Sen05622 05

SEN05622-05
HYDRAULIC PC490LC -10

EXCAVATOR SERIAL NUMBERS 80001 and up
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
PC490LC-10 80001and up
00 Index and foreword

1 00 Index and foreword
PC490LC-10 00-1
Index
Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-14
Important safety notice ....................................................................................................... 00-14
How to read the shop manual.............................................................................................. 00-21
Explanation of terms for maintenance standard .................................................................... 00-23
Handling equipment of fuel system devices .......................................................................... 00-25
Handling of intake system parts........................................................................................... 00-26
Handling of hydraulic equipment.......................................................................................... 00-27
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-29
Handling of electrical equipment.......................................................................................... 00-32
How to read electric wire code............................................................................................. 00-40
Precautions when performing operation ............................................................................... 00-43
Practical use of KOMTRAX ................................................................................................. 00-48
Standard tightening torque table.......................................................................................... 00-49
List of abbreviation ............................................................................................................. 00-55
Conversion table ................................................................................................................ 00-60
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawing......................................................................................................... 01-4
Specification ........................................................................................................................ 01-5
Table of weight..................................................................................................................... 01-8
Table of fuel, coolant and lubricants ....................................................................................... 01-9
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-3
Engine-related parts ............................................................................................................. 10-3
KVGT.................................................................................................................................. 10-5
EGR system piping drawing ................................................................................................ 10-11
EGR system circuit diagram ................................................................................................ 10-13
EGR valve......................................................................................................................... 10-14
EGR cooler........................................................................................................................ 10-16
KCCV layout drawing ......................................................................................................... 10-18
KCCV ventilator ................................................................................................................. 10-20
KDPF................................................................................................................................ 10-22
Cooling system .................................................................................................................. 10-26
Cooling fan pump ............................................................................................................... 10-29
Cooling fan motor............................................................................................................... 10-39
Power train............................................................................................................................... 10-47
Power train ........................................................................................................................ 10-47
Swing circle ....................................................................................................................... 10-49
Swing machinery ............................................................................................................... 10-50
Final drive ......................................................................................................................... 10-52
Undercarriage and frame........................................................................................................... 10-54
Track frame and idler cushion ............................................................................................. 10-54
Hydraulic system ...................................................................................................................... 10-56
Hydraulic component layout ................................................................................................ 10-56
Valve control...................................................................................................................... 10-58
Hydraulic tank.................................................................................................................... 10-60
CLSS ................................................................................................................................ 10-63
Main pump ........................................................................................................................ 10-68
Control valve ..................................................................................................................... 10-91
Swing motor .................................................................................................................... 10-146
Travel motor .................................................................................................................... 10-157
PPC valve ....................................................................................................................... 10-172
Solenoid valve ................................................................................................................. 10-191
00-2 PC490LC-10
Index
Attachment circuit selector valve ....................................................................................... 10-194

Center swivel joint ............................................................................................................ 10-197
Accumulator .................................................................................................................... 10-199
Work equipment ..................................................................................................................... 10-200
Work equipment............................................................................................................... 10-200
Work equipment shims ..................................................................................................... 10-201
Bucket play adjustment shim............................................................................................. 10-202
Cab and its attachments .......................................................................................................... 10-203
Cab mount and cab tipping stopper ................................................................................... 10-203
ROPS cab ....................................................................................................................... 10-204
Electrical system .................................................................................................................... 10-205
Electrical control system ................................................................................................... 10-205
Machine monitor system ................................................................................................... 10-254
KOMTRAX system ........................................................................................................... 10-272
Sensor ............................................................................................................................ 10-274
20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Testing engine speed ........................................................................................................... 30-8
Testing boost pressure ......................................................................................................... 30-9
Testing exhaust gas color ................................................................................................... 30-11
Testing and adjusting valve clearance .................................................................................. 30-13
Testing compression pressure............................................................................................. 30-16
Testing blowby pressure ..................................................................................................... 30-18
Testing engine oil pressure ................................................................................................. 30-19
Testing EGR valve and KVGT oil pressure............................................................................ 30-20
Testing fuel pressure .......................................................................................................... 30-21
Testing fuel leakage and return............................................................................................ 30-23
Bleeding air from fuel system .............................................................................................. 30-26
Testing fuel circuit for leakage ............................................................................................. 30-28
Handling cylinder cutout mode operation.............................................................................. 30-29
Handling no-injection cranking operation.............................................................................. 30-30
Testing and adjusting air conditioner compressor belt tension ................................................ 30-31
Replacing alternator belt ..................................................................................................... 30-32
Fuel doser cleaning procedure ............................................................................................ 30-33
Writing compensation values at replacement of injector and engine controller ......................... 30-36
Power train............................................................................................................................... 30-40
Testing swing circle bearing clearance ................................................................................. 30-40
Testing and adjusting track tension ...................................................................................... 30-41
Releasing remaining pressure from hydraulic circuit .............................................................. 30-42
Testing and adjusting oil pressure in work equipment, swing and travel circuits........................ 30-43
Testing oil pressure in control circuit..................................................................................... 30-48
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-49
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-52
Testing output pressure of solenoid valve ............................................................................. 30-57
Testing PPC valve output pressure ...................................................................................... 30-61
Adjusting play of work equipment and swing PPC valves....................................................... 30-63
Testing pump swash plate sensor ........................................................................................ 30-64
Testing fan speed............................................................................................................... 30-65
PC490LC-10 00-3
Index
Testing fan pump circuit oil pressure .................................................................................... 30-66

Checking fan pump EPC current ......................................................................................... 30-67
Testing fan pump EPC solenoid valve output pressure .......................................................... 30-68
Isolating the parts causing hydraulic drift in work equipment................................................... 30-69
Testing oil leakage ............................................................................................................. 30-71
Bleeding air from hydraulic circuit ........................................................................................ 30-74
Cab and its attachments ............................................................................................................ 30-77
Testing cab tipping stopper ................................................................................................. 30-77
Adjusting mirrors ................................................................................................................ 30-78
Electrical system ...................................................................................................................... 30-81
Special functions of machine monitor ................................................................................... 30-81
Adjusting rearview camera angle ....................................................................................... 30-150
Handling voltage circuit of engine controller........................................................................ 30-152
Handling battery disconnect switch .................................................................................... 30-153
Testing diodes ................................................................................................................. 30-154
Pm clinic ................................................................................................................................ 30-155
Check sheet .................................................................................................................... 30-159
40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting......................................................................................... 40-9
Troubleshooting points ......................................................................................................... 40-9
Sequence of events in troubleshooting................................................................................. 40-11
Checks before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation for troubleshooting of electrical system............................................................... 40-32
Classification and procedure for troubleshooting ................................................................... 40-38
Symptom and troubleshooting numbers ............................................................................... 40-41
Information in troubleshooting table ..................................................................................... 40-44
Connector list and layout .................................................................................................... 40-46
Connector contact identification........................................................................................... 40-57
T-branch box and T-branch adapter table ............................................................................. 40-96
Connection table of fuse box ............................................................................................. 40-101
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-103
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-106
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) .......................................................................................................... 40-107
Failure codes table........................................................................................................... 40-108
Troubleshooting by failure code (Display of code) ...................................................................... 40-117
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-117
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-118
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-119
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-120
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-121
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-122
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-123
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-124
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-125
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-126
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-127
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-128
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-129
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-130
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-134
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-136
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-138
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-139
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-140
00-4 PC490LC-10
Index
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-141

Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-143
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-144
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-145
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-147
Failure code [CA131] Throttle Sensor High Error................................................................. 40-149
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-151
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-153
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-155
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-157
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-159
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-161
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-163
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-165
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-167
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-169
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-171
Failure code [CA234] Eng Overspeed ................................................................................ 40-172
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-173
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-174
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-175
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-176
Failure code [CA273] PCV2 Short Error ............................................................................. 40-177
Failure code [CA274] PCV2 Open Error ............................................................................. 40-178
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-179
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-191
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-192
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-195
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-197
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-200
Failure code [CA442] Battery Voltage High Error................................................................. 40-202
Failure code [CA449] Rail Press Very High Error................................................................. 40-203
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-204
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-206
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-208
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-210
Failure code [CA553] Rail Press High Error ........................................................................ 40-212
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-213
Failure code [CA559] Rail Press Low Error......................................................................... 40-215
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-219
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-220
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-222
Failure code [CA691] Intake Temperature Sensor High Error ............................................... 40-224
Failure code [CA692] Intake Temperature Sensor Low Error ................................................ 40-226
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-228
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-229
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-230
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-231
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-233
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-234
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-237
PC490LC-10 00-5
Index
Failure code [CA1695] Sens supply 5 volt high error ........................................................... 40-240
Failure code [CA1696] Sens supply 5 volt low error............................................................. 40-241
Failure code [CA1843] Crankcase Pressure Sensor High Error ............................................ 40-243
Failure code [CA1844] Crankcase Press Sensor Low Error ................................................. 40-245
Failure code [CA1879] KDPF Delta Pressure Sensor High Error .......................................... 40-247
Failure code [CA1881] KDPF Delta Pressure Sensor Low Error ........................................... 40-249
Failure code [CA1883] KDPF Delta Pressure Sensor In Range Error.................................... 40-251
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-254
Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................ 40-262
Failure code [CA1924] Dosing Fuel Valve 1 Low Error......................................................... 40-264
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-266
Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-268
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-270
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-272
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...................................................... 40-273
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-276
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-278
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-280
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-282
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-284
Failure code [CA2265] Fuel feed pump open circuit error..................................................... 40-285
Failure code [CA2266] Fuel feed pump short circuit error..................................................... 40-287
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-289
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-291
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-293
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-295
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-297
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-298
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-300
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-302
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-304
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-306
Failure code [CA2555] Grid Htr Relay Open Circuit Error ..................................................... 40-307
Failure code [CA2556] Grid Htr Relay Short Circuit Error ..................................................... 40-309
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-311
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-313
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-320
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-321
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-325
Failure code [CA3133] KDPF Outlet Pressure Sensor High Error ......................................... 40-330
Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error .......................................... 40-332
Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error................................... 40-334
Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-338
Failure code [CA3251] KDOC Inlet Temperature High Error ................................................. 40-341
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-344
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-347
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-350
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-354
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-357
Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error....................................... 40-363
Failure code [CA3314] KDOC Inlet Temperature Sensor High Error ...................................... 40-366
Failure code [CA3315] KDOC Intlet Temperature Sensor In Range Error .............................. 40-370
Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error .................................... 40-375
Failure code [CA3317] KDOC Outlet Temperature Sensor High Error ................................... 40-378
00-6 PC490LC-10
Index
Failure code [CA3318] KDOC Outlet Temp Sensor In Range Error ....................................... 40-382
Failure code [CA3319] KDPF Outlet Temperature Sensor High Error .................................... 40-387
Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error..................................... 40-391
Failure code [CA3322] KDPF Outlet Temp Sensor In Range Error ........................................ 40-394
Failure code [CA3419] Mass Air Flow Sensor Power Supply High Error ................................ 40-399
Failure code [CA3421] Mass Air Flow Sensor Power Supply Low Error................................. 40-401
Failure code [D110KB] Battery Relay Drive S/C .................................................................. 40-403
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-405
Failure code [D811MC] KOMTRAX Error............................................................................ 40-408
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-409
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-410
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-412
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-413
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-414
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-415
Failure code [DA25KP] 5V Sensor1 Power Abnormality ...................................................... 40-417
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-419
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-422
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-424
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-425
Failure code [DA2RKR] CAN1 Discon ( Pump Con) ............................................................ 40-428
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-429
Failure code [DAF0MC] Monitor Error ................................................................................ 40-430
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-431
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-433
Failure code [DAFGMC] GPS Module Error........................................................................ 40-434
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-435
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-437
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-438
Failure code [DAZ9KQ] AC Model Selection Abnormality .................................................... 40-439
Failure code [DAZQKR] CAN2 Discon (AC)........................................................................ 40-440
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-445
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-450
Failure code [DGH2KA] Hyd Oil Temp Sensor Open ........................................................... 40-455
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-457
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ....................................... 40-459
Failure code [DHPAMA] Pump Press Sensor Abnormality ................................................... 40-461
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-464
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....................................................... 40-467
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ................................ 40-469
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality ................................. 40-472
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality....................................... 40-475
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality....................................... 40-478
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality ....................................... 40-481
Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality ...................................... 40-484
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-487
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality................................... 40-490
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ................................. 40-493
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality .................................. 40-496
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality .................................. 40-499
Failure code [DKR0MA] F pump S/P sensor Abnormality..................................................... 40-502
Failure code [DKR1MA] R pump S/P sensor Abnormality .................................................... 40-504
Failure code [DLM3KA] Fan speed sensor: Open circuit ...................................................... 40-506
Failure code [DLM3KB] Fan Speed Sensor Short Circuit ..................................................... 40-507
Failure code [DLM3MB] Fan Control Mismatch ................................................................... 40-508
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-509
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-513
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-515
PC490LC-10 00-7
Index
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-517
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-519
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-522
Failure code [DW7BKA] Fan Reverse Sol Open Circuit ....................................................... 40-524
Failure code [DW7BKB] Fan Reverse Sol Short Circuit ....................................................... 40-526
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-528
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-530
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-532
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-534
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ...................................................... 40-536
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ...................................................... 40-538
Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit ........................................ 40-540
Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit ........................................ 40-542
Failure code [DWK8KA] Swing C/O Solenoid Open Circuit .................................................. 40-544
Failure code [DWK8KB] Swing C/O Solenoid Short Circuit................................................... 40-546
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit..................................................... 40-548
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit..................................................... 40-550
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-552
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-554
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-556
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-558
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-560
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-562
Failure code [DXE4KA] Service Current EPC Disc. ............................................................. 40-564
Failure code [DXE4KB] Service Current EPC S/C ............................................................... 40-565
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................... 40-566
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................... 40-568
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit .................................................. 40-570
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit .................................................. 40-572
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-574
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-576
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-578
Failure code [DY2DKB] Wiper Drive (For) Short .................................................................. 40-580
Failure code [DY2EKB] Wiper Drive (Rev) Short ................................................................. 40-582
Troubleshooting of electrical system (E-mode) .......................................................................... 40-584
E-1 Engine does not start (Engine does not crank) .............................................................. 40-584
E-2 Manual preheater does not operate ............................................................................. 40-590
E-3 Automatic preheater does not operate ......................................................................... 40-593
E-4 While preheater is operating, engine preheating monitor does not light up....................... 40-595
E-5 While starting switch is turned ON, machine monitor displays nothing............................. 40-597
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level
monitor lights up in yellow.................................................................................... 40-600
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level
E-8 Engine coolant temperature monitor lights up in white while engine is running ................. 40-602
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-603
E-10 Charge level monitor lights up in red while engine is running ........................................ 40-604
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-605
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-606
E-13 Engine coolant temperature monitor lights up in red while engine is running .................. 40-607
E-14 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-608
E-15 Engine oil pressure monitor lights up in red while engine is running .............................. 40-609
E-16 Fuel gauge display does not move from minimum or maximum .................................... 40-610
E-17 Display of fuel gauge differs from actual fuel level ....................................................... 40-611
E-18 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-612
E-19 Display of engine coolant temperature gauge differs from actual coolant
temperature ....................................................................................................... 40-613
00-8 PC490LC-10
Index
E-20 Hydraulic oil temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-614
E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature ................ 40-616
E-22 Machine monitor does not display partially.................................................................. 40-617
E-23 Function switch does not operate............................................................................... 40-618
E-24 Automatic warm-up system does not work (in cold weather)......................................... 40-619
E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or
does not go off.................................................................................................... 40-620
E-26 Auto-decelerator is not operated or canceled with lever ............................................... 40-621
E-27 When working mode switch is operated, working mode selection screen is not
displayed ........................................................................................................... 40-622
E-28 When working mode is changed, setting of engine and hydraulic pump is not
changed............................................................................................................. 40-623
E-29 When travel speed switch is operated, travel speed monitor does not change ............... 40-624
E-30 When travel speed selection is changed, actual travel speed does not change .............. 40-625
E-31 Alarm buzzer cannot be canceled .............................................................................. 40-626
E-32 When starting switch is turned OFF, service meter is not displayed ............................... 40-627
E-33 Machine monitor cannot be set in service mode .......................................................... 40-628
E-34 All of work equipments, swing, and travel mechanism do not move............................... 40-629
E-35 All of work equipment, swing, and travel mechanism do not lock................................... 40-631
E-36 When swing brake cancel switch is set to CANCEL position, machine cannot
swing................................................................................................................. 40-632
E-37 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position .............................................................................................................. 40-634
E-38 One-touch power maximizing function does not operate properly, or indicator not
displayed on monitor ........................................................................................... 40-636
E-39 One-touch power maximizing function is not cancelled ................................................ 40-638
E-40 Alarm does not sound during travel ............................................................................ 40-639
E-41 Alarm does not stop sounding while machine is stopped.............................................. 40-641
E-42 Horn does not sound ................................................................................................ 40-642
E-43 Horn does not stop sounding..................................................................................... 40-644
E-44 When wiper switch is operated, wiper monitor does not light up or go off ....................... 40-645
E-45 When wiper switch is operated, windshield wiper does not operate............................... 40-646
E-46 When window washer switch is operated, window washer does not operate.................. 40-648
E-47 Boom LOWER indicator is not displayed properly with monitoring function .................... 40-649
E-48 Arm OUT indicator is not displayed properly with monitoring function ............................ 40-650
E-49 Arm IN indicator is not displayed properly with monitoring function................................ 40-651
E-50 Boom RAISE indicator is not displayed properly with monitoring function ...................... 40-652
E-51 Bucket CURL indicator is not displayed properly with monitoring function...................... 40-653
E-52 Bucket DUMP indicator is not displayed properly with monitoring function ..................... 40-654
E-53 Swing indicator is not displayed properly with monitoring function................................. 40-655
E-54 Travel indicator is not displayed properly with monitoring function................................. 40-656
E-55 Service indicator is not displayed properly with monitoring function............................... 40-657
E-56 Attachment hydraulic circuit cannot be changed.......................................................... 40-659
E-57 KOMTRAX system does not operate properly............................................................. 40-660
E-58 Machine push-up function cannot be canceled............................................................ 40-662
E-59 Machine push-up function does not operate................................................................ 40-664
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-665
Information described in troubleshooting table (H-mode) ..................................................... 40-665
System diagram of hydraulic equipment system ................................................................. 40-666
Failure mode and cause table ........................................................................................... 40-668
H-1 Speed or power of all work equipment, swing, and travel is low. ..................................... 40-674
H-2 Engine speed lowers significantly or engine stalls ......................................................... 40-676
H-3 Any of work equipment, swing and travel does not work ................................................ 40-678
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-679
H-5 Fine control performance or response is poor ............................................................... 40-680
H-6 Speed or power of boom is low.................................................................................... 40-681
H-7 Speed or power of arm is low ...................................................................................... 40-685
H-8 Speed or power of bucket is low .................................................................................. 40-689
PC490LC-10 00-9
Index
H-9 Work equipment does not move in single operation....................................................... 40-692

H-10 Hydraulic drift of work equipment is large ................................................................... 40-693
H-11 Time lag of work equipment is large ........................................................................... 40-697
H-12 Other work equipment moves when one of work equipment is relieved ......................... 40-698
H-13 One-touch power maximizing function does not work .................................................. 40-699
H-14 Machine push-up function does not work.................................................................... 40-700
H-15 In combined operation of work equipment , equipment having heavier load moves
slower. ............................................................................................................... 40-701
H-16 In combined operation of swing and boom RAISE, boom rising speed is low ................. 40-702
H-17 Travel speed drops largely in combined operation of swing and trave ........................... 40-703
H-18 Machine does not travel straight ................................................................................ 40-704
H-19 Travel speed is low................................................................................................... 40-706
H-20 Machine is hard to steer or travel power is low ............................................................ 40-708
H-21 Travel speed does not change, or travel speed is too low or high.................................. 40-710
H-22 One of tracks does not run ........................................................................................ 40-711
H-23 Upper structure does not swing ................................................................................. 40-712
H-24 Swing acceleration is poor or swing speed is low ........................................................ 40-714
H-25 Upper structure overruns excessively when it stops swinging....................................... 40-716
H-26 Shock is large when upper structure stops swinging.................................................... 40-718
H-27 Large unusual noise is heard when upper structure stops swinging .............................. 40-719
H-28 Swing drift on a slope is large .................................................................................... 40-720
H-29 Attachment circuit cannot be changed........................................................................ 40-722
H-30 Oil flow in attachment circuit cannot be controlled ....................................................... 40-723
H-31 Fan speed is abnormal (high, low, or 0 rpm)................................................................ 40-724
H-32 Unusual noise is heard from around fan ..................................................................... 40-725
Troubleshooting of engine (S-mode)......................................................................................... 40-726
Information mentioned in troubleshooting table (S mode)..................................................... 40-726
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-727
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-728
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) ...................................................................................................... 40-729
S-4 Engine startability is poor ............................................................................................ 40-730
S-5 Engine does not pick-up smoothly ............................................................................... 40-732
S-6 Engine stops during operation ..................................................................................... 40-734
S-7 Engine runs rough or is unstable ................................................................................. 40-736
S-8 Engine lacks power .................................................................................................... 40-737
S-9 KDPF gets clogged in a short time ............................................................................... 40-739
S-10 Engine oil consumption is excessive .......................................................................... 40-741
S-11 Engine oil becomes contaminated early...................................................................... 40-742
S-12 Fuel consumption is excessive .................................................................................. 40-743
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-744
S-14 Oil pressure drops .................................................................................................... 40-745
S-15 Fuel mixes into engine oil.......................................................................................... 40-746
S-16 Water mixes into engine oil (milky) ............................................................................. 40-747
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-748
S-18 Unusual noise is heard ............................................................................................. 40-749
S-19 Vibration is excessive ............................................................................................... 40-750
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-751
S-21 Active regeneration is executed frequently ................................................................. 40-752
S-22 Active regeneration takes a long time......................................................................... 40-753
S-23 White smoke is exhausted during active regeneration ................................................. 40-754
50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-14
Engine and cooling system ........................................................................................................ 50-19
00-10 PC490LC-10
Index
Removal and installation of supply pump assembly............................................................... 50-19

Removal and installation of injector assembly....................................................................... 50-26
Removal and installation of cylinder head assembly.............................................................. 50-33
Removal and installation of radiator assembly ...................................................................... 50-41
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-44
Removal and installation of aftercooler assembly .................................................................. 50-46
Removal and installation of cooling fan and fan motor assembly ............................................ 50-48
Removal and installation of engine and main pump assembly ................................................ 50-52
Removal and installation of engine front seal ........................................................................ 50-62
Removal and installation of engine rear seal......................................................................... 50-66
Removal and installation of engine hood assembly ............................................................... 50-71
Removal and installation of KDPF assembly......................................................................... 50-72
Removal and installation of KCCV assembly ........................................................................ 50-74
Removal and installation of air cleaner assembly .................................................................. 50-76
Power train system ................................................................................................................... 50-78
Removal and installation of travel motor and final drive assembly ........................................... 50-78
Disassembly and assembly of final drive .............................................................................. 50-79
Removal and installation of swing motor and swing machinery assembly ................................ 50-87
Disassembly and assembly of swing machinery.................................................................... 50-89
Removal and installation of swing circle assembly ................................................................ 50-96
Separation and connection of track shoe assembly ............................................................... 50-97
Removal and installation of sprocket.................................................................................... 50-99
Removal and installation of idler and idler cushion assembly ............................................... 50-100
Disassembly and assembly of idler .................................................................................... 50-101
Disassembly and assembly of idler cushion........................................................................ 50-104
Disassembly and assembly of track roller ........................................................................... 50-106
Disassembly and assembly of carrier roller......................................................................... 50-107
Removal and installation of revolving frame assembly ......................................................... 50-109
Removal and installation of counterweight assembly ............................................................50-111
Hydraulic system .................................................................................................................... 50-113
Removal and installation of center swivel joint assembly ..................................................... 50-113
Disassembly and assembly of center swivel joint ................................................................ 50-115
Removal and installation of hydraulic tank assembly ........................................................... 50-116
Removal and installation of main pump assembly ............................................................... 50-120
Removal and installation of control valve assembly ............................................................. 50-124
Disassembly and assembly of control valve........................................................................ 50-128
Disassembly and assembly of work equipment PPC valve................................................... 50-133
Disassembly and assembly of travel PPC valve.................................................................. 50-135
Work equipment ..................................................................................................................... 50-137
Removal and installation of work equipment assembly ........................................................ 50-137
Disassembly and assembly of work equipment cylinder....................................................... 50-140
Removal and installation of operator's cab assembly........................................................... 50-145
Removal and installation of operator's cab glass (adhered window glass) ............................. 50-150
Removal and installation of front window assembly ............................................................. 50-160
Removal and installation of floor frame assembly................................................................ 50-166
Removal and installation of air conditioner unit assembly..................................................... 50-172
Removal and installation of operator’s seat ........................................................................ 50-176
Removal and installation of seat belt .................................................................................. 50-178
Removal and installation of front wiper assembly ................................................................ 50-179
Removal and installation of air conditioner compressor assembly......................................... 50-186
Removal and installation of air conditioner condenser assembly .......................................... 50-189
Removal and installation of engine controller assembly ....................................................... 50-191
Removal and installation of pump controller assembly......................................................... 50-193
Removal and installation of machine monitor assembly ....................................................... 50-196
Removal and installation of pump swash plate sensor ......................................................... 50-198
Removal and installation of mass air flow and temperature sensor ....................................... 50-199
PC490LC-10 00-11
Index
Removal and installation of KOMTRAX terminal assembly .................................................. 50-201

60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Cooling fan pump ................................................................................................................. 60-5
Cooling fan motor................................................................................................................. 60-7
Power train system ..................................................................................................................... 60-8
Swing circle ......................................................................................................................... 60-8
Swing machinery ................................................................................................................. 60-9
Final drive ......................................................................................................................... 60-11
Sprocket............................................................................................................................ 60-13
Idler .................................................................................................................................. 60-16
Track roller ........................................................................................................................ 60-18
Carrier roller ...................................................................................................................... 60-19
Track shoe ........................................................................................................................ 60-20
Main pump ........................................................................................................................ 60-23
Control valve ..................................................................................................................... 60-25
Swing motor ...................................................................................................................... 60-36
Travel motor ...................................................................................................................... 60-38
PPC valve ......................................................................................................................... 60-41
Solenoid valve ................................................................................................................... 60-48
Attachment circuit selector valve ......................................................................................... 60-49
Center swivel joint .............................................................................................................. 60-50
Work equipment ....................................................................................................................... 60-51
Work equipment................................................................................................................. 60-51
Work equipment cylinder .................................................................................................... 60-60
80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller ..................................................................................................... 80-18
Compressor....................................................................................................................... 80-19
Condenser ........................................................................................................................ 80-20
Receiver drier .................................................................................................................... 80-21
Sunlight sensor .................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Input and output signals of the air conditioner controller ......................................................... 80-29
Parts and connectors layout................................................................................................ 80-31
Layout of air conditioner related parts and connectors ........................................................... 80-32
Testing air leakage (duct) .................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-39
Testing vent (mode) changeover.......................................................................................... 80-41
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
00-12 PC490LC-10
Index
Testing (dual) pressure switch for refrigerant......................................................................... 80-45

Testing relays .................................................................................................................... 80-47
Troubleshooting chart 1 ...................................................................................................... 80-48
Failure code list related to air conditioner.............................................................................. 80-53
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-54
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-55
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-56
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-58
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-60
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-61
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-62
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-64
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-65
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-66
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-67
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-69
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-72
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-74
Troubleshooting with gauge pressure................................................................................... 80-76
Connection of service tool................................................................................................... 80-79
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-81
Handling of compressor oil.................................................................................................. 80-83
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram .............................................................................................................. 90-11
Symbols in electric circuit diagram ....................................................................................... 90-11
Electrical circuit diagram ..................................................................................................... 90-15
Electric circuit diagram for air conditioner unit ....................................................................... 90-27
Index.................................................................................................................................................................... 1
PC490LC-10 00-13
Foreword, safety and general information
Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (ALL-1120-012-A-01-A)
(Rev. 2014/08)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
Safety points before starting. While working, always keep

