Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-00 – PDF DOWNLOAD

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-00 – PDF DOWNLOAD

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Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-00 – PDF DOWNLOAD

Language : English
Pages : 2948
Downloadable : Yes
File Type : PDF
Size: 71.8 MB

DESCRIPTION:

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-00 – PDF DOWNLOAD

SERIAL NUMBERS 85001 and up

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

General precautions
If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation
and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
• Always wear the protective eyeglasses when hitting parts
with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, always
agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang “UNDER REPAIR” warning tag in the operator’s
compartment Before starting work.
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work:
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible,
insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang “UNDER REPAIR” warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately.

VIDEO PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC490LC-11 Hydraulic Excavator Shop Manual SEN06738-00 – PDF DOWNLOAD

INDEX
00 INDEX AND FOREWORD 00-1
ABBREVIATION LIST 00-20
FOREWORD, SAFETY, BASIC INFORMATION 00-26
HOW TO READ THE SHOP MANUAL 00-26
SAFETY NOTICE FOR OPERATION 00-28
PRECAUTIONS TO PREVENT FIRE 00-36
ACTIONS IF FIRE OCCURS 00-38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00-39
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 00-40
PRECAUTIONS FOR DEF 00-41
STORE AdBlue/DEF 00-42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00-43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 00-46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00-53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00-55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00-56
PRACTICAL USE OF KOMTRAX 00-57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00-58
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 00-62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 00-66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 00-67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00-69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00-70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
00-72
HOW TO READ ELECTRICAL WIRE CODE 00-73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00-77
STANDARD TIGHTENING TORQUE TABLE 00-80
CONVERSION TABLE 00-87
01 SPECIFICATIONS 01-1
CONTENTS 01-2
ABBREVIATION LIST 01-3
SPECIFICATIONS 01-9
SPECIFICATION DRAWING 01-9
WORKING RANGE DRAWINGS 01-11
SPECIFICATIONS 01-12
WEIGHT TABLE 01-15
TABLE OF FUEL, COOLANT, AND LUBRICANTS 01-17
10 STRUCTURE AND FUNCTION 10-1
CONTENTS 10-2
ABBREVIATION LIST 10-5
UREA SCR SYSTEM 10-11
LAYOUT DRAWING OF UREA SCR SYSTEM 10-11
UREA SCR SYSTEM DIAGRAM 10-15
FUNCTION OF UREA SCR SYSTEM 10-16
COMPONENT PARTS OF UREA SCR SYSTEM 10-33
BOOT-UP SYSTEM 10-42
LAYOUT DRAWING OF BOOT-UP SYSTEM 10-42
SYSTEM OPERATING LAMP SYSTEM 10-44
BATTERY DISCONNECT SWITCH 10-45
ENGINE SYSTEM 10-46
LAYOUT DRAWING OF ENGINE SYSTEM 10-46
ENGINE CONTROL SYSTEM 10-49
AUTO-DECELERATION SYSTEM 10-52
ENGINE AUTOMATIC WARM-UP SYSTEM 10-54
OVERHEAT PREVENTION SYSTEM 10-56
INDEX 00 INDEX AND FOREWORD
00-2 PC490LC-11
TURBOCHARGER PROTECTION SYSTEM 10-59
AUTOMATIC IDLE STOP SYSTEM 10-61
COMPONENT PARTS OF ENGINE SYSTEM 10-64
COOLING SYSTEM 10-80
LAYOUT DRAWING OF COOLING SYSTEM 10-80
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN 10-83
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN 10-85
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN 10-88
COMPONENT PARTS OF COOLING SYSTEM 10-89
CONTROL SYSTEM 10-103
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 10-103
MACHINE MONITOR SYSTEM 10-106
KOMTRAX SYSTEM 10-108
COMPONENT PARTS OF CONTROL SYSTEM 10-109
HYDRAULIC SYSTEM 10-143
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10-143
CLSS 10-145
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10-164
PUMP AND VALVE CONTROL SYSTEM 10-171
COMPONENT PARTS OF HYDRAULIC SYSTEM 10-174
WORK EQUIPMENT SYSTEM 10-262
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10-262
STRUCTURE OF VALVE CONTROL 10-267
ONE-TOUCH POWER MAXIMIZING SYSTEM 10-268
MACHINE PUSH-UP SYSTEM 10-270
PPC LOCK SYSTEM 10-272
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10-273
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 10-275
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10-277
SWING SYSTEM 10-301
LAYOUT DRAWING OF SWING SYSTEM 10-301
SWING CONTROL SYSTEM DIAGRAM 10-307
COMPONENT PARTS OF SWING SYSTEM 10-311
TRAVEL SYSTEM 10-326
LAYOUT DRAWING OF TRAVEL SYSTEM 10-326
TRAVEL CONTROL SYSTEM DIAGRAM 10-330
COMPONENT PARTS OF TRAVEL SYSTEM 10-332
UNDERCARRIAGE AND FRAME 10-354
