Komatsu Hydraulic Loader WA490LC Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Loader WA490LC, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Loader WA490LC-10 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,814 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM025303 - Komatsu Hydraulic Loader WA490LC-10 Shop Manual.pdf
MAIN SECTIONS
CEBM025303...1
CONTENTS...2
SAFETY...17
Safety Notice...17
Important Safety Notice...17
General Precautions...17
Preparations For Work...19
Precautions During Work...19
GENERAL...22
HOW TO READ THE SHOP MANUAL...24
Volumes...24
Distribution And Updating...24
Filing Method...24
Revised Edition Mark...24
Revisions...24
Symbols...24
HOISTING INSTRUCTIONS...25
Hoisting...25
Making Signs...25
Precautions...25
Precautions for Sling Work...25
Precautions for Using Mobile Crane...26
Precautions for Using Overhead Hoist Crane...26
Selecting Wire Ropes...27
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS...28
Points to Remember When Handling Electric Equipment...28
Points to Remember When Handling Hydraulic Equipment...39
PUSH PULL COUPLER...41
Type 1...41
Disconnection...41
Connection...41
Type 2...42
Disconnection...42
Connection...42
Type 3...43
Disconnection...43
Connection...43
EXPLANATION OF MAINTENANCE STANDARD TERMS...44
HANDLING OF FUEL SYSTEM DEVICES...45
HANDLING OF INTAKE SYSTEM PARTS...46
STANDARD TIGHTENING TORQUE...47
Bolts And Nuts...47
Tightening Torque Of Hose Nuts...48
Tightening Torque Of Split Flange Bolts...48
Tightening Torque For Flared Nuts...48
Tightening Torques for Split Flanged Bolts...49
Tightening Torques For O-ring Boss Piping Joints...49
Table Of Tightening Torques For O-ring Boss Plugs...49
Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)...50
Tightening Torque For Face Seal Joints...50
ELECTRIC WIRE CODE...51
Classification By Thickness...51
Classification By Color And Code...51
How To Read Electric Wire Code...52
PRECAUTIONS FOR OPERATIONS...55
Precautions when Carrying Out Removal Work...55
Precautions when Carrying Out Installation Work...56
Precautions when Completing the Operation...57
CONVERSION TABLES...58
Method Of Using The Conversion Table...58
COATING MATERIALS...64
LIST OF ABBREVIATIONS...66
List of Abbreviations Used in the Shop Manual...66
List of Abbreviations Used in the Circuit Diagrams...70
01 GENERAL...71
SPECIFICATION DIMENSION DRAWINGS...72
Dimensions...72
Working Ranges...73
SPECIFICATIONS...74
WEIGHT TABLE...78
FUEL, COOLANT AND LUBRICANTS...80
10 STRUCTURE, FUNCTION & MAINTENANCE STD...83
ENGINE AND COOLING SYSTEM...86
Engine Related Parts...86
Radiator, Oil Cooler and Aftercooler...88
Cooling Fan Pump...90
Operation of Pump...93
Control of Delivery...96
Servo Valve...97
Cooling Fan Motor...99
Hydraulic Motor...101
Suction Valve...102
Reversible Valve...104
Safety Valve...106
POWER TRAIN SYSTEM...108
Power Train...108
Swing Circle...110
Swing machinery...112
Final Drive...114
UNDERCARRIAGE AND FRAME...116
Track Frame and Idler Cushion...116
HYDRAULIC SYSTEM...118
Hydraulic Component Layout...118
Valve Control...120
Hydraulic Tank...121
Oil Filler Port Cap...122
CLSS...124
Structure of CLSS...124
Basic Principle...125
Main Pump...130
LS valve...135
Operation...136
PC Valve...140
Operation...142
LS(PC)-EPC Valve...148
Operation...149
Control Valve...152
Functions and Operation by Valve...164
Unload Valve...168
LS Bypass Valve...170
Pressure Compensation Valve...171
Pressure Compensation Valve Inner Shuttle Valve...174
Boom Regeneration Circuit...176
Arm Regeneration Circuit...178
Merge-Divider Valve...180
LS Select Valve...183
Self Pressure Reducing Valve...184
Travel Junction Valve...187
Travel PPC Shuttle Valve...190
Boom Hydraulic Drift Preventive Valve...192
Arm Drift Preventive Valve...195
Suction Safety Valve For Drift Prevention Valve...198
Arm Quick Return Valve...199
Variable Back Pressure Valve...201
Main Relief Valve...202
2-Stage Safety-Suction Valve...204
Swing Motor...206
Swing Holding Brake...208
Swing 2-Stage Relief Valve...211
Swing Motor Reverse Prevention Valve...212
Travel Motor...215
Operation of Motor...218
Operation of Parking Brake...220
Brake Valve...222
Safety Valve (Bidirectional 2-Stage Set Safety Valve)...223
PPC Valve...227
Work Equipment and Swing PPC Valve...227
Travel PPC valve...233
1st-line Attachment PPC Valve (with EPC valve)...237
EPC valve...238
Solenoid Valve...242
Attachment Circuit Selector Valve...244
Center Swivel Joint...246
PPC Accumulator...247
WORK EQUIPMENT...248
Work Equipment...248
Work Equipment Shims...249
CAB AND ITS ATTACHMENTS...250
Cab Mount and Cab Tipping Stopper...250
ROPS Cab...251
ELECTRICAL SYSTEM...252
Engine Control...252
Engine Controller Function...255
Engine And Pump Combined Control Function...258
Pump and Valve Control Function...264
One-touch Power Maximizing Function...266