• Good arrangement conversations of the work between your fellow
• Correct work clothes workers and your self on any step of the work.
• Observance of work standard During the work, hang the warning tag of
• Practice of making and checking signals "UNDER WORKING" in the operator's
• Prohibition of operation and handling by compartment.
unlicensed workers • Only qualified workers must perform the work
• Safety check before starting work and operation which require license or
• Wearing protective goggles (for cleaning or qualification.
grinding work) • Keep the tools in good condition. And learn the
• Wearing shielding goggles and protectors (for correct way to use the tools, and use the proper
welding work) ones among them. Before starting the work,
• Good physical condition and preparation thoroughly check the tools, lift truck, service
• Precautions against work which you are not vehicle, etc.
used to or you are used to too much • If welding repairs is required, always have a
trained and experienced welder with good
General precautions knowledge of welding perform the work. When
k Inappropriate handling causes an extreme performing welding work, always wear welding
danger. Read and understand what is gloves, apron, shielding goggles, cap, etc.
described in the operation and maintenance • Before starting work, warm up your body
manual before operating the machine. Read thoroughly to start work under good condition.
and understand what is described in this • Avoid continuing work for long hours and take
manual before starting the work. rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
• Before performing any greasing or repairs, read place.
all the safety labels stuck to the machine. For
Preparation
the locations of the safety labels and detailed
• Before adding oil or making any repairs, place
explanation of precautions, see the operation
the machine on a firm and level ground, and
and maintenance manual.
apply the parking brake and chock the wheels or
• Locate a place in the repair workshop to keep
tracks to prevent the machine from moving.
the tools and removed parts. Always keep the
• Before starting work, lower the work equipment
tools and parts in their correct places. Always
(blade, ripper, bucket, etc.) to the ground. If it is
keep the work area clean and make sure that
not possible to lower the equipment to the
there is no dirt, water or oil on the floor. Smoke
ground, insert the lock pin or use blocks to
only in the areas provided for smoking. Never
prevent the work equipment from falling. And be
smoke while working.
sure to lock all the work equipment control levers
• When performing any work, always wear the
and hang a warning tag on them.
safety shoes and helmet. Do not wear loose
• When performing the disassembling or
work cloths, or clothes with buttons missing.
assembling work, support the machine securely
1. Always wear the protective eyeglasses when with blocks, jacks, or stands before starting the
hitting parts with a hammer. work.
2. Always wear the protective eyeglasses when • Remove all of mud and oil from the steps or
grinding parts with a grinder, etc. other places used to get on and off the machine
• When performing any work with 2 or more completely. Always use the handrails, ladders of
workers, always agree on the working procedure steps when getting on or off the machine. Never
00-14 PC490LC-10
jump on or off the machine. When the scaffold is floor, wipe it off immediately. Fuel or oil on the
not provided, use steps or stepladder to secure floor can cause you to slip and can even cause
your footing. fires.
• As a general rule, do not use gasoline to wash
Precautions during work parts. Do not use gasoline to clean the electrical
• For the machine equipped with the battery parts, in particular.
disconnect switch, check that the system • Reinstall the parts removed to their original
operating lamp is turned off before starting the places. Replace the damaged parts and the
work. Then, turn the battery disconnect switch to parts which must not be used with new ones.
OFF (Q) position and remove the switch key. For When installing the hoses and wiring harnesses,
the machine not equipped with the battery be careful that they are not damaged by
disconnect switch, remove the cable from the contacting with other parts when the machine is
battery before starting the work. Be sure to operated.
remove the negative end (-) of the battery cable • When connecting the high pressure hoses and
first. tubes, make sure that they are not twisted. The
• Release the remaining pressure in the circuits damaged high pressure hoses and tubes are
completely before the work when the parts in the very dangerous when they are installed. So, be
circuits of oil, fuel, coolant and air are extremely careful when connecting the high
disconnected or removed. When the cap of the pressure pipings. In addition, check that their
oil filter, drain plug or oil pressure pickup plug is connections are correct.
removed, loose them slowly to prevent the oil • When assembling or installing the parts, be sure
from spurting out. to tighten the bolts to the specified torque. When
• When removing or installing the checking plug or installing the protective parts such as guards, or
the piping in the fuel circuit, wait 30 seconds or the parts which vibrate violently or rotate at high
longer after the engine is shut down and start speeds, be sure to check that they are installed
the work after the remaining pressure is correctly.
released from the fuel circuit. • When aligning 2 holes, never insert your fingers
• Immediately after the engine is shut down, the or hand into the holes. Align the holes with care
coolant and oil in the circuits are hot. Be careful so that your fingers are not caught in the hole.
not to get scalded by the hot coolant and oil. • When measuring hydraulic pressure, check that
Start the work after checking that the coolant the measuring tools are correctly installed.
and oil are cooled down sufficiently. • Pay attention to safety when removing and
• Start the work after the engine is shut down. Be installing the tracks of the track type machines.
sure to shut down the engine when working on When removing the track, it separates suddenly.
or around the rotating parts in particular. When The workers should not stand at either end of
checking the machine without shutting down the the track.
engine (measuring oil pressure, rotational speed, • If the engine is operated for a long time in a
oil or coolant temperature), take extreme care closed place which is not ventilated well, you
not to get caught in the rotating parts or the may suffer from gas poisoning. Accordingly,
working equipment. open the windows and doors to ventilate the
• The hoist or crane must be used to sling the place well.
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and Precautions for slinging work and making
hook) for damage before the work. Use the signals
slings with ample capacity and install them to • Only one appointed worker must make signals
the proper places. Operate the hoist or crane and co-worker must communicate with each
slowly to prevent the component from hitting any other frequently. The appointed signaler must
other part. Do not work with any part still raised make specified signals clearly at the place
by the hoist or crane. where the signaler is well seen from the
• When removing the part which is under internal operator's seat and where the signaler can see
pressure or reaction force of the spring, always the working condition easily. The signaler must
leave 2 bolts in diagonal positions. Loosen those always stand in front of the load and guide the
2 bolts gradually and alternately and release the operator safely.
pressure, then, remove the part. 1. Do not stand under the load.
• When removing the part, be careful not to break 2. Do not step on the load.
or damage the electrical wiring. The damaged • Check the slings before starting sling work.
wiring may cause electrical fires. • Keep putting on the gloves during sling work.
• When removing piping, prevent the fuel or oil (Put on the leather gloves, if available.)
from spilling out. If any fuel or oil drips onto the
PC490LC-10 00-15
• Measure the weight of the load by the eye and a Slinging near the tip of the hook may cause
check its center of gravity. the rope to slip off the hook during hoisting.
• Use the proper sling according to the weight of The strength of the hook is maximum at its
the load and method of slinging. If too thick wire central part.
ropes are used to sling a light load, the load may
slip and fall.
• Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
k Slinging with one rope may cause turning

of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 deg. or smaller as a
rule. • Do not use twisted or kinked wire ropes.
• When hanging a heavy load (25kg or heavier), • When slinging up a load, observe the following.
the hanging angle of the rope must be narrower 1. Wind up the rope slowly until the wire rope
than that of the hook. tensions. When putting your hands on the
wire ropes, do not grasp them but press them
a When slinging a load with 2 ropes or more,
down from above. If you grasp them, your
the larger the hanging angle is, the larger the
fingers may be caught.
tension of each rope. The figure bellow
2. After the wire ropes are stretched, stop the
shows the variation of allowable load in kg
crane and check the condition of the slung
when hoisting is made with 2 ropes, each of
load, wire ropes, and pads.
which is allowed to sling up to 9.8 kN
3. If the load is unstable or the wire rope or
{1,000kg} a load vertically, at various
chains are twisted, lower the load and lift it
hanging angles. When the 2 ropes sling a
up again.
load vertically, up to 2,000 kg of total weight
4. Do not lift up the load at an angle.
can be suspended. This weight is reduced to
• When lowering a load, pay attention to the
1,000 kg when the 2 ropes make a hanging
following.
angle of 120 deg.. If the 2 ropes sling a 2,000
kg load at a hanging angle of 150 deg., each 1. When lifting down a load, stop it temporarily
rope is subjected to a force as large as 4,000 at 30 cm above the floor, and then lower it
kg. slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane

a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane

k The hoist or crane must be used to sling the
• When installing wire ropes to an angular load, components weighing 25 kg or heavier. A
apply pads to protect the wire ropes. If the load part weighing 25 kg or heavier in
is slippery, apply proper material to prevent the "disassembly and assembly" section is
wire rope from slipping.
indicated with the symbol of 4 .
• Use the specified eye bolts and fix wire ropes,
chains, etc. to them with shackles, etc. • Before starting work, check the wire ropes,
• Apply wire ropes to the middle part of the hook. brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter
00-16 PC490LC-10
for electric shock prevention, crane collision a The allowable load is calculated as one sixth of
prevention device, and energizing warning lamp, the breaking load of the rope to be used (safety
and check the following safety items. coefficient: 6).
• Observe the signals for sling work.
• Operate the hoist at a safe place. Precautions for disconnecting and connecting
• Be sure to check the directions of the direction hoses and tubes in air conditioner circuit
indication plate (north, south, east and west) and Disconnection
the operating button.
• Do not sling a load at an angle. Do not move the k When replacing the air conditioner unit, air
crane while the slung load is swinging. conditioner compressor, condenser or
• Do not raise or lower a load while the crane is receiver drier, etc., collect the refrigerant (air
moving longitudinally or laterally. conditioner gas: R134a) from the air
• Do not drag a sling. conditioner circuit before disconnecting the
• When lifting up a load, stop it just after it leaves air conditioner hoses.
the ground and check safety, and then lift it up.
a Ask a qualified person for collecting, adding and
• Consider the travel route in advance and lift up a
filling operations of the refrigerant (air
load to a safe height.
conditioner gas: R134a). (Only registered
• Place the control switch in a position where it will
persons can work.)
not be an obstacle to work and passage.
• After operating the hoist, do not swing the a Never release the refrigerant (air conditioner
control switch. gas: R134a) to the atmosphere.
• Remember the position of the main switch so
that you can turn off the power immediately in an k If refrigerant gas (air conditioner gas: R134a)
emergency. gets in your eyes, you may lose your sight.
• Shut down the main switch when the hoist stops And if it touches your skin, you may suffer
because of a blackout. When turning on a switch from frostbite. Put on protective eyeglasses,
which is turned OFF by the ground fault circuit gloves and working clothes with long
interrupter for electric shock prevention, check sleeves while collecting the refrigerant or
that the devices related to that switch are not in filling the air conditioner circuit with the
operating condition. refrigerant.
• If you find an obstacle around the hoist, stop the
• When loosening the nuts fixing air conditioner
operation.
hoses and tubes, be sure to use 2 wrenches;
• After finishing the work, stop the hoist at the
use one wrench to fix and use the other one to
specified position and raise the hook to at least 2
loosen the nut.
meters above the floor. Do not leave the sling
attached to the hook. Connection
• When installing the hose for the air conditioner
Selecting wire ropes
circuit, take care not to allow invasion of dirt,
• Select adequate ropes depending on the weight
dusts and water into the hose.
of the parts to be hoisted, referring to the table
• Check that the O-rings are fitted to the joints
below
when connecting the air conditioner piping.
Wire rope (JIS G3525, 6 x 37 - Type A)
• Once an O-ring is used, it is deformed and
(Standard Z twist wire ropes without galvanizing) deteriorated. Accordingly, do not reuse it.
Nominal • When removing the O-rings, use a soft tool so
diameter of rope Allowable load that the piping is not damaged.
mm kN ton • Check that the O-ring is not damaged or
10 8.8 0.9 deteriorated.
12 12.7 1.3 • Apply compressor oil for refrigerant (R134a) to
the O-ring.
14 17.3 1.7
16 22.6 2.3 a However, do not apply oil to the threaded
18 28.6 2.9 part of a bolt, nut or union.
20 35.3 3.6 Manufacturer Part name
25 55.3 5.6 DENSO ND-OIL8
30 79.6 8.1 VALEO THERMAL ZXL100PG (equivalent to
40 141.6 14.4 SYSTEMS PAG46)
50 221.6 22.6 SANDEN SP-10
60 318.3 32.4
PC490LC-10 00-17
• When tightening nuts of the air conditioner

hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of the air
conditioner piping.
For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".
00-18 PC490LC-10
Precautions to prevent fire (ALL-0000-17B-K-03-A)
• Fire caused by fuel, oil, coolant or window • Remove any dry leaves, chips, pieces of
washer fluid paper, coal dust, or any other flammable
Do not bring any flame or fire close to flammable materials accumulated or attached to or
substances such as fuel, oil, coolant or window around the engine exhaust manifold, muffler,
washer fluid.There is danger that they may catch or battery, or on the undercovers.
fire. Always observe the following. • To prevent fires from being caught, remove
• Do not smoke or use any flame near fuel or any flammable materials such as dry leaves,
other flammable substances. chips, pieces of paper, coal dust, or any
• Shut down the engine before adding fuel. other flammable materials accumulated
• Do not leave the machine when adding fuel around the cooling system (radiator, oil
or oil. cooler) or on the undercover.
• Tighten all the fuel and oil caps securely. • Fire coming from electric wiring
• Be careful not to spill fuel on overheated Short circuits in the electrical system can cause
surfaces or on parts of the electrical system. fire. Always observe the following.
• After adding fuel or oil, wipe up any spilled • Keep all the electric wiring connections clean
fuel or oil. and securely tightened.
• Put greasy rags and other flammable • Check the wiring every day for looseness or
materials into a safe container to maintain damage. Reconnect any loose connectors or
safety at the workplace. refasten wiring clamps. Repair or replace any
• When washing parts with oil, use a non- damaged wiring.
flammable oil. Do not use diesel oil or • Fire caused by piping
gasoline.There is danger that they may catch Check that all the clamps for the hoses and
fire. tubes, guards, and cushions are securely fixed
• Do not weld or use a cutting torch to cut any in position.
pipes or tubes that contain flammable liquids. If they are loose, they may vibrate during
• Determine well-ventilated areas for storing oil operation and rub against other parts. There is
and fuel. Keep the oil and fuel in the danger that this may lead to damage to the
specified place and do not allow hoses and cause high-pressure oil to spurt out,
unauthorized persons to enter. leading to fire and serious personal injury or
• When performing grinding or welding work death.
on the machine, move any flammable • Fire around the machine due to highly heated
materials to a safe place before starting. exhaust gas
Some machines are equipped with KDPF
(Komatsu Diesel Particulate Filter).
KDPF is a system for purifying soot in exhaust
gas. Its exhaust gas discharged during
purification process (regeneration) can be at
higher temperature than that from existing
models. Do not bring any flammable material
close to the outlet of the exhaust pipe.
• When there are thatched houses, dry leaves
or pieces of paper near the work site, set the
9 J D 0 1 7 2 0
system to disable the regeneration before
starting work to prevent fire hazards due to
highly heated exhaust gas.
See the operation and maintenance manual
for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
9 J D 0 1 7 2 1
follow the instructions in the operation and
• Fire caused by accumulation or attachment maintenance manual.
of flammable material
PC490LC-10 00-19
Actions if fire occurs (ALL-0000-17A-K-01-A)
• Turn the starting switch to OFF position to stop

the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature
environment).
When wearing cotton-work-gloves, wear rubber
gloves under them.
Dispose of waste materials (ALL-0000-99A-K-02-A)
To prevent pollution, pay full attention to the way to

dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce

poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.
00-20 PC490LC-10
How to read the shop manual (ALL-0320-010-A-01-A)
(Rev. 2012/10)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
PC490LC-10 00-21
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described.
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
indicated.
Tightening The tightening torques that require special attention during assembly
3 torque work are indicated.
The places to be coated with adhesives, grease, etc. during assembling
2 Coat
are indicated.
Oil, coolant The places where oil, coolant, etc. must be added and the quantity to be
5 added are indicated.
Places where oil, coolant, etc. must be drained and the quantity to be
6 Drain
drained are indicated.
Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
00-22 PC490LC-10
Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)
(Rev. 2012/10)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance • When some parts are repaired, the value of
• To be accurate, the finished dimension of a part performance/function is set to the standard
is slightly different from one to another. value.
• The finished dimension of a part specifies the
allowable difference from the standard
dimension which is set first.
• The dimension set as the standard is called the
standard dimension and the range of difference
from this standard dimension is called the
"tolerance".
• An indication example of a standard dimension
and tolerance is shown in the following table.
(The standard dimension is entered on the left
side and the tolerance is entered with a positive
or negative symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
• An indication example of a shaft and hole is
shown in the following table.
Standard interference
(The standard dimension is entered on the left
• When the diameter of a hole of a part shown in
side and the tolerance of the shaft is entered
with a positive or negative symbol at the center the given standard dimension and tolerance
table is smaller than that of the shaft to be
and that of the hole on the right side)
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,
PC490LC-10 00-23
the parts can not be used any longer. This value

is called "repair limit".
• If a part is worn to the repair limit, it must be
replaced or repaired.
• The performance and function of the products
lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
00-24 PC490LC-10
Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)
(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.
Use care for working environment

• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.
How to clean parts when dirt is stuck

• If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.
PC490LC-10 00-25
Handling of intake system parts (PC220-A900-2A4-K-00-A)
(Rev.2013/10)
• The Komatsu Variable Geometry Turbocharger
consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.
Be careful of working environment

• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
components which are removed, with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.
00-26 PC490LC-10
Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)
(Rev. 2012/10)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment

• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
Disassembly and maintenance work in the field

• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.
Plugging of opening (prevention of flowing out

of oil)
components which are removed (when plugs
are not prepared, seal with caps, tapes, vinyl
bags, etc.) to prevent entry of foreign material Replacing hydraulic oil while its temperature is
and flowing out of oil. Never leave the openings high
• When the hydraulic oil is warm, it flows easily. In
of the pipes and hoses without being covered or
addition, sludge can also be drained from the
plugged with cloth as foreign material may enter
them or environment may be polluted by the oil circuit together with the oil. So, it is better to
leaked. Do not discard the waste oil somewhere change the hydraulic oil while it is warm. When
or other. Hand it over to your customer for changing the hydraulic oil, the old oil must be
disposal, or dispose it by yourself. drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.
PC490LC-10 00-27
Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
00-28 PC490LC-10
Method of disconnecting and connecting of push-pull type coupler (ALL-

C930-001-P-00-A)
(Rev. 2012/01)
k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 (ALL-C930-925-P-01-A)
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move approximately 3.5mm
toward the hose, however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.
PC490LC-10 00-29
Type 2 (ALL-C930-925-P-02-A)
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
00-30 PC490LC-10
Type 3 (ALL-C930-925-P-03-A)
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)
PC490LC-10 00-31
Handling of electrical equipment (ALL-E000-2A4-P-01-A)
(Rev. 2012/11)
• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the wiring harness is pulled to disconnect the
occur because the male connector is not connector, or the components are lifted with a
properly inserted into the female connector,or crane while the wiring harness is still connected,
because one or both of connectors are or a heavy object hits the wiring harness, the
deformed or the position is not correctly aligned, crimping of the connector may separate, or the
or because there is corrosion or oxidization of soldering may be damaged, or the wiring
the contact surfaces. The corroded or oxidized harness may be broken.
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately 10
times.
00-32 PC490LC-10
blow it with compressed air and spray it with

electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.
High-pressure water entering connector

• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.
Entry of water, mud or dirt when disconnecting a

connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or
PC490LC-10 00-33
• Check that there is no oil, dirt or water stick

to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
• When removing a connector from a clip, pull harness with a dryer. But be careful not to
the connector in a parallel direction to the clip make it too hot as it causes short circuit.
for removing stoppers. a If there is any damage or breakage, replace
a If the connector is pried up and down or the connector.
to the right and left, the housing may 2. Fix the connector securely.
break. • Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.
3. Action to take after removing connectors

• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
Connecting connectors
1. Check the connector visually.
00-34 PC490LC-10
• If the connector clamp is removed, be sure to Drying wiring harness

return it to its original position. And check • If there is any oil or dirt on the wiring harness,
that it is securely installed. wipe it off with a dry cloth. Avoid washing by
using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
Handling of Deutsch connector (DT8-pin, DT12-
pin)
Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
a Hot air from the dryer can be used, but
regulate the time to use hot air in order to
prevent the connector or related parts from
Connection becoming too hot, as it causes deformation
1. Push in female connector (2) horizontally until or damage to the connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.
PC490LC-10 00-35
2. While pressing lock (L2), pull out connector (1).

Handling of connectors used on engine
Slide, lock type

(FRAMATOME-3, FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).
Connection
1. Insert the connector securely until a click is Connection
heard.
1. Insert the connector securely until a click is
(FRAMATOME-24)
heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type
(PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
00-36 PC490LC-10
Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
(AMP-3)
Push lock type
(BOSCH-3) Disconnection
Disconnection 1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
1. While pressing lock (C), pull out connector (3) in
• 114 series
Connection
heard.
• 107 series (SUMITOMO-2)
Disconnection
1. While pressing lock (E), pull out connector (5) in
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector Connection
with flat-head screwdriver [1], pull out 1. Insert the connector securely until a click is
connector (3) in the direction of the arrow. heard.
PC490LC-10 00-37
(SUMITOMO-3)
Disconnection
1. While pressing lock (E), pull out connector (5) in
a Pull the connector straight up.
Connection
1. Insert the connector to the end while aligning its
grove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".
Connection
heard.
(SUMITOMO-4)
Disconnection
1. While pressing lock (D), pull out connector (4) in
Handling controller
• The electronic circuits for control including the
microcomputers are assembled in the controller.
These electronic circuits in the controller must
be handled with care as they control the
machine.
• Do not place objects on top of the controller.
Connection
heard.
Turn-housing type (Round green connector)
(CANNON-4)
Disconnection
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the • Cover the control connectors with tape or a vinyl
arrow. bag. Never touch the connector contacts.
a Housing (H1) is left on the wiring harness • During rainy weather, do not leave the controller
side. in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
00-38 PC490LC-10
temperature even for a short period of time.

(Place it on a suitable dry stand.)
• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.
Precautions for troubleshooting electrical

circuits
• Be sure to turn the starting switch to "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.
PC490LC-10 00-39
How to read electric wire code (ALL-E500-030-P-00-A)

(Rev. 2012/10)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
(Type 2)
Heat- General wiring for extremely
resistant low- Heat-resistant cross cold weather specification
voltage wire AEX linked polyethylene -50 to +110
for Wiring at high ambient
automobile temperature place
00-40 PC490LC-10
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 —
Coating D
AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard — — — — — — — — —
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D
CAVS Standard — 1.6 — 1.8 — 2.1
a "f" of nominal No. denotes "flexible".
PC490LC-10 00-41
Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
a Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG — — — — R —
Ground B — — — — — B —
Start R — — — — — R —
Light RW RB RY RG RL — D —
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB — L —
Type of — — —
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Others Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —
00-42 PC490LC-10
Precautions when performing operation (ALL-1160-927-A-00-A)
(Rev. 2012/11)
• When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and
assembly" of the components, observe the following general cautions.
Precautions for removal and disassembly work

• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
a The O-rings in the table are emergency parts used for disassembly or transportation of the machine.
When assembling, confirm the part numbers in the parts book and use the parts conforming to the
using condition.
Disconnection of face seal type hoses and tubes
Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
PC490LC-10 00-43
Disconnection of taper seal type hoses and tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
Disconnection of split flange type hoses and tubes
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
04 38.1 17.5 07371-30400 07378-10400 07000-12021 01643-50823
00400 80825
07379- 01010-
05 42.9 19.8 07371-30500 07378-10500 07000-13022 01643-50823
00500 80830
07379- 07372-
06 47.6 22.2 07371-30640 07378-10600 07000-13025 01643-51032
00640 51035
07379- 07372-
10 52.4 26.2 07371-31049 07378-11000 07000-13032 01643-51032
01044 51035
07379- 07372-
58.7 30.2 07371-31255 07378-11200 07000-13038 01643-51032
01250 51035
12
07379- 01010-
66.7 31.8 07371-51260 07378-11210 07000-13038 01643-51232
01260 81245
07379- 07372-
14 69.9 35.8 07371-31465 07378-11400 07000-13048 01643-51232
01460 51240
00-44 PC490LC-10
No- Bolt pitch (mm) Hose side Tube side

minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445
01470 81455
07379- 07372-
77.8 42.8 07371-32076 07378-12000 07000-12060 01643-51232
02071 51240
20
07379- 01010-
96.8 44.5 07371-52080 07378-12010 07000-12060 01643-31845
02080 81865
07379- 07372-
24 88.9 50.8 07371-12484 07378-12400 07000-12070 01643-51232
02484 51240
07379- 07372-
30 106.4 62 07371-13010 07378-13000 07000-12085 01643-51645
03010 51650
07372-
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 01643-51645
51650
07379- 07372-
40 130.2 77.8 07371-14012 07378-14000 07000-12110 01643-51645
04012 51650
07372-
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 01643-51645
51655
Removal of pipe joints of O-ring boss type
Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
Removal of pipe joints of taper pipe thread type
PC490LC-10 00-45
Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R 1/ 8 07042-00108 07043-00108
02 R 1/ 4 07042-00211 07043-00211
03 R 3/ 8 07042-00312 07043-00312
04 R 1/ 2 07042-00415 07043-00415
06 R 3/ 4 07042-00617 07043-00617
10 R1 07042-01019 07043-01019
12 R1 1/4 07042-01222 07043-01222
14 R1 1/2 07042-01422 07043-01422
20 R2 07042-02026 07043-02026
Precautions for installation and assembly work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES), unless otherwise specified.
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply 2 to 3 drops of adhesive to the threaded
part.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and repair any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded part of each taper male
screws which receives pressure.
However, if the threaded part is difficult to degrease, you may use a seal tape.
• When winding a seal tape onto a right-handed taper male screw, wind it clockwise in the advancing
direction of the threads, seeing from the screw end and starting at the third thread.
a If you wind the seal tape in the opposite direction, it becomes loose and comes off or its end part is
pushed out, and that can cause oil leakage.
00-46 PC490LC-10
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start the engine, and run it at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end 4 to 5 times.
3. Operate the hydraulic cylinder 3 to 4 times to the end of its stroke.
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
Precautions at the time of completing work

Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Testing of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Cooling system for water leakage.
Fuel system for fuel leakage.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
PC490LC-10 00-47
Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)

(Rev. 2012/10)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX

• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice as well for the user and operator.
How to use KOMTRAX practically

With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.
How to operate KOMTRAX

For the operating method of each screen of KOMTRAX, see "Global KOMTRAX Web Reference Manual (For
Key Person)".
00-48 PC490LC-10
Standard tightening torque table (ALL-M140-03B-P-01-A)
(Rev. 2012/10)
Table of tightening torque for bolts and nuts

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6.0 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10.0 to 12.5}
(*1, *2) 17
14 22 157 to 196 {16 to 20}
24
16 245 to 309 {25 to 31.5}
(*1) 22
18 27 343 to 427 {35 to 43.5}
20 30 490 to 608 {50 to 62}
22 32 662 to 829 {67.5 to 84.5}
24 36 824 to 1,030 {84 to 105}
27 41 1,180 to 1,470 {120 to 150}
30 46 1,520 to 1,910 {155 to 195}
33 50 1,960 to 2,450 {200 to 250}
36 55 2,450 to 3,040 {250 to 310}
39 60 2,890 to 3,630 {295 to 370}
*1: Split flange bolt.
*2: Flanged bolt.
PC490LC-10 00-49
a Tighten the following flanged bolt on which "7" is stamped on its top to the tightening torque shown in the
following table.
Thread diameter Width across flats

Tightening torque (Nm {kgm})
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}
Unless otherwise specified, tighten the unified coarse threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-20UNC 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
5/16-18UNC 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
3/8-16UNC 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
7/16-14UNC 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
1/2-13UNC 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
9/16-12UNC 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
5/8-11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
3/4-10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
7/8-9UNC 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
1-8UNC 883 to 1,196 {90 to 122} 1,040 {106} 245 to 333 {25 to 34} 284 {29}
1 1/8-7UNC 1,187 to 1,608 {121 to 164} 1,393 {142} 333 to 451 {34 to 46} 392 {40}
1 1/4-7UNC 1,598 to 2,157 {163 to 220} 1,873 {191} 451 to 608 {46 to 62} 530 {54}
1 1/2-6UNC 2,354 to 3,177 {240 to 324} 2,765 {282} 657 to 892 {67 to 91} 775 {79}
00-50 PC490LC-10
Unless otherwise specified, tighten the unified fine threaded bolts and nuts to the torque shown in the table
below.
Type of bolt A B
Nominal No. - Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
threads per inch,
type of thread Range Target Range Target
1/4-28UNF 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
5/16-24UNF 34.3 to 39.2 {3.5 to 4} 37.3 {3.8} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
3/8-24UNF 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
7/16-20UNF 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
1/2-20UNF 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
9/16-18UNF 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.6 {6}
5/8-18UNF 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
3/4-16UNF 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
7/8-14UNF 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
1-14UNF 1,020 to 1,373 {104 to 140} 1,196 {122} 284 to 382 {29 to 39} 333 {34}
1 1/8-12UNF 1,353 to 1,844 {138 to 188} 1,598 {163} 382 to 520 {39 to 53} 451 {46}
1 1/4-12UNF 1,804 to 2,432 {184 to 248} 2,118 {216} 510 to 686 {52 to 70} 598 {61}
1 1/2-12UNF 2,707 to 3,658 {276 to 373} 3,177 {324} 765 to 1,030 {78 to 105} 892 {91}
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})

Nominal No. diameter across flats
(mm) (mm) Range Target
02 14 Varies 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 depending 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 on type of 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 connector. 128 to 186 {13.0 to 19.0} 157 {16.0}
PC490LC-10 00-51

10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.