LAYOUT DRAWING OF UNDERCARRIAGE 10-354
WORK EQUIPMENT 10-355
STRUCTURE OF WORK EQUIPMENT 10-355
FUNCTION OF WORK EQUIPMENT 10-356
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10-357
BUCKET CLEARANCE ADJUSTMENT SHIM 10-358
CAB AND ITS ATTACHMENTS 10-359
ROPS CAB 10-359
CAB MOUNT 10-360
CAB TIPPING STOPPER 10-361
20 STANDARD VALUE TABLE 20-1
CONTENTS 20-2
ABBREVIATION LIST 20-3
STANDARD VALUE TABLE FOR ENGINE 20-9
STANDARD VALUE TABLE FOR ENGINE: PC490LC-11 20-9
STANDARD VALUE TABLE FOR MACHINE 20-12
STANDARD VALUE TABLE FOR MACHINE: PC490LC-11 20-12
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20-28
STANDARD VALUE TABLE FOR ELECTRICAL 20-32
STANDARD VALUE TABLE FOR ELECTRICAL 20-32
00 INDEX AND FOREWORD INDEX
PC490LC-11 00-3
30 TESTING AND ADJUSTING 30-1
CONTENTS 30-2
ABBREVIATION LIST 30-6
RELATED INFORMATION ON TESTING AND ADJUSTING 30-12
TOOLS FOR TESTING AND ADJUSTING 30-12
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30-19
ENGINE AND COOLING SYSTEM 30-21
TEST ENGINE SPEED 30-21
TEST BOOST PRESSURE 30-24
TEST EXHAUST GAS COLOR 30-26
TEST AND ADJUST VALVE CLEARANCE 30-28
TEST COMPRESSION PRESSURE 30-32
TEST BLOWBY PRESSURE 30-35
TEST ENGINE OIL PRESSURE 30-37
TEST EGR VALVE AND VGT OIL PRESSURE 30-39
TEST FUEL PRESSURE 30-41
TEST FUEL RETURN RATE AND LEAKAGE 30-43
BLEED AIR FROM FUEL SYSTEM 30-46
TEST FUEL CIRCUIT FOR LEAKAGE 30-48
HANDLE CYLINDER CUT-OUT MODE OPERATION 30-50
HANDLE NO-INJECTION CRANKING OPERATION 30-51
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 30-52
CLEAN FUEL DOSER 30-54
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 30-56
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 30-62
TEST SCR RELATED FUNCTIONS 30-63
CLEAN AdBlue/DEF TANK 30-88
POWER TRAIN 30-92
TEST SWING CIRCLE BEARING CLEARANCE 30-92
UNDERCARRIAGE AND FRAME 30-93
TEST AND ADJUST TRACK TENSION 30-93
HYDRAULIC SYSTEM 30-95
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30-95
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
30-98
TEST OIL PRESSURE OF CONTROL CIRCUIT 30-110
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30-112
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30-116
TEST OUTLET PRESSURE OF SOLENOID VALVE 30-121
TEST PPC VALVE OUTLET PRESSURE 30-124
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 30-126
TEST PUMP SWASH PLATE SENSOR 30-127
TEST COOLING FAN SPEED 30-128
TEST OIL PRESSURE IN FAN PUMP CIRCUIT 30-129
TEST FAN PUMP EPC ELECTRIC CURRENT 30-131
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE 30-132
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 30-134
TEST OIL LEAKAGE 30-136
BLEED AIR FROM HYDRAULIC CIRCUIT 30-139
TEST AND CHARGE ACCUMULATOR (MANUFACTURED BY NOK) NITROGEN GAS PRESSURE
FOR ATTACHMENT (LOW PRESSURE SIDE) 30-144
TEST AND CHARGE ACCUMULATOR NITROGEN GAS PRESSURE FOR ATTACHMENT (HIGH
PRESSURE SIDE) 30-148
REPLACE ACCUMULATOR BLADDER ON HIGH PRESSURE SIDE FOR ACCUMULATOR PIPING
30-152
CAB AND ITS ATTACHMENTS 30-159
TEST CAB TIPPING STOPPER 30-159
METHOD FOR ADJUSTING MIRRORS 30-160
INDEX 00 INDEX AND FOREWORD
00-4 PC490LC-11
ELECTRICAL SYSTEM 30-166
SET AND OPERATE MACHINE MONITOR 30-166
METHOD FOR STARTING UP KOMTRAX SYSTEM 30-245
ADJUST REARVIEW CAMERA ANGLE 30-250
ADJUST KomVision CAMERA ANGLE 30-253
ADJUST KomVision RELATED ITEMS 30-255
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30-274
HANDLE BATTERY DISCONNECT SWITCH 30-275
TEST DIODES 30-276
Pm CLINIC 30-277
Pm CLINIC SERVICE 30-277
40 TROUBLESHOOTING 40-1
CONTENTS 40-2
ABBREVIATION LIST 40-13
RELATED INFORMATION ON TROUBLESHOOTING 40-19
GENERAL TROUBLESHOOTING POINTS 40-19
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40-20
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40-32
CHECKS BEFORE TROUBLESHOOTING 40-34
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40-36
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40-38
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 40-58
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40-71
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40-74
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40-78
CONNECTOR LIST AND LAYOUT 40-80
CONNECTOR CONTACT IDENTIFICATION 40-93
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40-133
FUSE LOCATION TABLE 40-139
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 40-141
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135]) 40-145
FAILURE CODES TABLE 40-147
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 40-166
FAILURE CODE [879AKA] 40-166
FAILURE CODE [879AKB] 40-167
FAILURE CODE [879BKA] 40-168
FAILURE CODE [879BKB] 40-170
FAILURE CODE [879CKA] 40-172
FAILURE CODE [879CKB] 40-173
FAILURE CODE [879DKZ] 40-174
FAILURE CODE [879EMC] 40-176
FAILURE CODE [879FMC] 40-177
FAILURE CODE [879GKX] 40-178
FAILURE CODE [989L00] 40-180
FAILURE CODE [989M00] 40-181
FAILURE CODE [989N00] 40-182
FAILURE CODE [A1U0N3] 40-183
FAILURE CODE [A1U0N4] 40-185
FAILURE CODE [A900FR] 40-187
