The Komatsu PC490LC-10 Crawler Excavator is a heavy production machine used for bulk earthmoving, quarry work, and demolition where downtime gets expensive fast. This Shop Manual (SEN05622-16) is what mechanics and field techs grab when a fault code won’t clear, a function is slow or dead, or a major component has to come apart. People usually want this manual when they’re beyond basic maintenance and need step‑by‑step repair and diagnostic guidance, not just fluid intervals and grease points.
What this manual helps you do
- Trace hydraulic issues in the multi‑pump system, from slow boom/arm functions to travel problems, using factory test points and diagnostic flow.
- Check and diagnose engine‑related complaints on the mid‑range diesel (hard start, power loss, smoke) with the proper inspection and test procedures.
- Follow correct disassembly and reassembly sequences for major components like final drives, swing machinery, cylinders, and pumps so you don’t damage parts in the dirt.
- Diagnose electrical and electronic faults using wiring information, connector locations, and typical test steps for sensors, switches, and controllers.
- Handle calibration and adjustment procedures after component replacement so machine functions and safety systems work as intended.
Who this is for
This Komatsu PC490LC-10 Crawler Excavator Shop Manual is aimed at field technicians, shop mechanics, and fleet maintenance leads who actually turn wrenches. If you’re just operating the machine or only need daily/weekly service info, you’re better off with the Operation & Maintenance Manual instead.
FAQ
Q: Is this a PDF I can download and search?
A: Yes, it’s a digital PDF you can download, search by keyword, and print specific pages for use at the machine.
Q: Is this deep enough for full rebuilds and serious troubleshooting?
A: Yes, a shop manual for the PC490LC-10 typically covers workshop‑level diagnostics, teardown, inspection, and reassembly procedures, not just basic service.
Q: How do I know if it matches my exact PC490LC-10 variant?
A: Check your machine’s model designation and compare it to PC490LC-10; if your serial tag matches that family, this SEN05622-16 shop manual is usually the correct reference.
Bottom line: If you’re repairing or troubleshooting a Komatsu PC490LC-10 on your own time and budget, this is the right manual; if you only need operating tips or basic service intervals, keep looking for the O&M book instead.
📘 Show Index
Table of Contents:
- 00 Index and foreword
- Index
- Foreword, safety and general information
- Important safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling equipment of fuel system devices
- Handling of intake system parts
- Handling of hydraulic equipment
- Method of disconnecting and connecting of push-pull type coupler
- Handling of electrical equipment
- How to read electric wire code
- Precautions when performing operation
- Practical use of KOMTRAX
- Standard tightening torque table
- List of abbreviation
- Conversion table
- 01 Specification
- Table of contents
- Specifications
- Specification drawing
- Working range drawing
- Specification
- Table of weight
- Table of fuel, coolant and lubricants
- 10 Structure and function
- Table of contents
- Engine and cooling system
- Engine-related parts
- VGT
- EGR system piping drawing
- EGR system circuit diagram
- EGR valve
- EGR cooler
- KCCV layout drawing
- KCCV ventilator
- KDPF
- Cooling system
- Cooling fan pump
- Cooling fan motor
- Power train
- Power train
- Swing circle
- Swing machinery
- Final drive
- Undercarriage and frame
- Track frame and idler cushion
- Hydraulic system
- Hydraulic component layout
- Valve control
- Hydraulic tank
- CLSS
- Main pump
- Control valve
- Swing motor
- Travel motor
- PPC valve
- Solenoid valve
- Attachment circuit selector valve
- Center swivel joint
- Accumulator
- Work equipment
- Work equipment
- Work equipment shims
- Bucket play adjustment shim
- Anti-drop valve
- Cab and its attachments
- Cab mount and cab tipping stopper
- ROPS cab
- Electrical system
- Electrical control system
- Machine monitor system
- KOMTRAX system
- Sensor
- 20 Standard value tables
- Table of contents
- Standard service value table
- Standard value table for engine
- Standard value table for machine
- 30 Testing and adjusting
- Table of contents
- Related information on testing and adjusting
- Tools for testing and adjusting
- Sketch of tools for testing and adjusting
- Engine and cooling system
- Testing engine speed
- Testing boost pressure
- Testing exhaust gas color
- Testing mass air flow and temperature sensor
- Testing and adjusting valve clearance