08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the table below.
a The table is applied to the threads coated with engine oil (wet threads)
00-52 PC490LC-10
Tightening torque (Nm {kgm}) Taper seal Face seal

Width
Nominal across Nominal No. - Thread root
No. of flats Thread size threads per diameter
Range Target
hose (mm) (mm) inch, type of (mm)
thread (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16-18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16-16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13 /16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1 3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Tightening torque (Nm {kgm}) Face seal

Outside Width
diameter of across flats Nominal No. - Thread root
pipe (mm) (mm) Range Target threads per inch, diameter (mm)
type of thread (reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1 3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})
6 10 ± 2 {1.02 ± 0.20}
8 24 ± 4 {2.45 ± 0.41}
10 43 ± 6 {4.38 ± 0.61}
12 77 ± 12 {7.85 ± 1.22}
14 —
PC490LC-10 00-53
Tightening torque table for 102, 107, and 114 series engines (joint bolts)
a Unless otherwise specified, tighten the metric joint bolts used on the 102, 107, and 114 series engines to
the torque shown in the table below.
Thread diameter (mm) Tightening torque (Nm {kgm})

6 8 ± 2 {0.81 ± 0.20}
8 10 ± 2 {1.02 ± 0.20}
10 12 ± 2 {1.22 ± 0.20}
12 24 ± 4 {2.45 ± 0.41}
14 36 ± 5 {3.67 ± 0.51}
Tightening torque table for tapered screws on 102,107, and 114 series engines (National taper pipe
thread (NPT))
a Unless otherwise specified, tighten the National taper pipe threaded (NPT) screws used on the 102, 107,
and 114 series engines to the torques shown in the table below.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgm}) Tightening torque (Nm {kgm})
1/16 15 ± 2 {1.53 ± 0.20} 5 ± 1 {0.51 ± 0.10}
1/ 8 20 ± 2 {2.04 ± 0.20 15 ± 2 {1.53 ± 0.20}
1/ 4 25 ± 3 {2.55 ± 0.31} 20 ± 2 {2.04 ± 0.20}
3/ 8 35 ± 4 {3.57 ± 0.41} 25 ± 3 {2.55 ± 0.31}
1/ 2 55 ± 6 {5.61 ± 0.61} 35 ± 4 {3.57 ± 0.41}
3/ 4 75 ± 8 {7.65 ± 0.82} 45 ± 5 {4.59 ± 0.51}
00-54 PC490LC-10
List of abbreviation (ALL-0360-005-A-00-A)

(Rev. 2015/01)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text (marked with a).
• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the shop manual

Purpose of use (major
Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
With this function, when the tires skid (wheels
Anti-skid Brake Travel and brake stop rotating), the brakes are released, and
ABS System when the wheels start to rotate, the brakes are
(HD, HM)
applied again.
Automatic Idling This function automatically sets the idle
AISS Engine
Setting System speed.
A lever is used to perform the steering
Advanced Joystick Steering operations instead of a steering wheel.
AJSS Steering System Moreover, it shifts gear and changes direction
(WA)
(FORWARD or REVERSE).
When the accelerator pedal is released while
Automatic Retarder Travel and brake the machine is traveling downhill, this function
ARAC automatically applies the retarder with a
Accelerator Control (HD, HM)
constant braking force.
When the accelerator pedal is released while
Travel and brake the machine is traveling downhill, this function
Automatic Retarder
ARSC automatically applies the retarder to ensure
Speed Control (HD, HM) that the machine speed does not accelerate
above the speed set by the operator.
Travel and brake When the tires spin on soft ground surfaces,
Automatic Spin
ASR this function automatically uses the optimum
Regulator (HD, HM) braking force to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake When the retarder is not being used, this
Brake cooling oil valve bypasses part of the brake cooling oil to
BCV
control valve (HD) reduce the load on the hydraulic pump.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine.
A regulator valve which is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and it is
Regulator
not used independently.
This system can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Hydraulic system
Sensing System (provides better combined operation than O.L.
S.S.).
Engine controller electronically controls
supply pump, common rail, and injector. This
CRI Common Rail Injection Engine
function maintains optimum fuel injection
amount and fuel injection timing.
Electronic control device uses the signals
Electronic Control from the sensors on the machine. This signal
ECM Electronic control system
Module indicates the optimum actuation to the
actuators. (Same as E.C.U.)
PC490LC-10 00-55

Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
Electronically This system ensures smooth high-speed
Travel travel by absorbing vibration of machine
ECSS Controlled Suspension
System (WA) during travel with hydraulic spring effect of
accumulator.
Electronic control device uses the signals
from the sensors on the machine. This signal
ECU Electronic Control Unit Electronic control system indicates the optimum actuation to the
actuators. (Same as E.C.M.)
This function recirculates part of exhaust gas
Exhaust Gas Engine to combustion chamber in order to reduce
EGR
Recirculation combustion temperature, controls emission of
NOx.
Equipment This system allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on the monitor.
Electromagnetic This mechanism allows actuators to be
EPC Hydraulic system
Proportional Control operated in proportion to the current supplied.
This structure protects the operator's head
from falling objects. (Falling Object Protective
Falling Object Cab and canopy Structure)
FOPS
Protective Structure
This performance is standardized as ISO
3449.
Forward-Neutral- Operation
F-N-R Forward-Neutral-Reverse
Reverse
Global Navigation A general term for positioning system using
GNSS Satellite System Communication satellites such as GPS, GALILEO, etc.
Communication
Global Positioning This system uses satellites to determine the
GPS System (KOMTRAX, KOMTRAX current location on the earth.
Plus)
This function uses a combination of hydraulic
Steering motor and bevel shaft to control difference in
Hydrostatic Steering
HSS travel speed of right and left tracks.
System (D) Accordingly machine can turn without using
steering clutch.
Transmission This function uses a combination of hydraulic
Hydro Static pump and hydraulic motor to shift the speed
HST
Transmission (D, WA) range steplessly without using gears.
Information and A general term for the engineering and its
Communication Intelligent Machine socially applied technology of information
ICT
Technology Control processing and communication.
This valve is installed at inlet port of pump,
Inlet Metering Actuator Engine and it adjusts fuel intake amount in order to
IMA
control fuel discharge of supply pump. Same
as I.M.V.
This is a device to detect the angular velocity
Inertial Measurement Intelligent Machine
IMU and acceleration of the 3 axes that control
Unit Control
motions.
This valve is installed at inlet port of pump,
and it adjusts fuel intake amount in order to
IMV Inlet Metering Valve Engine
control fuel discharge of supply pump. Same
as I.M.V. (I.M.A.)
This mechanism separates oil in blowby gas
Komatsu Closed Engine and returns it to the intake side to afterburn it
KCCV
Crankcase Ventilation there. It primarily consists of filters.
00-56 PC490LC-10

Komatsu Catalyzed This filter captures soot in exhaust gas.
KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine This is built in KDPF or assembled with the
Oxidation Catalyst
muffler.
This component is used to purify the exhaust
gas. KDOC (catalyst) and KCSF (filter to
Komatsu Diesel Engine capture soot) are built-in it.
KDPF
Particulate Filter
It is installed in place of the conventional
muffler.
This function recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
KVGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Image display equipment such as a monitor
LCD Liquid Crystal Display Machine monitor which assembles in the liquid crystal element.
It refers to semiconductor element that emits
LED Light Emitting Diode Electronic parts light when the voltage is applied in forward
direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Hydraulic system pump and controls discharge amount
corresponding to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
This indicates engine intake air flow.It is not
Engine used independently but it is used as combined
MAF Mass Air Flow
with sensor.Mass air flow sensor can be called
as MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Electric and hydraulic Device actuated to open electric or hydraulic
NC Normally Closed circuits that are normally closed if not
systems
actuated.
Electric and hydraulic Device actuated to close electric or hydraulic
NO Normally Open
systems circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Hydraulic system actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Hydraulic system A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
This valve is installed at inlet port of pump and
Pre-stroke Control Engine it adjusts fuel intake amount in order to control
PCV
Valve fuel discharge amount of supply pump.
PC490LC-10 00-57

Used for controlling proportional pressure.
Proportional Pressure Hydraulic system This system moves actuators in proportion to
PPC
Control the oil pressure.
Piston Pump and Hydraulic system
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and power Work equipment This function performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)
If a machine tips over, this structure protects
the operator with the seat belt fastened from
Roll-Over Protective being crushed. (Operator Protective Structure
ROPS Cab and canopy When Tipping)
Structure
This performance is standardized as ISO
3471.
Le Systeme Abbreviation for the "International System of
International d’ Unites Units". It is the universal unit system and "a
SI (International unit Unit single unit for a single quantity" is the basic
system) principle applied.
It refers to an actuator consisting of a solenoid
and an iron core that is moved by the
SOL Solenoid Electric system
magnetic force when the solenoid is
energized.
Hydraulic and electric Solenoid valve that switches over direction of
TWV 2-Way Valve
systems flow.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
00-58 PC490LC-10
Abbreviation Actual word spelled out

SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
PC490LC-10 00-59
Conversion table (ALL-2150-931-A-00-A)

(Rev. 2012/10)
Method of using the conversion table

• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the 2 lines cross as (C). This point (C) gives the value when converting the unit from
millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-60 PC490LC-10
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilograms to pounds
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
l to U.S. Gallons
1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC490LC-10 00-61
l to U.K. Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1,005
140 1,013 1,020 1,027 1,034 1,042 1,049 1,056 1,063 1,071 1,078
150 1,085 1,092 1,099 1,107 1,114 1,121 1,128 1,136 1,143 1,150
160 1,157 1,165 1,172 1,179 1,186 1,193 1,201 1,208 1,215 1,222
170 1,130 1,237 1,244 1,251 1,259 1,266 1,273 1,280 1,288 1,295
180 1,302 1,309 1,316 1,324 1,331 1,338 1,345 1,353 1,360 1,367
190 1,374 1,382 1,389 1,396 1,403 1,410 1,418 1,425 1,432 1,439
00-62 PC490LC-10
kg/cm2 to lb/in22
1 kg/cm2 = 14.2233 lb/in22
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC490LC-10 00-63
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-64 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
01 Specification
2 01 Specification
PC490LC-10 01-1
01 Specification
Table of contents
Table of contents (ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawing......................................................................................................... 01-4
Specification ........................................................................................................................ 01-5
Table of weight..................................................................................................................... 01-8
Table of fuel, coolant and lubricants ....................................................................................... 01-9
01-2 PC490LC-10
01 Specification
Specification drawing
Specifications (ALL-2111-001-A-00-A)
Specification drawing (PC400_10-2110-931-A-00-A)
Item Unit PC490LC-10

Machine weight kg 46,660
Bucket capacity m3 1.9
Engine model – Komatsu SAA6D125E-6 diesel engine
Engine flywheel horsepower
• Net [ISO 9249/SAE J1349] kW {HP}/ 268 {359}/1,900 {1,900}
• Gross [SAE J1995] min-1 {rpm} 270 {362}/1,900 {1,900}
A Overall length mm 11,930
Overall height (including head
B mm 3,635
guard)
C Overall width mm 3,590
D Shoe width mm 700
E Height of machine cab mm 3,350
F Tail swing radius mm 3,645
G Overall crawler length mm 5,385
Distance between tumbler mm 4,350
H
centers
J Min. ground clearance mm 700
Traveling speed (Lo/Mi/Hi) km/h 3.0/4.2/5.5
Continuous swing speed min-1 {rpm} 9.1 {9.1}
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output
measured of an independent engine. While, net denotes the value measured of an engine under the
condition essentially the same as that when it is installed on machine.
PC490LC-10 01-3
01 Specification
Working range drawing
Working range drawing (PC400_10-2110-931-A-01-A)
Item Unit PC490LC-10

A Max. digging reach mm 12,030
B Max. digging depth mm 7,755
C Max. digging height mm 10,980
D Max. vertical wall digging depth mm 6,805
E Max. dumping height mm 7,630
F Min. dumping height mm –
G Max. reach at ground level mm 11,810
01-4 PC490LC-10
01 Specification
Specification
Specification (PC400-2111-931-A-00-A)
Machine model PC490LC-10

Serial number 80001 and up
Bucket capacity m3 1.9
Machine weight kg 46,660
Performance
Working range
Max. digging depth mm 7,755
Max. vertical wall digging depth mm 6,805
Max. digging reach mm 12,030
Max. reach at ground level mm 11,810
Max. digging height mm 10,980
Max. dumping height mm 7,630
Max. digging force
256.0 {26,100}
(when one-touch power max. function is kN {kg}
(244.6 {28,000})
turned on)
Continuous swing speed min-1 {rpm} 9.1 {9.1}
Swing operation max. slope angle deg. 20
Traveling speed (Lo/Mi/Hi) km/h 3.0/4.2/5.5
Gradeability deg. 35
Ground pressure (Standard shoe) kPa {kg/cm2} 64.7 {0.66}
Dimensions
Overall length mm 11,930
Overall width mm 3,590
Overall width of track mm 3,590
Overall width of track when extended mm 3,090
Overall height mm 3,635
Ground clearance of upper structure mm 1,385
bottom
Min. ground clearance mm 700
Tail swing radius mm 3,645
Min. swing radius of work equipment mm 4,735
Maximum height at minimum swing radius
mm 9,275
of work equipment
Overall crawler length mm 5,385
Distance between tumbler centers mm 4,350
Machine cab height mm 3,350
Width of standard shoe mm 700
PC490LC-10 01-5
01 Specification
Specification

Engine
Model SAA6D125E–6
4-cycle, water-cooled, in-line and vertical type,
Type direct injection type with turbocharger and air-
cooled aftercooler
Number of cylinders – bore x stroke mm 6 - 125 x 150
Total piston displacement l {cc} 11.045 {11,045}
Performance
Rated horsepower
• Net [ISO 9249/SAE J1349] kW {HP}/min-1 268 {359}/1,900 {1,900}
• Gross [SAE J1995] {rpm} 270 {362}/1,900 {1,900}
Nm {kgm}/min-1
Max. torque 1,510 {154}/1,400 {1,400}
{rpm}
Max. speed with no load
• At mounted on machine 1,930 {1,930}
min-1 {rpm}
• At bear engine 1,000 {1,000}
Min. speed with no load min-1 {rpm} 1,000 {1,000}
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
Starting motor 24 V, 11.0 kW
Alternator 24 V, 50 A
Battery (*1) 12 V, 140 Ah x 2
Radiator type Aluminum wave type, 4 rows
*1: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output
measured of an independent engine. While, net denotes the value measured of an engine under the
condition essentially the same as that when it is installed on machine.
Undercarriage
Carrier roller 2 (each side)
Track roller 8 (each side)
Track shoe Assembly type, triple grouser, 49 (each side)
01-6 PC490LC-10
01 Specification
Specification

Hydraulic system
Hydraulic pump
Variable displacement piston type (HPV210 +
Type x quantity
210) x 1
Delivery l/min 347 x 2
Set pressure MPa {kg/cm2} 37.2 {380}
Control valve
Type x quantity 7-spool and 1-spool type: 1
Operating method Hydraulic
Hydraulic motor
Variable displacement piston type
Travel motor (KMV200ADT-2) x 2
(with brake valve and parking brake)
Fixed displacement piston type (KMF230ABE-
Swing motor 5) x 1
(with safety valve and parking brake)
Boom cylinder (*2)
Type Double-acting piston
Cylinder inner diameter mm 160
Piston rod diameter mm 110
Stroke mm 1,570
Max. distance between pins mm 3,830
Min. distance between pins mm 2,260
Arm cylinder (*2), (*3)
Stroke mm 1,820
Bucket cylinder
Stroke mm 1,270
Hydraulic tank Box-shaped closed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled (CF40-1)
*2: With head side cushion.
*3: With bottom side cushion.
PC490LC-10 01-7
01 Specification
Table of weight
Table of weight (PC400-2120-931-A-00-A)
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine assembly 1,660
• Engine 1,435
• Damper 14.7
• Main pump 320
Radiator and oil cooler assembly 253
Hydraulic tank and filter assembly (excluding hydraulic oil) 226
Fuel tank assembly (not including fuel) 292
Revolving frame 3,482
Operator's cab (including head guard and front half guard) 520
Operator seat 35
Counterweight 9,952
Swing machinery 509
Control valve 264
Swing motor 105
Travel motor 220 x 2
Center swivel joint 40
Track frame assembly (Not including piping) 13,258
• Track frame 7,298
• Swing circle 707
• Idler 287 x 2
• Idler cushion 508 x 2
• Carrier roller 34 x 4
• Track roller 84 x 16
• Final drive (including travel motor and sprocket) 751 x 2
Separation and connection of track shoe assembly
• Triple grouser shoe (700 mm) 5,740
Boom assembly 3,380
Arm assembly 1,622
Bucket assembly 1,366
Boom cylinder assembly 360 x 2
Arm cylinder assembly 510
Bucket cylinder assembly 302
Bucket link assembly 258
Boom pin 92+20 x 2+73+27+54
Arm pin 17+23
Bucket pin 38 x 2
Bucket link pin 34 x 2
01-8 PC490LC-10
01 Specification
Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants (PC400-RA19-05A-K-01-A)
a For details of the notes (Notes 1, Note 2... ) in the table, see the Operation and Maintenance Manual.
Unit: l
PC490LC-10
Reservoir
Specified capacity Refill capacity
Engine oil pan 42 38
Swing machinery case 20 20
Final drive case (right and left respectively) 11 11
Damper case 1.6 —
Hydraulic system 472 248
Cooling system 44 44
Fuel tank 650 —
PC490LC-10 01-9
01 Specification
Table of fuel, coolant and lubricants
01-10 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
10 Structure and function

3 10 Structure and function
PC490LC-10 10-1
Table of contents

10 Structure and function ................................................................................................................... 10-1
Engine-related parts ............................................................................................................. 10-3
KVGT.................................................................................................................................. 10-5
EGR system piping drawing ................................................................................................ 10-11
EGR system circuit diagram ................................................................................................ 10-13
EGR valve......................................................................................................................... 10-14
EGR cooler........................................................................................................................ 10-16
KCCV layout drawing ......................................................................................................... 10-18
KCCV ventilator ................................................................................................................. 10-20
KDPF................................................................................................................................ 10-22
Cooling system .................................................................................................................. 10-26
Cooling fan pump ............................................................................................................... 10-29
Cooling fan motor............................................................................................................... 10-39
Power train............................................................................................................................... 10-47
Power train ........................................................................................................................ 10-47
Swing circle ....................................................................................................................... 10-49
Swing machinery ............................................................................................................... 10-50
Final drive ......................................................................................................................... 10-52
Hydraulic component layout ................................................................................................ 10-56
Valve control...................................................................................................................... 10-58
Hydraulic tank.................................................................................................................... 10-60
CLSS ................................................................................................................................ 10-63
Main pump ........................................................................................................................ 10-68
Control valve ..................................................................................................................... 10-91
Swing motor .................................................................................................................... 10-146
Travel motor .................................................................................................................... 10-157
PPC valve ....................................................................................................................... 10-172
Solenoid valve ................................................................................................................. 10-191
Attachment circuit selector valve ....................................................................................... 10-194
Center swivel joint ............................................................................................................ 10-197
Accumulator .................................................................................................................... 10-199
Work equipment ..................................................................................................................... 10-200
Work equipment............................................................................................................... 10-200
Work equipment shims ..................................................................................................... 10-201
Bucket play adjustment shim............................................................................................. 10-202
Cab mount and cab tipping stopper ................................................................................... 10-203
ROPS cab ....................................................................................................................... 10-204
Electrical control system ................................................................................................... 10-205
Machine monitor system ................................................................................................... 10-254
KOMTRAX system ........................................................................................................... 10-272
Sensor ............................................................................................................................ 10-274
10-2 PC490LC-10
Engine-related parts
Engine and cooling system (ALL-R401-001-K-00-A)
Engine-related parts (PC400-A001-041-K-00-A)
1. Alternator (*1)
PC490LC-10 10-3
Engine-related parts
2. EGR cooler (*1)

3. Starting motor (*1)
4. Damper assembly
4a. Drive plate
4b. Torsion spring
4c. Stopper pin
4d. Friction plate
5. KCCV ventilator (*1)
6. Air cleaner (*1)
7. KVGT (*1)
8. KDPF (*1)
9. Engine oil filter (*1)
10. Rear engine mount
11. Engine controller (*1)
12. Vibration damper
13. Front engine mount
14. Auto-tensioner (*1)
*1: For details, see Engine Shop Manual.
Function (PC400-A001-042-K-00-A)
• KVGT (7) is a turbocharger which can vary the cross-sectional area in the exhaust circuit.
• EGR cooler (2) is a device which cools the exhaust gas with the coolant.
• KDPF (8) is a device which has KDOC (catalyzer) and KCSF (filter to catch soot) for purification of the
exhaust gas.
• KCCV ventilator (5) is a mechanism which mainly consists of filters and separates oil from blowby gas and
to return the gas to the air intake side for afterburning.
Specifications (PC400-A001-030-K-00-A)
Damper type Wet type

Oil used for damper TO30
Damper oil capacity (l) 1.6
10-4 PC490LC-10
KVGT
KVGT (ENG125-AA10-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and denotes the variable displacement
turbocharger.
a The shape is subject to machine models.
PC490LC-10 10-5
KVGT
1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine impeller
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
Operation (ENG125-AA10-044-K-00-A)
1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
• The new exhaust gas regulation not only requires to control emissions at high engine speed but also at
low engine speed. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
• To obtain a high EGR ratio especially at low engine speed, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speed.
• The turbine impeller (T) drives the blower impeller (C) via a shaft to send a large amount of air to the
cylinders for combustion. When the air flow from KVGT (2) increases, more fuel can be injected, and the
engine output increases.
• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.
10-6 PC490LC-10
KVGT
a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
• Exhaust gas enters from (C) of turbine housing (4), and flows out from (D) through section (P). Section (P)
is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
• The passage area varies when push rod (8) slides right or left.
• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled
at the EPC valve installed to the front cover, and also controls the right/left slide of push rod (8).
• Exhaust gas flows through vanes (6) and rotates turbine impeller (11), the torque of which rotates blower
impeller (10) via shaft (9). This works as a compressor and the air entered from (A) is compressed and
sent out from (B).
• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speed), push
rod (8) slides to the right to narrow section (P).
• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases,
and more air (oxygen) is inhaled.
• The turbocharger speed is sensed by KVGT speed sensor (2).
When nozzle ring is closed

• At low engine speed, exhaust gas inlet passage (P) is narrowed (L1). (Not completely closed.)
• When the turbine inlet pressure increases while the nozzle ring is closed, the flow speed to the turbine
increases and the turbocharger speed increases.
PC490LC-10 10-7
KVGT
When nozzle ring is open

• At high engine speed, exhaust gas inlet passage (P) is widened (L2).
• As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet
passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).
a Nozzle ring (7), vane (6) and rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.
Hydraulic actuator operation
• Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to the front cover.
• The force for the movement is the oil pressure supplied from boost pump (12).
10-8 PC490LC-10
KVGT
• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).
1. Air cleaner
2. Mass air flow and temperature sensor
PC490LC-10 10-9
KVGT
3. KVGT
4. KVGT speed sensor
5. KVGT position sensor
6. Hydraulic actuator
7. Engine controller
8. EPC valve (for KVGT)
9. KDPF
10. EGR system (EGR cooler and EGR valve)
11. EGR valve lift sensor
C. Blower impeller
T. Turbine impeller
KVGT control system

• Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and
KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil
pressure controlled by EPC valve (8), and then move the piston.
• A good response at high altitudes is maintained by sensing high elevations with the ambient pressure
sensor, and automatically controlling the fuel injection and the KVGT.
• The KVGT is protected by controlling its speed to prevent overspeed.
Lubrication
• Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication
• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil
pan.
Cooling
• Coolant from the cylinder block enters the center housing to cool the KVGT.
• Returning coolant flows from the center housing to the radiator.
10-10 PC490LC-10
EGR system piping drawing
EGR system piping drawing (ENG125-A9J0-04D-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation

1. KVGT
2. EGR valve
3. Air intake connector
4. Intake manifold
5. Exhaust manifold
6. EGR cooler
7. Mixing connector
Function (ENG107-A9J0-042-K-00-A)
• EGR valve (driven hydraulically)

Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is
higher than the boost pressure, the exhaust gas flows to the air intake side.
PC490LC-10 10-11
EGR system piping drawing
• EGR cooler
Cools the exhaust gas.
Engine coolant is used for cooling.
• Air intake connector
Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.
• Each sensor
Controls the EGR according to the operating condition.
Troubleshoots the system.
• Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to
ensure clean exhaust at all times.
• Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.
10-12 PC490LC-10
EGR system circuit diagram
EGR system circuit diagram (ENG125-A9J0-052-K-00-A)
1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR cooler
6. EGR valve
7. Hydraulic actuator (power piston)
8. EPC valve (for EGR valve)
10. Exhaust manifold
11. Boost pump
12. Intake manifold
13. Charge (boost) pressure and temperature sensors
15. Mixing connector
C: Blower impeller
T: Turbine impeller
Operation (ENG125-A9J0-044-K-00-A)
• The engine controller outputs signals for opening EGR valve (6) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
• When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10)
through EGR piping to EGR cooler (5).
• The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in
mixing connector (15), and then flows into intake manifold (12).
PC490LC-10 10-13
EGR valve
EGR valve (ENG125-A9K1-041-K-00-A)
1. Valve
2. Spring
3. Power piston
4. Spool
5. Spring
7. EPC valve (for EGR)
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
C: Servo drive oil inlet
D: Servo drive oil outlet
Structure
• The EGR valve consists of the EGR gas flow control mechanism and the EPC valve .
• An EPC valve is provided for EGR valve control, and an EPC valve for KVGT control is installed to front
cover.
10-14 PC490LC-10
EGR valve
Operation (ENG107-A9K1-044-K-00-A)
• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve
flows into port (E).
• Spool (4) is pressed to the right by the reaction force of spring (5), and EGR valve (1) is closed by the
reaction force of spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side.
• To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a
position whereat this control pressure and the force of spring (5) are balanced.
• The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port
(C) pushes power piston (3) to the left.
• Oil from the boost oil pump acts on power piston (3) and generates force (Fp).
• When force (Fp) becomes larger than reaction force (Fs) of spring (2), EGR valve (1) opens and then
exhaust gas will flow to the intake side.
• Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at
a position determined by spool (4).
• The valve position is controlled by the engine controller by controlling the spool position with the control
pressure of the EPC valve.
• A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in
contact with power piston (3).
• Position of spool (4) is sensed by the EGR valve lift sensor.
PC490LC-10 10-15
EGR cooler
EGR cooler (ENG125-A9L0-041-K-00-A)
1. Header plate
4. Shell
A: EGR gas inlet
B: EGR gas outlet (to EGR valve)
C: Coolant inlet
D: Coolant outlet
E: Air vent
F: Air vent
2. Flat tube
3. Inner fin
Operation (ENG125-A9L0-044-K-00-A)
• The EGR gas enters from (A) and flows through 9 flat tubes (2).
10-16 PC490LC-10
EGR cooler
• Coolant enters from (C) and flows around flat tube (2) in shell (4) and then goes out from (D).
• The EGR gas is effectively cooled by flat tubes (2) with inner fins (3) and flows out from EGR gas outlet
(B).
PC490LC-10 10-17
KCCV layout drawing
KCCV layout drawing (ENG125-A180-04D-K-00-A)
KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

1. KCCV ventilator
2. KVGT
3. Check valve
4. CDR valve
A: Blowby gas
B: Engine oil-free blowby gas (to KVGT)
C: Engineoil that C is separated (to oilpan)
• Formerly blowby gas (A) was discharged to the atmosphere as is. However, the tightened exhaust gas
regulation no longer permits releasing blowby gas to the atmosphere.
• Since blowby gas (A) contains engine oil components, which may cause the following problems when
recirculated to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil
2. Abnormal engine combustion
3. Malfunction of sensors due to adherence of engine oil
10-18 PC490LC-10
KCCV layout drawing
Operation (ENG125-A180-044-K-00-A)
a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.
1. Air cleaner
2. KVGT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the KVGT.
• Separated engine oil (C) flows through a check valve and falls to the oil pan.
PC490LC-10 10-19
KCCV ventilator
KCCV ventilator (ENG125-A18H-041-K-00-A)
1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
7. Heater tube
A: Blowby gas inlet (engine breather)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlets
Function (ENG125-A18H-042-K-00-A)
• When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
• There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
• Warmed engine coolant is conducted to the locations that pose potential problem of freezing to prevent it
from happening.
10-20 PC490LC-10
KCCV ventilator
Operation (ENG107-A18H-044-K-00-A)
• Blowby gas enters (A) and large oil particles in the engine oil mist are separated when it flows through the
hole of impactor (5) in filter (6).
• Small oil particles are separated by filter (6).
• The separated oil flows along the case wall to oil drain port (C), and then flows into the oil pan.
• When the crankcase pressure becomes negative, CDR valve (2) operates to prevent the crankcase
pressure from becoming excessively negative.
• The crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
• If the engine controller judges from the value sensed by the crankcase pressure sensor (3) that the filter is
clogged, it displays failure code CA555 and then displays CA556 if the pressure increases further.
• Relief valve (4) is installed inside case (1) and operates to protect the KCCV ventilator and engine when
filter (6) is blocked.
CDR valve (ENG107-A18A-041-K-00-A)
CDR: Abbreviation for Crankcase Depression Regulator
1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
• When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases, the
reaction force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and
temporarily blocks the flow.
• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.
PC490LC-10 10-21
KDPF
KDPF (ENG125-A9H0-041-K-00-A)
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. Inlet unit
2. KDOC inlet temperature sensor
3. KDOC outlet temperature sensor
4. KCSF unit
5. Aggregate connector box
6. KDPF outlet temperature sensor
7. Outlet unit
8. KDPF differencial pressure sensor port
9. KDPF differencial pressure sensor
10. KDPF differential pressure sensor port
11. KDOC unit
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From KVGT
B: Exhaust
C: Water drain
• The KDPF consists of the following components: inlet unit (1) to introduce exhaust gas, KDOC unit (11)
that houses an oxidation catalyst, KCSF unit (4) that houses a soot collecting filter with a catalyzer, and
outlet unit (7) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit
(4).
10-22 PC490LC-10
KDPF
• KDOC unit (11) consists of a ceramic honeycomb coated with oxidation catalyst material. By using this
ceramic honeycomb, it regenerates (*1) NO (nitrogen monoxide) to NO2 (nitrogen dioxide) in exhaust gas.
• The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
• The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
• The KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (11). This ceramic honeycomb collects soot.
• Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
• Temperature signals from these three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
• The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Denotes to purification (oxidation) processing of soot.
k While engine is running and for some time after engine is stopped, the surface of KDPF and
nearby piping are extremely hot. Be careful not to get burned when working near the KDPF.
Function (ENG125-A9H0-042-K-00-A)
A: Flow of exhaust gas