FAILURE CODE [A900N6] 40-188
FAILURE CODE [A900NY] 40-189
FAILURE CODE [AA10NX] 40-190
FAILURE CODE [AB00KE] 40-192
FAILURE CODE [AQ10N3] 40-195
FAILURE CODE [AS00N3] 40-197
FAILURE CODE [AS00R2] 40-199
FAILURE CODE [AS00R3] 40-200
00 INDEX AND FOREWORD INDEX
PC490LC-11 00-5
FAILURE CODE [AS00R4] 40-201
FAILURE CODE [AS00R5] 40-202
FAILURE CODE [AS00R6] 40-203
FAILURE CODE [AS00ZK] 40-204
FAILURE CODE [AS10KM] 40-205
FAILURE CODE [AS10NR] 40-206
FAILURE CODE [AS10NT] 40-207
FAILURE CODE [B@BAZG] 40-208
FAILURE CODE [B@BAZK] 40-209
FAILURE CODE [B@BCNS] 40-211
FAILURE CODE [B@BCQA] 40-212
FAILURE CODE [B@BCZK] 40-214
FAILURE CODE [B@HANS] 40-216
FAILURE CODE [CA115] 40-217
FAILURE CODE [CA122] 40-218
FAILURE CODE [CA123] 40-220
FAILURE CODE [CA131] 40-222
FAILURE CODE [CA132] 40-224
FAILURE CODE [CA135] 40-226
FAILURE CODE [CA141] 40-228
FAILURE CODE [CA144] 40-230
FAILURE CODE [CA145] 40-232
FAILURE CODE [CA153] 40-234
FAILURE CODE [CA154] 40-237
FAILURE CODE [CA187] 40-240
FAILURE CODE [CA221] 40-242
FAILURE CODE [CA222] 40-244
FAILURE CODE [CA227] 40-246
FAILURE CODE [CA234] 40-247
FAILURE CODE [CA238] 40-248
FAILURE CODE [CA239] 40-250
FAILURE CODE [CA249] 40-252
FAILURE CODE [CA256] 40-254
FAILURE CODE [CA271] 40-256
FAILURE CODE [CA272] 40-258
FAILURE CODE [CA273] 40-259
FAILURE CODE [CA274] 40-261
FAILURE CODE [CA322] 40-262
FAILURE CODE [CA323] 40-264
FAILURE CODE [CA324] 40-266
FAILURE CODE [CA325] 40-268
FAILURE CODE [CA331] 40-270
FAILURE CODE [CA332] 40-272
FAILURE CODE [CA343] 40-274
FAILURE CODE [CA351] 40-275
FAILURE CODE [CA352] 40-276
FAILURE CODE [CA356] 40-279
FAILURE CODE [CA357] 40-281
FAILURE CODE [CA386] 40-283
FAILURE CODE [CA441] 40-284
FAILURE CODE [CA442] 40-286
FAILURE CODE [CA449] 40-287
FAILURE CODE [CA451] 40-288
FAILURE CODE [CA452] 40-290
FAILURE CODE [CA515] 40-292
FAILURE CODE [CA516] 40-294
FAILURE CODE [CA553] 40-296
FAILURE CODE [CA555] 40-297
INDEX 00 INDEX AND FOREWORD
00-6 PC490LC-11
FAILURE CODE [CA556] 40-298
FAILURE CODE [CA559] 40-299
FAILURE CODE [CA595] 40-304
FAILURE CODE [CA687] 40-305
FAILURE CODE [CA689] 40-307
FAILURE CODE [CA691] 40-309
FAILURE CODE [CA692] 40-311
FAILURE CODE [CA697] 40-313
FAILURE CODE [CA698] 40-314
FAILURE CODE [CA731] 40-315
FAILURE CODE [CA778] 40-316
FAILURE CODE [CA1117] 40-319
FAILURE CODE [CA1664] 40-320
FAILURE CODE [CA1669] 40-323
FAILURE CODE [CA1673] 40-324
FAILURE CODE [CA1677] 40-325
FAILURE CODE [CA1678] 40-326
FAILURE CODE [CA1682] 40-327
FAILURE CODE [CA1683] 40-329
FAILURE CODE [CA1684] 40-331
FAILURE CODE [CA1686] 40-333
FAILURE CODE [CA1691] 40-334
FAILURE CODE [CA1694] 40-337
FAILURE CODE [CA1695] 40-339
FAILURE CODE [CA1696] 40-340
FAILURE CODE [CA1712] 40-342
FAILURE CODE [CA1713] 40-345
FAILURE CODE [CA1714] 40-347
FAILURE CODE [CA1715] 40-348
FAILURE CODE [CA1776] 40-349
FAILURE CODE [CA1777] 40-352
FAILURE CODE [CA1843] 40-355
FAILURE CODE [CA1844] 40-357
FAILURE CODE [CA1879] 40-360
FAILURE CODE [CA1881] 40-363
FAILURE CODE [CA1883] 40-365
FAILURE CODE [CA1885] 40-368
FAILURE CODE [CA1887] 40-370
FAILURE CODE [CA1921] 40-372
FAILURE CODE [CA1922] 40-375
FAILURE CODE [CA1923] 40-380
FAILURE CODE [CA1924] 40-382
FAILURE CODE [CA1925] 40-384
FAILURE CODE [CA1927] 40-386
FAILURE CODE [CA1928] 40-388
FAILURE CODE [CA1942] 40-390
FAILURE CODE [CA1963] 40-391
FAILURE CODE [CA1977] 40-394
FAILURE CODE [CA1993] 40-397
FAILURE CODE [CA2185] 40-400
FAILURE CODE [CA2186] 40-402
FAILURE CODE [CA2249] 40-404
FAILURE CODE [CA2265] 40-405
FAILURE CODE [CA2266] 40-407
FAILURE CODE [CA2271] 40-409
FAILURE CODE [CA2272] 40-411
FAILURE CODE [CA2349] 40-413
FAILURE CODE [CA2353] 40-415
00 INDEX AND FOREWORD INDEX
PC490LC-11 00-7
FAILURE CODE [CA2357] 40-417
FAILURE CODE [CA2381] 40-418
FAILURE CODE [CA2382] 40-420
FAILURE CODE [CA2383] 40-422
FAILURE CODE [CA2386] 40-424
FAILURE CODE [CA2387] 40-426
FAILURE CODE [CA2555] 40-427
FAILURE CODE [CA2556] 40-430
FAILURE CODE [CA2637] 40-432
FAILURE CODE [CA2639] 40-434
FAILURE CODE [CA2732] 40-437
FAILURE CODE [CA2733] 40-439
FAILURE CODE [CA2741] 40-441
FAILURE CODE [CA2765] 40-442
FAILURE CODE [CA2771] 40-443
FAILURE CODE [CA2777] 40-449
FAILURE CODE [CA2878] 40-452
FAILURE CODE [CA2881] 40-455
FAILURE CODE [CA2976] 40-458
FAILURE CODE [CA3133] 40-460
FAILURE CODE [CA3134] 40-462
FAILURE CODE [CA3135] 40-464
FAILURE CODE [CA3142] 40-467
FAILURE CODE [CA3143] 40-468
FAILURE CODE [CA3144] 40-469
FAILURE CODE [CA3146] 40-471
FAILURE CODE [CA3147] 40-472
FAILURE CODE [CA3148] 40-473
FAILURE CODE [CA3151] 40-475
FAILURE CODE [CA3165] 40-481
FAILURE CODE [CA3167] 40-483
FAILURE CODE [CA3229] 40-486
FAILURE CODE [CA3231] 40-488
FAILURE CODE [CA3232] 40-490
FAILURE CODE [CA3235] 40-494
FAILURE CODE [CA3239] 40-496
FAILURE CODE [CA3241] 40-499
FAILURE CODE [CA3242] 40-502
FAILURE CODE [CA3251] 40-505
FAILURE CODE [CA3253] 40-507
FAILURE CODE [CA3254] 40-510
FAILURE CODE [CA3255] 40-513
FAILURE CODE [CA3256] 40-517
FAILURE CODE [CA3311] 40-519