- Testing compression pressure
- Testing blowby pressure
- Testing engine oil pressure
- Testing EGR valve and KVGT oil pressure
- Testing fuel pressure
- Testing fuel leakage and return
- Bleeding air from fuel system
- Testing fuel circuit for leakage
- Handling cylinder cutout mode operation
- Handling no-injection cranking operation
- Testing and adjusting air conditioner compressor belt tension
- Replacing alternator belt
- Fuel doser cleaning procedure
- Writing compensation values at replacement of injector and engine controller
- Power train
- Testing swing circle bearing clearance
- Undercarriage and frame
- Testing and adjusting track tension
- Hydraulic system
- Releasing remaining pressure from hydraulic circuit
- Releasing remaining pressure onmachines equipped with anti-dropvalve for arm with maximum arm INposture
- Releasing remaining pressure onmachines equipped with anti-dropvalve for arm with maximum armOUT posture
- Testing and adjusting oil pressure in work equipment, swing and travel circuits
- Testing oil pressure in control circuit
- Testing and adjusting oil pressure in pump PC control circuit
- Testing and adjusting oil pressure in pump LS control circuit
- Testing output pressure of solenoid valve
- Testing PPC valve output pressure
- Adjusting play of work equipment and swing PPC valves
- Testing pump swash plate sensor
- Testing fan speed
- Testing fan pump circuit oil pressure
- Checking fan pump EPC current
- Testing fan pump EPC solenoid valve output pressure
- Isolating the parts causing hydraulic drift in work equipment
- Testing oil leakage
- Bleeding air from hydraulic circuit
- Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side)
- Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side)
- Replacing accumulator bladder on high pressure side for accumulator piping
- Cab and its attachments
- Testing cab tipping stopper
- Adjusting mirrors
- Electrical system
- Special functions of machine monitor
- Adjusting rearview camera angle
- Handling voltage circuit of engine controller
- Handling battery disconnect switch
- Testing diodes
- Pm clinic
- 40 Troubleshooting
- Table of contents
- Related information on troubleshooting
- Troubleshooting points
- Sequence of events in troubleshooting
- Checks before troubleshooting
- Inspection procedure before troubleshooting
- Preparation for troubleshooting of electrical system
- Classification and procedure for troubleshooting
- Symptom and troubleshooting numbers
- Information in troubleshooting table
- Connector list and layout
- Connector contact identification
- T-branch box and T-branch adapter table
- Connection table of fuse box
- Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
- Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors)
- Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135])
- Failure codes table
- Troubleshooting by failure code (Display of code)
- Failure code [879AKA] A/C Inner Sensor Open Circuit
- Failure code [879AKB] A/C Inner Sensor Short Circuit
- Failure code [879BKA] A/C Outer Sensor Open Circuit
- Failure code [879BKB] A/C Outer Sensor Short Circuit
- Failure code [879CKA] Ventilating Sensor Open Circuit
- Failure code [879CKB] Ventilating Sensor Short Circuit
- Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit
- Failure code [879EMC] Ventilation Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- Failure code [879GKX] Refrigerant Abnormality
- Failure code [989L00] Engine Controller Lock Caution 1
- Failure code [989M00] Engine Controller Lock Caution 2
- Failure code [989N00] Engine Controller Lock Caution 3
- Failure code [A1U0N3] HC Desorb Request 1
- Failure code [A1U0N4] HC Desorb Request 2
- Failure code [AA10NX] Air Cleaner Clogging
- Failure code [AB00KE] Charge Voltage Low
- Failure code [B@BAZG] Eng Oil Press Low
- Failure code [B@BAZK] Eng Oil Level Low
- Failure code [B@BCNS] Eng Water Overheat
- Failure code [B@BCZK] Eng Water Level Low
- Failure code [B@HANS] Hyd Oil Overheat
- Failure code [CA115] Eng Ne and Bkup Speed Sens Error
- Failure code [CA122] Chg Air Press Sensor High Error
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA135] Eng Oil Press Sensor High Error
- Failure code [CA141] Eng Oil Press Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sensor 2 Supply Volt Low Error
- Failure code [CA221] Ambient Press Sensor High Error
- Failure code [CA222] Ambient Press Sensor Low Error
- Failure code [CA227] Sensor 2 Supply Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sensor Supply Volt Error
- Failure code [CA239] Ne Speed Sens Supply Volt High Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA273] PCV2 Short Error