1. KDOC(oxidation catalyzer)
2. KCSF
3. Sealing (made of ceramics)
4. Cell
5. Ceramics honeycomb
• The KDPF purifies the exhaust gas by catching most of the granulous or chain-like soot formed by the PM
(particulates in air such as soot) included in the exhaust from the engine.
• KCSF (2) is made of ceramic.
PC490LC-10 10-23
KDPF
• Inside the KCSF (2), there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
• The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1)
(oxidation catalyzer), in operating conditions with relatively high exhaust gas temperatures. (This is
referred to as "passive regeneration".)
• On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low
load operations, the deposit of soot in KCSF (2) increases.
• The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating based on the KCSF (2) differential pressure sensor signals.
• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
• During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. (This operation is called "exhaust temperature-raising
control")
• As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
• Fuel is injected from (fuel doser) installed to the outlet portion of turbocharger. (Fuel dosing) Fuel that is
injected into this piping mixes with exhaust gas and combusts (oxidizes) soot by the action of KDOC (1).
• Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
the KCSF (2) will increase.
• If the soot deposit in the KCSF (2) exceeds a certain level, it will be necessary to perform "manual
stationary regeneration" to burn away (oxidize) the soot in the KCSF (2).
• If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
• If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration"
Types of regeneration (ENG107-A9H0-042-K-01-A)
a Regeneration refers to a process of purifying (oxidizing) the soot deposited in the soot collecting filter
(KCSF) inside the KDPF.
1. Passive regeneration
When the exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will be
stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration
1) Automatic regeneration
If the soot deposit exceeds a certain level, the engine controller switches to exhaust temperature-
raising control (*1), performs fuel dosing (*2), and automatically starts the regeneration process.
Another type of automatic regeneration is performed by the engine controller at certain intervals,
regardless of the amount of soot deposited in the KCSF.
*1: The fuel injection timing and the KVGT are controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process. No.
1, 2, and 3 injectors are used for fuel dosing.
2) Manual stationary regeneration (*3)
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request on the screen. The operator must perform regeneration by operating
the machine monitor on its screen. A regeneration feature is also provided for the technician who
should use this feature from the machine monitor menu after engine controller replacement, KDPF
replacement, and KCSF ash cleaning. (= Regeneration for service (*3))
*3:For details, see the Shop Manual for the applicable machine.
• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.
10-24 PC490LC-10
KDPF
• When certain conditions are met, the engine controller automatically switches control to increase
the exhaust temperature to dry the KCSF. If some of the conditions for automatic drying are not met,
manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping
KDPF regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause
KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the
KDPF, leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a
ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is
low. Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the KVGT automatically
operates and the engine sound changes. The flow of exhaust gas through the KDPF changes
and the exhaust sound changes, but this is normal.
a During automatic regeneration and manual stationary regeneration, especially at low
temperatures, white smoke may come out from the exhaust pipe for a short time, but this is
normal. Be sure to perform regeneration at a well ventilated place since carbon monoxide can
be produced.
a During automatic regeneration and manual stationary regeneration, a strange odor may be
smelled from the exhaust pipe, but this is normal.
a During automatic regeneration and manual stationary regeneration, the exhaust temperature at
the exhaust pipe can exceed 650 °C. Make sure that there is no flammable material near the
exhaust system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe,
and pay sufficient attention to safety of the environment.
a KDPF temperature values are shown below for reference.
DOC_In (KDOC inlet DOC_Out (KDOC outlet KDPF_Out (KDPF outlet
temperature sensor) temperature sensor) temperature sensor)
Not regenerating (idling) 100 to 250 °C
Regenerating (under
exhaust temperature-raising 100 to 250 °C 400 to 550 °C
control: 1,000 rpm)
PC490LC-10 10-25
Cooling system
Cooling system (PC400-B000-041-K-00-A)
10-26 PC490LC-10
Cooling system
1. Aftercooler
2. Aftercooler inlet hose
3. Air conditioner condenser
4. Radiator
5. Oil cooler
6. Aftercooler outlet hose
7. Oil cooler inlet
8. Oil cooler outlet
9. Radiator drain valve
10. Radiator cap
11. Radiator inlet hose
12. Shroud
13. Radiator outlet hose
14. Fan guard
15. Reservoir tank
16. Cooling fan motor
17. Fan
P. From fan pump
T. To oil cooler
TC. To hydraulic tank
Specifications (PC400-B000-030-K-00-A)
Radiator Oil cooler Aftercooler

Core type 4 - array aluminum mesh 4 - array aluminum mesh
CF40 - 1
core core
Fin pitch (mm) 3.5/2 3.5/2 4.0/2
PC490LC-10 10-27
Cooling system
Radiator Oil cooler Aftercooler

Total heat dissipation area
(m2) 93.11 18.56 x 2 29.98
Pressure valve cracking
0.05 {0.5} — —
pressure (MPa {kg/cm2})
Vacuum valve cracking
-0.005 {-0.05} — —
pressure (MPa {kg/cm2})
10-28 PC490LC-10
Cooling fan pump
Cooling fan pump (PC400-B450-041-K-00-A)
PF1: Pump discharge port

PFEPB: EPC output pressure pickup plug
PFEPC: EPC valve source pressure input port
PFS: Pump suction port
TFO: Drain port
1. Servo valve
2. Breather
3. EPC valve
PC490LC-10 10-29
Cooling fan pump
1. Shaft
2. Servo piston
3. Spring
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Case
10. Oil seal
11. Ball retainer
10-30 PC490LC-10
Cooling fan pump
Structure
• Cylinder block (7) is supported to shaft (1) by spline (11).
• Shaft (1) is supported by the front and rear bearings (12).
• The tip of piston (6) has a spherical hollow in which shoe (5) is being held by crimping.
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) slides around ball (13).
• Piston (6) performs the reciprocation axially inside each cylinder chamber of cylinder block (7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation.
• This surface is designed so that the oil pressure balance is maintained at a suitable level.
• The oil is sucked into and discharged from each cylinder in cylinder block (7) through valve plate (8).
Specifications (PC400-B450-030-K-00-A)
Model LPV45
Type Variable displacement swash plate type piston pump
Theoretical delivery (cm3/rev) 45
Rated delivery pressure (MPa {kg/cm2) 13.9 {142}

Rated speed (rpm) 2,580
Function (PC400-B450-042-K-00-A)
• The pump converts the engine speed and torque transmitted to its shaft into oil pressure and delivers
pressurized oil corresponding to the load.
• It is possible to change the delivery by changing the swash plate angle.
PC490LC-10 10-31
Cooling fan pump
Operation of pump (PC400-B450-044-K-00-A)
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Tilting of rocker cam (4) around ball retainer (13). As a result angle (a) between center line (X) of rocker
cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
10-32 PC490LC-10
Cooling fan pump
• If angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane (A)
works as a cam for shoe (5).
• Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Each piston (6) sucks and discharges oil by (F) - (E).
• If cylinder block (7) rotates and the volume of chamber (E) is decreased, the oil is discharged from
chamber (E) during this process.
• The volume of chamber (F) is increased and the oil is sucked in chamber (F) during this process.
PC490LC-10 10-33
Cooling fan pump
• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is 0),
the difference between volumes (E) and (F) inside cylinder block (7) is 0.
• Suction and discharge of pressurized oil is not performed in this stage. Namely pumping action is not
performed. (Actually, however, a zero swash plate angle never occurs.)
• Swash plate angle (a) is in proportion to the pump delivery.
10-34 PC490LC-10
Cooling fan pump
Control of delivery
• If swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, or delivery
(Q) is increased.
• Swash plate angle (a) is changed by servo piston (10).
• Servo piston (10) moves in a linear reciprocating movement according to the signal pressure from servo
valve.
• This linear movement is transmitted to rocker cam (4).
• Rocker cam (4) supported by ball retainer (13) slides around ball retainer (13).
PC490LC-10 10-35
Cooling fan pump
Servo valve (PC400-B4H0-041-K-00-A)
P: EPC valve source pressure port

PE: Control piston pressure
PH: Pump delivery pressure
T: Drain port
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring
9. EPC valve
10-36 PC490LC-10
Cooling fan pump
Function (PC400-B4H0-042-K-00-A)
• The servo valve controls the pump so that the input current (i) to the EPC valve relates to pump discharge
(Q) as shown in the figure below.
Operation (PC400-B4H0-044-K-00-A)
• The output pressure of the EPC valve enters piston chamber (C) and pushes piston (6).
• Piston (6) pushes spool (5) and moves to a position where it is balanced with the spring.
• Land (PE) of the servo piston pressure passage is connected to pump delivery pressure passage (PH)
through the notch of spool (5), so the pump delivery pressure is transmitted to servo piston (10).
• Rocker cam (9) is pushed up by servo piston (10), and then its position is fed back and lever (2) moves to
compress spring (8).
PC490LC-10 10-37
Cooling fan pump
• If spool (5) is pushed back, the pump delivery circuit and servo piston circuit are disconnected.
• The pressure in the servo piston chamber decreases and rocker cam (9) moves toward the maximum
swash plate angle.
• These processes are repeated until the swash plate stabilizes at an angle where the EPC output pressure
is balanced with the force of spring (8).
• As the EPC output pressure increases, the swash plate angle decreases. As the EPC output pressure
decreases, the swash plate angle increases.
10-38 PC490LC-10
Cooling fan motor
Cooling fan motor (PC400-B5L0-041-K-00-A)
1. Cooling fan reverse solenoid valve

2. Cooling fan speed sensor
P: From fan pump
T: To oil cooler
TC: To hydraulic tank
Specifications (PC400-B5L0-030-K-00-A)
Model LMF110(65)
Capacity (cc/rev) 65.1
Rated flow (l/min) 80.7
Check valve cracking pressure (kPa {kg/cm2}) 78.5 {0.8}
Safety valve cracking pressure (kPa {kg/cm2}) 18.6 {190}
PC490LC-10 10-39
Cooling fan motor
1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston assembly
6. Cylinder block
7. Valve plate
8. End cover
9. Center spring
11. Suction valve spring
12. Suction valve
13. Cooling fan reverse solenoid valve
14. Pilot valve
15. Reversible-valve spool
16. Safety valve
17. Reversible-valve spring
10-40 PC490LC-10
Cooling fan motor
Hydraulic motor (ALL-B5N0-001-K-00-A)
Function (PC400-B5N0-042-K-00-A)
• This hydraulic motor is called a swash plate type axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump into rotary motion.
Operation (PC400-B5N0-044-K-00-A)
• The pressurized oil sent from the pump flows through valve plate (7) into cylinder block (5).
• This pressurized oil can flow only to one side of (Y - Y) line connecting the top dead center and bottom
dead center of the stroke of piston (4).
• The pressurized oil sent to one side of cylinder block (5) pushes piston (4) (four or five pistons).
• A single piston generates force F1 [F1 (kg) = P(kg/cm2) x xD2/4(cm2)].
• This force works on thrust plate (2).
• Since thrust plate (2) is fixed with the specific angle (a) to output shaft (1), the force is divided into
components (F2) and (F3).
• Among them, radial component (F3) generates torque (T = F3 x ri) against the (Y - Y) line connecting the
top dead center and bottom dead center.
• The combined force of the torque [T=s (F3xri)] rotates cylinder block (5) through piston (4).
• This cylinder block (5) is connected to output shaft (1) with the spline.
• Output shaft (1) rotates to transmit the torque.
PC490LC-10 10-41
Cooling fan motor
Suction valve (ALL-B6D0-001-K-00-A)

Function (PC400-B6D0-041-K-00-A)
• When the pump stops rotating, the pressurised oil does not flow into the motor.
• Since the motor continues to rotate with the force of inertia, the pressure on the outlet side of the motor
increases.
• When the pressurized oil stops from inlet port (P), suction valve (1) sucks in the pressurized oil on the
outlet side and supplies it to port (MA) where there is not sufficient oil to prevent cavitation.
Operation (PC400-B6D0-044-K-00-A)
When pump is started
• The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure.
• The starting torque is generated in the motor, and the motor starts rotating.
• The pressurized oil on the motor outlet (MB) side returns through port (T) to the tank.
10-42 PC490LC-10
Cooling fan motor
When stopped
• When the engine stops, the pump speed becomes 0 rpm.

• The pressurized oil from the pump is not supplied to port (P).
• Since the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to
stop.
• If the motor shaft is revolved by the inertial force while the pressurized oil flow to port (P) is reducing, the
pressurized oil in port (T) on the outlet side is sent by suction valve (1) to (MA) side to prevent cavitation.
PC490LC-10 10-43
Cooling fan motor
Reversible valve (PC400-B6E0-041-K-00-A)

When cooling fan reverse solenoid valve is "de-energized"
• If coil (1) is "de-energized", the pressurized oil from the pump is shut off by spool (2).
• Port (C) opens for the hydraulic tank circuit.
• Spool (3) is pushed to the right by spring (4).
• Port (MA) opens and pressurized oil flows in to rotate the motor in normal direction (clockwise).
10-44 PC490LC-10
Cooling fan motor
When cooling fan reverse solenoid valve is "energized"
• If coil (1) is "energized", spool (2) is switched.

• The pressurized oil from the pump flows to spool chamber (D) through port (C).
• The pressurized oil flowed in chamber (D) compresses spring (4).
• Spool (3) moves to the left.
• Port (MB) opens and pressurized oil flows in to rotate the motor in reverse direction (counterclockwise).
Safety valve (ALL-B6G0-001-K-00-A)
Function (PC400-B6G0-042-K-00-A)
• When the engine is started, the pressure in port (P) of the fan motor is increased in some cases.
• Safety valve (1) is provided in order to protect the fan system circuit.
PC490LC-10 10-45
Cooling fan motor
Operation (PC400-B6G0-044-K-00-A)
• When the pressure in port (P) rises above the cracking pressure of safety valve (1), its valve (2) opens
and releases pressurized oil to port (T).
• By this operation, the generation of the abnormally high pressure in port (P) is prevented.
10-46 PC490LC-10
Power train
Power train (ALL-C100-001-K-00-A)
Power train (PC400-C100-041-K-00-A)
1. Control valve
1a. Self-pressure reducing valve
1b. Pump merge-divider valve
1c. Travel junction valve
2. Main pump
3. Engine
4. Travel motor
5. Final drive
6. Swing motor
6a. 2-stage swing relief valve
7. Center swivel joint
8. Idler
PC490LC-10 10-47
Power train
9. PPC lock solenoid valve

10. 2-stage swing relief solenoid valve
11. Travel junction solenoid valve
12. Travel speed increase solenoid valve
13. Swing holding brake solenoid valve
14. Machine push-up solenoid valve
15. Attachment selector solenoid valve (for machines ready for installation of attachment)
16. 2-stage relief solenoid valve
17. Swing machinery
18. Swing circle
10-48 PC490LC-10
Swing circle
Swing circle (PC400_10-J110-041-K-00-A)
1. Swing circle pinion grease filler port

2. Inner race (number of teeth: 84)
3. Ball
4. Outer race
5. Seal
a. Inner race soft zone position
b. Outer race soft zone stamp "S" position
Specifications (PC400_10-J110-030-K-00-A)
Reduction ratio - 84/13 = -6.462

Grease G2-LI
Grease quantity (l) 33.0
PC490LC-10 10-49
Swing machinery
Swing machinery (PC400_10-J130-041-K-00-A)
1. Swing pinion (number of teeth: 13)

2. Cover
3. Case
10-50 PC490LC-10
Swing machinery
4. No. 2 planetary gear (number of teeth: 25)

5. No. 2 sun gear (number of teeth: 16)
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No.1 planetary gear (number of teeth: 24)
11. No.1 planetary carrier
12. No. 2 planetary carrier
13. Drain plug
Specifications (PC400_10-J130-030-K-00-A)
Reduction ratio ((19 + 68) / 19 x (16 + 68) / 16) = 24.039

Swing reduction ratio 24.039 x (84 / 13) = 155.329
Swing speed (rpm) 9.4
PC490LC-10 10-51
Final drive
Final drive (PC400-DF10-041-K-00-A)
1. Level plug
2. Drain plug
10-52 PC490LC-10
Final drive
4. No. 1 sun gear (Number of teeth: 10)

5. No. 2 sun gear (number of teeth: 18)
8. Cover
9. Ring gear (number of teeth: 98)
10. Sprocket
11. Floating seal
12. Travel motor
Specifications (PC400-DF10-030-K-00-A)
Reduction ratio -((10+98)/10x(18+98)/18)+1=-68.600

Lubricating oil level (l)
11
(per set)
PC490LC-10 10-53
Track frame and idler cushion
Undercarriage and frame (ALL-DT00-001-K-00-A)
Track frame and idler cushion (PC400-DT20-041-K-00-A)
1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Idler cushion
9. Front guard
Specifications (PC400-DT20-030-K-00-A)
• Number of track rollers

Model Quantity (each side)
PC490LC-10 8
• Standard shoe
Model PC490LC-10
Shoe width (mm) 700
10-54 PC490LC-10
Link pitch (mm) 228.6

Number of shoes (each side) 49
PC490LC-10 10-55
Hydraulic component layout
Hydraulic system (ALL-C000-001-K-00-A)
Hydraulic component layout (PC400-C000-04D-K-00-A)
1. Bucket cylinder
10-56 PC490LC-10
Hydraulic component layout
2. Arm cylinder
3. R.H. PPC valve for work equipment
4. Swing motor
5. Control valve
6. Oil cooler
8. Solenoid valve
9. Accumulator (for PPC circuit)
10. Cooling fan pump
11. Main pump
12. Hydraulic tank
13. Travel motor
14. L.H. PPC valve for work equipment
15. Center swivel joint
16. Travel PPC valve
17. Attachment 1 PPC valve (*1)
18. Boom cylinder
*1: Machine ready for installation of attachment
PC490LC-10 10-57
Valve control
Valve control (PC400-PK01-041-K-00-A)
1. Travel PPC valve

2. Attachment 1 PPC valve (*1)
3. Attachment 1 control pedal (*1)
4. L.H. travel lever
5. R.H. travel lever
6. R.H. PPC valve for work equipment
7. R.H. work equipment control lever (for boom and bucket control)
8. Solenoid valve
9. Accumulator (for PPC circuit)
10. Control valve
11. Relay block
12. L.H. work equipment control lever (for arm and swing control)
13. L.H. PPC valve for work equipment
10-58 PC490LC-10
Valve control
14. Travel pedal

15. Lock pin (*1)
*1: Machine ready for installation of attachment
PC490LC-10 10-59
Hydraulic tank
Hydraulic tank (PC400-PM30-041-K-00-A)
1. Suction strainer
2. Filter element
3. Strainer
4. Bypass valve
5. Drain valve
6. Oil filler port cap
7. Hydraulic tank
8. Breather
9. Sight gauge
10. Main pump
Specifications (PC400-PM30-030-K-00-A)
Hydraulic tank capacity (l) 335

Amount of oil in hydraulic tank (l) 248
Bypass valve set pressure (MPa {kg/cm2}) 0.15 ± 0.03 {1.5 ± 0.3}
10-60 PC490LC-10
Hydraulic tank
Oil filler port cap (PC400-AD1C-041-K-00-A)
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
Prevention of negative pressure in tank

• The hydraulic tank is sealed and pressurized. When the oil level in the hydraulic tank drops, negative
pressure is generated in the tank. To prevent this negative pressure generation, seam valve (4) is opened
to draw the atmosphere to the tank.
(Suction valve set pressure:
0 to 0.49 kPa {0 to 0.005 kg/cm2})
Prevention of pressure rise in tank

• When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic
cylinders operate and the oil level and temperature increase in the tank.
If the pressure in the tank rises above the set value, bottom plate (2) is pushed up to release the pressure
in the tank.
(Relief valve set pressure:
16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2})
Breather (PC400-AD1D-041-K-00-A)
1. Nut
2. Cover
3. Filter element
4. Case
5. Valve assembly
6. Body
PC490LC-10 10-61
Hydraulic tank
Prevention of negative pressure in tank

• The hydraulic tank is sealed and pressurized. When the oil level in the hydraulic tank drops, negative
pressure is generated in the tank.
To prevent this negative pressure generation, valve assembly (5) is opened to draw the atmosphere to the
tank.
(Suction valve set pressure:
0.002 ± 0.3 MPa {0.02 ± 0.003 kg/cm2})
Prevention of pressure rise in tank

• When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic
cylinders operate and the oil level and temperature increase in the tank.
If the pressure in the tank rises above the set value, valve assembly (5) is pushed up to release the
pressure in the tank.
(Relief valve set pressure:
0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})
10-62 PC490LC-10
CLSS
CLSS (ALL-PNJ1-001-K-00-A)
a CLSS: Abbreviation for Closed center Load Sensing System

Structure of CLSS (ALL-PNJ1-041-K-00-A)
Features
• Fine control not influenced by load
• Control performance that allows digging even when fine control operation is turned on
• Ease of combined operation enabled by the flow divider function that is determined by the opening areas
of spools during combined operations
• Energy saving by variable pump control
Configuration
• CLSS consists of variable capacity piston pump, control valve, and actuators.
• The main pump consists of pump itself, PC valve and LS valve.
PC490LC-10 10-63
CLSS
Basic principle
Pump swash plate angle control

• The pump swash plate angle (pump discharged volume) is controlled so that LS differential pressure
(dPLS), which is the difference between pump delivery pressure (PP) and LS pressure (PLS)) (load
pressure of actuator) at control valve outlet, is constant.
• [LS differential pressure (dPLS) = Pump delivery pressure (PP) - LS pressure (PLS)]
• The pump swash plate angle shifts toward the maximum position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate
angle shifts toward the minimum position.
10-64 PC490LC-10
CLSS
LS differential pressure (d
d PLS) and pump swash plate angle
a See "Main pump" for the explanation of the operation.
Pressure compensation control
PC490LC-10 10-65
CLSS
• A pressure compensation valve is installed to the outlet port side of each control valve to balance the load
pressure.
• When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the
load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
System diagram
a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.
1. Front pump
2. Rear pump
3. Main relief valve
4. Unload valve
5. Merge-divider valve
6. Control valve
10-66 PC490LC-10
CLSS
7. Actuator
8. Pump circuit
9. LS circuit
10. Tank circuit
11. Valve
12. Spring
13. LS bypass plug
14. LS valve
15. PC valve
PC490LC-10 10-67
Main pump
Main pump (PC400-C200-041-K-00-A)

Model: HPV210+210
IMF: Front pump PC mode selector current

IMR: Rear pump PC mode selector current
10-68 PC490LC-10
Main pump
ISIG: LS set pressure selector current

PAF: Front pump delivery port
PAR: Rear pump delivery port
PBR: Rear pump pressure input port
PBF: Front pump pressure input port
PD1F: Air bleeder
PD1R: Case drain port
PD2F: Drain plug
PD2R: Drain plug
PENF: Front pump control pressure pickup port
PENR: Rear pump control pressure pickup port
PEPC: EPC basic pressure input port
PEPB: EPC source pressure pickup port
PFC: Front pump delivery pressure pickup port
PLSF: Front pump load pressure input port
PLSFC: Front pump load pressure pickup port
PLSR: Rear pump load pressure input port
PLSRC: Rear pump load pressure pickup port
PMF: Front pump PC mode selector pressure pickup port
PMR: Rear pump PC mode selector pressure pickup port
PRC: Rear pump delivery pressure pickup port
PS: Pump suction port
PSIG: LS set selector pressure pickup port
OCP: Oil level pick-up port
BMP: Oil filler port
1. Front pump
2. LS-EPC valve
3. Front pump PC-EPC valve
4. Rear pump PC-EPC valve
5. Rear pump
6. Rear pump PC valve
7. Rear pump swash plate sensor
8. Rear pump LS valve
9. Front pump LS valve
10. Front pump swash plate sensor
11. Front pump PC valve
PC490LC-10 10-69
Main pump
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. PC valve
13. Servo piston
14. Slider
10-70 PC490LC-10
Main pump
15. Spline
16. Bearing
17. LS valve
18. Bevel gear
19. Impeller pinion
20. Impeller shaft
21. Impeller pump
23. Involute spline
24. Impeller
25. Swash plate sensor
Outline
• This pump consists of two variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve,
and swash plate sensor.
Function
• The pump converts the engine torque transmitted to its shaft (1) into oil pressure and delivers pressurized
oil corresponding to the load.
• It is possible to change the delivery by changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by spline (15).
• Shaft (1) is supported by each bearing (16) at the front and rear.
• The tip of piston (6) has a spherical hollow in which shoe (5) is being held by crimping.
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) conducts high pressure oil to cylinder surface (B) with cradle (2), which is secured to the
case, and forms a static pressure bearing when it slides.
• Piston (6) performs the reciprocation axially inside each cylinder chamber of cylinder block (7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation.
• This surface is designed so that the oil pressure balance is maintained at a suitable level.
• The oil is sucked into and discharged from each cylinder in cylinder block (7) through valve plate (8).
• Impeller pump (21) and impeller pinion (19) are integrated as a single unit at impeller shaft (20), and are
connected to shaft (1) via bevel gear (18).
• Since they rotate together with shaft (1), the drawn pressurized oil is sent into cylinder block (7) by
centrifugal force to help suction.
Operation (PC220-C200-044-K-00-A)
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
PC490LC-10 10-71
Main pump
• If swash plate angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7),
plane (A) functions as a cam against shoe (5).
• Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Each piston (6) sucks and discharges oil by (F) - (E).
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• The volume of chamber (F) grows larger and, in this process, the oil is sucked.
• As center line (X) of rocker cam (4) matches the axis of cylinder block (7) (swash plate angle = 0), the
difference between volumes (E) and (F) inside cylinder block (7) equals 0.
• Suction and delivery of pressurized oil is not carried out in this state. Namely pumping action is not
performed. (Actually, however, the swash plate angle is not set to 0 deg.)
Control of discharged volume

• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and pump
discharged volume (Q) increases.
• Swash plate angle (a) is changed by servo piston (13).
• Servo piston (13) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• This linear reciprocating movement is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• Output pressure (PEN) of the LS valve is transmitted to the pressure chamber of the large diameter piston
side.
• The areas receiving the pressure on the right and left sides of servo piston (13) are different from each
other, and discharged volume pressure (self pressure) (PP) of the main pump is constantly transmitted to
the pressure chamber of the small diameter piston side.
• The movement of servo piston (13) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter piston side (PEN) and by the ratio of the areas receiving the pressure
of the small diameter piston and large diameter piston.
10-72 PC490LC-10
Main pump
LS valve (PC-C2J0-041-K-00-A)
a LS: Abbreviation for Load Sensing
PC490LC-10 10-73
Main pump
PA: Pump port

PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: LS mode selector pilot port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut
Function (PC400-C2J0-042-K-00-A)
• The LS (load sensing) valve detects the load of the actuator and controls the discharge amount.
• This valve controls pump delivery (Q) with the differential pressure (dPLS) [= (PP) - (PLS)] (called the LS
differential pressure) between pump delivery pressure (PP) and control valve outlet pressure (PLS).
• This valve receives main pump delivery pressure (PP), pressure (PLS) (called the LS pressure) coming
from the control valve output, and pressure (PSIG) (called the LS set selector pressure) from the
proportional solenoid valve.
• The relation between the pump delivery (Q) and the differential pressure (dPLS) [= (PP) - (PLS)] between
the main pump pressure (PP) and LS pressure (PLS) is changed by the LS set pressure selector current
(ISIG) of the LS-EPC valve as shown in the figure below.
• When the (ISIG) changes from 0 A to 1 A, the spring setting force will change accordingly, to let the center
of the standard value range of the pump delivery selector point vary within the range from 1.18 MPa {12
kg/cm2} to 2.65 MPa {27 kg/cm2}.
10-74 PC490LC-10
Main pump
Operation (PC400-C2J0-044-K-00-A)
When control valve is in the NEUTRAL position
• The LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) on the outlet of
control valve is transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port
(H) of sleeve (8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery
pressure (self pressure) (PP) determine the position of spool (6).
• However, magnitude of the output pressure (PSIG) (called the LS selector pressure) of the EPC valve for
the LS valve entering port (G) also changes the position of spool (6). (Setting force of the spring is
changed.)
PC490LC-10 10-75
Main pump
• Before the engine is started, servo piston (12) is pushed to the left. (See the following figure) (See the
following figure.)
• If the control lever is in the neutral position when the engine is started, LS pressure (PLS) is set to 0 MPa
{0 kg/cm2}. (It is interconnected to the drain circuit via the control valve spool)
• Spool (6) is pushed to the right, and port (C) and port (D) will be connected.
• Pump pressure (PP) is conducted to the larger diameter end of the pump from the port (K).
• The same pump pressure (PP) is conducted to the smaller diameter end of the pump at the port (J).
• According to the area difference of servo piston (12), the servo piston is moved to the right, in the direction
which makes the swash plate angle minimum. (See the previous figure.)
When pump delivery is increased
10-76 PC490LC-10
Main pump
• When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) decreases (for example, when the control valve open area increases and
pump delivery pressure (PP) decreases), the combined force of LS pressure (PLS) and the force of spring
(4) pushes spool (6) to the left.
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve and drain port are connected, the pressure between ports (D) and (K) becomes drain
pressure (PT). (PC valve operation will be explained later.)
• The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and
pump pressure (PP) is constantly applied to port (J) on the small diameter side. Accordingly, servo piston
(12) is pushed to the left and the swash plate is moved to increase the delivery.
• At this time, when the output pressure from the EPC valve for the LS valve enters port (G), a force is
applied on piston (7) to move the piston to the right.
• If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential
pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6)
are connected.
When pump delivery is decreased
• When servo piston (12) moves to the right (the direction that reduces pump delivery) and LS differential
pressure (dPLS) increases (for example, when the control valve open area decreases and pump delivery
pressure (PP) increases), the force caused by pump delivery pressure (PP) pushes spool (6) to the right.
• The movement of spool (6) transmits pump delivery pressure (PP) to the large diameter end of the piston
through port (C) , port (D) and port (K).
PC490LC-10 10-77
Main pump
• Although pump delivery pressure (PP) is applied to port (J) on the small diameter piston side, servo piston
(12) is pushed to the right by the area difference between the large diameter piston side and small
diameter piston side of servo piston (12). As the result, the swash plate angle becomes smaller.
• When the LS set selector pressure (PSIG) enters port (G), the spring (4) setting force is weakened.
When servo piston is balanced
• The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of
the piston, the area receiving the pressure at the small diameter end and the pressure conducted to the
large diameter end of the piston, respectively.
• When the force exerted by main pump pressure (PP) of the LS valve is balanced with the combined force
exerted by LS pressure (PLS) and spring (4), and the relationship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (12) stops in that position.
• The swash plate of the pump is held at the intermediate position. [Spool (6) is stopped at a position where
the opening area from port (D) to port (E) and the distance from port (C) to port (D) is almost the same.]
• The relationship between the area receiving the pressure at both ends of servo piston (12) is (A0) : (A1) =
3 : 5, and the pressures transmitted to both ends of the piston when the piston is balanced is (PP) : (PEN)
C 5 : 3.
• Force of spring (4) is adjusted in such that position of balanced stop of spool (6) is determined when
median of the specified value is (PP) - (PLS) = 1.7 MPa {17.75 kg/cm2}.
• If (PSIG) [LS-EPC valve output pressure ranging from 0 to 2.9 MPa {0 to 30 kg/cm 2}] is transmitted to port
(G), position of balanced stop will change in proportion to (PSIG) pressure within a range of (PP) - (PLS) =
1.7 MPa {17.75 kg/cm2} to 0.27 MPa {2.78 kg/cm2}.
10-78 PC490LC-10
Main pump
PC valve (PC-C2K0-041-K-00-A)
a PC: Abbreviation for Pressure Compensation
PA: Pump port

PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
Function (PC400-C2K0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depends on the delivery pressure) even if the travel of
the control valve is increased extremely. This is to ensure the horsepower absorbed by the pump not to
exceed the engine horsepower, when pump delivery pressures (PP1) (self pressure) and (PP2) (other
pump's pressure) are high.
• If the pump delivery pressure increases due to increased load during work, this valve decreases the pump
delivery.
• And if the pump delivery pressure goes low, it increases the pump delivery.
• The relation between the average delivery pressure of front and rear pumps [(PP1) + (PP2)] / 2 and pump
delivery (Q) is as shown in the following figure, as a parameter for each current (X) value applied to the
PC-EPC valve solenoid.
• The controller continues counting the actual engine speed.
• If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to
recover the speed.
• When the load increases and the engine speed decreases below a preset value, the controller increases
the command current to the PC-EPC valve solenoid depending on the amount of engine speed decrease,
to decrease the swash plate angle.
PC490LC-10 10-79
Main pump
Operation (PC400-C2K0-044-K-00-A)
When the pump controller is normal
When load on the actuator is small and pump pressures (PP1) and (PP2) are low
Work of PC-EPC valve solenoid (1)

• Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
10-80 PC490LC-10
Main pump
• Spool (3) stops at a position when the combined forces of springs (4) and (6), pump pressure (PP1) (self
pressure), and pump pressure (PP2) (other pump's pressure) acting on spool (3) are balanced.
• Depending on this position, the pressure output from the PC valve [port (C) pressure] varies.
• The amperage of the command current (X) depends on the type of work (lever operation), work mode
selection, engine speed setting, and the actual engine speed.
a Other pump's pressure denotes the pressure of the pump situated on the opposite side.
For the front pump pressure, the other pump's pressure is that of the rear pump. And for the rear pump
pressure, the other pump's pressure is that of the front pump.
Action of spring
• The spring force of springs (4) and (6) in the PC valve depends on the position of the swash plate.
• When servo piston (9) moves to the right, spring (6) is compressed.
• When the piston moves further to the right, the piston comes in contact with seat (5) and spring (6) is fixed.
• Then, only spring (4) operates.
• When servo piston (9) compresses or decompresses springs (4) and (6), the spring load varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring loads of springs (4) and (6) are also varied by the PC-EPC valve solenoid command current
(X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Self pressure (PP1) enters the small diameter side of servo piston (9) and port (B), and other pump's
pressure (PP2) enters port (A).
• When pressures (PP1) and (PP2) are low, spool (3) is on the left.
• Port (C) and port (D) are connected, and the pressure entering the LS valve will be drain pressure (PT).
PC490LC-10 10-81
Main pump
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump delivery goes to increase.
• Springs (4) and (6) extend according to the movement of servo piston (9), and the reaction force of spring
decreases.
• When the reaction force of spring decreases, spool (3) moves to the right. Ports (C) is disconnected from
port (D), and pump delivery pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
• Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the
thrust caused by pressures (PP1) and (PP2), the thrust generated by the PC-EPC valve solenoid, and the
force of springs (4) and (6) acting on the spool (3) are balanced.
When load on the actuator is large and pump pressures (PP1) and (PP2) are high
Outline
• When the load is large and the pump delivery pressures (PP1) and (PP2) are high, the thrust moving
spool (3) to the right increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP2), because
a part of the pressure from port (B) flows through the LS valve and port (C) to port (D), as shown above.
• When spool (3) moves to the left, the openings of ports (C) and (D) widen.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
• Servo piston (9) will stop at a position further to the right than the position when pump pressures (PP1)
and (PP2) are low.
10-82 PC490LC-10
Main pump
Operation
• When ports (E) and (G) of the LS vave are connected, the pressure enters from port (J) to the large
diameter side of servo piston (9), and servo piston (9) stops moving.
• When pump pressure (PP2) increases more and spool (3) moves further to the right, pump pressure (PP1)
flows to port (C) to minimize the pump delivery.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed, and spool (3) is pushed
back.
• The relation between the average pump pressure [(PP1)+(PP2)]/2 and servo piston (9) position are
plotted as a bent line because two springs (4) and (6) are used.
• The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q)
becomes as shown below.
• When the command current (X) input to PC-EPC valve solenoid (1) increases, the plotted line indicating
the relation between the average pump pressure (PP1+PP2)/2 and average pump delivery (Q) makes
parallel translation by a distance proportional to the PC-EPC valve solenoid thrust.
• Since PC-EPC valve solenoid (1) thrust is added to the thrust pressing spool (3) to the right, the curve
indicating relation between the average pump pressure (PP1+PP2)/2 and average pump delivery (Q)
shifts from (A) to (B) as the command current (X) is increased.
PC490LC-10 10-83
Main pump
When the pump controller malfunctions and the emergency pump drive switch is at the ON position
When load on the main pump is small
• If the pump controller fails, turn "ON" the emergency pump drive switch and select the resistor side.
• In this case, power must be taken directly from the battery, however, a resistor is needed to control the
current supplied to PC-EPC valve solenoid (1).
• Since the current is constant, the thrust applied to piston (2) is constant.
• When main pump pressures (PP1) and (PP2) are low, the combined force of PC-EPC valve solenoid (1)
thrust and the pump pressure is smaller than the force of springs. Spool (3) stays balanced at the left.
• Port (C) is connected to port (D) at drain pressure, and the pressure at the large diameter side of servo
piston (9) comes to drain pressure (PT) through the LS valve.
• Since the pressure at the small diameter side of the piston is large, servo piston (9) moves in the direction
to increase the delivery.
10-84 PC490LC-10
Main pump
When load on the main pump is large
• As mentioned before, when the emergency pump drive switch is turned "ON", the command current (X)
sent to PC-EPC valve solenoid (1) is constant.
• Therefore, the thrust applied by piston (2) to spool (3) comes to constant.
• When main pump pressures (PP1) and (PP2) increase, spool (3) moves to a position further to the right
than when the main pump load is small, and stays balanced as shown above.
• Since the pressure from port (B) flows into port (C), servo piston (9) moves to the right (delivery
decreases), and stops at a position further to the right than when the pump load is small.
• When the emergency pump drive switch is turned "ON", the curve indicating the relation between the
pump pressure (PP) and delivery (Q) is plotted in accordance with the current supplied through the
resistor to the PC-EPC valve solenoid.
• When the emergency pump drive switch is turned "ON", the curve is plotted as (B), which is shifted toward
the left than curve (A) for a normal pump controller.
PC490LC-10 10-85
Main pump
LS (PC)-EPC valve (PC300-C2M0-041-K-00-A)
LS: Abbreviation for Load Sensing

PC: Abbreviation for Pressure Compensation
EPC: Abbreviation for Electromagnetic Proportional Control
10-86 PC490LC-10
Main pump
C: To LS(PC) valve
P: From self-pressure reducing valve
T: To hydraulic tank
1. Connector
2. Coil
3. Valve body
4. Spring
5. Spool
6. Rod
7. Plunger
Function (PC-C2M0-042-K-00-A)
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
• When the EPC valve receives signal current (i) from the controller, it develops EPC output pressure
proportional to the amperage of the current and supplies the pressure to the control valve.
PC490LC-10 10-87
Main pump
Operation (PC-C2M0-044-K-00-A)
When signal current is zero amp. (coil is de-energized)
• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
• Port (P) is closed, and the pressurized oil from the self-pressure reducing valve does not flow to the LS
(PC) valve.
• The pressurized oil from the LS (PC) valve is drained to the tank through port (C) and then port (T).
10-88 PC490LC-10
Main pump
When signal current is minute (coil is energized)
• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
reaction force exerted by spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and port (P) is shut off from port (C).
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the force
exerted by pressure at port (C) and the reaction force exerted by spring (4).
• The circuit pressure between the EPC valve and LS (PC) valve is controlled in proportion to the amperage
of signal current.
PC490LC-10 10-89
Main pump
When signal current is maximum (coil is energized)
• Coil (2) is energized when signal current is supplied to coil (2).

• As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and LS (PC) valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.
10-90 PC490LC-10
Control valve
Control valve (PC400-C030-041-K-00-A)
a This section describes only on 8-spool valve (7-spool valve with service valves).
A1: To bucket cylinder bottom

A2: To L.H. travel motor
PC490LC-10 10-91
Control valve
A3: To boom cylinder bottom

A4: To swing motor
A5: To R.H. travel motor
A6: To arm cylinder head
A-1: To boom cylinder bottom
A-2: To attachment
B1: To bucket cylinder head
B2: To L.H. travel motor
B3: To boom cylinder head
B4: To swing motor
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To attachment
B-2: To attachment
BP1: From LS select solenoid valve
BP5: From machine push-up solenoid valve
BP6: From attachment selector solenoid valve
P1: From R.H. work equipment PPC valve (bucket CURL)
P2: From R.H. work equipment PPC valve (bucket DUMP)
P3: From travel PPC valve (L.H. travel reverse)
P4: From travel PPC valve (L.H. travel forward)
P5: From R.H. work equipment PPC valve (boom RAISE)
P6: From R.H. work equipment PPC valve (boom LOWER)
P7: From L.H. work equipment PPC valve (swing LEFT)
P8: From L.H. work equipment PPC valve (swing RIGHT)
P9: From travel PPC valve (R.H. travel reverse)
P10: From travel PPC valve (R.H. travel forward)
P11: From L.H. work equipment PPC valve (arm OUT)
P12: From L.H. work equipment PPC valve (arm IN)
P-3: From R.H. attachment PPC valve
P-4: From R.H. attachment PPC valve
PLS1: To front pump LS valve
PLS2: To rear pump LS valve
PLSC: LS pressure pickup port
PP1: From rear pump
PP2: From front pump
PPC: Pilot source pressure pickup port
PP1S: Front pump oil pressure sensor mounting port
PP2S: Rear pump oil pressure sensor mounting port
PPS2: To rear pump LS valve
PR: To solenoid valve, PPC valve, and EPC valve
PST: From travel junction solenoid valve
PX1: From 2-stage relief solenoid valve
PX2: From 2-stage relief solenoid valve
T: To tank
T1: To tank
TS: To tank
10-92 PC490LC-10
Control valve
TSW: From swing motor

IS1: Pump merge-divider EPC valve (for main spool) drive signal
IS2: Pump merge-divider EPC valve (for LS spool) drive signal
IS3: Variable back pressure solenoid valve drive signal
1. Variable back pressure valve
2. Variable back pressure solenoid valve
3. Pump merge-divider EPC valve (for main spool)
4. Pump merge-divider EPC valve (for LS spool)
5. Arm hydraulic drift prevention valve (if equipped)
6. Boom drift prevention valve
7. Boom Hi and arm Hi valves
8. Boom Hi check valve
9. 8-spool valve
10. Cover A
11. Service valve
12. Arm quick return valve
13. Cover B
14. Pump merge-divider valve
PC490LC-10 10-93
Control valve
1. Pressure compensation valve (Arm OUT)

2. Pressure compensation valve (R.H. travel REVERSE)
3. Pressure compensation valve (LEFT swing)
4. Pressure compensation valve (Boom RAISE)
5. Pressure compensation valve (L.H. travel REVERSE)
6. Pressure compensation valve (Bucket CURL)
7. Pressure compensation valve (Boom Hi raise)
8. Pressure compensation valve (service)
9. Pressure compensation valve (arm Hi IN)
10-94 PC490LC-10
Control valve
10. Pressure compensation valve (Bucket DUMP)

11. Pressure compensation valve (L.H. travel FORWARD)
12. Pressure compensation valve (Boom LOWER)
13. Pressure compensation valve (RIGHT swing)
14. Pressure compensation valve (R.H. travel FORWARD)
15. Pressure compensation valve (Arm IN)
17. Unload valve
19. Spool (service)
20. Spool (Arm Hi)
21. Spool (Bucket)
22. Spool (L.H. travel)
23. Spool (Boom)
24. Spool (swing)
25. Spool (R.H. travel)
26. Spool (Arm)
27. Spool (Boom Hi)
PC490LC-10 10-95
Control valve
1. Suction valve (Arm OUT)

2. Suction valve (R.H. travel REVERSE)
3. Suction valve (Boom RAISE)
4. Suction valve (L.H. travel REVERSE)
5. Suction valve (Boom Hi RAISE)
6. Suction-safety valve (Service)
7. 2-stage suction safety valve (Service)
8. Suction safety valve (arm Hi IN)
9. Suction safety valve (Bucket DUMP)
10-96 PC490LC-10
Control valve
10. Suction valve (L.H. travel FORWARD)

11. 2-stage suction-safety valve (boom LOWER)
12. Suction valve (R.H. travel FORWARD)
13. Suction safety valve (Arm IN)
14. LS shuttle valve (Arm)
15. LS shuttle valve (R.H. travel)
16. LS select valve
17. LS shuttle valve (Boom)
18. LS shuttle valve (Left travel)
19. LS shuttle valve (Bucket)
20. LS shuttle valve (service)
21. LS check valve
PC490LC-10 10-97
Control valve
1. Unload valve
2. Suction safety valve for hydraulic drift prevention valve (boom RAISE and arm OUT)
4. Variable back pressure valve
Arm valve
5. Arm hydraulic drift prevention valve (if equipped)
6. LS shuttle valve
7. Pressure compensation valve (IN)
8. Spool
10-98 PC490LC-10
Control valve
9. Suction safety valve (IN)

10. Regeneration circuit check valve
11. Suction valve (OUT)
12. Pressure compensation valve (OUT)
R.H. travel valve

13. LS shuttle valve
14. Pressure compensation valve (FORWARD)
15. Spool
16. Suction valve (FORWARD)
17. Suction valve (REVERSE)
18. Pressure compensation valve (REVERSE)
Swing valve
19. LS select valve
20. Pressure compensation valve (R.H.)
21. Spool
22. Pressure compensation valve (L.H.)
PC490LC-10 10-99
Control valve
1. Return spring
2. Merge-divider valve (for LS)
3. Valve (Sequence valve)
4. Spring (Sequence valve)
5. Merge-divider valve (Main)
6. Return spring
Boom valve
7. Boom drift prevention valve
8. LS shuttle valve
10-100 PC490LC-10
Control valve
9. Pressure compensation valve (LOWER)

10. Spool
11. Suction safety valve (LOWER)
12. Regeneration circuit check valve
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)
L.H. travel valve

15. Merge-divider valve (travel junction valve)
16. Return spring
18. Pressure compensation valve (FORWARD)
19. Spool
20. Suction valve (FORWARD)
21. Suction valve (REVERSE)
22. Pressure compensation valve (REVERSE)
Bucket valve
24. Pressure compensation valve (DUMP)
25. Spool
26. Safety-suction valve (DUMP)
27. Suction safety valve (CURL)
28. Pressure compensation valve (CURL)
PC490LC-10 10-101
Control valve
Boom Hi and arm Hi valves

1. Boom Hi check valve
2. Arm quick return valve
3. Pressure compensation valve (Arm Hi IN)
10-102 PC490LC-10
Control valve
4. Spool (arm Hi)

5. Suction-safety valve (arm Hi IN)
6. Spool (boom Hi)
7. Suction valve (Boom Hi RAISE)
8. Pressure compensation valve (Boom Hi RAISE)
Service valve
9. LS shuttle valve
10. Pressure compensation valve
11. Spool
12. 2-stage suction safety valve
13. Suction-safety valve
15. Unload valve
17. LS bypass plug
Structure
• The control valves of the following types are set.
7-spool valve (without service valve)
8-spool valve (7-spool valve with service valve)
• The control valve consists of a 7-spool valve (unit type) and a service valve, and a merge-divider valve,
variable back pressure valve and boom hydraulic drift prevention valve and arm quick return valve are
installed to them.
• Since all the valves are assembled together with connecting bolts and their passes are connected to each
other inside the assembly, the assembly is compact and easy to maintain.
• With one spool provided for one work equipment, this control valve is simple in structure.
PC490LC-10 10-103
Control valve
Hydraulic circuit diagram and valve names (PC400-C030-054-K-00-A)
1. Arm valve
2. R.H. travel valve
3. Swing valve
10-104 PC490LC-10
Control valve
4. Boom valve
5. L.H. travel valve
6. Bucket valve
7. Boom Hi valve
8. Arm Hi valve
9. Service valve
10.Arm valve spool
11.R.H. travel valve spool
12.Swing valve spool
13.Boom valve spool
14.L.H. travel valve spool
15.Bucket valve spool
16.Boom Hi spool
17.Arm Hi spool
18.Service spool
19.Pressure compensation valve
20.Suction valve
21.Check valve(for boom regeneration circuit)
22.Check valve(for arm regeneration circuit)
23.Pump merge-divider EPC valve (for LS spool)
24.Pump merge-divider EPC valve (for main spool)
25.LS shuttle valve
26.LS bypass plug
27.LS select valve
28.Pump merge-divider valve
29.Arm quick return valve
30.Arm hydraulic drift prevention valve (if equipped)
31.Self-pressure reducing valve
32.Travel junction valve
33.Variable back pressure valve
34.Variable back pressure solenoid valve
35.Boom drift prevention valve
36.Boom Hi check valve
37.Main relief valve (boom, L.H. travel, bucket, attachment)
Set pressure:
35.9 ± 0.25 MPa {366 ± 2.5 kg/cm2}(160 l/min)
When one-touch power max. switch is set to ON position:
38.5 ± 0.25 MPa {392.5 ± 2.5 kg/cm2}(190 l/min)
38.Main relief valve (for arm, right travel and swing circuits)
Set pressure:
35.9 ± 0.25 MPa {366 ± 2.5 kg/cm2}(160 l/min)
When one-touch power max. switch is set to ON position:
38.5 ± 0.25 MPa {392.5 ± 2.5 kg/cm2}(190 l/min)
39.Unload valve (boom, L.H. travel, bucket,attachment)
Cracking pressure: 3.1 ± 0.5 MPa {32 ± 5 kg/cm2}
40.Unload valve (for arm, R.H. travel, and swing circuits)
Cracking pressure: 3.1 ± 0.5 MPa {32 ± 5 kg/cm2}
41.Suction-safety valve
Set pressure: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2}
42.Suction-safety valve
43.2-stage suction safety valve
1st stage set pressure: 20.1 ± 0.5 MPa {205 ± 5 kg/cm2}
2nd stage set pressure: 17.2 ± 0.5 MPa {175 ± 5 kg/cm2}
44.2-stage suction safety valve
1st stage set pressure: 28.4 ± 0.5 MPa {290 ± 5 kg/cm2}
2nd stage set pressure: 14.7 ± 0.5 MPa {150 ± 5 kg/cm2}
45.Suction safety valve for hydraulic drift prevention valve
PC490LC-10 10-105
Control valve
Unload valve (PC220-PQD5-041-K-00-A)
1. LS circuit
2. Valve
3. Pump circuit
4. Tank circuit
5. Spring
Function (PC220-PQD5-042-K-00-A)
• When all control valves are at HOLD, this valve serves to drain as same amount of oil as the pump
discharged volume with swash plate angle at the minimum.
• The pump pressure becomes the pressure corresponding to the set load of spring (5) in the valve (referred
to as P1).
• Since LS pressure is drained from LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}.
Operation (ALL-PQD5-044-K-00-A)
• Pressure of pump circuit (3) is received by the end of valve (2).
• Since the control valve is in NEUTRAL position, pressure of LS circuit (1) is 0 MPa {0 kg/cm 2}.
• Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available.
• If this pressure grows larger than the force of spring (5), valve (2) moves to the left.
• Ports (b) and (c) are interconnected, and the pump pressurized oil flows to tank circuit (4).
• The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to tank circuit
(4).
• When this valve is actuated, the LS pressure becomes nearly equal to the tank pressure.
• Since the pump delivery pressure - LS circuit pressure during unloading is larger than pump LS control
pressure, the signal is output to minimize the pump swash plate angle.
• During operation (when a given work is done within the discharged volume available with the minimum
swash plate angle), the delivery pressure corresponding to the minimum pump swash plate angle is set to
LS pressure + P1 pressure.
• The LS differential pressure (dPLS) with the swash plate angle at the minimum becomes P1 pressure.
Operation of relief valve

• When cylinder reaches its stroke end, main relief valve opens.
• Pump discharged volume (Q) is relieved to the tank. (For details, see " System diagram" of "Structure of
CLSS".
• Since the pump delivery pressure (PP) and LS pressure (PLS) do not flow neither to the upstream nor
downstream, they become approximately the same and LS differential pressure (dPLS) becomes 0 MPa
{0 kg/cm2}.
• As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve, LS valve operates to
make the pump swash plate angle maximum.
• Mechanically, operation of PC valve has priority over that of LS valve.
• The pump is maintained at the minimum swash plate angle due to PC valve cut-off function.
10-106 PC490LC-10
Control valve
Introduction of LS pressure (PC220-C2A4-041-K-00-A)
a LS: Abbreviation for Load Sensing
1. Main pump
2. Main spool
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function (PC220-C2A4-042-K-00-A)
• The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted and led to LS shuttle valve (7) as LS pressure.
• Connected to actuator port (B) through valve (4), and makes LS pressure C actuator load pressure.
• In main spool (2), leading hole (a) with a small diameter also acts as an orifice.
• LS pressure works as source pressure when closing unload vale while control lever is operated, and this
pressure also functions as operating pressure when pressure compensation valve is compensated.
PC490LC-10 10-107
Control valve
Operation (PC220-C2A4-044-K-00-A)
• When main spool (2) is operated, the pump pressure is transmitted to port (c) through leading hole (a) and
is led to LS circuit.
• When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens and the
pressurized oil flows.
LS bypass plug (PC400-PNSH-041-K-00-A)
1. Main pump
2. Main spool
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function (ALL-PNSH-042-K-00-A)
• This valve relieves the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
• Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
• Depending on the bypass flow from LS bypass plug (5), pressure loss is generated due to the circuit
resistance from orifice (c) of main spool (2) to LS shuttle valve (4).
• Effective LS differential pressure drops to improve a dynamic stability of the actuator.
Pressure compensation valve (PC300-L6D0-040-K-00-A)
When the work equipment is operated independently and the load pressure is the maximum
(When the load pressure is higher than that of other work equipment during a combined operation)
10-108 PC490LC-10
Control valve
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
• Pressure compensation valve works as the load check valve.
• If the pump pressure (LS pressure) is lower than the load pressure at port (c), shuttle valve (3) in pressure
compensation valve piston (4) interconnects spring chamber (E) and port (C).
• The force of spring (5) operates piston (4) and valve (2) to the closing direction.
Integrated pressure compensation valve

• When a high peak pressure or continuous and repetitive peak pressure (as in breaker operation) is
generated in the actuator circuit, valve (2) may collide with valve chamber seat (C), producing high stress
in the parts.
• To prevent this, a pressure compensation valve with integrated valve (2) and piston (4) is used.
• With this machine, this valve is adopted for the travel valve, bucket valve (cylinder bottom), arm Hi valve
(cylinder bottom), and the service valve.
• If high peak pressure is generated at port (C), valve (7) does not collide with the valve chamber.
• With a bucket valve, etc., port (C) and spring chamber (E) are designed to interconnect before valve (7) is
seated.
PC490LC-10 10-109
Control valve
When compensated
(When the load pressure is lower than that of other work equipment during a combined operation)
Function
• The pressure compensation valve is closed by the LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment.
• Since the spool meter-in upstream pressure at port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure port (A) pressure] - downstream pressure [port (B) pressure]
becomes equal to all the spools in operation.
• Pump flow is divided according to the ratio of the meter-in opening areas.
Operation
• Spring chamber (E) is interconnected to port (D).
• Piston (4) and valve (2) are moved in the closing direction (to the right) by the LS circuit pressure of port
(F) from other work equipment.
• Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled by the LS
pressure.
10-110 PC490LC-10
Control valve
Area ratio of pressure compensation valve
Function
• The condition of oil flow division changes according to the area ratio of pressure compensation valve
portions (A1) and (A2). Area ratio = (A2)/(A1)
• When the area ratio is equal to 1: As the spool meter-in downstream pressure is equal to the maximum
load pressure, the oil flow is divided in the same ratio as the opening area ratio.
• When the area ratio is more than 1: As the spool meter-in downstream pressure is higher than the
maximum load pressure, the oil flow is divided in a ratio smaller than the opening area ratio.
• When area ratio is below 1: As the spool meter-in downstream pressure is smaller than the maximum load
pressure, the oil flow is divided in a ratio larger than the opening area ratio.
PC490LC-10 10-111
Control valve
Shuttle valve in pressure compensation valve (PC220-L6D3-040-K-00-A)

When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
Operation
• Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is
disconnected from port (C).
• Holding pressure at port (A) is transmitted to the spring chamber (B) to push piston (4) to the left so that
piston (4) is not separated from valve (2).
10-112 PC490LC-10
Control valve
When traveling
Structure
• Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve
without shuttle valve (5) is adopted.
PC490LC-10 10-113
Control valve
Boom regeneration circuit (PC220-L511-040-K-00-A)

When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)
1. Main pump
2. Boom valve spool
4. Suction safety valve
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the
cylinder head when the boom is lowered.
Operation
• When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from the
cylinder bottom flows to drain circuit (B) from the notch of boom spool (2).
• The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom
through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
10-114 PC490LC-10
Control valve
When cylinder head pressure is higher than bottom pressure (digging operation, etc.)
Function
• Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to
the head.
PC490LC-10 10-115
Control valve
Arm regeneration circuit (PC220-L911-040-K-00-A)

When cylinder head pressure is higher than bottom pressure
1. Main pump
2. Arm valve spool
4. Suction safety valve
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit installed between the cylinder head and cylinder bottom increases the oil flowing
to the cylinder bottom (pump discharged volume + regeneration flow) during arm IN operation in order to
accelerate the cylinder.
Operation
• When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the
cylinder head flows to drain circuit (B) through the notch of arm spool (2).
• The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder
bottom through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
10-116 PC490LC-10
Control valve
When cylinder head pressure is lower than bottom pressure
Function
• Check valve (6) installed to regeneration circuit (C) closes and shuts off the oil flowing from the cylinder
head to the bottom.
PC490LC-10 10-117
Control valve
Merge-divider valve (PC220-PP30-040-K-00-A)