FAILURE CODE [CA3312] 40-521
FAILURE CODE [CA3313] 40-524
FAILURE CODE [CA3314] 40-525
FAILURE CODE [CA3315] 40-526
FAILURE CODE [CA3316] 40-529
FAILURE CODE [CA3317] 40-530
FAILURE CODE [CA3318] 40-531
FAILURE CODE [CA3319] 40-533
FAILURE CODE [CA3321] 40-534
FAILURE CODE [CA3322] 40-536
FAILURE CODE [CA3419] 40-539
FAILURE CODE [CA3421] 40-541
FAILURE CODE [CA3497] 40-543
FAILURE CODE [CA3498] 40-544
INDEX 00 INDEX AND FOREWORD
00-8 PC490LC-11
FAILURE CODE [CA3543] 40-545
FAILURE CODE [CA3545] 40-552
FAILURE CODE [CA3547] 40-554
FAILURE CODE [CA3558] 40-555
FAILURE CODE [CA3559] 40-557
FAILURE CODE [CA3562] 40-559
FAILURE CODE [CA3563] 40-561
FAILURE CODE [CA3567] 40-564
FAILURE CODE [CA3568] 40-567
FAILURE CODE [CA3571] 40-571
FAILURE CODE [CA3572] 40-573
FAILURE CODE [CA3574] 40-575
FAILURE CODE [CA3575] 40-577
FAILURE CODE [CA3577] 40-579
FAILURE CODE [CA3578] 40-581
FAILURE CODE [CA3582] 40-583
FAILURE CODE [CA3583] 40-589
FAILURE CODE [CA3596] 40-591
FAILURE CODE [CA3649] 40-593
FAILURE CODE [CA3681] 40-595
FAILURE CODE [CA3682] 40-600
FAILURE CODE [CA3713] 40-606
FAILURE CODE [CA3717] 40-609
FAILURE CODE [CA3718] 40-610
FAILURE CODE [CA3725] 40-611
FAILURE CODE [CA3748] 40-614
FAILURE CODE [CA3751] 40-616
FAILURE CODE [CA3755] 40-618
FAILURE CODE [CA3866] 40-620
FAILURE CODE [CA3867] 40-624
FAILURE CODE [CA3868] 40-627
FAILURE CODE [CA3899] 40-631
FAILURE CODE [CA3911] 40-633
FAILURE CODE [CA3912] 40-637
FAILURE CODE [CA3932] 40-639
FAILURE CODE [CA3933] 40-641
FAILURE CODE [CA3934] 40-643
FAILURE CODE [CA3935] 40-646
FAILURE CODE [CA3936] 40-648
FAILURE CODE [CA4151] 40-650
FAILURE CODE [CA4152] 40-654
FAILURE CODE [CA4155] 40-658
FAILURE CODE [CA4156] 40-660
FAILURE CODE [CA4157] 40-663
FAILURE CODE [CA4158] 40-665
FAILURE CODE [CA4159] 40-666
FAILURE CODE [CA4161] 40-667
FAILURE CODE [CA4162] 40-670
FAILURE CODE [CA4163] 40-673
FAILURE CODE [CA4164] 40-675
FAILURE CODE [CA4165] 40-677
FAILURE CODE [CA4166] 40-679
FAILURE CODE [CA4168] 40-681
FAILURE CODE [CA4169] 40-684
FAILURE CODE [CA4171] 40-686
FAILURE CODE [CA4249] 40-689
FAILURE CODE [CA4251] 40-691
FAILURE CODE [CA4259] 40-693
00 INDEX AND FOREWORD INDEX
PC490LC-11 00-9
FAILURE CODE [CA4261] 40-695
FAILURE CODE [CA4277] 40-698
FAILURE CODE [CA4281] 40-702
FAILURE CODE [CA4459] 40-705
FAILURE CODE [CA4461] 40-708
FAILURE CODE [CA4658] 40-711
FAILURE CODE [CA4731] 40-715
FAILURE CODE [CA4732] 40-716
FAILURE CODE [CA4739] 40-717
FAILURE CODE [CA4768] 40-718
FAILURE CODE [CA4769] 40-720
FAILURE CODE [CA4842] 40-723
FAILURE CODE [CA4952] 40-727
FAILURE CODE [CA5115] 40-729
FAILURE CODE [CA5179] 40-732
FAILURE CODE [CA5181] 40-734
FAILURE CODE [CA5383] 40-736
FAILURE CODE [D110KB] 40-738
FAILURE CODE [D19JKZ] 40-740
FAILURE CODE [D811MC] 40-743
FAILURE CODE [D862KA] 40-744
FAILURE CODE [D8ALKA] 40-746
FAILURE CODE [D8ALKB] 40-749
FAILURE CODE [D8AQKR] 40-751
FAILURE CODE [D8G1KT] 40-758
FAILURE CODE [D8G6KT] 40-759
FAILURE CODE [DA20MC] 40-760
FAILURE CODE [DA22KK] 40-761
FAILURE CODE [DA25KP] 40-764
FAILURE CODE [DA29KQ] 40-767
FAILURE CODE [DA2LKA] 40-769
FAILURE CODE [DA2LKB] 40-772
FAILURE CODE [DA2QKR] 40-774
FAILURE CODE [DA2RKR] 40-783
FAILURE CODE [DAF0MB] 40-784
FAILURE CODE [DAF0MC] 40-785
FAILURE CODE [DAF8KB] 40-786
FAILURE CODE [DAF9KQ] 40-788
FAILURE CODE [DAFGMC] 40-789
FAILURE CODE [DAFLKA] 40-790
FAILURE CODE [DAFLKB] 40-793
FAILURE CODE [DAFQKR] 40-795
FAILURE CODE [DAZ9KQ] 40-803
FAILURE CODE [DAZQKR] 40-804
FAILURE CODE [DB2QKR] 40-811
FAILURE CODE [DB2RKR] 40-819
FAILURE CODE [DBP0KM] 40-823
FAILURE CODE [DBP0KT] 40-824
FAILURE CODE [DBP5KB] 40-825
FAILURE CODE [DBP5KY] 40-828
FAILURE CODE [DBPQKR] 40-831
FAILURE CODE [DDNRKA] 40-839
FAILURE CODE [DDNRKY] 40-841
FAILURE CODE [DDNS00] 40-843
FAILURE CODE [DGH2KA] 40-845
FAILURE CODE [DGH2KB] 40-847
FAILURE CODE [DHA4KA] 40-849
FAILURE CODE [DHAAMA] 40-851
INDEX 00 INDEX AND FOREWORD
00-10 PC490LC-11
FAILURE CODE [DHACMA] 40-853
FAILURE CODE [DHPAMA] 40-855
FAILURE CODE [DHPBMA] 40-858
FAILURE CODE [DHS3MA] 40-861
FAILURE CODE [DHS4MA] 40-864
FAILURE CODE [DHS8MA] 40-867
FAILURE CODE [DHS9MA] 40-870
FAILURE CODE [DHSAMA] 40-873
FAILURE CODE [DHSBMA] 40-876
FAILURE CODE [DHSCMA] 40-879
FAILURE CODE [DHSDMA] 40-882
FAILURE CODE [DHSFMA] 40-885
FAILURE CODE [DHSGMA] 40-888
FAILURE CODE [DHSHMA] 40-891
FAILURE CODE [DHSJMA] 40-894
FAILURE CODE [DHSVMA] 40-897
FAILURE CODE [DKR0MA] 40-900
FAILURE CODE [DKR1MA] 40-903
FAILURE CODE [DKULKA] 40-906
FAILURE CODE [DKULKB] 40-908
FAILURE CODE [DKULKY] 40-910
FAILURE CODE [DLM3KA] 40-912
FAILURE CODE [DLM3KB] 40-914
FAILURE CODE [DLM3MB] 40-916
FAILURE CODE [DR10KA] 40-917
FAILURE CODE [DR12KA] 40-920
FAILURE CODE [DR20KA] 40-922
FAILURE CODE [DR21KX] 40-924
FAILURE CODE [DR30KA] 40-926
FAILURE CODE [DR31KX] 40-928
FAILURE CODE [DR40KA] 40-930
FAILURE CODE [DUMBKA] 40-932
FAILURE CODE [DUMBKB] 40-935
FAILURE CODE [DV20KB] 40-937
FAILURE CODE [DW43KA] 40-939