- Failure code [CA274] PCV2 Open Error
- Failure code [CA322] Inj #1(L#1) Open/Short Error
- Failure code [CA323] Inj #5(L#5) Open/Short Error
- Failure code [CA324] Inj #3(L#3) Open/Short Error
- Failure code [CA325] Inj #6(L#6) Open/Short Error
- Failure code [CA331] Inj #2(L#2) Open/Short Error
- Failure code [CA332] Inj #4(L#4) Open/Short Error
- Failure code [CA343] ECM Critical Internal Failure
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sensor 1 Supply Volt Low Error
- Failure code [CA356] Mass Air Flow Sensor High Error
- Failure code [CA357] Mass Air Flow Sensor Low Error
- Failure code [CA386] Sensor 1 Supply Volt High Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA515] Rail Press Sens Sup Volt High Error
- Failure code [CA516] Rail Press Sens Sup Volt Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CA555] Crankcase Press High Error 1
- Failure code [CA556] Crankcase Press High Error 2
- Failure code [CA559] Rail Press Low Error
- Failure code [CA595] Turbo Speed High Error 2
- Failure code [CA687] Turbo Speed Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA691] Intake Temperature Sensor High Error
- Failure code [CA692] Intake Temperature Sensor Low Error
- Failure code [CA697] ECM Internal Temp Sensor High Error
- Failure code [CA698] ECM Int Temp Sensor Low Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1117] Persistent Data Lost Error
- Failure code [CA1664] KDOC Malfunction
- Failure code [CA1691] Regeneration Ineffective
- Failure code [CA1695] Sens supply 5 volt high error
- Failure code [CA1696] Sens supply 5 volt low error
- Failure code [CA1843] Crankcase Pressure Sensor High Error
- Failure code [CA1844] Crankcase Press Sensor Low Error
- Failure code [CA1879] KDPF Delta Pressure Sensor High Error
- Failure code [CA1881] KDPF Delta Pressure Sensor Low Error
- Failure code [CA1883] KDPF Differential Pressure Sensor In Range Error
- Failure code [CA1921] KDPF Soot Load High Error 1
- Failure code [CA1922] KDPF Soot Load High Error 2
- Failure code [CA1923] Dosing Fuel Valve 1 High Error
- Failure code [CA1924] Dosing Fuel Valve 1 Low Error
- Failure code [CA1925] Dosing Fuel Valve 1 In Range Error
- Failure code [CA1927] Dosing Fuel Press Sens High Error
- Failure code [CA1928] Dosing Fuel Press Sens Low Error
- Failure code [CA1942] Crankcase Press Sens In Range Error
- Failure code [CA1963] Dosing Fuel Valve 1 Servo Error
- Failure code [CA1977] Fuel Doser Open/Short Error
- Failure code [CA1993] KDPF Differential Pressure Low Error
- Failure code [CA2185] Throt Sensor Sup Volt High Error
- Failure code [CA2186] Throt Sensor Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CA2265] Fuel feed pump open circuit error
- Failure code [CA2266] Fuel feed pump short circuit error
- Failure code [CA2271] EGR Valve Pos Sens High Error
- Failure code [CA2272] EGR Valve Pos Sens Low Error
- Failure code [CA2349] EGR Valve Solenoid Open Error
- Failure code [CA2353] EGR Valve Solenoid Short Error
- Failure code [CA2357] EGR Valve Servo Error
- Failure code [CA2381] VGT Pos Sens High Error
- Failure code [CA2382] VGT Pos Sens Low Error
- Failure code [CA2383] VGT Solenoid Open Error
- Failure code [CA2386] VGT Solenoid Short Error
- Failure code [CA2387] VGT Servo Error
- Failure code [CA2555] Grid Htr Relay Open Circuit Error
- Failure code [CA2556] Grid Htr Relay Short Circuit Error
- Failure code [CA2637] KDOC Face Plugging
- Failure code [CA2639] Manual Stationary Regeneration Request
- Failure code [CA2732] Dosing Fuel Valve 2 High Error
- Failure code [CA2733] Dosing Fuel Valve 2 Low Error
- Failure code [CA2741] Dosing Fuel Valve Swap Error
- Failure code [CA2765] Inj Trim Data Error
- Failure code [CA2878] Dosing Fuel Valve 2 Servo Error
- Failure code [CA2881] Dosing Fuel Pressure Low Error 1
- Failure code [CA3133] KDPF Outlet Pressure Sensor High Error
- Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error
- Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error
- Failure code [CA3167] Fuel Doser Degradation
- Failure code [CA3251] KDOC Inlet Temperature High Error
- Failure code [CA3253] KDOC Temp Error – Non Regeneration
- Failure code [CA3254] KDOC Outlet Temp High Error 1
- Failure code [CA3255] KDPF Temp Error – Non Regeneration
- Failure code [CA3256] KDPF Outlet Temp High Error 1
- Failure code [CA3311] KDOC Outlet Temp High Error 2
- Failure code [CA3312] KDPF Outlet Temp High Error 2
- Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error
- Failure code [CA3314] KDOC Inlet Temperature Sensor High Error
- Failure code [CA3315] KDOC Intlet Temperature Sensor In Range Error
- Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error
- Failure code [CA3317] KDOC Outlet Temperature Sensor High Error
- Failure code [CA3318] KDOC Outlet Temp Sensor In Range Error
- Failure code [CA3319] KDPF Outlet Temperature Sensor High Error
- Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error
- Failure code [CA3322] KDPF Outlet Temp Sensor In Range Error
- Failure code [CA3419] Mass Air Flow Sensor Power Supply High Error
- Failure code [CA3421] Mass Air Flow Sensor Power Supply Low Error
- Failure code [D110KB] Battery Relay Drive S/C
- Failure code [D19JKZ] Personal Code Relay Abnormality
- Failure code [D811MC] KOMTRAX Error
- Failure code [D862KA] GPS Antenna Open Circuit
- Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
- Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
- Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
- Failure code [DA20MC] Pump Controller Malfunction
- Failure code [DA22KK] Pump Solenoid Power Low Error
- Failure code [DA25KP] 5V Sensor1 Power Abnormality
- Failure code [DA29KQ] Model Selection Abnormality
- Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con)
- Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con)
- Failure code [DA2QKR] CAN2 Discon (Pump Con)
- Failure code [DA2RKR] CAN1 Discon ( Pump Con)
- Failure code [DAF0MB] Monitor ROM Abnormality
- Failure code [DAF0MC] Monitor Error
- Failure code [DAF8KB] Camera Power Supply Short Circuit
- Failure code [DAF9KQ] Model Selection Abnormality
- Failure code [DAFGMC] GPS Module Error
- Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor)
- Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)
- Failure code [DAFQKR] CAN2 Discon (Monitor)
- Failure code [DAZ9KQ] AC Model Selection Abnormality
- Failure code [DAZQKR] CAN2 Discon (AC)
- Failure code [DB2QKR] CAN2 Discon (Engine Con)
- Failure code [DB2RKR] CAN1 Discon (Engine Con)
- Failure code [DGH2KA] Hyd Oil Temp Sensor Open
- Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
- Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit
- Failure code [DHPAMA] Pump Press Sensor Abnormality
- Failure code [DHPBMA] R Pump Press Sensor Abnormality
- Failure code [DHS3MA] Arm IN PPC Sen. Abnormality
- Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality
- Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality
- Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality
- Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality
- Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality
- Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality
- Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
- Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality
- Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality
- Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality
- Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality
- Failure code [DKR0MA] F pump S/P sensor Abnormality
- Failure code [DKR1MA] R pump S/P sensor Abnormality
- Failure code [DLM3KA] Fan speed sensor: Open circuit
- Failure code [DLM3KB] Fan Speed Sensor Short Circuit
- Failure code [DLM3MB] Fan Control Mismatch
- Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
- Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
- Failure code [DV20KB] Travel Alarm Short Circuit
- Failure code [DW43KA] Travel Speed Sol Open Circuit
- Failure code [DW43KB] Travel Speed Sol Short Circuit
- Failure code [DW45KA] Swing Brake Sol Open Circuit
- Failure code [DW45KB] Swing Brake Sol Short Circuit
- Failure code [DW7BKA] Fan Reverse Sol Open Circuit
- Failure code [DW7BKB] Fan Reverse Sol Short Circuit
- Failure code [DW91KA] Travel Junction Sol Open Circuit
- Failure code [DW91KB] Travel Junction Sol Short Circuit
- Failure code [DWA2KA] Attachment Sol Open Circuit
- Failure code [DWA2KB] Attachment Sol Short Circuit
- Failure code [DWK0KA] 2-stage Relief Sol Open Circuit
- Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
- Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit
- Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit
- Failure code [DWK8KA] Swing C/O Solenoid Open Circuit
- Failure code [DWK8KB] Swing C/O Solenoid Short Circuit
- Failure code [DX16KA] Fan Pump EPC Sol Open Circuit
- Failure code [DX16KB] Fan Pump EPC Sol Short Circuit
- Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
- Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
- Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
- Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
- Failure code [DXE0KA] LS-EPC Sol Open Circuit
- Failure code [DXE0KB] LS-EPC Sol Short Circuit
- Failure code [DXE4KA] Service Current EPC Disc.