When oil flowing from two pumps are merged [pump merge-divider valve changeover signals (IS1)
and (IS2) are OFF]
1. Main spool
2. Spring
3. LS spool
4. Spring
A. LS circuit (for bucket valve)
D. LS circuit (for bucket valve)
B. LS circuit (for arm valve)
C. LS circuit (for arm valve)
9. Pump merge-divider EPC valve (for main spool changeover)
10. Pump merge-divider EPC valve (for LS spool changeover)
Function
• This valve merges the pressurized oil (P1) and (P2) from the two pumps or divides them (enables them to
flow to respective control valve groups).
• This valve merges or divides LS circuit pressures as well.
10-118 PC490LC-10
Control valve
Operation
• Since drive signal (IS1) of the EPC valve for the main spool is OFF, the output pressure of the pump
merge-divider EPC valve is 0 MPa {0 kg/cm2}.
• Main spool (1) is pressed to the right by spring (2). As a result, ports (E) and (F) are interconnected.
• Pressurized oil (P1) and (P2) discharged from the two pumps merge at ports (E) and (F), and flow to the
control valve which requires the oil.
• Since drive signal (IS2) of the EPC valve for LS spool (3) is also OFF, LS spool (3) is pressed to the right
by spring (4). As a result, ports (A) and (B) are interconnected and ports (B) and (C) are interconnected.
• The LS pressures transmitted from respective control valve spools through LS circuits (A), (B), (C), and
(D) are transmitted to all the pressure compensation valves.
When oil flowing from two pumps are divided [pump merge-divider valve changeover signals (IS1)
and (IS2) are ON]
Operation
• Since drive signal (IS1) of the main spool is ON, main spool (1) is moved to the left by the output pressure
from the pump merge-divider EPC valve. As a result, port (E) is disconnected from port (F).
• The pressurized oil from the two pumps are sent to respective control valve groups.
Pressure P1: To bucket, left travel, boom
Pressure P2: To swing, right travel, arm
• When drive signal (IS2) of the EPC valve for LS spool (3) becomes ON, LS spool (3) is also moved to the
left by the output pressure from the pump merge-divider EPC valve. As a result, ports (A) and (C) are
interconnected, and other ports remain disconnected from each other.
• The LS pressures transmitted from respective control valve spools through LS circuits (A), (B), (C), and
(D) are transmitted to respective control valves.
PC490LC-10 10-119
Control valve
LS selector valve (PC220-J6PA-041-K-00-A)
a The illustration shows the condition when the combined operation of swing and R.H. travel is performed.
[When pilot pressure (BP) is supplied]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing valve spool
6. R.H. travel valve spool
7. Arm valve spool
8. LS shuttle valve
9. LS circuit
Function (PC300-J6PA-042-K-00-A)
• This valve prevents the high LS pressure of the swing valve from entering the LS circuits of work
equipment valves when the swing and boom RAISE are in combined operation.
• This valve prevents high pressure generated at swing drive to improve operability of work equipment.
Operation (ALL-J6PA-044-K-00-A)
When pilot pressure (BP) is shut off

• Since pilot pressure (BP) is shut off, piston (3) is pressed to the left by force of spring (2).
• If the swing lever is moved, swing LS pressure (P1) passing through swing spool (5) enters port (A).
• Swing LS pressure (P1) presses valve (1) to the left, and port (A) and port (B) are interconnected.
• Swing LS pressure (P1) is transmitted from port (A) to LS shuttle valve (8) through port (B).
10-120 PC490LC-10
Control valve
When pilot pressure (BP) is supplied

• When pilot pressure (BP) is supplied, pilot pressure (BP) moves piston (3) to the right against the force of
spring (2).
• When piston (3) moves to the right, valve (1) disconnects ports (A) and (B).
• Since ports (A) and (B) are disconnected, swing LS pressure (P1) is not transmitted to LS shuttle valve
(8).
• Swing LS pressure (P1) cannot affect other LS circuits, even if it rises.
Self-pressure reducing valve (PC220-PL30-042-K-00-A)

Function
• This valve serves to reduce the delivery pressure of main pump and provide it for solenoid valves, EPC
valves, etc. for use as the control pressure.
Operation (ALL-PL30-044-K-00-A)
When engine is stopped

• Poppet (11) is pressed against the seat by spring (12), so port (PR) is disconnected from port (TS).
• Valve (14) is pressed to the left by spring (13), so port (P2) is disconnected from (TS).
• Valve (7) is pressed to the left by spring (8), so port (P2) is disconnected from port (A2).
PC490LC-10 10-121
Control valve
10-122 PC490LC-10
Control valve
PC490LC-10 10-123
Control valve
When load pressure (P2) is low

a When all control levers are in NEUTRAL position, or when load pressure (A2) is lower than output
pressure (PR) of the self-pressure reducing valve
• Force of spring (8) and the force exerted by the pressure (PR) (0 MPa {0 kg/cm 2}, when engine is stopped),
are applied to valve (7) in the direction to disconnect the circuit ports (P2) and (A2).
• When the pressurized oil flows in from port (P2), valve (7) balances at a position where [Force (Area fd x
Pressure P2) = Force of spring (8) + Force (Area fd x Pressure PR)] holds.
• The opening of valve (7) is adjusted so that pressure (P2) remains at a constant level higher than pressure
(PR).
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
10-124 PC490LC-10
Control valve
When load pressure (P2) is high

• As load pressure (A2) increases with the digging operation, etc, the pump discharged volume increases
accordingly.
• Pressure (P2) increases, and [Force (Area fd x Pressure P2] becomes larger than [Force of spring (8) +
Force (Area fd x Pressure PR)]. As a result, valve (7) moves fully to the right.
• Since the area of the opening between ports (P2) and (A2) increases, the passage resistance reduces,
reducing the engine horsepower loss.
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
PC490LC-10 10-125
Control valve
When abnormally high pressure is generated

• If pressure (PR) of the self-pressure reducing valve becomes abnormally high, ball (16) contracts spring
(15) and separates from the seat.
• This allows the pressurized oil to flow to drain port (TS) from port (PR), lowering pressure (PR).
• As a result, components such as PPC valves and solenoid valves are protected from abnormally high
pressure.
Travel junction valve (PC400-C6C0-042-K-00-A)

Function
• When travel control lever is operated for straight-travel, travel junction valve does not receive the pilot
pressure (PST) from travel junction solenoid valve, thus right and left travel circuits interconnect each
other, and equal amount of oil is supplied to right and left travel motors to secure straight-travel ability.
• When travel control lever is operated for turning, travel junction valve receives the pilot pressure (PST)
from travel junction solenoid valve, thus right and left travel circuits are shut off each other, and
independent amount of oil is supplied to right and left travel motors to secure turning ability.
10-126 PC490LC-10
Control valve
Operation (PC400-C6C0-044-K-00-A)
When pilot pressure (PST) is shut off (travel junction)
• If pilot pressure (PST) from the travel junction solenoid valve is shut off, travel junction spool (2) is pressed
back towards right by the force of spring (1). As a result, ports (PTL) and (PTR) are interconnected.
• If the oil flow rates to the R.H. and L.H. travel motors become different from each other, the oil flows
through the opening of travel junction spool (2) from port of higher pressure side to port of lower pressure
side supplying the difference of oil to the lower pressure side so that the oil flow rates to both motors will
be equalized.
PC490LC-10 10-127
Control valve
When pilot pressure (PST) is supplied (travel independent)
• When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2)
compresses spring (1) to the left side and ports (PTL) and (PTR) are disconnected.
• The oil flow rate to both right and left motors becomes independent.
Travel PPC shuttle valve (PC300-C6V1-042-K-00-A)
a PPC: Abbreviation for Proportional Pressure Control
10-128 PC490LC-10
Control valve
Function
• If arm IN operation is performed when the machine is traveling up a steep, the pilot pressure from the
travel PPC valve serves to restrict the travel of each spool of arm so that the oil flow rate to each cylinder
is restricted.
• To limit the travel of the arm spool, the pilot pressure from the travel PPC valve passes through the internal
circuit of control valves and acts on the spool.
Operation (PC300-C6V1-044-K-00-A)
When travel lever is in NEUTRAL
• The oil in the stroke limiting signal chamber (a) passes through orifices (5) and (6) of respective pistons (3)
and (4) built in the travel spring case, and then is drained through the travel PPC valve.
• When boom RAISE (or arm IN) operation is performed, spool (1) moves to the left until it contacts the end
face of spring case (2) (st0).
PC490LC-10 10-129
Control valve
Travel operation
• If the right REVERSE (or FORWARD) travel is performed, the pilot pressure from the travel PPC valve
moves spool (7) to the left (or right).
• Spool (7) pushes piston (3) to close orifice (5) and shut off stroke regulation signal chamber (a) and the
drain circuit of the travel PPC valve.
• At this time, the pilot pressure from the travel PPC valve passes through orifice (6) of piston (4) and acts
on the left end of piston (8) and pushes piston (8) to the right.
• When arm IN operation is performed, spool (1) moves to the left.
• Maximum stroke of the spool is limited to (st1) for the amount of movement (st2) of piston (8) to the right.
Boom hydraulic drift prevention valve (PC220-L6C0-042-K-00-A)
Function
• While boom is not operated by the right work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from boom cylinder bottom through spool (1) to prevent the boom from
drifting hydraulically.
10-130 PC490LC-10
Control valve
Operation (ALL-L6C0-044-K-00-A)
In boom "RAISE" operation
• When operating boom "RAISE", the pressurized oil from the control valve exerts a left-hand force on the
right side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which
inside diameter is seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, the pressurized oil from the control valve passes through the opening of poppet (5) and flows
to the boom cylinder bottom.
PC490LC-10 10-131
Control valve
In boom "NEUTRAL" operation
• When the boom is operated to "NEUTRAL" position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of boom cylinder bottom exerts a right-hand force on the left side of ring-shaped
area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat
diameter (d2).
• The combined force of right-hand force on area (S) and the spring force of spring (4) moves poppet (5) to
the right.
• The circuit from control valve to boom cylinder bottom shuts off, then the oil pressure of the boom cylinder
bottom side is kept.
10-132 PC490LC-10
Control valve
In boom "LOWER" operation
• When operating boom "LOWER", the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the boom cylinder bottom flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
Arm hydraulic drift prevention valve (PC220-L9K0-042-K-00-A)
(if equipped)
Function
• While arm is not operated by the left work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from arm cylinder head through spool (1) to prevent the arm from drifting
hydraulically.
PC490LC-10 10-133
Control valve
Operation (PC-L9K0-044-K-00-A)
In arm "arm OUT" operation
• During arm "arm OUT" operation, the pressurized oil from the control valve exerts a left-hand force on the
right side of area (S) of ring-shaped surface, of which outside diameter is equal to diameter (d1) of poppet
(5) and of which inside diameter is equal to seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, pressurized oil from the control valve flows to the arm cylinder head through the opening of
poppet (5).
10-134 PC490LC-10
Control valve
In arm "NEUTRAL" operation
• When the arm is operated to "NEUTRAL" position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of arm cylinder head exerts a right-hand force on the left side of ring-shaped area
(S), of which outside diameter is equal to diameter (d1) of poppet (5) and of which inside diameter is equal
to seat diameter (d2).
• The combined force of right-hand force on area (S) and the reaction force of spring (4) moves poppet (5)
to the right.
• The circuit from control valve to arm cylinder head shuts off, then the oil pressure of the arm cylinder head
side is kept.
PC490LC-10 10-135
Control valve
In arm "arm IN" operation
• When arm is operated "arm IN", the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the arm cylinder head flows from orifice (c) to drain port (T) through orifice (a) and
chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
10-136 PC490LC-10
Control valve
Operation (PC220-L9K2-044-K-00-A)
Operation when abnormally high pressure is generated
• If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B)
opens check valve (6) to actuate safety valve (3).
• When the arm hydraulic drift prevention valve (optional) is installed to the arm cylinder head circuit, the
pressurized oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure,
whichever has higher pressure, opens check valve (6) or (6A) to actuate safety valve (3).
PC490LC-10 10-137
Control valve
Arm quick return valve (PC220-L9K1-042-K-00-A)

Function
• Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed.
• The valve reduces this pressure loss.
Operation (PC300-L9K1-044-K-00-A)
In arm "arm OUT" operation
• In arm "arm OUT" operation, the pilot pressure from the PPC valve pushes pilot piston (1).
• The pressurized oil in chamber (b) inside the valve is drained through orifice (c).
• The pressurized oil of the arm cylinder bottom side flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• If the pressure in chamber (b) drops lower than that of port (A), the force exerted on the pressure receiving
surface of [Area (S2) of fd2 (surface of seat diameter)] on the port (A) side exceeds the combined force of
the force exerted on the pressure receiving surface [Area (S1) of fd1] on the chamber (b) side of valve (2)
and the spring force.
• The result is, (Force exerted on surface of fd2 > Force exerted on surface of fd1 + Force of spring).
• Valve (2) is pressed to the left and pressurized oil flows from port (A) to port (B).
• The pressurized oil of the arm cylinder bottom side is drained directly to the tank from port (B).
10-138 PC490LC-10
Control valve
In arm "NEUTRAL" operation
• When the arm is operated from arm "arm OUT" to "NEUTRAL", the pilot pressure from PPC valve is shut
off.
• The pressurized oil that flows in through orifice (a) in valve (2) and is drained, is stopped by pilot piston (1).
• The holding pressure of the arm cylinder bottom side exerts the right-hand force on the left side of ring-
shaped surface, whose area is equal to the area of (S2 - S1) of valve (2).
• The combined force of the right-hand force exerted on the ring-shaped surface and the spring force of the
spring (3) moves valve (2) to the right and shuts off port (A) and port (B).
Variable back pressure valve (PC220-PQ81-042-K-00-A)
Function
• This valve creates back pressure in the drain circuit to prevent cavitation caused by negative pressure in
each actuator circuit (motors, cylinders, etc.).
• In order to reduce output loss, this valve reduces the back pressure in the drain circuit when any operation
other than the travel and swing is performed.
Operation (ALL-PQ81-044-K-01-A)
When engine is stopped

• Pressurized oil is not supplied from the main pump to self-pressure reducing valve (1).
• No oil pressure is transmitted from variable back pressure solenoid valve (3) to spring chamber (C), and
valve (6) is pressed to the right by the reaction force of spring (5).
• Drain circuit (A) of the control valve is interconnected to port (T) through orifice (b) of valve (6).
PC490LC-10 10-139
Control valve
10-140 PC490LC-10
Control valve
When engine is running (during swing or travel operation)

• The pressurized oil (PR) from self-pressure reducing valve (1) flows to variable back pressure solenoid
valve (3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is "OFF", pressurized oil (PR) is flown
to spring chamber (C) of variable back pressure valve (4).
• Pressurized oil (PR) transmitted to spring chamber (C) exerts a force on the left end face of valve (6)
(surface of fd), and it pushes valve (6) to the right as a combined force with the reaction force of spring
(5).
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = (Area of
surface fd) x Pressure (PR) + Reaction force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.
PC490LC-10 10-141
Control valve
When engine is running (other than swing or travel operation)

• The pressurized oil from self-pressure reducing valve (1) flows to variable back pressure solenoid valve
(3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is "ON", the pressurized oil (PR) from
self-pressure reducing valve (1) flown to spring chamber (C) of variable back pressure valve (4) is drained
through variable back pressure solenoid valve (3).
• Only the reaction force of spring (5) pushes valve (6) to the right.
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = Reaction
force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.
10-142 PC490LC-10
Control valve
Main relief valve (PC400-PQ91-041-K-00-A)
1. Spring
2. Poppet
Function (PC220-PQ91-042-K-00-A)
• This valve has two selectable settings for its set pressure.
• If the extra power is necessary, this valve is set to the high-pressure setting when pilot pressure (P) is
applied to it from the 2-stage relief solenoid valve.
• The relief valve set pressure is determined by the load at installed height of spring (1). (1st stage set
pressure)
• When the 1st stage set pressure is set correctly, the 2nd stage set pressure does not need to be set.
Setting the 1st stage set pressure completes the setting of the 2nd stage set pressure.
Operation (PC-PQ91-044-K-00-A)
When pilot pressure (P) is shut off (low pressure setting)

• The set pressure is determined by the load at installed height of spring (1).
When pilot pressure (P) is supplied (high pressure setting)

• The load at installed height of spring (1) is added with the force exerted by pilot pressure (P) applied to the
area of diameter (d1) of poppet (2), raising the set pressure to higher level.
2-stage suction-safety valve (PC300-PQJ2-041-K-00-A)
[To be installed to port (B) on the boom cylinder head side and port (B) of the service valve]
PC490LC-10 10-143
Control valve
1. Spring
2. Piston
3. Spring
4. Holder
Function (PC220-PQJ2-042-K-00-A)
• This valve has two settings for its set pressure.
• This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment
circuit selector solenoid valve.
• ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment
(breaker, crusher, etc.).
• The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure
side)
• The set pressure of the low-pressure setting is determined by the travel of the piston.
Operation (ALL-PQJ2-044-K-00-A)
When pilot pressure (P) is shut off (high pressure setting)
• Since pilot pressure (P) is shut off, piston (2) is pressed to the left by force of spring (3). [Load at installed
height of spring (1) < Load at installed height of spring (3).]
• The load at installed height of spring (1) becomes maximum, inducing high-pressure setting.
• Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
10-144 PC490LC-10
Control valve
When pilot pressure (P) is supplied (low pressure setting)
• When pilot pressure (P) is supplied, the pilot pressure is transmitted to part (A) through passage (B).
• The pilot pressure acts on the pressure receiving diameter at part (A) [(d1) – (d2)] of piston (2).
• Piston (2) compresses spring (3) by receiving pilot pressure and moves to the right until it contacts holder
(4).
• Since spring (1) is expanded and reducing its load at installed height, the set pressure is lowered.
• The amount of pressurized oil for stroke of piston (2) is drained from passage (C) via chamber (D) .
PC490LC-10 10-145
Swing motor
Swing motor (PC300-J610-041-K-00-A)
MA: From control valve (LEFT swing port)

MB: From control valve (RIGHT swing port)
B: From swing holding brake solenoid valve
S: From control valve (variable back pressure valve)
PU: 2-stage relief solenoid valve
1. Reversing prevention valve
2. 2-stage swing relief valve
10-146 PC490LC-10
Swing motor
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
PC490LC-10 10-147
Swing motor
10. Cylinder block

11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Check valve spring
16. Shuttle valve
17. Shuttle valve spring
Specifications (PC400-J610-030-K-00-A)
Type KMF230ABE - 5
Theoretical delivery (cm3/rev) 229.4
2-stage swing relief valve pressure (MPa {kg/cm2}) 27.9 {285}
Low-pressure setting 260
2-stage swing relief oil flow (l/min)
High-pressure setting 100
Brake release pressure (MPa{kg/cm2}) 1.9 ± 0.4 {19 ± 4}
Swing holding brake (PC300-J6A0-044-K-00-A)

When solenoid valve is de-energized
• As the swing holding brake is de-energized, the pressurized oil from the self-pressure reducing valve is
blocked.
• Port (B) is connected to tank circuit.
• Brake piston (7) is pushed downward by brake spring (1).
• Disc (5) and plate (6) are pushed against each other to apply the brake.
10-148 PC490LC-10
Swing motor
When solenoid valve is energized
• As the swing holding brake solenoid valve is energized, the valve is switched.
• The pressurized oil from self-pressure reducing valve enters port (B), and flows into brake chamber (a).
• After entering chamber (a), the pressurized oil compresses brake spring (1) and moves brake piston (7)
upward.
• Disc (5) is separated from plate (6), releasing the brake.
Relief valve (PC220-J6B1-041-K-00-A)

• The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).
Function (PC220-J6B1-044-K-00-A)
• When the swing is stopped, control valve (6) blocks the motor outlet circuit, but the motor rotation is
continued by inertial force.
• If the pressure of motor outlet circuit becomes abnormally high, it may cause damage to the motor.
• In order to prevent the motor damage, the relief valve relieves the abnormally high pressure to port (S)
from the motor outlet (high-pressure side).
PC490LC-10 10-149
Swing motor
Operation (PC300-J6B1-044-K-00-A)
When swinging is started
• When swing is started RIGHT, the pressurized oil from the pump is supplied to port (MA) through control
valve (6).
• The pressure at port (MA) rises, the starting torque is generated in the motor, and the motor starts to
rotate.
• Pressurized oil is supplied to port (PU) of the motor, increasing the set pressure of the motor.
• During swing acceleration, the pilot pressure from 2-stage swing relief solenoid valve (7) is applied to port
(PU) to restrict the relief volume.
• The pressurized oil from the outlet of the motor passes the control valve (6) through port (MB) and returns
to the tank.
10-150 PC490LC-10
Swing motor
When swing is stopped
• When the swing operation is returned to the NEUTRAL from RIGHT swing operation, the supply of
pressurized oil from the pump to port (MA) is stopped.
• The pressurized oil from the motor outlet cannot return to the tank since the return circuit to the tank is
blocked by control valve (6). Thus, pressure on port (MB) increases.
• If the pressure in port (MB) becomes too high, the pressurized oil returns to the hydraulic tank through
relief valve (1) and port (S).
• Rotation resistance is generated on the motor and hence the brake starts working.
• When the pressure at port (MB) comes to be higher than that at port (MA), shuttle valve (4) is pressed.
• The pressure in chamber (C) becomes the same as that of port (MB), and is increased to the set pressure
of relief valve (1).
• A high braking torque works on the motor, thereby stopping the motor.
• While relief valve (1) is actuated, the relieved pressurized oil and the pressurized oil from port (S) are
supplied to port (MA) through the check valve (3).
• Thus, cavitations is prevented from generating on port (MA).
PC490LC-10 10-151
Swing motor
2-stage swing relief valve (PC300-JA1A-041-K-00-A)
1. Valve seat
2. Valve
3. Piston
4. Spring
5. Spring
6. Piston
7. Rod
Function (PC300-JA1A-042-K-00-A)
• This valve has two selectable settings for set pressure.
• The set pressure of this valve is determined by the load at installed length of spring (4).
• During swing acceleration, this valve receives pilot pressure (PU) from the 2-stage swing relief solenoid
valve and decreases the relief quantity (drain quantity).
• If pressure (P) is constant, energy loss can be reduced by decreasing oil flow (Q), or relief quantity (drain
quantity), according to the formula of [Energy loss = Pressure (P) x Oil flow (Q)]. Decrease of energy loss
leads to the improvement of fuel consumption.
A: Pilot pressure blocked (low-pressure setting)

B: Pilot pressure applied (high-pressure setting)
P: 27.9 MPa {285 kg/cm2}
Q1: 260 l/min
Q2: 100 l/min
10-152 PC490LC-10
Swing motor
Operation (PC300-JA1A-044-K-00-A)
When pilot pressure (PU) is blocked (low-pressure setting)

• The set pressure is determined by the load at installed length of spring (4).
When pilot pressure (PU) is applied (high-pressure setting)

• During swing acceleration, pilot pressure (PU) from the 2-stage swing relief solenoid valve acts on the
power receiving area (d2 – d1).
• Spring (4) is compressed, the load at installed length of the spring is increased, and then the passage
between valve (2) and valve seat (1) is narrowed while the pump delivery is decreased by the controller.
As a result, the flow rate in hydraulic relief decreases when relief pressure is constant.
PC490LC-10 10-153
Swing motor
Swing motor reverse prevention valve (PC-J6B2-041-K-00-A)
MA: From control valve (left swing port)

MB: From control valve (right swing port)
10-154 PC490LC-10
Swing motor
T1: To hydraulic tank

T2: To hydraulic tank
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Explanatory drawing of effects
Function (PC220-J6B2-042-K-00-A)
• At the stop of swing operation, the upper structure may swing back. This is due to inertia of the mass of
the upper structure, the backlash and rigidity of the swing machinery system, and compressibility of the
hydraulic oil. This valve prevents such movement.
• The valve contributes to prevention of load spillage when the swing is stopped and also contributes to
reduction in the cycle time (enhances the positioning performance, enabling you to proceed to the next
work quicker than ever).
PC490LC-10 10-155
Swing motor
Operation (PC220-J6B2-044-K-00-A)
When brake pressure is generated in port (MB)
• Pressure (MB) is led to chamber (d) through notch (g).

• As (D1 > D2) holds in regards to circle areas of spool (5), spring (6) is compressed and spool (5) is moved
to the left.
• Port (MB) and chamber (e) are interconnected to each other.
• Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the
pressurized oil is blocked. Thus the braking force is ensured.
When motor reversing pressure is generated in port (MA)
• The trapped pressure in port (MB) turns the motor in the opposite direction. (1st reverse rotation)
• Reversing pressure is generated in port (MA). Pressure (MA) is transmitted to chamber (a).
• As (D3 > D4) holds in regard to circle areas of spool (2), spring (3) is compressed and spool (2) is moved
to the right.
• Port (MA) and chamber (b) are interconnected to each other.
• Port (b) is interconnected to port (f) through the drilled hole (h) in spool (5). This bypasses the reversing
pressure in port (MA) to port (T), thereby preventing the 2nd reverse rotation of the motor.
10-156 PC490LC-10
Travel motor
Travel motor (PC400-C400-041-P-00-A)
1. Bleeder
L.H. travel motor
PA: From control valve (L.H. travel REVERSE port)
PB: From control valve (L.H. travel FORWARD port)
R.H. travel motor

PA: From control valve (R.H. travel FORWARD port)
PB: From control valve (R.H. travel REVERSE port)
PI: From travel speed acceleration valve
B: Plug (Brake release pressure port)
MA: Port (PA) pressure pickup port
MB: Port (PB) pressure pickup port
PC490LC-10 10-157
Travel motor
1. Output shaft
2. Motor case
3. Piston
4. Cylinder block
5. Valve plate
6. End cover
7. Slow return valve
8. Regulator piston
9. Plate
10-158 PC490LC-10
Travel motor
10. Disc
11. Check valve spring
12. Check valve
13. Counterbalance valve spool
14. Spool return spring
15. Safety valve
16. Regulator valve
17. Spring
18. Brake spring
19. Brake piston
20. Check valve
Specifications (PC400-C400-030-P-00-A)
Model KMV200ADT-2
Min. 130 ± 3.5
Theoretical delivery (cm3/rev)
Max. 200 ± 3.5
Rated pressure: MPa {kg/cm2} 37.3 {380}
When capacity is maximized 2,650
Rated speed (rpm)
When capacity is minimized 1,550
Brake release pressure (MPa{kg/cm2}) 0.98 {10}
Travel speed selector pressure (MPa {kg/cm2}) 0.78 {8.0}
PC490LC-10 10-159
Travel motor
Operation of motor (PC400-C400-044-K-00-A)

At low-speed travel setting (motor swash plate angle is at maximum)
• When the solenoid valve is de-energized, the pilot pressure oil from the self-pressure reducing valve does
not flow to port (P).
• Regulator valve (16) is pushed down by spring (17).
• Pressurized oil from control valve that flowed to end cover (6) through check valve (20), then flows to
chamber (b) through regulator valve (16).
• Force that moves regulator piston (8) downward is generated.
• Valve seat (5) and cylinder block (4) work in a direction that maximizes the swash plate angle. As a result,
motor capacity is maximized and the travel speed is set to the low speed travel.
10-160 PC490LC-10
Travel motor
At high-speed travel setting (motor swash plate angle is at minimum)
• When the solenoid valve is energized, the pilot pressure oil from the self-pressure reducing valve flows to
port (P).
• The oil pushes regulator valve (9) upward.
• Pressurized oil in chamber (b) drained to case, and it flows to chamber (a) through regulator valve (16).
• Force is moves regulator piston (8) upward is generated.
• Valve seat (5) and cylinder block (4) work in a direction that minimizes that swash plate angle. As a result,
motor capacity is minimized and the travel speed is set to high speed travel.
PC490LC-10 10-161
Travel motor
Operation of parking brake (PC400-C4A0-044-K-00-A)