Machine Push-up Function...268
Auto-Deceleration Function...270
Engine Automatic Warm-up Function...272
Overheat Prevention Function...274
Turbocharger Protection Function...275
Swing Control Function...276
Quick Warm-Up Function...278
Swing 2-Stage Relief Function...278
Travel Control Function...280
PPC Lock Function...282
Oil Flow Adjuster Function For Attachment...284
Hydraulic Fan Control Function...286
Fan Rotation Control...286
Engine Output Control...287
Fan Reverse Rotation Function...288
System Component Part...290
Pump Controller...294
Resistor for PC-EPC valve...299
CAN Terminating Resistor...300
MACHINE MONITOR SYSTEM...301
Machine Monitor...302
Input and Output Signals...303
Display...306
Gauges...308
Caution Monitor...310
Pilot Monitor...314
Switches...316
Guidance ICON and Function Switch...318
Operator Mode Function...322
Service Mode Function...324
KOMTRAX SYSTEM...326
KOMTRAX Terminal...327
Input and Output Signals...328
SENSORS...330
Ambient Pressure Sensor...330
Engine Oil Pressure Sensor...331
Charge Pressure Sensor...331
Charge Temperature Sensor...332
Coolant Temperature Sensor...332
Ne (Crankshaft) Speed Sensor...333
Bkup (Camshaft) Speed Sensor...333
Common Rail Pressure Sensor...334
EGR Valve Lift Sensor...335
KVGT Speed Sensor...336
KVGT Position Sensor...336
Mass Air Flow and Temperature Sensor...337
Dosing Fuel Pressure Sensor...338
KDPF Differential Pressure and Outlet Pressure Sensor...338
KDOC Inlet Temperature Sensor...339
KDOC Outlet Temperature Sensor...339
KDPF Outlet Temperature Sensor...340
Crankcase Pressure Sensor...340
Engine Oil Level Sensor...341
Fuel Level Sensor...342
Coolant Level Sensor...343
Hydraulic Oil Temperature Sensor...343
Front Pump Oil Pressure Sensor...344
Rear Pump Oil Pressure Sensor...345
PPC Oil Pressure Sensor...346
Air Cleaner Clogging Sensor...347
Front Pump Swash Plate Sensor...348
Rear Pump Swash Plate Sensor...349
Cooling Fan Speed Sensor...350
20 STD VALUE TABLES...351
STANDARD SERVICE VALUE TABLES...352
Standard Value Table for Engine...352
Standard Value Table for Machine...354
Engine Speed...354
Travel of Control Valve Spool...354
Travel of Control Lever...355
Operating Effort of Control Lever and Pedal...355
Hydraulic Oil Pressure...356
Swing...357
Travel...358
Work Equipment...360
Performance in Combined Operation...362
Pump Swash Plate Sensor...362
Characteristics of PC Flow Control...362
Fan...363
Main Pump...363
Posture of Machine for Measuring Performance and Measurement Procedure...365
Control Valve: Spool Travel...365
Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing...365
Swing 2: Amount of Hydraulic Drift of Swing...365
Travel 1: Travel Speed, Idle Running (Without Load)...365
Travel 2: Travel Speed (Actual Run), Travel Deviation...366
Travel 3: Travel Deviation...366
Travel 4: Hydraulic Drift of Travel...366
Work Equipment 1: Hydraulic Drift of Work Equipment...366
Work Equipment 2: Boom Speed...367
Work Equipment 3: Arm Speed...367
Work Equipment 4: Bucket Speed...367
Work Equipment 5: Boom Time Lag...367
Work Equipment 6: Arm Time Lag...368
Work Equipment 7: Bucket Time Lag...368
Work Equipment 8: PC Flow Characteristics Control...368
30 TESTING & ADJUSTING...369
GENERAL INFORMATION...372
Tools for Testing, Adjusting, and Troubleshooting...372
Sketch of Tools for Testing and Adjusting...378
ENGINE AND COOLING SYSTEM...382
Checking Engine Speed...382
Measuring Boost Pressure...384
Measuring Exhaust Gas Temperature...386
Measuring Exhaust Gas Color...388
Measuring and Adjusting Valve Clearance...390
Testing...390
Adjusting...393
Measuring Compression Pressure...394
Measuring Engine Oil Pressure...399
Measuring EGR Valve and KVGT Oil Pressure...401
Measuring Fuel Pressure...403
Measuring Fuel Leakage and Return...405
Testing...405
Measuring return rate from injector...407
Bleeding Air from Fuel System...409
Bleeding Air...410
Checking Fuel Circuit for Leakage...413
Handling Cylinder Cut-Out Mode Operation...414
Handling No-Injection Cranking Operation...414
Checking and Adjusting Air Conditioner Compressor Belt Tension...415
Checking...415
Adjusting...416
Replacing Fan Belt...417
Replacing...417
Fuel Doser Cleaning Procedure...419
Removal...419
Cleaning...420
Installation...422
Writing Compensation Values at Replacement of Injector and Engine Controller...423
Connection of PC...423
Starting INSITE...424
POWER TRAIN...429
Testing Swing Circle Bearing Clearance...429
Testing...429
UNDERCARRIAGE AND FRAME...431
Testing and Adjusting Track Shoe Tension...431
Testing...431
Adjusting...431
HYDRAULIC SYSTEM...433
Releasing Remaining Pressure from Hydraulic Circuit...433
Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits...435
Testing...435
Adjusting...437
Measuring Oil Pressure in Control Circuit...441
Measuring and Adjusting Oil Pressure in Pump PC Control Circuit...443