- Failure code [DXE4KB] Service Current EPC S/C
- Failure code [DXE5KA] Merge-divider Main Sol Open Circuit
- Failure code [DXE5KB] Merge-divider Main Sol Short Circuit
- Failure code [DXE6KA] Merge-divider LS Sol Open Circuit
- Failure code [DXE6KB] Merge-divider LS Sol Short Circuit
- Failure code [DY20KA] Wiper Working Abnormality
- Failure code [DY20MA] Wiper Parking Abnormality
- Failure code [DY2CKB] Washer Drive Short Circuit
- Failure code [DY2DKB] Wiper Drive (For) Short
- Failure code [DY2EKB] Wiper Drive (Rev) Short
- Troubleshooting of electrical system (E-mode)
- E-1 Engine does not start (Engine does not crank)
- E-2 Manual preheater does not operate
- E-3 Automatic preheater does not operate
- E-4 While preheater is operating, engine preheating monitor does not light up
- E-5 While starting switch is turned ON, machine monitor displays nothing
- E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow
- E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow
- E-8 Engine coolant temperature monitor lights up in white while engine is running
- E-9 Hydraulic oil temperature monitor lights up in white while engine is running
- E-10 Charge level monitor lights up in red while engine is running
- E-11 Fuel level monitor lights up in red while engine is running
- E-12 Air cleaner clogging monitor lights up in yellow while engine is running
- E-13 Engine coolant temperature monitor lights up in red while engine is running
- E-14 Hydraulic oil temperature monitor lights up in red while engine is running
- E-15 Engine oil pressure monitor lights up in red while engine is running
- E-16 Fuel gauge display does not move from minimum or maximum
- E-17 Display of fuel gauge differs from actual fuel level
- E-18 Engine coolant temperature gauge display does not move from minimum or maximum
- E-19 Display of engine coolant temperature gauge differs from actual coolant temperature
- E-20 Hydraulic oil temperature gauge display does not move from minimum or maximum
- E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature
- E-22 Machine monitor does not display partially
- E-23 Function switch does not operate
- E-24 Automatic warm-up system does not work (in cold weather)
- E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off
- E-26 Auto-decelerator is not operated or canceled with lever
- E-27 When working mode switch is operated, working mode selection screen is not displayed
- E-28 When working mode is changed, setting of engine and hydraulic pump is not changed
- E-29 When travel speed switch is operated, travel speed monitor does not change
- E-30 When travel speed selection is changed, actual travel speed does not change
- E-31 Alarm buzzer cannot be canceled
- E-32 When starting switch is turned OFF, service meter is not displayed
- E-33 Machine monitor cannot be set in service mode
- E-34 All of work equipments, swing, and travel mechanism do not move
- E-35 All of work equipment, swing, and travel mechanism do not lock
- E-36 When swing brake cancel switch is set to CANCEL position, machine cannot swing
- E-37 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position
- E-38 One-touch power maximizing function does not operate properly, or indicator not displayed on monitor
- E-39 One-touch power maximizing function is not cancelled
- E-40 Alarm does not sound during travel
- E-41 Alarm does not stop sounding while machine is stopped
- E-42 Horn does not sound
- E-43 Horn does not stop sounding
- E-44 When wiper switch is operated, wiper monitor does not light up or go off
- E-45 When wiper switch is operated, windshield wiper does not operate
- E-46 When window washer switch is operated, window washer does not operate
- E-47 Boom LOWER indicator is not displayed properly with monitoring function
- E-48 Arm OUT indicator is not displayed properly with monitoring function
- E-49 Arm IN indicator is not displayed properly with monitoring function
- E-50 Boom RAISE indicator is not displayed properly with monitoring function
- E-51 Bucket CURL indicator is not displayed properly with monitoring function
- E-52 Bucket DUMP indicator is not displayed properly with monitoring function
- E-53 Swing indicator is not displayed properly with monitoring function
- E-54 Travel indicator is not displayed properly with monitoring function
- E-55 Service indicator is not displayed properly with monitoring function
- E-56 Attachment hydraulic circuit cannot be changed
- E-57 KOMTRAX system does not operate properly
- E-58 Machine push-up function cannot be canceled
- E-59 Machine push-up function does not operate
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Information described in troubleshooting table (H-mode)
- System diagram of hydraulic equipment system
- Failure mode and cause table
- H-1 Speed or power of all work equipment, swing, and travel is low.