When starting traveling
• When the travel lever is operated, the pressurized oil from the pump acts on counterbalance valve spool
(13) to make the parking brake circuit.
• The pressurized oil flows to chamber (e) of brake piston (19), and compresses spring (18), pushing piston
(19) to the right.
• Since the force pressing plate (9) and disc (10) to each other is eliminated, they are separated and the
brake is released.
10-162 PC490LC-10
Travel motor
When stopping traveling
• When the travel lever is returned to NEUTRAL, counterbalance valve spool (13) returns to the neutral
position, and the parking brake circuit is blocked.
• Pressurized oil in chamber (e) of brake piston (19) keeps flowing through orifice of slow return valve (7)
until counterbalance valve spool (13) is returned to neutral position.
• At the point when counterbalance valve spool (13) is returned to neutral position, pressurized oil is drained
to the case from orifice (f) of brake piston (19).
• Brake piston (19) is pressed to the right by spring (18).
• Plate (9) and disc (10) are pressed against each other, and the brake is applied.
• When brake piston (19) is returned, the flow of pressurized oil is restricted by slow return valve (7).
• The restriction of the return flow of pressurized oil delays the application of the parking brake. The parking
brake is applied after the machine has stopped.
Brake valve (PC400-C4Q0-041-K-00-A)
• Brake valve consists of check valve (1), counterbalance valve (2), and safety valve (3).
PC490LC-10 10-163
Travel motor
Counterbalance valve and check valve (PC400-C4N0-042-K-00-A)
Function
• When the machine travels down a slope, its travel speed tends to get faster than the motor (engine) speed
because of the downward force generated from its own weight.
• If the machine travels with the engine at low speed, the motor may run idle, and the machine runs out of
control, causing a very dangerous situation.
• These valves serve to prevent the above problem by enabling the machine to travel at a speed that
matches the engine speed (pump delivery).
10-164 PC490LC-10
Travel motor
Operation (PC400-C4N0-044-K-00-A)
Operation when pressurized oil is supplied
• If the travel lever is operated, the pressurized oil is supplied from the control valve to port (PA).
• The oil opens check valve (12A), and flows from motor inlet port (MA) to motor outlet port (MB).
• Since the motor outlet circuit is blocked by check valve (12B) and spool (13), the pressure of the supply
side circuit increases.
PC490LC-10 10-165
Travel motor
• The pressurized oil of the supply side circuit flows through orifices (E1) and (E2) of spool (13) to chamber
(S1).
• If the pressure in chamber (S1) becomes higher than the reaction force of the spool selector pressure,
spool (13) is pushed to the right.
• Both motor outlet port (MB) and port (PB) are connected to outlet passage (B1). As the result, the motor
outlet side opens and the motor rotates.
10-166 PC490LC-10
Travel motor
Brake operation at travelling downhill
• When the machine almost run out of control during downhill travel, the motor runs idle and the pressure of
the inlet side circuit decreases.
• The pressure in chamber (S1) decreases, as the oil is drained through orifices (E1) and (E2).
• If the pressure in chamber (S1) becomes lower than the spool selector pressure, spool (13) is returned to
the left by reaction force of spring (14) and outlet side port (MB) is throttled.
• Pressure of the motor outlet side circuit increases and rotational resistance is generated in the motor,
preventing the machine from running out of control.
• Spool (13) moves to a position where pressure of outlet side port (MB) is balanced against the sum of
pressures of machine's own weight and pressure of motor inlet port.
• Narrowing down the motor outlet side circuit in this way allows the machine to travel at a speed that
matches the pump delivery.
Safety valve (Bidirectional 2-stage setting safety valve) (PC400-C660-041-K-00-A)
Specifications (PC400-C660-030-K-00-A)
High-pressure setting
40.2 {410}
(at start of travel and during travel)
Set pressure (MPa {kg/cm2)
Low-pressure setting
27.5 {280}
(when stopped)
Function (PC400-C660-042-K-00-A)
• As long as the machine is stopped (or it travels down a slope), the counterbalance valve blocks the inlet
and outlet circuits of the motor.
• Since the motor is rotated by inertial force, pressure in the motor outlet port is abnormally increased,
potentially resulting in damages on the motor and piping.
• The safety valve releases this abnormal pressure to the inlet port of the motor in order to prevent damages
to the equipment.
PC490LC-10 10-167
Travel motor
Operation (PC400-C660-044-K-00-A)
Bidirectional action
When pressure in chamber (MB) has become high (when rotated clockwise)
• As long as the machine travel is stopped (or it is travelling downhill), the check valve of counterbalance
valve closes chamber (MB) of the outlet port circuit.
• As motor tends to keep rotating by inertial force, the pressure at outlet (MB) increases.
• When the pressure exceeds the set pressure, the force [difference of circle area between (D1) and (D2) x
pressure] retracts spring (2).
• Poppet (1) is moved to the left, and pressurized oil flows to chamber (MA) of opposite side circuit.
10-168 PC490LC-10
Travel motor
When pressure in chamber (MA) has become high (when rotated counterclockwise)
• As long as the machine travel is stopped (or it is travelling downhill), the check valve of counterbalance
valve closes chamber (MA) of the outlet port circuit.
• As motor tends to keep rotating by inertial force, the pressure at outlet (MA) increases.
• When the pressure exceeds the set pressure, the force [difference of circle area between (D1) and (D3) x
pressure] retracts spring (2).
• Poppet (1) is moved to the left, and pressurized oil flows to chamber (MB) of opposite side circuit.
PC490LC-10 10-169
Travel motor
Operation of mechanism varying set pressure
When starting travel (high-pressure setting)
• If the travel lever is operated, the pressurized oil from the pump moves spool (19) to the right.
• The pressurized oil open the pilot circuit to the safety valve, and it flows to chamber (G) through chamber
(H) and passage (J).
• Piston (3) is pushed to the right, spring (2) is compressed and the set load is increased.
• The set pressure of the safety valve changes to high-pressure setting, providing a large tractional force.
10-170 PC490LC-10
Travel motor
When travel is stopped (low-pressure setting)
• When the travel lever is set to the NEUTRAL position, the pressure in chamber (PA) drops, spool (24)
returns to the neutral position.
• Until spool (24) returns to the neutral position, the pressurized oil in chamber (J) keeps on flowing through
passage (H) and chamber (G) to chamber (PA).
• Piston (3) is moves to the left, the set load is decreased.
• The set pressure of the safety valve changes to low-pressure setting, reducing shocks when the travel
speed is reduced.
PC490LC-10 10-171
PPC valve
PPC valve (ALL-CW10-001-P-00-A)

Work equipment and swing PPC valve (PC-PL28-041-K-00-A)
10-172 PC490LC-10
PPC valve
L.H. work equipment control lever

P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
P3: To control valve (LEFT swing port)
P4: To control valve (RIGHT swing port)
R.H. work equipment control lever

P1: To control valve (boom LOWER port)
P2: To control valve (boom RAISE port)
P3: To control valve (bucket CURL port)
P4: To control valve (bucket DUMP port)
T: To hydraulic oil tank
PC490LC-10 10-173
PPC valve
10-174 PC490LC-10
PPC valve
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter
Operation (PC-PL28-044-K-00-A)
When valve is in neutral
• Ports (A) and (B) of the valve and ports (P1) and (P2) of the PPC valve are connected respectively
through fine control hole (f) of spool (1) to drain chamber (D).
PC490LC-10 10-175
PPC valve
When valve is in fine control range
(neutral to fine control range)
• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• Almost at the same time when fine control hole (f) is disconnected from drain chamber (D), it is connected
to pump pressure chamber (PP).
• The pilot pressure oil of main pump is transmitted from port (P1) to port (A) through fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the stroke of the control lever.
• The pressure in port (P1) also increases in proportion to the stroke of the control lever.
• Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool.
10-176 PC490LC-10
PPC valve
(when control lever is returned)
• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the pressure
in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• When the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D) and connected to pump pressure chamber
(PP) almost at the same time.
• The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to
the lever position.
• When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
chamber (B) to replenish the port with pressurized oil.
PC490LC-10 10-177
PPC valve
When control lever is fully operated
• Disc (5) pushes down piston (4), and retainer (9) pushes down spool (1).
(PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) through fine control hole (f') into drain chamber (D).
Travel PPC valve (PC-C6V0-041-K-00-A)
10-178 PC490LC-10
PPC valve

P1: To control valve (L.H. travel REVERSE port)
P2: To control valve (L.H. travel FORWARD port)
P3: To control valve (R.H. travel REVERSE port)
P4: To control valve (R.H. travel FORWARD port)
PC490LC-10 10-179
PPC valve
1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper
10-180 PC490LC-10
PPC valve
Operation (PC-C6V0-044-K-00-A)
When valve is in neutral
• Ports (A) and (B) of the valve and ports (P1) and (P2) of the PPC valve are connected respectively
through fine control hole (f) of spool (1) to drain chamber (D).
PC490LC-10 10-181
PPC valve
(neutral to fine control range)
• When piston (4) is pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downwards.
• Almost at the same time when fine control hole (f) is disconnected from drain chamber (D), it is connected
to pump pressure chamber (PP).
• The pilot pressure of control pump is transmitted from port (P1) to port (A) through fine control hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Spool (1) moves up and down to balance the force of metering spring (2) with the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the stroke of the control lever.
• The pressure in port (P1) also increases in proportion to the stroke of the control lever.
• Accordingly, the control valve spool moves to a position at which the pressure in chamber (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the return spring of the control valve spool.
10-182 PC490LC-10
PPC valve
(when control lever is returned)
• When lever (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the
pressure in port (P1).
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• When the pressure in port (P1) decreases too much, spool (1) is pushed down by metering spring (2).
(PP) almost at the same time.
• The pump pressure is supplied until the pressure in port (P1) recovers to the pressure corresponding to
the lever position.
• When the spool of control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
chamber (B) to replenish the port with pressurized oil.
PC490LC-10 10-183
PPC valve
When control lever is fully operated
• Lever (5) pushes down piston (4), and retainer (9) pushes down spool (1).
(PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) through fine control hole (f') into drain chamber (D).
1st-line attachment PPC valve (with EPC valve) (PC-PL29-041-K-00-A)
(if equipped)
PPC: Abbreviation for Proportional Pressure Control
a For details of operation, see "Work equipment and swing PPC valve".
10-184 PC490LC-10
PPC valve

P1: To control valve (service valve 1 port)
P2: To control valve (service valve 1 port)
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
PC490LC-10 10-185
PPC valve
6. Block
7. Valve body
8. EPC valve
EPC valve (PC-PL2B-041-K-00-A)

(if equipped)

C: To PPC valve (R.H. attachment)
1. Valve body
2. Plug
3. Spool
4. Push pin
5. Coil
10-186 PC490LC-10
PPC valve
6. Plunger
7. Connector
Function (PC-PL2B-042-K-00-A)
• The EPC valve consists of the proportional solenoid part and the hydraulic valve part.
• When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the
amperage of current is generated and outputted to the control valve.
Operation (PC-PL2B-044-K-00-A)
When signal current is zero amp. (coil is de-energized)

• Since the signal current from the controller does not flow through coil (5), coil (5) is de-energized.
• Spool (2) is pushed to the right by spring (3).
• Port (P) is blocked, so the pressurized oil from the front pump does not flow to the control valve.
• The pressurized oil from the control valve is drained to the tank through port (C) and port (T).
PC490LC-10 10-187
PPC valve
10-188 PC490LC-10
PPC valve
When signal current is minute (coil is energized)

• When minute signal current flows through coil (5), coil (5) is energized and the thrust pushing plunger (6)
leftward is generated.
• Push pin (4) pushes spool (2) to the left, and the pressurized oil from port (P) flows to port (C).
• The pressure in port (C) increases and the combined force of the force applied on surface (a) of spool (2)
and the reaction force of spring (3) become larger than the thrust of plunger (6).
• Spool (2) is pressed to the right, so port (P) is disconnected from port (C) and port (C) is connected to port
(T).
• Spool (2) moves to a position where the thrust of plunger (6) is equal to the total of the force exerted by the
pressure in port (C) and the force of spring (3).
• Thus, the circuit pressure between the EPC valve and the control valve is controlled in proportion to the
amperage of the signal current.
PC490LC-10 10-189
PPC valve
When signal current is maximum (coil is energized)

• Coil (5) is energized when the signal current flows through coil (5).
• As the signal current is the maximum, the thrust of plunger (6) is also maximized.
• Spool (2) is pushed to the left by push pin (4).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and control valve is maximized.
• Port (T) is blocked, so no pressurized oil flows to the hydraulic tank.
10-190 PC490LC-10
Solenoid valve
Solenoid valve (PC400-PQPT-041-K-00-A)
a The figure shows the type for a machine ready for installing attachments.
A1: To PPC valve

A2: To swing motor 2-stage relief valve [Port (PU)]
PC490LC-10 10-191
Solenoid valve
A3: To control valve [Port (PST)]

A4: To travel motor [Port (Pi)]
A5: To swing motor [Port (B)]
A6: To control valve (boom valve) [Port (BP5)]
A7: To attachment circuit selector valve
A8: To control valve [Port (PX1 and PX2)]
ACC: To accumulator (for PPC circuit)
2. Swing 2-stage relief solenoid valve
7. Attachment selector solenoid valve (for machines ready for installation of attachment)
Solenoid valve
9. Coil (ON/OFF type)
10. Push pin
11. Spool
12. Spring
13. Plug
14. Sleeve
15. Block
Check valve
16. Plunger
17. Spring
18. Plug
Operation (ALL-PQPT-044-K-00-A)
Operation of check valve
• This valve is installed between port (P) and PPC solenoid valve. When the engine is stopped, the reaction
force of spring (2) pushes plunger (1) to the left and port (ACC) and port (P) is disconnected, thus holding
the pressure in the accumulator.
• When the engine is running, the pilot pressure in port (P) pushes plunger (1) to the right, and port (P) and
port (ACC) are interconnected.
10-192 PC490LC-10
Solenoid valve
Operation of solenoid valve
When solenoid valve is "de-energized" (circuit is disconnected)
• Coil (1) is de-energized when the signal current does not flow to coil (1).
• Spool (2) is pushed back to the left with the reaction force of spring (3).
• Port (P) and port (A) are disconnected and pilot oil does not flow from port (A) to the actuator. At the same
time, port (T) opens and oil from actuator is drained to the hydraulic tank.
When solenoid valve is "energized" (circuit is interconnected)
• Coil (1) is energized when the signal current flows to coil (1).
• Accordingly, spool (2) is pushed to the right by push pin (4).
• Port (P) and port (A) are open and pilot oil flows from port (A) to the actuator. At the same time, port (T)
closes and oil from actuator does not flow to the hydraulic tank.
PC490LC-10 10-193
Attachment circuit selector valve
Attachment circuit selector valve (PC300-PQJ3-041-K-00-A)
(if equipped)
PI: From attachment selector solenoid valve

V: To port of control valve for attachment 1
ACC: To accumulator
ATT: To attachment
TS: To hydraulic tank
1. Spool
Function (PC220-PQJ3-042-K-00-A)
• When the breaker is installed, return oil from the breaker is directly drained to the hydraulic tank bypassing
main valve with this valve.
• When the other attachment (crusher etc.) is installed, attachment circuit and main valve are
interconnected with this valve.
10-194 PC490LC-10
Operation (PC-PQJ3-044-K-00-A)
When attachment other than breaker is installed
• Spool (1) is pressed to the left by the force of spring (2).

• Port (ATT) is interconnected to port (V) and is disconnected from port (T). Thus, the attachment is
interconnected to the control valve.
PC490LC-10 10-195
When breaker is installed
• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is disconnected from port (V) and is interconnected to port (T).
• The pressurized oil returning from the breaker returns directly to the hydraulic tank via port (T) without
passing through the control valve.
10-196 PC490LC-10
Center swivel joint
Center swivel joint (PC300-J8E0-041-K-00-A)
PC490LC-10 10-197
Center swivel joint
A1: To L.H. reverse travel motor [Port (PB)]

A2: From control valve [port (A2)]
B1: To L.H. forward travel motor [Port (PA)]
B2: From control valve [port (B2)]
C1: To R.H. reverse travel motor [Port (PA)]
C2: From control valve [port (A5)]
D1: To R.H. forward travel motor [Port (PB)]
D2: From control valve [port (B5)]
DR1: From R.H. and L.H. travel motors [port (T)]
DR2: To hydraulic tank
E1: To R.H. and L.H. travel motors [port (Pi)]
E2: From travel speed acceleration valve
1. Cover
2. Rotor
3. Slipper seal
4. O-ring
5. Shaft
10-198 PC490LC-10
Accumulator
Accumulator (PC-PL40-001-K-00-A)
PPC accumulator (PC-PL40-041-K-00-A)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications (PC-PL40-030-K-00-A)
Gas to be used Nitrogen gas

Volume of gas (cc) 300
Charged pressure 1.18 {12}
(MPa {kg/cm2}) (at 80°C)
Max. operating pressure
6.86 {70}
(MPa {kg/cm2})
Function (PC-PL40-042-K-01-A)
• This accumulator is installed to the solenoid valve. Even if the engine is stopped while the work equipment
is raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of the
compressed nitrogen gas in the accumulator to operate the spool and lower the work equipment by its
own weight.
PC490LC-10 10-199
Work equipment
Work equipment (ALL-L000-001-K-00-A)
Work equipment (PC-L410-041-K-00-A)
1. Bucket
2. Bucket link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder
10-200 PC490LC-10
Work equipment shims
Work equipment shims (PC400-L413-040-K-00-A)

Outline
• There are two types of the work equipment shims; one is the iron shims and the other is the plastic shims.
• The work equipment shims are inserted so that the clearance in each joint of the work equipment will be
the standard value.
Function
Iron shims
• The iron shims are primarily inserted in the parts that need to be greased every 50 hours.
• One purpose of the iron shims is to reduce the play of the work equipment in the lateral direction.
a The shims need to be inserted on only the right or left side and do not need to be inserted on the
adjustment side, depending on the adjusting quantity of the clearance.
Plastic shims
• The plastic shims are primarily inserted in the parts that need to be greased every 500 hours.
• The purposes of the plastic shims are to reduce the play of the work equipment in the lateral direction and
prevent squeaks and scuffing caused by rubbing of the steel parts at the end faces of the joint portions.
• Combined with the greasing interval extension bushings, the plastic shims prevent squeaks caused by
lack of grease and extend the greasing intervals.
• The plastic shims are inserted in every contact face of each part so that the steel parts at the end faces of
the joint portion will not come in contact with each other.
a Combined with the greasing interval extension bushings and dust seals, the plastic shims extend the
greasing interval to 500 hours.
PC490LC-10 10-201
Bucket play adjustment shim
Bucket play adjustment shim (PC300-LBKB-040-K-00-A)

Outline
• The separated iron shims are used for the connection of arm and bucket.
• By adjusting the number of shims, play at connecting part can be adjusted.
a Play can be reduced with a mechanism by deleting some shims when the play becomes large.
10-202 PC490LC-10
Cab mount and cab tipping stopper
Cab and its attachments (ALL-K000-001-K-00-A)
Cab mount and cab tipping stopper (PC300-K138-041-K-00-A)
1. Front damper
2. Rear damper
3. Cab tipping stopper
Structure
• 4 dampers are located in front and rear of cab (2 each), and fix cab and floor frame onto revolving frame.
• Oil-filled damper is used to absorb vibration.
• Cab tipping stopper (3) installed at a place in the rear section aims to secure the cab when the machine
tips over.
• As shown in following table, various dampers are available upon its mounting location.
Color of identifying seal
Location of damper Bent of craw
(printing)
Front left Yes Red (205)
Front right Yes Red (205)
Rear left None Green (270)
Rear right None Green (270)
PC490LC-10 10-203
ROPS cab
ROPS cab (PC-K000-041-K-00-A)
a ROPS: Abbreviation for Roll-Over Protective Structure
1. Front window
2. Windshield wiper
3. Head lamp
4. Ceiling window
5. KOMTRAX communication antenna
6. KOMTRAX GPS antenna
7. Radio antenna
8. Door
9. Mirror
Function (PC220-K000-042-K-00-A)
• ROPS cab protects the operator fastening a seat belt from being crushed when the machine rolls over.
10-204 PC490LC-10
Electrical control system
Electrical system (ALL-RA1D-001-K-01-A)
Electrical control system (PC220-C050-001-K-00-A)
General system drawing (PC400-C050-051-K-00-A)
a Items marked with "*1" in drawing may or may not be installed.
PC490LC-10 10-205
10-206 PC490LC-10
PC490LC-10 10-207
Engine controller function (PC400-AK60-042-K-00-A)
1. Battery disconnect switch

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Engine shutdown secondary switch
9. Lock lever
10. PPC lock switch
11. Starting motor cut-off relay (for PPC lock)
12. Starting motor cut-off relay (for personal code)
13. Fuel control dial
14. Safety relay
15. Starting motor
16. Supply pump
17. Sensors
18. Machine monitor
19. KOMTRAX terminal
20. Pump controller
Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a The engine does not start until the lock lever is set to the LOCK position.
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal receives an engine cut command issued through external operation.
• When you cannot stop the engine due to stuck starting switch (6), engine shutdown secondary switch (7)
is usable for stopping the engine.
Start engine
• If starting switch (6) is turned to the ON position, engine controller (8) sends command current to fuel
supply pump (16).
10-208 PC490LC-10
For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an
electrical failure occurs.
• If starting switch (6) is turned to the START position when lock lever (9) is in the LOCK position, starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in the FREE position, starting motor cut-off relay (11) cuts off the starting current to
starting motor (15), thus the engine does not start. This is the neutral safety mechanism.
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the
signal to machine monitor (18).
Machine monitor (18) causes starting motor cut-off relay (12) to cut off the starting current to starting motor
(15), therefore the engine does not start.
Engine speed control

• Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8)
selects lower throttle signal, and sends command current to fuel supply pump (16).
Fuel supply pump (16) adjusts the fuel injection rate to control the engine speed.
Engine stopped
• If starting switch (6) is turned to the OFF position, the current from ACC terminal of starting switch (6) to
engine controller (8) is cut off, and consequently the command current to fuel supply pump (16) is cut off.
Fuel supply pump (16) stops fuel feed, decreasing the engine speed until the engine stops.
Stopping the engine with engine shutdown secondary switch

• If engine shutdown secondary switch (7) is turned to the Stop Engine position, the current from ACC
terminal of starting switch (6) to engine controller (8) is forcibly cut off.
Above induces the same state as when starting switch (6) is turned to the OFF position, stopping the
engine.
PC490LC-10 10-209
Engine and pump combined control function (PC400-C3W0-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
9. Machine monitor
10. Emergency pump drive switch
12. Supply pump
13. Sensors
10-210 PC490LC-10

16. One-touch power maximizing switch
17. Front pump oil pressure sensor
18. Rear pump oil pressure sensor
19. Oil pressure sensor
20. Oil pressure switch
21. Front pump
21a. Servo
21b. LS valve
21c. PC valve
22. Rear pump
22a. Servo
22b. LS valve
22c. PC valve
23. Control valve
23c.Travel junction valve
26. LS-EPC valve
27a. EPC valve
27b. Servo
Input/Output signal
a. Front pump PC-EPC valve drive signal
b. Rear pump PC-EPC valve drive signal
c. Solenoid valve GND
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Oil pressure sensor signal
h. One-touch power maximizing switch signal
i. Oil pressure switch signal
j. 1st throttle signal
k. Supply pump control signal
l. Sensor signals
m. Cooling fan pump EPC valve drive signal
Function
• This function allows the operator to select any of the six working modes of P, E, L, ATT-P, ATT-E and B
with the working mode selector switch of the machine monitor. The most suitable combination of engine
torque (T) and pump absorption torque can be selected depending on the work contents of the machine. If
None is selected for the attachment in the default setting of the service mode, one of the three modes of P,
E and L is selectable.
PC490LC-10 10-211
• The pump controller calculates the pump absorption upper limit torque based on the working mode, speed
setting by the fuel control dial, and actual engine speed, and controls the pump to maintain it near the
setting matching point for each mode even at high loads.
• When the engine speed is lowered, the controller prevents the engine from stopping by throttling the pump
absorption torque.
Control method in each mode

P, E, ATT-P and ATT-E modes
Max. matching point
Working mode Max. matching point
P and ATT-P (during work) 232 kW/1,720 rpm {312HP/1,720 rpm}
E and ATT-E (during work) 210 kW/1,720 rpm {281HP/1,720 rpm}
• In P, E, ATT-P and ATT-E modes, the engine speed is always controlled so that it is kept around the
matching point specified for each mode.
• At light loads, the engine operates at high speeds. As the load increases, the engine speed decreases
while the torque is increased, until the matching point with pump absorption torque upper limit (PT) is
reached. [See (1) in graph]
10-212 PC490LC-10
• As the load increases further, the engine speed decreases further. [See (2) in graph]
• The controller lowers the pump absorption upper limit torque (PT) to reduce the load on the engine. [See
(3) in graph]
• As the engine load decreases, the engine speed increases. [See (4) in graph]
• The controller raises the pump absorption upper limit torque (PT) to maintain it near the matching point.
[See (5) in graph]
• To save fuel consumption, the controller lowers the engine matching speed (Nm) at low loads (low delivery
and torque). [See (6) in graph]
B and L modes
Working mode Partial horsepower
B 83%
L 74%
Max. matching point
Working mode Max. matching point
B 193 kW/1,655 rpm {259 HP/1,655 rpm}
L 1171 kW/1,525 rpm {230HP/1,525 rpm}
PC490LC-10 10-213
• In B or L mode, engine horsepower is controlled to a constant level.

• The controller controls the pump absorption upper limit torque (PT) to keep the engine torque constant
along the equal engine horsepower curve.
Control function during travel

• Traveling the machine in E, ATT-E or B mode leaves the working mode unchanged, but raises the pump
absorption torque and engine speed (N) to values same as those in P mode.
• When traveling in L mode, the work mode and engine speed (N) remains unchanged, while the pump
absorption torque rises.
10-214 PC490LC-10
Control function that becomes available when emergency pump drive switch is turned on
• If the controller gets out of order and no work is possible because the main pump does not work properly,
operating emergency pump drive switch (1) temporarily enables to maintain functions of the machine with
absorption torques quite similar to those in the E mode.
In this case, a constant current flows from the battery to the PC-EPC valve, so the oil pressure sensing by
the PC-EPC valve only is performed.
a: Emergency (when abnormal)
b: Normal
PC490LC-10 10-215
a Emergency pump drive switch (1) is an alternative type. If the machine is operated at Emergency (a)
position when the machine is normal condition, action level L03 will be shown on the display.
10-216 PC490LC-10
Pump and valve control function (PC400-C3W1-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
12. Supply pump
13. Sensors
PC490LC-10 10-217

16. Front pump
16a. Servo
16b. LS valve
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
18d. Main relief valve
18e. Variable back pressure valve
21. LS-EPC valve
22. Pump merge-divider EPC valve (for main spool)
23. Pump merge-divider EPC valve (for LS spool)
26. Variable back pressure solenoid valve
27a. EPC valve
27b. Servo
Input/Output signal
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Pump merge-divider EPC valve (for main spool) drive signal
h. Pump merge-divider EPC valve (for LS spool) drive signal
i. Travel junction solenoid valve drive signal
j. 2-stage relief solenoid valve drive signal
k. Variable back pressure solenoid valve drive signal
l. 1st throttle signal
m. Supply pump control signal
n. Sensor signals
o. Cooling fan pump EPC valve drive signal
Function
• The LS control function, cut-off function, and 2-stage relief function enable the machine to maintain the
optimum matching under various working conditions.
10-218 PC490LC-10
LS control function
• According to the actuator operation, the output pressure from the LS-EPC valve to LS valve varies in order
to change the selector point for pump delivery amount [LS differential pressure (DLS) setting] in the LS
valve.
• The build-up time of pump delivery amount will be optimized, and the ease of combined operation and fine
control will be improved.
A: 0 MPa {0 kg/cm2}
B: EPC pressure (Psig) = 2.6 MPa {27 kg/cm2}
Cut-off function
• PC-EPC current (J) is increased and the flow at relief is decreased to minimize fuel consumption.
Operating condition for turning on cutoff function
When the one-touch power maximizing function is not activated and the average of front pump and rear
pump oil pressure sensor values is 27.5 MPa {279 kg/cm2} or higher.
The cut-off function does not work, however, while the machine is travelling in P mode, swing lock switch is
in the ON position.
A: PC-EPC current at cutoff

2-stage relief function
• If the operating conditions of 2-stage relief function are met, relief pressure during work increases.
Operating conditions for 2-stage relief function Relief pressure
• When traveling
• Swing lock switch is ON. 34.8 MPa {355 kg/cm2}
• At boom LOWER operation O
• When one-touch power maximizing function is turned on 37.2 MPa {380 kg/cm2}
• When L mode is selected
Variable back pressure function

• Set pressure of the back pressure valve varies depending on the operating conditions of the machine.
PC490LC-10 10-219
Operating conditions Setting of back pressure valve

When swinging and travelling High-pressure setting
When operation other than swinging or travelling Low-pressure setting
One-touch power maximizing function (PC400-PT23-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
12. Supply pump
13. Sensors
14. One-touch power maximizing switch
10-220 PC490LC-10

17. Front pump
17a. Servo
17b. LS valve
17c. PC valve
18. Rear pump
18a. Servo
18b. LS valve
18c. PC valve
19. Control valve
Input/Output signal
d. CAN signal
e. 2-stage relief solenoid valve drive signal
f. Pump oil pressure sensor signal
g. One-touch power maximizing switch signal
h. 1st throttle signal
i. Supply pump control signal
j. Sensor signals
Function
• By operating the one-touch power maximizing switch on the L.H. work equipment control lever knob, the
power is maximized for a limited time.
• This can be used when extra digging force is needed for a while, for example, when digging out a rock
during excavating work.
• If the one-touch power maximizing switch is pressed in P mode, E mode, ATT-P mode or ATT-E mode
when the load pressure is high, the hydraulic force will increase by approx. 7%, thereby boosting the
digging force.
• The functions are automatically set as follows.
Function Setting
Engine and pump combined control Matching at rated output point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Cut-off function Cancel
PC490LC-10 10-221
a This function maintains the power maximizing operation as long as one-touch power max. switch (1) is
pressed. This function, however, is cancelled in about 8.5 seconds regardless of pressing of the switch.
Machine push-up function (PC400-PTL1-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
10-222 PC490LC-10
7. Pump controller
9. Machine monitor
12. Supply pump
13. Sensors
14. Machine push-up switch
17. Front pump
17a. Servo
17b. LS valve
17c. PC valve
18. Rear pump
18a. Servo
18b. LS valve
18c. PC valve
19. Control valve
24. Suction-safety valve
25. Boom valve
26. Boom cylinder
Input/Output signal
d. CAN signal
e. 2-stage relief solenoid valve drive signal
f. Pump oil pressure sensor signal
g. One-touch power maximizing switch signal
j. Sensor signals
PC490LC-10 10-223
Function
• This function allows increasing the boom press force by use of machine push-up switch (1).
• Use it when you want to increase press force of the boom in ditching or mass excavation in hard ground.
Function Setting
Boom cylinder head
OFF Safety valve set pressure
14.7 MPa {150 kg/cm2}
Boom cylinder head
ON Safety valve set pressure
28.4 MPa {290 kg/cm2}
Auto-deceleration function (PC400-AF60-042-K-00-A)
1. Pump controller
3. Machine monitor
10-224 PC490LC-10
5. Supply pump
6. Sensors
9. Main pump
10. Control valve
Input/Output signal
a. CAN signal
b. Oil pressure sensor signal
c. Oil pressure switch signal
d. 1st throttle signal
e. Supply pump control signal
f. Sensor signals
Function
• When all the control levers are set to NEUTRAL for waiting for a dump truck or work, the engine speed is
automatically reduced to a controlled speed, and fuel consumption and noise are lowered.
• When any control lever is operated, the engine speed returns immediately to the speed that is set by the
fuel control dial.
Operation
Control lever: NEUTRAL