Testing...443
Adjusting...445
Measuring and Adjusting Oil Pressure in Pump LS Control Circuit...447
Testing...447
Checking Oil Pressure with Sensor Adapter (Special Tool)...451
Adjusting...452
Measuring Solenoid Valve Output Pressure...453
Testing...453
Operating Condition...455
Measuring PPC Valve Output Pressure...457
Adjusting Play of Work Equipment and Swing PPC Valves...459
Testing Pump Swash Plate Sensor...460
Measuring Fan Pump Circuit Oil Pressure...461
Checking Fan Pump EPC Current...462
Measuring Fan Pump EPC Solenoid Valve Output Pressure...463
Isolating the Parts Causing Hydraulic Drift in Work Equipment...465
Measuring Oil Leakage...467
Bleeding Air From Hydraulic Circuit...471
Bleeding Air...472
CAB AND ITS ATTACHMENTS...475
Checking Cab Tipping Stopper...475
Adjusting Mirrors...476
ELECTRICAL SYSTEM...479
Special Functions of Machine Monitor...479
Upper Part Of Machine Monitor (Display Portion)...480
Upper Part of Machine Monitor (Switch Portion)...480
Lower Part of Machine Monitor (Switch Portion)...480
Ordinary Functions and Special Functions of Machine Monitor...480
Operator Mode (Outline)...483
Service Mode...502
Angle Adjustment of Rear View Camera...566
Handling Voltage Circuit of Engine Controller...568
Handling Battery Disconnect Switch...569
Testing Diodes...570
PM CLINIC...571
PM Clinic Service...571
Check Items Related to Engine...573
Check Items Related to Oil Pressure...574
Check Sheet...575
1. Engine...575
2. Work equipment speed...576
3. Hydraulic drift of work equipment...576
4. Hydraulic circuit...577
Visual Check of Welded Structures...580
Undercarriage Inspection Report...581
40 TROUBLESHOOTING...583
GENERAL INFORMATION ON TROUBLESHOOTING...591
Points to Remember When Troubleshooting...591
Sequence of Events in Troubleshooting...593
Checks Before Troubleshooting...595
Testing Procedure Before Troubleshooting...597
Walk-Around Check...597
Checking in Accordance with Checking Procedure...599
Preparation Work for Troubleshooting of Electrical System...605
Preparation Work...605
Classification and Procedure for Troubleshooting...610
Classification of Troubleshooting...610
Procedure for Troubleshooting...610
Symptom of Probable Failure and Troubleshooting No...614
Information Mentioned in Troubleshooting Table...618
DIAGNOSTIC PROCEDURE FOR WIRING HARNESS...620
Open Circuit Of Pressure Sensor System...620
Connector list...623
Layout of connectors...628
Connection Table for Connector Pin Numbers...634
T-Branch Box and T-Branch Adapter Table...669
Fuse List and Location...673
Connection Table of Fuse Box...673
Locations of Fusible Links...674
Location of Fuse Box and Fuse Numbers...674
Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)...675
FAILURE CODE (DISPLAY OF CODE)...678
Failure Codes Table...678
879AKA - Air Conditioner Inner Sensor Disconnection...685
879AKB - Air Conditioner Inner Sensor Disconnection...685
879BKA - A/C Outer Sensor Open Circuit...685
879BKB - A/C Outer Sensor Short Circuit...685
879CKA - Ventilating Sensor Open Circuit...685
879CKB - Ventilating Sensor Short Circuit...685
879DKZ - Sunlight Sensor Open or Short Circuit...685
879EMC - Ventilation Damper Abnormality...686
879FMC - Air Mix Damper Abnormality...686
879GKX - Refrigerant Abnormality...686
989L00 - Engine Controller Lock Caution 1...687
989M00 - Engine Controller Lock Caution 2...687
989N00 - Engine Controller Lock Caution 3...688
A1U0N3 - KDPF Dry Request (HC Release) 1...689
A1U0N4 - KDPF Dry Request (HC Release) 2...691
AA10NX - Air Cleaner Clogging...694
AB00KE - Charge Voltage Low...696
B@BAZG - Engine Oil Pressure Low...698
B@BAZK - Eng Oil Level Low...700
B@BCNS - Engine Coolant Overheat...702
B@BCZK - Radiator Coolant Level Low...704
B@HANS - Hyd Oil Overheat...706
CA115 - Eng Ne and Bkup Speed Sens Error...707
CA122 - Chg Air Press Sensor High Error...708
CA123 - Chg Air Press Sensor Low Error...710
CA131 - Throttle Sensor High Error...712
CA132 - Throttle Sensor Low Error...714
CA135 - Eng Oil Press Sensor High Error...716
CA141 - Eng Oil Press Sensor Low Error...718
CA144 - Coolant Temp Sens High Error...720
CA145 - Coolant Temp Sens Low Error...722
CA153 - Chg Air Temp Sensor High Error...724
CA154 - Chg Air Temp Sensor Low Error...726
CA187 - Sensor 2 Supply Volt Low Error...728
CA221 - Ambient Press Sensor High Error...730
CA222 - Ambient Press Sensor Low Error...732
CA227 - Sensor 2 Supply Volt High Error...734
CA234 - Eng Overspeed...735
CA238 - Ne Speed Sensor Supply Volt Error...736
CA239 - Ne Speed Sens Supply Volt High Error...738
CA271 - IMV/PCV1 Short Error...740
CA272 - IMV/PCV1 Open Error...742
CA273 - PCV2 Short Error...744
CA274 - PCV2 Open Error...746
CA322 - Inj #1 (L#1) Open/Short Error...748
CA323 - Inj #5 (L#5) Open/Short Error...750
CA324 - Inj #3 (L#3) Open/Short Error...752
