT..............................................................................................................................3249 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT.........................................................................................................3250 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT........................................................................................................3250 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT......................................................................................3250 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT........................................................................................................3250 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...................................................................................................3251 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT....................................................................................................3251 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT........................................................................................................3251 FUNCTION OF DUAL PRESSURE SWITCH.................................................................................................................................3252 AIR CONDITIONER CONTROLLER...........................................................................................................................................3253 STRUCTURE OF AIR CONDITIONER CONTROLLER..........................................................................................................................3253 COMPRESSOR...........................................................................................................................................................3254 STRUCTURE OF COMPRESSOR..........................................................................................................................................3254 SPECIFICATIONS OF COMPRESSOR.....................................................................................................................................3254 FUNCTION OF COMPRESSOR...........................................................................................................................................3254 CONDENSER............................................................................................................................................................3255 STRUCTURE OF CONDENSER...........................................................................................................................................3255 SPECIFICATIONS OF CONDENSER......................................................................................................................................3255 FUNCTION OF CONDENSER............................................................................................................................................3255 RECEIVER DRIER.......................................................................................................................................................3256 STRUCTURE OF RECEIVER DRIER......................................................................................................................................3256 SPECIFICATIONS OF RECEIVER DRIER.................................................................................................................................3256 FUNCTION OF RECEIVER DRIER.......................................................................................................................................3256 SENSORS FOR AIR CONDITIONER SYSTEM...................................................................................................................................3257 STRUCTURE OF SUNLIGHT SENSOR.....................................................................................................................................3257 FUNCTION OF SUNLIGHT SENSOR......................................................................................................................................3257 STRUCTURE OF AMBIENT TEMPERATURE SENSOR..........................................................................................................................3257 FUNCTION OF AMBIENT TEMPERATURE SENSOR...........................................................................................................................3257 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER..............................................................................................3259 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER....................................................................................................3261 AIR CONDITIONER SYSTEM DIAGRAM...........................................................................................................................................3263 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...............................................................................................................3264 FUNCTION OF AIR CONDITIONER CONTROLLER...........................................................................................................................3265 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS............................................................................................3266 TESTING AIR LEAKAGE (DUCT)...............................................................................................................................................3270 METHOD FOR TESTING AIR LEAKAGE (DUCT)................................................................................................................................3270 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION....................................................................................................................3272 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR.......................................................................3273 TEST VENT (MODE) CHANGEOVER..............................................................................................................................................3274 METHOD FOR TESTING VENT (MODE) CHANGEOVER............................................................................................................................3274 TESTING FRESH/RECIRC AIR CHANGEOVER......................................................................................................................................3276 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER.......................................................................................................................3276 TEST SUNLIGHT SENSOR.....................................................................................................................................................3277 METHOD FOR TESTING SUNLIGHT SENSOR...................................................................................................................................3277 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT..............................................................................................................................3278 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................................................................................................3278 TEST RELAYS..............................................................................................................................................................3279 METHOD FOR TESTING RELAYS............................................................................................................................................3279 AIR CONDITIONER TROUBLESHOOTING CHART 1..................................................................................................................................3280 AIR CONDITIONER TROUBLESHOOTING CHART 2..................................................................................................................................3281 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...........................................................................................................................3284 FAILURE CODE [879AKA]....................................................................................................................................................3286 FAILURE CODE [879AKB]....................................................................................................................................................3287 FAILURE CODE [879BKA]....................................................................................................................................................3288 FAILURE CODE [879BKB]....................................................................................................................................................3290 FAILURE CODE [879CKA]....................................................................................................................................................3292 FAILURE CODE [879CKB]....................................................................................................................................................3293 FAILURE CODE [879DKZ]....................................................................................................................................................3294 FAILURE CODE [879EMC]....................................................................................................................................................3296 FAILURE CODE [879FMC]....................................................................................................................................................3297 FAILURE CODE [879GKX]....................................................................................................................................................3298 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...........................................................................................3300 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)............................................................................................3301 