FAILURE CODE [DW43KB] 40-941
FAILURE CODE [DW43KY] 40-943
FAILURE CODE [DW45KA] 40-945
FAILURE CODE [DW45KB] 40-948
FAILURE CODE [DW45KY] 40-951
FAILURE CODE [DW4CKY] 40-953
FAILURE CODE [DW7BKA] 40-954
FAILURE CODE [DW7BKB] 40-956
FAILURE CODE [DW7BKY] 40-958
FAILURE CODE [DW91KA] 40-959
FAILURE CODE [DW91KB] 40-961
FAILURE CODE [DW91KY] 40-963
FAILURE CODE [DWA2KA] 40-965
FAILURE CODE [DWA2KB] 40-967
FAILURE CODE [DWA2KY] 40-969
FAILURE CODE [DWK0KA] 40-971
FAILURE CODE [DWK0KB] 40-973
FAILURE CODE [DWK0KY] 40-975
FAILURE CODE [DWK2KA] 40-977
FAILURE CODE [DWK2KB] 40-979
FAILURE CODE [DWK2KY] 40-981
FAILURE CODE [DWK8KA] 40-983
FAILURE CODE [DWK8KB] 40-985
00 INDEX AND FOREWORD INDEX
PC490LC-11 00-11
FAILURE CODE [DWK8KY] 40-987
FAILURE CODE [DX16KA] 40-989
FAILURE CODE [DX16KB] 40-991
FAILURE CODE [DXA8KA] 40-993
FAILURE CODE [DXA8KB] 40-995
FAILURE CODE [DXA9KA] 40-997
FAILURE CODE [DXA9KB] 40-999
FAILURE CODE [DXE0KA] 40-1001
FAILURE CODE [DXE0KB] 40-1003
FAILURE CODE [DXE4KA] 40-1005
FAILURE CODE [DXE4KB] 40-1007
FAILURE CODE [DXE4KY] 40-1009
FAILURE CODE [DXE5KA] 40-1011
FAILURE CODE [DXE5KB] 40-1013
FAILURE CODE [DXE6KA] 40-1015
FAILURE CODE [DXE6KB] 40-1017
FAILURE CODE [DXE7KA] 40-1019
FAILURE CODE [DXE7KB] 40-1021
FAILURE CODE [DXE7KY] 40-1023
FAILURE CODE [DXE8KA] 40-1025
FAILURE CODE [DXE8KB] 40-1027
FAILURE CODE [DXE8KY] 40-1029
FAILURE CODE [DXE9KA] 40-1031
FAILURE CODE [DXE9KB] 40-1033
FAILURE CODE [DXE9KY] 40-1035
FAILURE CODE [DXEAKA] 40-1037
FAILURE CODE [DXEAKB] 40-1039
FAILURE CODE [DXEAKY] 40-1041
FAILURE CODE [DY20KA] 40-1043
FAILURE CODE [DY20MA] 40-1045
FAILURE CODE [DY2CKB] 40-1047
FAILURE CODE [DY2DKB] 40-1050
FAILURE CODE [DY2EKB] 40-1052
FAILURE CODE [F313KA] 40-1054
FAILURE CODE [F313KB] 40-1056
FAILURE CODE [F318KB] 40-1059
FAILURE CODE [F318KY] 40-1062
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 40-1064
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40-1064
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40-1070
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40-1073
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 40-1075
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING 40-1077
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE
OIL LEVEL MONITOR LIGHTS UP IN YELLOW 40-1080
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR
COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 40-1081
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
40-1082
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
40-1083
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING
40-1084
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1085
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1086
E-13 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1087
INDEX 00 INDEX AND FOREWORD
00-12 PC490LC-11
E-14 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1088
E-15 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
40-1089
E-16 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40-1090
E-17 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 40-1092
E-18 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM 40-1093
E-19 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATURE 40-1094
E-20 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM 40-1095
E-21 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE
40-1097
E-22 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 40-1098
E-23 FUNCTION SWITCH DOES NOT OPERATE 40-1099
E-24 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 40-1100
E-25 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF 40-1101
E-26 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 40-1102
E-27 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED 40-1103
E-28 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED 40-1104
E-29 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE 40-1105
E-30 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE 40-1106
E-31 ALARM BUZZER CANNOT BE CANCELED 40-1108
E-32 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION
40-1109
E-33 SERVICE MODE CANNOT BE SELECTED 40-1110
E-34 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 40-1111
E-35 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 40-1113
E-36 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING 40-1114
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE 40-1117
E-38 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR
NOT DISPLAYED ON MONITOR 40-1119
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 40-1121
E-40 ALARM DOES NOT SOUND DURING TRAVEL 40-1122
E-41 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 40-1124
E-42 HORN DOES NOT SOUND 40-1125
E-43 HORN DOES NOT STOP SOUNDING 40-1129
E-44 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF
40-1131
E-45 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 40-1132
E-46 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE
40-1134