CA325 - Inj #6 (L#6) Open/Short Error...754
CA331 - Inj #2 (L#2) Open/Short Error...756
CA332 - Inj #4 (L#4) Open/Short Error...758
CA343 - ECM Critical Internal Failure...760
CA351 - Injectors Drive Circuit Error...761
CA352 - Sensor 1 Supply Volt Low Error...762
CA356 - Mass Air Flow Sensor High Error...764
CA357 - Mass Air Flow Sensor Low Error...766
CA386 - Sensor 1 Supply Volt High Error...768
CA441 - Battery Voltage Low Error...770
CA442 - Battery Voltage High Error...772
CA449 - Rail Press Very High Error...773
CA451 - Rail Press Sensor High Error...774
CA452 - Rail Press Sensor Low Error...776
CA515 - Rail Press Sens Sup Volt Low Error...778
CA516 - Rail Press Sens Sup Volt High Error...780
CA553 - Rail Press High Error...782
CA555 - Crankcase Press High Error 1...783
CA556 - Crankcase Press High Error 2...784
CA559 - Supply Pump Press Low Error 1...785
CA595 - Turbo Speed High Error 2...789
CA687 - Turbo Speed Low Error...790
CA689 - Eng Ne Speed Sensor Error...792
CA691 - Intake Air Temp Sens High Error...794
CA692 - Intake Air Temp Sens Low Error...796
CA697 - ECM Internal Temp Sensor High Error...798
CA698 - ECM Internal Temp Sensor Low Error...799
CA731 - Eng Bkup Speed Sens Phase Error...800
CA778 - Eng Bkup Speed Sensor Error...801
CA1117 - Partial Data Lost Error...804
CA1664 - KDOC Malfunction...806
CA1691 - Regeneration Ineffective...808
CA1695 - Sensor 5 Supply Volt High Error...812
CA1696 - Sensor 5 Supply Volt Low Error...814
CA1843 - Crankcase Press Sens High Error...816
CA1844 - Crankcase Press Sens Low Error...818
CA1879 - KDPF Differential P Sensor High Error...821
CA1881 - KDPF Differential P Sensor Low Error...823
CA1883 - KDPF Differential Pressure Sensor In Range Error...825
CA1921 - KDPF Soot Load High Error 1...829
CA1922 - KDPF Soot Load High Error 2...831
CA1923 - Doser Solenoid Valve 1 High Error...836
CA1924 - Fuel Doser Sol Valve 1 Low Error...838
CA1925 - Doser Solenoid Valve 1 In Range Error...841
CA1927 - Doser Fuel Pressure Sensor High Error...844
CA1928 - Doser Fuel Pressure Sensor Low Error...846
CA1942 - Crankcase Press Sens In Range Error...848
CA1963 - Doser Solenoid Valve 1 Servo Error...850
CA1977 - Doser Open Short Circuit Error...852
CA1993 - KDPF Differential Pressure Low Error...854
CA2185 - Throt Sensor Sup Volt High Error...856
CA2186 - Throt Sensor Sup Volt Low Error...858
CA2249 - Rail Press Very Low Error...860
CA2265 - Fuel Feed Pump Open Error...862
CA2266 - Fuel Feed Pump Short Error...864
CA2271 - EGR Valve Pos Sens High Error...866
CA2272 - EGR Valve Pos Sens Low Error...868
CA2349 - EGR Valve Solenoid Low Error...870
CA2353 - EGR Valve Solenoid current High Error...872
CA2357 - EGR Valve Servo Error...874
CA2373 - Exhaust Manifold Press Sens High Error...876
CA2374 - Exhaust Manifold Press Sens Low Error...878
CA2375 - EGR Orifice Temp Sens High Error...880
CA2376 - EGR Orifice Temp Sens Low Error...882
CA2381 - KVGT Pos Sens High Error...884
CA2382 - KVGT Pos Sens Low Error...886
CA2383 - KVGT Solenoid Open Error...890
CA2386 - KVGT Solenoid Short Error...892
CA2387 - KVGT Valve Servo Error...894
CA2554 - Exh Manifold Press Sens In Range Error...895
CA2555 - Grid Htr Relay Open Circuit Error...896
CA2556 - Grid Htr Relay Volt High Error...898
CA2637 - KDOC Blocked...900
CA2639 - Manual Stationary Regeneration Request...902
CA2732 - Dozer Solenoid Valve 2 High Error...904
CA2733 - Doser Solenoid Valve 2 Low Error...906
CA2741 - Dozer Solenoid Valve 1 Connection Error...908
CA2765 - Injector Trim Data Mismatch...910
CA2878 - Doser Solenoid Valve 2 Servo Error...912
CA2973 - Chg Air Press Sensor In Range Error...919
CA3133 - KDPF Outlet Press Sens High Error...920
CA3134 - KDPF Outlet Press Sens Low Error...922
CA3135 - KDPF Outlet Press Sens In Range Error...924
CA3251 - KDOC Inlet Temp High Error...928
CA3253 - KDOC Temp Error - Non Regeneration...931
CA3254 - KDOC Outlet Temp High Error 1...933
CA3255 - KDPF Temp Error - Non Regeneration...936
CA3256 - KDPF Outlet Temp High Error 1...937
CA3311 - KDOC Outlet Temp High Error 2...938
CA3312 - KDPF Outlet Temp High Error 2...939
CA3313 - KDOC Inlet Temp Sensor Low Error...942
CA3314 - KDOC Inlet Temp Sens High Error...946
CA3315 - KDOC Inlet Temp Sens In Range Error...950
CA3316 - KDOC Outlet Temp Sens Low Error...954
CA3317 - KDOC Outlet Temp Sens High Error...958
CA3318 - KDOC Outlet Temp Sens In Range Error...962
CA3319 - KDPF Outlet Temp Sens High Error...966
CA3321 - KDPF Outlet Temp Sens Low Error...970
CA3322 - KDPF Outlet Temp Sens In Range Error...974
CA3419 - Mass Air Flow (MAF) Sensor Sup Volt High Error...978
CA3421 - Mass Air Flow (MAF) Sensor Sup Volt Low Error...980
D110KB - Battery Relay Output Voltage...982
D19JKZ - Personal Code Relay Abnormality...984
D811MC - KOMTRAX Error...987
D862KA - GPS Antenna Open Circuit...987