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...................................................................................3302 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER......................................................................................................................3303 TROUBLESHOOTING USING GAUGE PRESSURE.....................................................................................................................................3304 CONNECTION OF SERVICE TOOL...............................................................................................................................................3307 METHOD FOR CONNECTING SERVICE TOOL...................................................................................................................................3307 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS..................................................................................3309 HANDLE COMPRESSOR OIL....................................................................................................................................................3311 PC490HRD-11E0 K100 BOOM CHANGE SYSTEM....................................................................................................................................3313 AUXILLARY CONNECTIONS................................................................................................................................................3313 WORKSTAND BRACKET....................................................................................................................................................3316 90 CIRCUIT DIAGRAMS..........................................................................................................................................................3319 CONTENTS.................................................................................................................................................................3320 ABBREVIATION LIST........................................................................................................................................................3321 HYDRAULIC CIRCUIT DIAGRAM (PC490)........................................................................................................................................3327 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................3327 HYDRAULIC CIRCUIT DIAGRAM (1/3)......................................................................................................................................3331 HYDRAULIC CIRCUIT DIAGRAM (2/3)......................................................................................................................................3333 HYDRAULIC CIRCUIT DIAGRAM (3/3)......................................................................................................................................3335 HYDRAULIC CIRCUIT DIAGRAM (PC490HRD).....................................................................................................................................3337 HYDRAULIC CIRCUIT DIAGRAM (1/2)......................................................................................................................................3339 HYDRAULIC CIRCUIT DIAGRAM (2/2)......................................................................................................................................3341 HYDRAULIC CIRCUIT DIAGRAM (1/8)......................................................................................................................................3343 HYDRAULIC CIRCUIT DIAGRAM (2/8)......................................................................................................................................3345 HYDRAULIC CIRCUIT DIAGRAM (3/8)......................................................................................................................................3347 HYDRAULIC CIRCUIT DIAGRAM (4/8)......................................................................................................................................3349 HYDRAULIC CIRCUIT DIAGRAM (5/8)......................................................................................................................................3351 HYDRAULIC CIRCUIT DIAGRAM (6/8)......................................................................................................................................3353 HYDRAULIC CIRCUIT DIAGRAM (7/8)......................................................................................................................................3355 HYDRAULIC CIRCUIT DIAGRAM (8/8)......................................................................................................................................3357 ELECTRICAL CIRCUIT DIAGRAM (PC490).......................................................................................................................................3359 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...........................................................................................................................3359 ELECTRICAL CIRCUIT DIAGRAM (1/11)....................................................................................................................................3363 ELECTRICAL CIRCUIT DIAGRAM (2/11)....................................................................................................................................3365 ELECTRICAL CIRCUIT DIAGRAM (3/11)....................................................................................................................................3367 ELECTRICAL CIRCUIT DIAGRAM (4/11)....................................................................................................................................3369 ELECTRICAL CIRCUIT DIAGRAM (5/11)....................................................................................................................................3371 ELECTRICAL CIRCUIT DIAGRAM (6/11)....................................................................................................................................3373 ELECTRICAL CIRCUIT DIAGRAM (7/11)....................................................................................................................................3375 ELECTRICAL CIRCUIT DIAGRAM (8/11)....................................................................................................................................3377 ELECTRICAL CIRCUIT DIAGRAM (9/11)....................................................................................................................................3379 ELECTRICAL CIRCUIT DIAGRAM (10/11)...................................................................................................................................3381 ELECTRICAL CIRCUIT DIAGRAM (11/11)...................................................................................................................................3383 ELECTRICAL CIRCUIT DIAGRAM (PC490HRD)....................................................................................................................................3385 ELECTRICAL CIRCUIT DIAGRAM (1/17)....................................................................................................................................3387 ELECTRICAL CIRCUIT DIAGRAM (2/17)....................................................................................................................................3389 ELECTRICAL CIRCUIT DIAGRAM (3/17)....................................................................................................................................3391 ELECTRICAL CIRCUIT DIAGRAM (4/17)....................................................................................................................................3393 ELECTRICAL CIRCUIT DIAGRAM (5/17)....................................................................................................................................3395 ELECTRICAL CIRCUIT DIAGRAM (6/17)....................................................................................................................................3397 ELECTRICAL CIRCUIT DIAGRAM (7/17)....................................................................................................................................3399 ELECTRICAL CIRCUIT DIAGRAM (8/17)....................................................................................................................................3401 ELECTRICAL CIRCUIT DIAGRAM (9/17)....................................................................................................................................3403 ELECTRICAL CIRCUIT DIAGRAM (10/17)...................................................................................................................................3405 ELECTRICAL CIRCUIT DIAGRAM (11/17)...................................................................................................................................3407 ELECTRICAL CIRCUIT DIAGRAM (12/17)...................................................................................................................................3409 ELECTRICAL CIRCUIT DIAGRAM (13/17)...................................................................................................................................3411 ELECTRICAL CIRCUIT DIAGRAM (14/17)...................................................................................................................................3413 ELECTRICAL CIRCUIT DIAGRAM (15/17)...................................................................................................................................3415 ELECTRICAL CIRCUIT DIAGRAM (16/17)...................................................................................................................................3417 ELECTRICAL CIRCUIT DIAGRAM (17/17)...................................................................................................................................3419 INDEX.........................................................................................................................................................................3421
DESCRIPTION:
KOMATSU PC490HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00740 – PDF DOWNLOAD
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.
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