E-47 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-1135
E-48 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-1136
E-49 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-1137
E-50 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1138
E-51 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-1139
00 INDEX AND FOREWORD INDEX
PC490LC-11 00-13
E-52 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-1140
E-53 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1141
E-54 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION40-1142
E-55 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
40-1143
E-56 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 40-1145
E-57 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40-1146
E-58 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 40-1147
E-59 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 40-1149
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 40-1150
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 40-1150
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 40-1151
FAILURE MODE AND CAUSE TABLE 40-1153
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 40-1161
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 40-1162
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 40-1164
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 40-1165
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 40-1166
H-6 SPEED OR POWER OF BOOM IS LOW 40-1168
H-7 ARM SPEED OR POWER IS LOW 40-1174
H-8 BUCKET SPEED OR POWER IS LOW 40-1179
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 40-1182
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 40-1183
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 40-1185
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 40-1187
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT
MOVES 40-1188
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 40-1189
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 40-1190
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 40-1191
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 40-1192
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 40-1193
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER 40-1194
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY
40-1195
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW
40-1196
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 40-1197
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 40-1199
H-24 TRAVEL SPEED IS LOW 40-1202
H-25 ONE OF TRACKS DOES NOT RUN 40-1204
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 40-1205
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 40-1206
H-28 SWINGS ONLY IN ONE DIRECTION 40-1207
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) 40-1208
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION 40-1209
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT) 40-1210
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT) 40-1211
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 40-1212
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING40-1213
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)40-1214
INDEX 00 INDEX AND FOREWORD
00-14 PC490LC-11
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
40-1215
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 40-1216
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 40-1217
TROUBLESHOOTING OF ENGINE (S-MODE) 40-1218
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 40-1218
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
40-1219
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40-1220
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) 40-1221
S-4 ENGINE STARTABILITY IS POOR 40-1222
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 40-1224
S-6 ENGINE STOPS DURING OPERATION 40-1226
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 40-1228
S-8 ENGINE LACKS POWER 40-1229
S-9 KDPF GETS CLOGGED IN A SHORT TIME 40-1231
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40-1233
S-11 OIL BECOMES CONTAMINATED QUICKLY 40-1234
S-1 FUEL CONSUMPTION IS EXCESSIVE 40-1235
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
40-1236
S-14 OIL PRESSURE DROPS 40-1237
S-15 FUEL MIXES INTO ENGINE OIL 40-1239
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 40-1240
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 40-1241
S-18 UNUSUAL NOISE IS HEARD 40-1242
S-19 VIBRATION IS EXCESSIVE 40-1243
S-2 AIR CANNOT BE BLED FROM FUEL CIRCUIT 40-1244
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 40-1245
S-22 ACTIVE REGENERATION TAKES TIME 40-1247
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 40-1249
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 40-1250
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 40-1252
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 40-1253
50 DISASSEMBLY AND ASSEMBLY 50-1
CONTENTS 50-2
ABBREVIATION LIST 50-7