D8AQKR - CAN2 Discon (KOMTRAX)...992
DA20MC - Pump Controller...993
DA22KK - Pump Solenoid Power Low Error...994
DA25KP - 5 V Sensor 1 Power Abnormality...996
DA29KQ - Model Selection Abnormality...1000
DA2QKR - CAN2 Discon (Pump Con)...1008
DA2RKR - CAN1 Discon (Pump Con)...1011
DAF0MB - Monitor Memory Error...1012
DAF0MC - Monitor Error...1013
DAF8KB - Camera Power Supply Short Circuit...1014
DAF9KQ - Model Selection Abnormality...1016
DAFGMC - GPS Module Error...1017
DAFQKR - CAN2 Discon...1022
DAZ9KQ - A/C Model Selection Abnormality...1023
DAZQKR - CAN2 Discon (AC)...1024
DB2QKR - CAN2 Discon (Engine Con)...1030
DB2RKR - CAN1 Discon (Engine Con)...1036
DGH2KA - Hyd Oil Temp Sensor Open...1042
DGH2KB - Hyd Oil Temp Sensor Short Circuit...1044
DHA4KA - Air Cleaner Clog Sensor Open Circuit...1046
DHPAMA - F Pump Press Sensor Abnormality...1047
DHPBMA - R Pump Press Sensor Abnormality...1050
DHS3MA - Arm In PPC Press Sensor Abnormality...1053
DHS4MA - Bucket Curl PPC Press Sensor Abnormality...1056
DHS8MA - Boom Raise PPC Press Sensor Abnormality...1060
DHS9MA - Boom Lower PPC Press Sensor Abnormality...1064
DHSAMA - Swing RH PPC Press Sensor Abnormality...1068
DHSBMA - Swing LH PPC Press Sensor Abnormality...1072
DHSCMA - Arm Out PPC Press Sensor Abnormality...1076
DHSDMA - Bucket Dump PPC Press Sensor Abnormality...1080
DHSFMA - Travel Fwd LH PPC Press Sensor Abnormality...1084
DHSGMA - Travel Fwd RH PPC Press Sensor Abnormality...1088
DHSHMA - Travel Rev LH PPC Press Sensor Abnormality...1092
DHSJMA - Travel Rev RH PPC Press Sensor Abnormality...1096
DKR0MA - F Pump Swash Plate Sensor Abnormality...1100
DKR1MA - R Pump Swash Plate Sensor Abnormality...1104
DLM3KB - Fan Speed Sensor: Short circuit...1110
DV20KB - Travel Alarm Short Circuit...1112
DW43KA - Travel Speed Sol Open Circuit...1114
DW43KB - Travel Speed Sol Short Circuit...1116
DW45KA - Swing Brake Sol Open Circuit...1118
DW45KB - Swing Brake Sol Short Circuit...1122
DW91KA - Travel Junction Sol Open Circuit...1130
DW91KB - Travel Junction Sol Short Circuit...1132
DWA2KA - Attachment Sol Open Circuit...1134
DWA2KB - Attachment Sol Short Circuit...1136
DWK0KA - 2-Stage Relief Sol Open Circuit...1138
DWK0KB - 2-Stage Relief Sol Short Circuit...1140
DWK2KA - Variable Back Press Sol Open Circuit...1142
DWK2KB - Variable Back Press Sol Short Circuit...1144
DWK8KA - Swing Press Cut-Off Sol Open Circuit...1146
DWK8KB - Swing Press Cut-Off Sol Short Circuit...1148
DXA8KA - PC-EPC (F) Sol Open Circuit...1154
DXA8KB - PC-EPC (F) Sol Short Circuit...1156
DXA9KA - PC-EPC (R) Sol Open Circuit...1158
DXA9KB - PC-EPC (R) Sol Short Circuit...1162
DXE0KA - LS-EPC Sol Open Circuit...1164
DXE0KB - LS-EPC Sol Short Circuit...1166
DXE4KA - Attachment Flow EPC Open Circuit...1168
DXE4KB - Attachment Flow EPC Short Circuit...1170
DXE5KA - Merge-divide Main Sol Open Circuit...1172
DXE5KB - Merge-divide Main Sol Short Circuit...1174
DXE6KA - Merge-divide LS Sol Open Circuit...1176
DXE6KB - Merge-divide LS Sol Short Circuit...1178
DY20KA - Wiper Working Abnormality...1180
DY20MA - Wiper Parking Abnormality...1184
DY2EKB - Wiper Drive (Rev) Short Circuit...1188
ELECTRICAL SYSTEM (E-MODE)...1190
E-1 Engine Does Not Start (Engine Does Not Rotate)...1190
E-2 Manual Pre-Heating System Does Not Work...1198
E-3 Automatic Pre-Heating System Does Not Work...1202
E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated...1204
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...1206
E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow...1209
E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow...1209
E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running...1210
E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running...1210
E-10 Charge Level Monitor Lights Up While Engine is Running...1211
E-11 Fuel Level Monitor Lights Up in Red While Engine is Running...1211
E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running...1211
E-13 Engine Coolant Temperature Monitor Lights Up in Red While Engine is Running...1212
E-14 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running...1212
E-15 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running...1213
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum...1214
E-17 Display of Fuel Gauge Differs from Actual Fuel Level...1216
E-18 Coolant Temperature Gauge Indicate Either Min or Max and Does Not Move...1217
E-20 Hydraulic Oil Temperature Gauge Indicate Either Min or Max and Does Not Move...1220
E-21 Hydraulic Oil Temperature Gauge Differs from Actual oil Temperature...1222
E-22 Machine Monitor Does Not Display Partially...1223
E-23 Function Switch Does Not Work...1223
E-24 Automatic Pre-Heating System Does Not Work (In Cold Weather)...1224
E-25 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated...1225