- H-2 Engine speed lowers significantly or engine stalls
- H-3 Any of work equipment, swing and travel does not work
- H-4 Unusual sound is heard from around hydraulic pump
- H-5 Fine control performance or response is poor
- H-6 Speed or power of boom is low
- H-7 Speed or power of arm is low
- H-8 Speed or power of bucket is low
- H-9 Work equipment does not move in single operation
- H-10 Hydraulic drift of work equipment is large
- H-11 Time lag of work equipment is large
- H-12 Other work equipment moves when one of work equipment is relieved
- H-13 One-touch power maximizing function does not work
- H-14 Machine push-up function does not work
- H-15 In combined operation of work equipment , equipment having heavier load moves slower.
- H-16 In combined operation of swing and boom RAISE, boom rising speed is low
- H-17 Travel speed drops largely in combined operation of swing and trave
- H-18 Machine does not travel straight
- H-19 Travel speed is low
- H-20 Machine is hard to steer or travel power is low
- H-21 Travel speed does not change, or travel speed is too low or high
- H-22 One of tracks does not run
- H-23 Upper structure does not swing
- H-24 Swing acceleration is poor or swing speed is low
- H-25 Upper structure overruns excessively when it stops swinging
- H-26 Shock is large when upper structure stops swinging
- H-27 Large unusual noise is heard when upper structure stops swinging
- H-28 Swing drift on a slope is large
- H-29 Attachment circuit cannot be changed
- H-30 Oil flow in attachment circuit cannot be controlled
- H-31 Fan speed is abnormal (high, low, or 0 rpm)
- H-32 Unusual noise is heard from around fan
- Troubleshooting of engine (S-mode)
- Information mentioned in troubleshooting table (S mode)
- S-1 When starting switch is turned to START position, engine is not cranked
- S-2 The engine cranks but exhaust smoke does not come out
- S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not)
- S-4 Engine startability is poor
- S-5 Engine does not pick-up smoothly
- S-6 Engine stops during operation
- S-7 Engine runs rough or is unstable
- S-8 Engine lacks power
- S-9 KDPF gets clogged in a short time
- S-10 Engine oil consumption is excessive
- S-11 Engine oil becomes contaminated early
- S-12 Fuel consumption is excessive
- S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
- S-14 Oil pressure drops
- S-15 Fuel mixes into engine oil
- S-16 Water mixes into engine oil (milky)
- S-17 Coolant temperature rises too high (overheating)
- S-18 Unusual noise is heard
- S-19 Vibration is excessive
- S-20 Air cannot be bled from fuel circuit
- S-21 Active regeneration is executed frequently
- S-22 Active regeneration takes a long time
- S-23 White smoke is exhausted during active regeneration
- 50 Disassembly and assembly
- Table of contents
- Related information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Engine and cooling system
- Removal and installation of supply pump assembly
- Removal and installation of injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of radiator assembly
- Removal and installation of hydraulic oil cooler assembly
- Removal and installation of aftercooler assembly
- Removal and installation of cooling fan and fan motor assembly
- Removal and installation of engine and main pump assembly
- Removal and installation of engine front seal
- Removal and installation of engine rear seal
- Removal and installation of engine hood assembly
- Removal and installation of KDPF assembly
- Removal and installation of KCCV assembly
- Removal and installation of air cleaner assembly
- Power train system
- Removal and installation of travel motor and final drive assembly
- Disassembly and assembly of final drive
- Removal and installation of swing motor and swing machinery assembly
- Disassembly and assembly of swing machinery
- Removal and installation of swing circle assembly
- Undercarriage and frame
- Separation and connection of track shoe assembly
- Removal and installation of sprocket
- Removal and installation of idler and idler cushion assembly
- Disassembly and assembly of idler
- Disassembly and assembly of idler cushion
- Disassembly and assembly of track roller
- Disassembly and assembly of carrier roller
- Removal and installation of revolving frame assembly
- Removal and installation of counterweight assembly
- Hydraulic system
- Removal and installation of center swivel joint assembly
- Disassembly and assembly of center swivel joint
- Removal and installation of hydraulic tank assembly