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 50-13
HOW TO READ THIS MANUAL 50-13
COATING MATERIALS LIST 50-15
SPECIAL TOOLS LIST 50-19
SKETCHES OF SPECIAL TOOLS 50-31
ENGINE AND COOLING SYSTEM 50-37
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50-37
REMOVE AND INSTALL INJECTOR ASSEMBLY 50-52
REMOVE AND INSTALL FUEL DOSER ASSEMBLY 50-68
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 50-71
REMOVE AND INSTALL EGR VALVE ASSEMBLY 50-94
REMOVE AND INSTALL EGR COOLER ASSEMBLY 50-98
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 50-107
REMOVE AND INSTALL ALTERNATOR BELT 50-110
REMOVE AND INSTALL RADIATOR ASSEMBLY 50-118
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 50-123
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 50-132
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 50-136
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 50-142
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 50-180
00 INDEX AND FOREWORD INDEX
PC490LC-11 00-15
REMOVE AND INSTALL ENGINE REAR OIL SEAL 50-187
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 50-197
REMOVE AND INSTALL FUEL TANK ASSEMBLY 50-216
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 50-224
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 50-235
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 50-248
REMOVE AND INSTALL KDPF ASSEMBLY 50-253
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 50-262
REMOVE AND INSTALL SCR ASSEMBLY 50-275
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 50-282
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 50-292
REMOVE AND INSTALL KCCV ASSEMBLY 50-306
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 50-311
REMOVE AND INSTALL AdBlue/DEF INJECTOR 50-322
REMOVE AND INSTALL AdBlue/DEF PUMP 50-331
REMOVE AND INSTALL AdBlue/DEF HOSE 50-334
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 50-348
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50-352
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 50-359
POWER TRAIN 50-362
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 50-362
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 50-364
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 50-375
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 50-378
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 50-388
UNDERCARRIAGE AND FRAME 50-390
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 50-390
REMOVE AND INSTALL SPROCKET 50-395
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 50-397
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 50-400
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 50-407
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 50-413
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY 50-419
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 50-424
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 50-429
HYDRAULIC SYSTEM 50-432
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 50-432
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 50-436
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 50-439
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 50-450
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 50-460
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 50-471
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 50-478
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 50-481
WORK EQUIPMENT 50-484
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 50-484
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 50-492
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM 50-495
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 50-498
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 50-499
CAB AND ITS ATTACHMENTS 50-506
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 50-506
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) 50-520
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 50-532
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 50-541
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 50-556
REMOVE AND INSTALL OPERATOR’S SEAT 50-569
REMOVE AND INSTALL SEAT BELT 50-574
INDEX 00 INDEX AND FOREWORD
00-16 PC490LC-11
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 50-576
ELECTRICAL SYSTEM 50-590
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 50-590
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 50-593
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50-601
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 50-608
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 50-610
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 50-612
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 50-615
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 50-618
REMOVE AND INSTALL KomVision CAMERA 50-622
REMOVE AND INSTALL GATEWAY CONTROLLER ASSEMBLY 50-625
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 50-635
REMOVE AND INSTALL COMMUNICATION TERMINAL 50-652