E-26 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated...1226
E-27 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated...1227
E-28 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed...1227
E-29 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated...1227
E-30 Travel Speed Does Not Change When Travel Speed is Shifted...1228
E-31 Alarm Buzzer Does Not Stop Sounding...1229
E-32 When Starting Switch is Turned OFF, Service Meter is Not Displayed...1229
E-33 Machine Monitor Service Mode Cannot be Selected...1230
E-34 All of Work Equipment, Swing and Travel Does Not Work...1232
E-35 All of Work Equipment, Swing and Travel Can Not be Locked...1234
E-36 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled...1236
E-37 Swing Brake Does Not Operate While Swing Brake Cancel Switch is set to NORMAL position...1238
E-38 One-Touch Power Maximizing Function Does Not Work Or Pilot Monitor is Not Displayed...1240
E-39 One-Touch Power Maximizing Function Cannot be Released...1243
E-40 Travel Alarm Does Not Sound When Machine Travels...1244
E-41 Travel Alarm Does Not Stop Sounding When Machine Stops...1246
E-42 Horn Does Not Sound...1248
E-43 Horn Does Not Stop Sounding...1250
E-44 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated...1251
E-45 Wiper Does Not Operate When Wiper Switch is Operated...1252
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated...1254
E-47 Boom LOWER Indication is Not Displayed Properly With Monitoring Function...1254
E-48 Arm DUMP Indication is Not Displayed Properly With Monitoring Function...1254
E-49 Arm IN Indication is Not Displayed Properly With Monitoring Function...1254
E-50 Boom RAISE Indication is Not Displayed Properly With Monitoring Function...1255
E-51 Bucket CURL Indication is Not Displayed Properly With Monitoring Function...1255
E-52 Bucket DUMP Indication is Not Displayed Properly With Monitoring Function...1255
E-53 Swing Indication is Not Displayed Properly With Monitoring Function...1255
E-54 Travel Indication is Not Displayed Properly With Monitoring Function...1256
E-55 Attachment is Not Displayed Properly With Monitoring Function...1257
E-56 Attachment Hydraulic Circuit Cannot be Changed...1260
E-57 KOMTRAX System Does Not Work Properly...1262
E-58 Machine Push-up Function is Not Canceled...1264
HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...1268
Information Mentioned in Troubleshooting Table (H Mode)...1268
Failure Mode and Cause Table...1270
H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power...1276
H-2 Engine Speed Lowers Significantly or Engine Stalls...1278
H-3 All of Work Equipment, Swing and Travel Does Not Work...1280
H-4 Unusual Sound is Heard from Around Hydraulic Pump...1280
H-5 Fine Control Performance or Response is Poor...1281
H-6 Boom Operation Lacks Speed or Power...1282
H-7 Arm Operation Lacks Speed or Power...1286
H-8 Bucket Operation Lacks Speed or Power...1290
H-9 Work Equipment Does Not Move in Single Operation...1293
H-10 Hydraulic Drift of Boom is Large...1294
H-11 Time Lag of Work Equipment is Large...1298
H-13 One-Touch Power Maximizing Function Does Not Work...1300
H-14 Machine Push Up Function Does Not Work...1301
H-15 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower...1302
H-16 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low...1303
H-17 Travel Speed Drops Largely In Combined Operations of Swing and Travel...1303
H-18 Machine Does Not Travel Straight...1304
H-19 Travel Speed is Too Low...1306
H-20 Machine is Hard to Steer or Travel Power is Low...1308
H-21 Travel Speed Does Not Change, or Travel Speed is Too Low or High...1311
H-22 One of Tracks Does Not Run...1312
H-23 Upper Structure Does Not Swing to the Right or Left...1313
H-24 Swing Acceleration is Poor or Swing Speed is Low...1315
H-25 Upper Structure Overruns Excessively When it Stops Swinging...1317
H-26 Shock is Large When Upper Structure Stops Swinging...1319
H-27 Large Unusual Noise is Heard When Upper Structure Stops Swinging...1320
H-28 Swing Drift On a Slope is Large...1321
H-29 Attachment circuit cannot be Changed...1323
H-30 Oil Flow in Attachment Circuit Cannot be Controlled...1324
ENGINE (S-MODE)...1328
Information Mentioned in Troubleshooting Table (S-Mode)...1328
S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank...1329
S-2 When Engine Cranks, Exhaust Smoke Does Not Come Out...1330
S-3 Fuel is Being Injected But Engine Does Not Start (Incomplete Combustion: Engine Cranks but Does Not Start)...1331
S-4 Start ability is Poor...1333
S-5 Engine Does Not Pick Up Smoothly...1335
S-6 Engine Stops During Operation...1337
S-7 Engine Runs Rough or is Unstable...1339
S-8 Engine Lacks Power...1340
S-9 Exhaust Smoke is Black (KDPF Gets Clogged in a Short Time)...1342
S-10 Engine Oil Consumption is Excessive...1344
S-11 Oil Becomes Contaminated Early...1345