- Removal and installation of main pump assembly
- Removal and installation of control valve assembly
- Disassembly and assembly of control valve
- Disassembly and assembly of work equipment PPC valve
- Disassembly and assembly of travel PPC valve
- Work equipment
- Removal and installation of work equipment assembly
- Disassembly and assembly of work equipment cylinder
- Remove and install anti-drop valve assembly for boom
- Remove and install anti-drop valveassembly for arm
- Disassemble and assemble antidropvalve assembly
- Cab and its attachments
- Removal and installation of operator's cab assembly
- Removal and installation of operator's cab glass (adhered window glass)
- Removal and installation of front window assembly
- Removal and installation of floor frame assembly
- Removal and installation of air conditioner unit assembly
- Removal and installation of operator’s seat
- Removal and installation of seat belt
- Removal and installation of work equipment control lever assembly
- Removal and installation of front wiper assembly
- Electrical system
- Removal and installation of air conditioner compressor assembly
- Removal and installation of air conditioner condenser assembly
- Removal and installation of engine controller assembly
- Removal and installation of pump controller assembly
- Removal and installation of machine monitor assembly
- Removal and installation of pump swash plate sensor
- Removal and installation of mass air flow and temperature sensor
- Removal and installation of KOMTRAX terminal assembly
- 60 Maintenance standard
- Table of contents
- Engine and cooling system
- Engine mount
- Cooling system
- Cooling fan pump
- Cooling fan motor
- Power train system
- Swing circle
- Swing machinery
- Final drive
- Undercarriage and frame
- Sprocket
- Track frame and idler cushion
- Idler
- Track roller
- Carrier roller
- Track shoe
- Hydraulic system
- Main pump
- Control valve
- Swing motor
- Travel motor
- PPC valve
- Solenoid valve
- Attachment circuit selector valve
- Anti-drop valve for boom
- Anti-drop valve for arm
- Center swivel joint
- Work equipment
- Work equipment
- Work equipment cylinder
- 80 Appendix
- Table of contents
- Air conditioner components
- Precautions for refrigerant
- Air conditioner component
- Configuration and function of refrigeration cycle
- Outline of refrigeration cycle
- Air conditioner unit
- Dual pressure switch
- Air conditioner controller
- Compressor
- Condenser
- Receiver drier
- Sunlight sensor
- Outer temperature sensor (outside air temperature sensor)
- Procedure for testing and troubleshooting
- Circuit diagram and arrangement of connector pins
- System diagram
- Input and output signals of the air conditioner controller
- Parts and connectors layout
- Layout of air conditioner related parts and connectors
- Testing air leakage (duct)
- Testing with self-diagnosis function
- How to open the electrical system abnormality record screen in service mode of the machine monitor
- Testing vent (mode) changeover
- Testing FRESH/RECIRC air changeover
- Testing sunlight sensor
- Testing (dual) pressure switch for refrigerant
- Testing relays
- Troubleshooting chart 1
- Troubleshooting chart 2
- Information in troubleshooting table
- Failure code list related to air conditioner
- Failure code [879AKA] A/C Inner sensor Open Circuit
- Failure code [879AKB] A/C Inner sensor Short Circuit
- Failure code [879BKA] A/C Outer sensor Open Circuit
- Failure code [879BKB] A/C Outer sensor Short Circuit
- Failure code [879CKA] Ventilating sensor Open Circuit
- Failure code [879CKB] Ventilating sensor Short Circuit
- Failure code [879DKZ] Sunlight sensor Open or Short Circuit
- Failure code [879EMC] Ventilating Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- Failure code [879GKX] Refrigerant Abnormality
- A-1 Troubleshooting for power supply system (Air conditioner does not operate)
- A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
- A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
- A-4 Troubleshooting for FRESH/RECIRC air changeover
- Troubleshooting with gauge pressure
- Connection of service tool
- Precautions for disconnecting and connecting air conditioner piping
- Handling of compressor oil
- 90 Diagrams and drawings
- Table of contents
- Hydraulic circuit diagram
- Symbols in hydraulic circuit diagram
- Hydraulic circuit diagram
- Electric circuit diagram
- Symbols in electric circuit diagram
- Electrical circuit diagram
- Electric circuit diagram for air conditioner unit
- INDEX
Komatsu