60 MAINTENANCE STANDARD 60-1
CONTENTS 60-2
ABBREVIATION LIST 60-3
ENGINE AND COOLING SYSTEM 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT 60-9
MAINTENANCE STANDARD OF COOLING SYSTEM 60-10
MAINTENANCE STANDARD OF COOLING FAN PUMP 60-11
MAINTENANCE STANDARD OF COOLING FAN MOTOR 60-13
POWER TRAIN 60-14
MAINTENANCE STANDARD OF SWING CIRCLE 60-14
MAINTENANCE STANDARD OF SWING MACHINERY 60-15
MAINTENANCE STANDARD OF FINAL DRIVE 60-17
MAINTENANCE STANDARD OF SPROCKET 60-19
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 60-20
UNDERCARRIAGE AND FRAME 60-22
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 60-22
MAINTENANCE STANDARD OF IDLER 60-24
MAINTENANCE STANDARD OF TRACK ROLLER 60-26
MAINTENANCE STANDARD OF CARRIER ROLLER 60-28
MAINTENANCE STANDARD OF TRACK SHOE 60-29
MAINTENANCE STANDARD OF TRIPLE SHOE 60-32
HYDRAULIC SYSTEM 60-33
MAINTENANCE STANDARD OF MAIN PUMP 60-33
MAINTENANCE STANDARD OF SWING MOTOR 60-35
MAINTENANCE STANDARD OF TRAVEL MOTOR 60-38
MAINTENANCE STANDARD OF CONTROL VALVE 60-41
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 60-52
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM 60-54
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 60-56
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60-59
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 60-62
MAINTENANCE STANDARD OF SOLENOID VALVE 60-65
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE 60-66
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 60-67
WORK EQUIPMENT 60-68
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 60-68
MAINTENANCE STANDARD OF BOOM CYLINDER 60-77
MAINTENANCE STANDARD OF ARM CYLINDER 60-78
MAINTENANCE STANDARD OF BUCKET CYLINDER 60-79
80 APPENDIX 80-1
CONTENTS 80-2
ABBREVIATION LIST 80-4
AIR CONDITIONER SYSTEM 80-10
PRECAUTIONS FOR REFRIGERANT 80-10
00 INDEX AND FOREWORD INDEX
PC490LC-11 00-17
AIR CONDITIONER COMPONENT 80-11
SPECIFICATIONS OF AIR CONDITIONER 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80-14
OUTLINE OF REFRIGERATION CYCLE 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80-17
AIR CONDITIONER UNIT 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT 80-21
AIR CONDITIONER CONTROLLER 80-25
COMPRESSOR 80-26
CONDENSER 80-27
RECEIVER DRIER 80-28
SENSORS FOR AIR CONDITIONER SYSTEM 80-29
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
80-31
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 80-33
AIR CONDITIONER SYSTEM DIAGRAM 80-35
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 80-36
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
80-38
TESTING AIR LEAKAGE (DUCT) 80-42
METHOD FOR TESTING AIR LEAKAGE (DUCT) 80-42
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 80-44
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR 80-45
TEST VENT (MODE) CHANGEOVER 80-46
METHOD FOR TESTING VENT (MODE) CHANGEOVER 80-46
TESTING FRESH/RECIRC AIR CHANGEOVER 80-48
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 80-48
TEST SUNLIGHT SENSOR 80-49
METHOD FOR TESTING SUNLIGHT SENSOR 80-49
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 80-50
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 80-50
TEST RELAYS 80-51
METHOD FOR TESTING RELAYS 80-51
AIR CONDITIONER TROUBLESHOOTING CHART 1 80-52
AIR CONDITIONER TROUBLESHOOTING CHART 2 80-53
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80-56
FAILURE CODE [879AKA] 80-58
FAILURE CODE [879AKB] 80-59
FAILURE CODE [879BKA] 80-60
FAILURE CODE [879BKB] 80-62
FAILURE CODE [879CKA] 80-64
FAILURE CODE [879CKB] 80-65
FAILURE CODE [879DKZ] 80-66
FAILURE CODE [879EMC] 80-68
FAILURE CODE [879FMC] 80-69
FAILURE CODE [879GKX] 80-70
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
80-72
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
80-74
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) 80-77
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80-79
TROUBLESHOOTING USING GAUGE PRESSURE 80-81
CONNECTION OF SERVICE TOOL 80-84
METHOD FOR CONNECTING SERVICE TOOL 80-84
INDEX 00 INDEX AND FOREWORD
00-18 PC490LC-11
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS 80-86
HANDLE COMPRESSOR OIL 80-88
90 CIRCUIT DIAGRAMS 90-1
CONTENTS 90-2
ABBREVIATION LIST 90-3
HYDRAULIC CIRCUIT DIAGRAM 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90-9
HYDRAULIC CIRCUIT DIAGRAM (1/2) 90-13
HYDRAULIC CIRCUIT DIAGRAM (2/2) 90-15
ELECTRICAL CIRCUIT DIAGRAM 90-17
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 90-17
ELECTRICAL CIRCUIT DIAGRAM(1/11) 90-21
ELECTRICAL CIRCUIT DIAGRAM(2/11) 90-23
ELECTRICAL CIRCUIT DIAGRAM(3/11) 90-25
ELECTRICAL CIRCUIT DIAGRAM(4/11) 90-27
ELECTRICAL CIRCUIT DIAGRAM(5/11) 90-29
ELECTRICAL CIRCUIT DIAGRAM(6/11) 90-31
ELECTRICAL CIRCUIT DIAGRAM(7/11) 90-33
ELECTRICAL CIRCUIT DIAGRAM(8/11) 90-35
ELECTRICAL CIRCUIT DIAGRAM(9/11) 90-37
ELECTRICAL CIRCUIT DIAGRAM(10/11) 90-39
ELECTRICAL CIRCUIT DIAGRAM(11/11) 90-41
INDEX 1

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