S-12 Fuel Consumption is Excessive...1346
S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)...1347
S-14 Oil Pressure Drops...1348
S-15 Fuel is Contaminated in Engine Oil...1350
S-16 Coolant Mixes in Engine Oil (Oil Becomes Cloudy White)...1351
S-17 Coolant Temperature Rises Too High (Overheating)...1352
S-18 Unusual Noise is Heard...1353
S-19 Vibration is Excessive...1354
S-20 Air Cannot be Bled from Fuel Circuit...1355
S-21 Automatic Regeneration is Operated Frequently...1356
S-22 Active Regeneration is Operated for Long...1357
S-23 White Smoke Comes Out in the Process of Active Regeneration...1358
50 DISASSEMBLY & ASSEMBLY...1359
HOW TO READ THIS SECTION...1364
Removal and Installation of Assemblies...1364
Special Tools...1364
Removal...1364
Installation...1364
Disassembly and Assembly of Assemblies...1365
Special Tools...1365
Disassembly...1365
Assembly...1366
Coating Materials List...1367
SPECIAL TOOLS LIST...1372
Sketches of Special Tools...1376
CONNECTOR REPAIR PROCEDURES...1382
Stripping Insulation...1382
Wire Inspection...1382
Contact Terminal Removal (HD30 Type)...1383
Crimping Contact Terminal (HD30 Type)...1384
Insertion of Contact Terminal (HD30 Type)...1385
Contact Terminal Removal (DT Type)...1386
Crimping Contact Terminal (DT Type)...1387
Insertion of Contact Terminal (DT Type)...1388
ENGINE AND COOLING SYSTEM...1389
Supply Pump Assembly...1389
Removal...1389
Installation...1394
Fuel Injector Assembly...1398
Removal...1398
Installation...1402
Cylinder Head Assembly...1408
Removal...1408
Installation...1416
Radiator Assembly...1422
Removal...1422
Installation...1424
Hydraulic Oil Cooler Assembly...1426
Removal...1426
Installation...1428
Aftercooler Assembly...1430
Removal...1430
Installation...1432
Cooling Fan and Fan Motor Assembly...1434
Removal...1434
Installation...1438
Engine and Main Pump Assembly...1440
Removal...1440
Installation...1450
Engine Front Oil Seal...1454
Removal...1454
Installation...1456
Engine Rear Oil Seal...1460
Removal...1460
Installation...1462
Engine Hood Assembly...1466
Removal...1466
Installation...1466
KDPF Assembly...1467
Removal...1467
Installation...1469
KCCV Assembly...1470
Removal...1470
Installation...1470
Air Cleaner Assembly...1472
Removal...1472
Installation...1473
POWER TRAIN...1474
Travel Motor and Final Drive Assembly...1474
Removal...1474
Installation...1475
Final Drive...1476
Disassembly...1476
Assembly...1480
Swing Motor and Swing Machinery...1486
Removal...1486
Installation...1487
Swing Machinery...1488
Disassembly...1488
Assembly...1492
Swing Circle Assembly...1497
Removal...1497
Installation...1497
UNDERCARRIAGE AND FRAME...1498
Separation and Connection of Track Shoe Assembly...1498
Separation Track...1498
Connecting Track...1499
Sprocket...1501
Removal...1501
Installation...1501
Idler and Idler Cushion Assembly...1502
Removal...1502
Installation...1502
Idler...1503
Disassembly...1503
Assembly...1504
Idler Cushion...1507
Disassembly...1507
Assembly...1508
Track Roller...1510
Assembly...1510
Carrier Roller...1511
Assembly...1511
Revolving Frame Assembly...1513
Removal...1513
Installation...1515
Counterweight Assembly...1517
Removal...1517
Installation...1519
HYDRAULIC SYSTEM...1520
Center Swivel Joint Assembly...1520
Removal...1520
Installation...1521
Center Swivel Joint...1522
Disassembly...1522
Assembly...1523
Hydraulic Tank Assembly...1524
Removal...1524
Installation...1527
Main Pump Assembly...1530
Removal...1530
Installation...1533
Control Valve Assembly...1536
Removal...1536
Installation...1540
Procedures for Replacing Pressure Compensation Valve Seal Rings...1541
Assembly...1543
Work Equipment PPC Valve...1546
Disassembly...1546
Assembly...1546
Travel PPC Valve...1548
Disassembly...1548
Assembly...1548
WORK EQUIPMENT...1550
Work Equipment...1550
Removal...1550
Installation...1552
Work Equipment Cylinder...1554
Disassembly...1554
Assembly...1557
CAB AND ITS ATTACHMENTS...1560
Operator's Cab Assembly...1560
Removal...1560
Installation...1566
Operator Cab Glass (Fixed Glass)...1568
Removal...1569
Installation...1570
Front Window Assembly...1580
Removal...1580
Installation...1583
Floor Frame Assembly...1588
Removal...1588
Installation...1595
Air Conditioner Unit Assembly...1598
Removal...1598
Installation...1603
Operator's Seat...1604
Removal...1604
Installation...1606
Seat Belt...1608
Removal...1608
Installation...1609
Front Wiper Assembly...1610
Removal...1610
Installation...1616
ELECTRIC SYSTEM...1622
Air Conditioner Compressor Assembly...1622
Removal...1622
Installation...1623
Air Conditioner Condenser Assembly...1626
Removal...1626
Installation...1626
Engine Controller Assembly...1628
Removal...1628
Installation...1629
Pump Controller Assembly...1630
Removal...1630
Installation...1632
Machine Monitor Assembly...1634
Removal...1634
Installation...1636
Pump Swash Plate Sensor...1638
Removal...1638
Installation...1638
Mass Air Flow and Temperature Sensor...1640
Removal...1640
Installation...1641
KOMTRAX Terminal Assembly...1642
Removal...1642
Installation...1643
60 MAINTENANCE STD...1645
ENGINE AND COOLING SYSTEM...1646
Engine Mounts...1646
Cooling System...1648
Cooling Fan Pump...1650
Servo Valve...1651
Cooling Fan Motor...1652
POWER TRAIN...1653
Swing Circle...1653
Swing Machinery...1654
Final Drive...1656
UNDERCARRIAGE AND FRAME...1658
Sprocket...1658
Track Frame and Idler Cushion...1660
Idler...1662
Track Roller...1664
Carrier Roller...1666
Track Shoe...1668
Triple Grouser Shoe...1671
HYDRAULIC SYSTEM...1672
Main pump...1672
Control Valve...1675
General View...1675
Swing Motor...1686
Travel Motor...1689
PPC Valve...1692
Work Equipment and Swing PPC Valve...1692
Travel PPC Valve...1696
1st-Line Attachment PPC Valve (with EPC Valve)...1700
EPC Valve...1702
Solenoid Valve...1704
Attachment Circuit Selector Valve...1705
For Low-Pressure Circuit...1705
Center Swivel Joint...1706
WORK EQUIPMENT...1707
Work equipment...1707
Dimensions of Arm...1712
Work Equipment Cylinder...1718
Boom Cylinder...1718
Arm Cylinder...1719
Bucket Cylinder...1720
80 AIR CONDITIONER...1721
AIR CONDITIONER...1723
Precautions for Refrigerant...1723
AIR CONDITIONER COMPONENT...1724
STRUCTURE AND FUNCTION...1727
Overview...1728
Compression (Compressor)...1728
Condensation (Condenser)...1728
Expansion (Expansion valve)...1728
Evaporation (Evaporator)...1728
AIR CONDITIONER UNIT...1730
Function...1731
Temperature Control...1731
Over-cooling (Freezing) Prevention...1731
Air Flow Adjustment...1731
Vent (Mode) Changeover...1731
FRESH/RECIRC Air Changeover...1732
Automatic Air Conditioner...1732
Selection Pattern Of Vent (Mode) Changeover Door...1732
Selection Pattern Of Air Mix Door (6)...1732
Functions of Major Components...1733
Evaporator...1733
Heater Core...1733
Evaporator Temperature Sensor...1733
Servomotor...1733
Expansion Valve...1734
DUAL PRESSURE SWITCH...1736
AIR CONDITIONER CONTROLLER...1736
AIR CONDITIONER COMPRESSOR...1737
AIR CONDITIONER CONDENSER...1738
RECEIVER DRIER...1739
SUNLIGHT SENSOR...1740
OUTSIDE AIR TEMPERATURE SENSOR...1740
PROCEDURE FOR TESTING AND TROUBLESHOOTING...1741
Basic Inspection and Troubleshooting Sequence...1742
Air Conditioner Circuit Diagram and Arrangement of Connector Pins...1743
System Diagram...1744
Air Conditioner Controller Input and Output Signals...1745
PARTS AND CONNECTORS LAYOUT...1747
Layout of Air Conditioner Related Parts and Connectors...1748
TESTING AIR LEAKAGE (DUCT)...1751
TESTING WITH SELF-DIAGNOSIS FUNCTION...1753
How to Enter Air Conditioner Electrical Systems Screen in Service Mode of the Machine Monitor...1754
TESTING VENT (MODE) CHANGEOVER...1756
TESTING FRESH/RECIRC AIR CHANGEOVER...1758
TESTING SUNLIGHT SENSOR...1759
TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT...1760
TESTING RELAY...1761
Troubleshooting Chart 1...1762
Troubleshooting Chart 2...1763
INFORMATION IN TROUBLESHOOTING TABLE...1766
Information in Troubleshooting Table...1766
FAILURE CODES FOR AIR CONDITIONER...1768
879AKA - A/C Inner Sensor Open Circuit...1769
879AKB - A/C Inner Sensor Short Circuit...1769
879BKA - A/C Outer Sensor Open Circuit...1770
879BKB - A/C Outer Sensor Short Circuit...1772
879CKA - Ventilating Sensor Open Circuit...1774
879CKB - Ventilating Sensor Short Circuit...1775
879DKZ - Sunlight Sensor Open or Short Circuit...1776
879EMC - Ventilation Damper Abnormality...1778
879FMC - Air Mix Damper Abnormality...1779
879GKX - Refrigerant Abnormality...1780
A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)...1782
A-2 Troubleshooting of Compressor System (Air is Not Cooled)...1784
A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)...1788
A-4 Troubleshooting for FRESH/RECIRC Air Changeover...1790
Troubleshooting with Gauge Pressure...1792
[Measurement Condition for Pressure]...1792
Testing Refrigerant Pressure...1795
Check...1796
Precautions for Disconnecting and Connecting Refrigerant Piping...1798
Disconnection...1798
Connection...1798
Tightening Torque for Joint Portion of Refrigerant Piping...1799
HANDLING OF COMPRESSOR OIL...1800
Oil Level Control of Compressor...1800
Refilling of Compressor Oil...1800
Replacement of compressor in case of compressor seizure or breakage...1801
Other cases...1801
Applying compressor oil to O-rings...1802
90 DIAGRAMS AND SCHEMATICS...1803
HYDRAULIC SYSTEM...1805
Hydraulic Circuit Diagram & Name of Valves...1806
Hydcircuit Diagram (1/2)...1806
Hydraulic Diagram (2/2)...1808
ELECTRICAL SYSTEM...1809
Electrical Circuit Symbols...1809
Air Conditioner Electrical Circuit...1810
Electrical Circuit Diagram (1/5)...1811
Electrical Circuit Diagram (2/5)...1812
Electrical Circuit Diagram (3/5)...1813
Electrical Circuit Diagram (4/5)...1814
Electrical Circuit Diagram (5/5)...1815