• If all control levers are in NEUTRAL position for 4 seconds or more while the engine runs at a speed
higher than approx. 1,000 rpm, the engine speed is decelerated to approx. 1,000 rpm and held at this level
until any control lever is operated.
When any control lever is operated

• If any control lever is operated when the engine speed is maintained at the controlled speed (approx.
1,000 rpm), the engine speed increases immediately to the speed set with the fuel control dial.
A: All work equipment control levers in NEUTRAL

B: All work equipment control levers in OPERATED
C: Fuel control dial set speed
D: Controlled engine speed (approx. 1,000 rpm)
E: 4 seconds
PC490LC-10 10-225
F: Max. 2 seconds
G: Max. 1 second
Engine automatic warm-up function (PC400-AP13-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
10. Air conditioner unit
10-226 PC490LC-10

13. Supply pump
14. Sensors
15. Hydraulic oil temperature sensor
16. Front pump
16a. Servo
16b. LS valve
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
21a. EPC valve
21b. Servo
Input/Output signal
d. CAN signal
e. Hydraulic oil temperature signal
f. 1st throttle signal
g. Supply pump control signal
h. Sensor signals
i. Cooling fan pump EPC valve drive signal
Function
• Raises the engine speed automatically to warm up the engine if the coolant temperature is low after start-
up of the engine.
Operational conditions (all required) Operation

Coolant temperature: Max. 30 °C o
Engine speed: 1,250 rpm
Engine speed: Max. 1,250 rpm
O
Cancellation conditions (either one required) Disableed
Coolant temperature: Min. 30 °C
Auto Duration of automatic warming-up: Min. o
10 minutes Engine speed: as desired
Fuel control dial: Held at over 70% of
Manual full speed (MAX) for 3 seconds or more
PC490LC-10 10-227
Overheat prevention function (PC400-B717-042-K-00-A)
a See "Engine automatic warm-up function" section for system circuit diagram.
• Prevents overheat to protect the engine and hydraulic components by reducing load on the pump and
lowering the engine speed if the coolant or hydraulic oil temperature becomes too high.
Operating Operation and actions

Conditions for cancellation
condition taken
Hydraulic oil temperature: Below 95
Work mode: Travel °C
Hydraulic oil o o
Engine speed: Remains • Under above condition, controller
temperature: Min. unchanged.
95 °C is returned to the condition
Travel speed: Down before operation of function
(automatic reset).

condition taken
Working mode: P, E,
ATT-P and ATT-E modes
Coolant Coolant temperature: Max. 95 °C
temperature: Min. Engine speed: Remains
Hydraulic oil temperature: Max. 95 °
100 °C unchanged.
o o C
or • Sends torque control
• Under above condition, controller
signal to lower the
Hydraulic oil is returned to the condition
pump absorption
temperature: Min. before operation of function
torque and reduce
100 °C (automatic reset).
the load on the
engine.

condition taken
Working mode: P, E,
ATT-P and ATT-E modes
Coolant Coolant temperature: Max. 102 °C
temperature: Min. Engine speed: Remains
Hydraulic oil temperature: Max. 102
102 °C unchanged.
o o °C
or • Sends torque control
• Under above condition, controller
signal to lower the
Hydraulic oil is returned to the condition
pump absorption
temperature: Min. before operation of function
torque and reduce
102 °C (automatic reset).
the load on the
engine.

condition taken
Working mode: B mode
Engine speed: Remains Coolant temperature: Max. 102 °C
Coolant
unchanged.
temperature: Min. Hydraulic oil temperature: Max. 102
102 °C o Alarm monitor: Lights up o °C
or • Sends torque control • Under above condition, controller
signal to lower the is returned to the condition
Hydraulic oil
pump absorption before operation of function
temperature: Min.
torque and reduce (automatic reset).
102 °C
the load on the
engine.
10-228 PC490LC-10

condition taken
Coolant temperature: Max. 105 °C
Coolant Hydraulic oil temperature: Max. 105
temperature: Min. Working mode: Any °C
105 °C o mode o Fuel control dial: Returns to low idle
or Engine speed: Low idle (MIN) position.
Hydraulic oil Alarm monitor: Lights up • Under above condition, controller
temperature: Min. Alarm buzzer: Sounds is returned to the condition
105 °C before operation of function
(manual reset).
Turbocharger protection function (PC400-AA90-042-K-00-A)
a See "Engine automatic warm-up function" section for system circuit diagram.
• Prevents seizure of the turbocharger by limiting the engine speed if the engine speed is increased
exponentially when starting the engine.
Operating condition Operation

o Turbocharger protection
Engine oil pressure: below 50 kPa {0.51 kg/cm2}
(See the following figure.)
A: Start engine
B: Duration of turbocharger protection (approximately 0 – 20 sec.)
C: Modulating time (approx. 1 sec.)
D: 500 rpm
E: Approx. 1,000 rpm
F: 1,770 rpm(*1)
*1: Working mode: P mode
Fuel control dial: When full speed (MAX) position travel lever is operated
PC490LC-10 10-229
Swing control function (PC400-JA01-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. swing brake cancel switch
7. Swing lock switch
8. Pump controller
9. Machine monitor
12. Main pump
13. Control valve
14. Swing motor
14a. 2-stage relief valve
16. 2-stage swing relief solenoid valve
Input/Output signal
a. Swing holding brake cancel signal
b. Swing holding brake solenoid valve drive signal
c. CAN signal
d. Solenoid valve GND
e. 2-stage swing relief solenoid valve drive signal
f. Oil pressure sensor signal
10-230 PC490LC-10
g. Oil pressure switch signal
Function
Swing lock and swing holding brake function
• On machines with swing lock (manual), swing can be locked at any position by turning swing lock switch
(1) to the ON position.
• Interlocked with the swing operation, the swing holding brake (auto lock) prevents hydraulic drift from
occurring after the swing stops.
• Interlocked with the L.H. and R.H. work equipment control levers and attachment control pedals
operations, the swing holding brake is canceled to reduce the load on the swing equipment during
excavation work.
Swing lock switch OFF ON

Swing lock monitor Off Lights up
Function Swing holding brake Swing lock
• When the L.H. and R.H. work equipment
control levers and attachment control • Swing holding brake applies and
pedals are set to NEUTRAL, the swing locks the swing.
holding brake works in approx. 7 sec. • Even if the L.H. work equipment
Operation • When the L.H. and R.H. work equipment control lever is operated for swing,
control levers or attachment control the swing holding brake cannot be
pedals are operated, the swing holding canceled, and the upper structure
brake is canceled and the upper does not swing.
structure becomes free to swing.
A: When work equipment control lever or attachment control pedal is operated (Swing brake canceled)
B: When work equipment control levers and attachment control pedals are in the NEUTRAL position
C: Swing holding brake applied
D: Approx. 7 sec.
PC490LC-10 10-231
Swing holding brake release function

• If the controller gets out of order and no swing is possible because the swing holding brake does not work
properly, operating swing brake cancel switch (2) releases the swing holding brake and allows swing
operation.
a: Release (Emergency)
b: Normal
Swing holding brake Release Normal
cancel switch (When controller has trouble) (When the controller is normal)
Swing lock switch ON OFF ON OFF
Swing lock canceled Swing holding brake

Swing brake Swing lock works Swing lock works
(*) works
*1: Hydraulic brake applied by relief valve.
a Even if swing brake cancel switch (2) is set to the CANCEL (a) position, swing holding brake is not
released while swing lock switch is set to the ON position.
a When the swing holding brake is released, only the hydraulic brake with the relief valve is effective for
holding the upper structure. So, note that, when the swing stops on a slope, a hydraulic drift may occur.
a Swing brake cancel switch (2) is of the alternative type. When the switch is turned to the CANCEL (a)
position, the swing lock monitor in the machine monitor blinks.
Quick warm-up function

• If swing lock switch (1) is turned to the ON position, the pump cut-off function is cancelled and the main
relief pressure increases.
• If the work equipment is relieved with the main relief pressure increased, the hydraulic oil temperature
increases quickly and the warm-up time can be shortened.
Operating condition Main relief pressure
34.8 MPa {355 kg/cm2}
• Swing lock switch: ON O
37.2 MPa {380 kg/cm2}
10-232 PC490LC-10
2-stage swing relief function

• During swing acceleration, the set pressure of the 2-stage swing relief valve is changed to decrease the
flow rate to hydraulic relief and improve the fuel consumption ratio.
Operating condition Flow rate to hydraulic relief
• During swing acceleration 260 l/min
(excluding sharp change operation of swing O
direction) 100 l/min
Relation between set pressure and flow
A: Pilot pressure blocked (low-pressure setting)

B: Pilot pressure applied (high-pressure setting)
P: 27.9 MPa {285 kg/cm2}
Q1: 260 l/min
Q2: 100 l/min
Characteristics of 2-stage relief valve
A: Oil flow at low-pressure setting

B: Oil flow at high-pressure setting
C: Flow necessary for swing
Z: Area where the loss by relief flow is reduced (fuel consumption improved)
PC490LC-10 10-233
Travel control function (PC400-C7H1-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Supply pump
6. Sensors
10. Travel alarm
11. Front pump
11a. Servo
11b. LS valve
11c. PC valve
12. Rear pump
12a. Servo
12b. LS valve
12c. PC valve
10-234 PC490LC-10
13. Control valve

14. Travel motor
17. LS-EPC valve
Input/Output signal
a. Oil pressure sensor signal
b. CAN signal
c. LS-EPC valve drive signal
d. Solenoid valve GND
e. Travel junction solenoid valve drive signal
f. Travel speed increase solenoid valve drive signal
g. Oil pressure sensor signal
h. Travel alarm buzzer operation signal
i. 1st throttle signal
j. Supply pump control signal
k. Sensor signals
Function
Travel speed selection function
1. Travel speed manual change
• Switching the travel speed selector switch to Hi, Mi or Lo changes the motor capacity, which changes
the machine travel speed.
Travel speed selector switch Lo (low speed) Mi (medium speed) Hi (high speed)
Motor flow rate (%) 90 80 100
Motor capacity Max. Min. Min.
Travel speed (km/h) 3.0 4.2 5.5
2. Travel speed automatic change
1) Automatic selection according to engine speed
• If you adjust the engine speed to 1,200 rpm or less with the fuel control dial, the travel speed does
not switch to Hi when the machine is traveling in Mi, and automatically changes to Mi when the
machine is travelling in Hi.
2) Automatic change by pump delivery pressure
• If the travel circuit oil pressure increases on an uphill with the travel speed selector switch in Hi, and
the travel circuit oil pressure of 32.3 MPa {330 kg/cm2} or above continues for 0.5 seconds or more,
the travel motor capacity is switched to that for medium speed travel (equivalent to Mi)
automatically (the travel speed switch position remains in Hi).
• If the travel circuit oil pressure decreases on a level ground or downhill during low speed travel
caused by the automatic speed change due to increase in the load on the travel circuit, and the
travel circuit oil pressure of 18.6 MPa {190 kg/cm2} or below continues for 0.5 seconds or more, the
travel motor capacity is switched back to that for speed of Hi automatically.
PC490LC-10 10-235
A: 18.6 MPa {190 kg/cm2}

B: 32.3 MPa {330 kg/cm2}
C: Min. 0.5 sec.
D: Min. 0.5 sec.
Function to control pump during travel
a See "Engine and pump combined control function" for details.
Travel junction function

• The controller detects the pilot pressure when travel control lever is operated, and judges the operator's
intention, the straight travel or turning operation.
• For straight-travel, a signal is sent to the travel interconnection solenoid valve, controlling the pump flow
between the right and left to be equal, to prevent travel deviation and improve straight-travel ability.
• For turning operation, the signal to the travel junction solenoid valve is shut off. This separates the pump
flow rate to the right and left travel motors from each other and improves the traction while turning.
PPC lock function (PC400-PX16-042-K-00-A)
10-236 PC490LC-10

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Main pump
10. Control valve
Function
• Interlocked with the lock lever, PPC lock switch is turned off when the lock lever is moved to the LOCK
position.
• When the PPC lock switch is turned off, current to the PPC lock solenoid valve is shut off. Even if each
control lever or pedal is operated, the work equipment and machine do not move.
Oil flow adjuster function for attachment (PC400-PT24-042-K-00-A)
(for machine with provision for attachment)
PC490LC-10 10-237

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
12. Supply pump
13. Sensors
15. Front pump
15a. Servo
15b. LS valve
15c. PC valve
16. Rear pump
16a. Servo
10-238 PC490LC-10
16b. LS valve
16c. PC valve
17. Control valve
18. Attachment selector solenoid valve
20. Oil flow adjuster EPC valve for attachment
23. Attachment circuit selector valve
24. Attachment
25. Accumulator
Input/Output signal
d. CAN signal
e. Attachment selector solenoid valve drive signal
f. Oil flow adjuster EPC valve drive signal for attachment
g. Oil pressure switch signal
j. Sensor signals
Function
• Setting of the working mode and oil flow rate on the machine monitor controls the oil flow to the
attachment when the attachment control pedal is fully depressed.
• Attachment operation switches depending on the working mode as shown below.
Working mode Attachment operation
ATT–P, ATT–E Double-acting
B Single-acting
PC490LC-10 10-239
Hydraulic fan control function (PC400-B440-001-K-00-A)

Fan rotation control (PC400-B440-042-K-00-A)
2. Coolant temperature sensor
3. Engine speed sensor
5. Main pump
6. Cooling fan pump
6a. Servo
6b. EPC valve
7. Pump controller
8. Self-pressure reducing valve
10-240 PC490LC-10
11. Cooling fan
Input/Output signal
a. Hydraulic oil temperature sensor signal
b. CAN signal (coolant temperature sensor signal and engine speed sensor signal)
c. Cooling fan speed sensor signal
Function
• Fan speed is controlled by engine speed, hydraulic oil temperature and coolant temperature.
• Decreasing fan speed when these temperatures are low reduces noises and consumption of extra fuel.
Engine output control (PC400-B440-042-K-01-A)
2. Coolant temperature sensor
3. Engine speed sensor
5. Main pump
6. Cooling fan pump
6a. Servo
6b. EPC valve
7. Pump controller
8. Self-pressure reducing valve
11. Cooling fan
Input/Output signal
a. Hydraulic oil temperature sensor signal
PC490LC-10 10-241
b. CAN signal (coolant temperature sensor signal and engine speed sensor signal)
c. Cooling fan speed sensor signal
• Pump controller calculates horse power consumed by fan. It controls engine output power curves (A) and
(B) by controlling fan speed to prevent consumption of extra fuel.
• Consumption of engine output (when fan speed changes)

Fan reverse rotation function (PC400-B440-042-K-02-A)
1. Cooling fan
4. Reversible valve
5. Solenoid valve
6. Pump controller
7. Cooling fan pump
7a. Servo
7b. EPC valve
10-242 PC490LC-10
8. Machine monitor
Input/Output signal
a. Cooling fan speed sensor signal
b. Cooling fan reverse signal
c. Control signal of cooling fan pump flow rate
d. CAN signal
• The cooling devices can be cleaned easily by rotating the fan in reverse.
• The fan rotation direction is reversed by operating the machine monitor.
• Upon receiving fan reverse signal from the machine monitor, the pump controller drives the fan reverse
rotation ON/OFF solenoid valve to switch the reversible valve. As a result, the fan rotates in a reverse
direction.
• The fan speed during reverse rotation is controlled based on only the engine speed, regardless of the
ambient temperature, hydraulic oil temperature, and coolant temperature.
• The auto-deceleration function is canceled during the fan reverse operation. Accordingly, the engine
speed does not lower even if the levers are set in NEUTRAL.
• Since the main pump delivery is minimized, the normal operation of the machine cannot be performed.
System component parts (ALL-RA1C-001-K-00-A)
Engine controller (PC220-AP70-041-K-00-A)
Engine controller input and output signals (PC400-AP70-03C-K-00-A)

• The following is the list of the symbols used for signal classification in the input/output signal table.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-CE01)]
PC490LC-10 10-243
Pin No. Signal name Signal category

1 (*1) –
2 Engine oil pressure sensor B
3 Crankcase pressure sensor B
4 (*1) –
5 Charge temperature sensor B
6 Intake temperature MAF sensor B
7 CAN_C(+) E
8 CAN_B(+)(KOMNET/r) E
9 Bkup (camshaft) speed sensor (+) B
10 (*1) –
11 (*1) –
12 (*1) –
13 GND C
14 Coolant temperature sensor B
15 Charge pressure sensor B
16 Ambient pressure sensor B
17 CAN_C(-) E
18 CAN_B(-)(KOMNET/r) E
19 (*1) –
20 (*1) –
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow sensor B
24 (*1) –
25 (*1) –
26 Ne (crankshaft) speed sensor (+) B
27 (*1) –
28 (*1) –
29 (*1) –
30 (*1) –
31 (*1) –
32 (*1) –
33 (*1) –
34 (*1) –
35 (*1) –
37 NE (crankshaft) speed sensor (-) C
38 (*1) –
39 (*1) –
40 (*1) –
41 (*1) –
42 (*1) –
43 Injector #4 (+) D
49 (*1) –
50 (*1) –
51 (*1) –
52 (*1) –
10-244 PC490LC-10
Pin No. Signal name Signal category

53 Injector #4 (–) C
59 GND C
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(2)[ECM J2(CN-CE02)]
Pin No. Signal name Input/output
1 Supply pump #2 (–) C
2 Supply pump #2 (+) D
3 (*1) –
4 Supply pump #1 (–) C
5 Supply pump #1 (+) D
6 EGR actuator (+) D
7 (*1) –
8 Fuel dozer solenoid valve #2 (+) D
9 Fuel dozer solenoid valve #1 (+) D
10 KVGT actuator (+) D
11 (*1) –
12 (*1) –
13 (*1) –
14 (*1) –
15 (*1) –
16 EGR actuator (-) C
17 (*1) –
18 GND C
19 (*1) –
20 KVGT actuator (-) C
21 GND C
22 (*1) –
23 (*1) –
24 CAN_B(+) E
25 CAN_B(-) E
26 (*1) –
27 (*1) –
28 (*1) –
29 (*1) –
30 Power supply of dosing fuel pressure sensor (5 V) A
31 Power supply of common rail pressure sensor (5 V) A
32 KVGT speed sensor (+) B
33 KVGT speed sensor (-) C
34 (*1) –
35 (*1) –
36 Dosing fuel pressure sensor B
37 (*1) –
38 KVGT position sensor B
39 (*1) –
40 (*1) –
PC490LC-10 10-245

41 (*1) –
42 (*1) –
43 (*1) –
44 (*1) –
45 (*1) –
46 (*1) –
47 GND C
48 (*1) –
49 (*1) –
50 HC dozing solenoid (+) D
51 (*1) –
52 (*1) –
53 (*1) –
54 (*1) –
55 Common rail pressure sensor B
56 (*1) –
57 (*1) –
58 (*1) –
59 EGR valve lift sensor B
60 HC dozing solenoid (-) C
DRC26-60P(3)[CN-CE03]
1 Electric power supply (24 V) A
2 Electric power supply (24 V) A
3 Starting switch ACC signal B
4 Electrical intake air heater relay (+) D
5 (*1) –
6 (*1) –
7 (*1) –
8 (*1) –
9 System operating lamp (in-use signal) D
10 (*1) –
11 Unswitched power supply (24 V) A
12 Unswitched power supply (24 V) A
13 (*1) –
14 Dozing pump relay drive D
15 (*1) –
16 (*1) –
17 CAN_A(+)(KOMNET/c) E
18 CAN_A(-)(KOMNET/c) E
19 Sensor GND C
20 (*1) –
21 GND (return from power supply) C
23 (*1) –
24 (*1) –
25 (*1) –
26 (*1) –
27 (*1) –
28 (*1) –
10-246 PC490LC-10

29 (*1) –
30 (*1) –
33 (*1) –
34 (*1) –
35 (*1) –
36 (*1) –
37 (*1) –
38 (*1) –
39 (*1) –
40 (*1) –
41 Fuel control dial GND C
42 Fuel control dial power supply (5 V) A
43 KDPF pressure sensor GND C
44 (*1) –
45 KDOC inlet temperature sensor B
46 (*1) –
47 (*1) –
48 KDOC outlet temperature sensor B
49 (*1) –
50 (*1) –
51 Fuel control dial B
52 KDPF pressure sensor power supply (5 V) A
53 (*1) –
54 KDPF outlet temperature sensor B
55 KDPF differential pressure sensor B
56 (*1) –
57 (*1) –
58 KDPF outlet pressure sensor B
59 (*1) –
60 (*1) –
PC490LC-10 10-247
Pump controller (PC-C3V1-041-K-00-A)
Input and output signals (PC400-C3V1-03C-K-00-A)

AMP-81P[CN-CP01]
1 Unswitched power supply (24 V) Input
2 Unswitched power return Input
3 Window washer Output
4 Unswitched power supply (24 V) Input
5 Unswitched power return Input
6 Potentiometer power supply (5 V) Output
7 CAN(R)_H Input/output
8 Service oil pressure sensor Input
9 (*1) –
10 (*1) –
11 Front pump oil pressure sensor Input
12 R.H. swing PPC oil pressure sensor Input
13 Boom LOWER PPC oil pressure switch Input
14 Arm IN PPC oil pressure sensor Input
15 L.H. travel REVERSE PPC pressure sensor Input
16 (*1) –
17 (*1) –
10-248 PC490LC-10

18 GND (analog signal) –
19 (*1) –
20 Swing lock switch Input
21 Model Select 3 Input
22 (*1) –
23 (*1) –
24 Starting switch ACC signal Input
25 Fan speed sensor –
26 CAN(R)_L Input/output
27 (*1) –
28 Hydraulic oil temperature sensor Input
29 (*1) –
30 Rear pump oil pressure sensor Input
31 L.H. swing PPC oil pressure sensor Input
32 Boom RAISE PPC oil pressure sensor Input
33 (*1) –
34 L.H. travel FORWARD PPC oil pressure sensor Input
35 Service PPC oil pressure switch Input
36 (*1) –
37 (*1) –
38 (*1) –
39 Swing holding brake cancel switch Input
41 (*1) –
42 One-touch power max. switch Input
44 Pulse signal return –
45 CAN(C)_H Input/output
46 GND (analog signal) Input
47 (*1) –
48 (*1) –
49 Front pump swash plate sensor Input
50 Bucket DUMP PPC oil pressure sensor Input
51 Arm OUT PPC oil pressure sensor Input
52 (*1) –
53 R.H. travel reverse oil pressure sensor Input
54 (*1) –
55 (*1) –
56 Wiper motor reverse (W) Input
57 (*1) –
60 (*1) –
61 Starting switch C signal Input
62 External drive signal Input
63 NC –
64 CAN(C)_L Input/output
65 (*1) –
66 (*1) –
67 (*1) –
68 Rear pump swash plate sensor Input
69 Bucket CURL PPC oil pressure sensor Input
PC490LC-10 10-249

70 (*1) –
71 (*1) –
72 R.H. travel FORWARD PPC oil pressure sensor Input
73 (*1) –
74 (*1) –
75 Wiper motor stop (P) Input
76 Cab front window open limit switch Input
78 (*1) –
79 PPC lock switch Input
81 (*1) –
AMP-40P[CN-CP02]
82 (*1) –
83 (*1) –
84 (*1) –
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 (*1) –
88 LS-EPC valve Output
89 Merge-divider EPC valve (LS) Output
90 (*1) –
91 (*1) –
92 (*1) –
93 Travel speed increase solenoid valve Output
94 2-stage relief solenoid valve Output
95 (*1) –
96 Front pump PC-EPC valve Output
97 Oil flow adjusting EPC valve for attachment Output
98 (*1) –
99 (*1) –
100 System-in-use signal Output
101 Swing holding brake solenoid valve Output
102 (*1) –
103 Fan pump EPC valve –
104 Rear pump PC-EPC valve Output
105 (*1) –
106 (*1) –
107 Travel alarm Output
108 Battery relay drive Output
109 2-stage relief solenoid valve Output
110 (*1) –
111 (*1) –
112 Merge-divider EPC valve (main) Output
113 Variable back pressure solenoid valve Output
114 Wiper motor (-) Output
115 GND (solenoid) Input
116 Solenoid power supply Input
10-250 PC490LC-10

119 Wiper motor (+) Output
Fuel control dial (PC-AGJ7-041-K-01-A)
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function (PC400-AGJ7-042-K-00-A)
• This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate.
• As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes
and a throttle signal is sent to the engine controller.
• The hatched areas in the graph are the error detection areas. If the throttle voltage is within the area, the
engine speed drops down to low idle.
PC490LC-10 10-251
Resistor for PC-EPC valve (PC-C3VR-041-K-00-A)
a PC: Abbreviation for Pressure Compensation

a EPC: Abbreviation for Electromagnetic Proportional Control
1. Resistance
2. Connector
Specifications (PC220-C3VR-030-K-00-A)
Resistance: 20 z
Function (PC-C3VR-042-K-00-A)
• When the emergency pump drive switch or the emergency work equipment drive switch is turned to "ON"
position, this resistor sends an electric current to each PC-EPC valve that is appropriate for their condition.
a No electric current flows in the normal condition.
CAN terminating resistor (PC220-Q2V1-041-K-00-A)
a CAN: Abbreviation for Controller Area Network
10-252 PC490LC-10
1. Connector (with built-in resistor)
Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z
Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.
PC490LC-10 10-253
Machine monitor system
Machine monitor system (PC-Q170-042-K-01-A)
1. Machine monitor
2. Battery
3. Pump controller
5. Air conditioner controller
6. KOMTRAX terminal
7. Sensors and switches
8. Wiper motor and window washer motor
9. Camera
Input and output signals
a. Power supply
b. CAN signal
c. Sensor and switch signals
d. Drive signal
e. Camera signal
Function
• The monitor system keeps the operator informed of all machine functions, by monitoring the machine
conditions by using the sensors and switches installed in various parts of the machine and processing
them instantly to display on the machine monitor.
10-254 PC490LC-10
The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has trouble
2. Machine status display (coolant temperature, hydraulic oil temperature, fuel level, etc.)
3. Display of camera image
• The switches on the machine monitor have an operating function to control the machine.
Machine monitor (PC-Q180-042-K-01-A)
Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If a failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.
Precautions on the machine monitor display

• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this
is not a failure or a defect. Products having 10 or less black or bright spots conform the product
specification; such the condition is quite normal.
• When the engine is started, the battery voltage may drop suddenly, depending on the ambient
temperature and the condition of the battery. In this case, the machine monitor display may go off for a
moment. However, this phenomenon is not a failure.
• Continuous operation of the machine monitor may display blue bright spots on the screen having a black
background; it is quite normal.
Blue bright spots can never be a problem as the screen has usually blue or white background. (White in
the LCD is made up of red, green and blue.)
Input and output signals (PC-Q180-03C-K-00-A)

070-18P[CN-CM01]
PC490LC-10 10-255
Pin No. Signal name Input/Output signal

1 Continuous power supply (24 V) Input
2 Continuous power supply (24 V) Input
3 GND (continuous power supply) -
4 GND (continuous power supply) -
5 External start signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) -
8 (*1) -
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 (*1) -
14 (*1) -
15 Fuel level sensor Input
16 Charge level (Alternator R terminal) Input
17 (*1) -
18 (*1) -
070-12P [CN-CM02]
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input
4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 Quick coupler Input
7 CAN (C) terminating resistor terminal -
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 CAN (R) terminating resistor terminal -
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output
070-20P [CN-CM03]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
10-256 PC490LC-10

16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
070-8P [CN-CM04]
1 Camera power supply (8 V) Output
2 Camera NTSC signal 1 Input
5 GND (Camera power supply) -
6 Switching camera 2 to original/mirror image Output
7 Switching camera 3 to original/mirror image Output
8 Shield GND -
PC490LC-10 10-257
Display (PC400-Q1LA-042-K-00-A)
A: Standard screen
B: Check before starting screen
C: Screen with maintenance time reminder
D: Warning screen
E: Guidance screen
F: Camera image screen
a Camera image screen (F) shown in the figure is an example when two or more cameras are installed
1. Message monitor
2. KDPF regeneration monitor
3. Engine stop monitor
4. Seat belt monitor
5. Air conditioner monitor
6. Wiper monitor
10-258 PC490LC-10
7. Swing lock monitor

8. Preheating monitor
9. Service meter
10. Auto-deceleration monitor
11. Working mode monitor
12. Travel speed monitor
13. Fuel level gauge
14. Fuel level monitor
15. ECO gauge
16. Fuel consumption gauge
17. Hydraulic oil temperature monitor
18. Hydraulic oil temperature gauge
19. Engine coolant temperature monitor
20. Engine coolant temperature gauge
21. Radiator coolant level monitor
22. Charge level monitor
23. Engine oil pressure monitor
24. Engine oil level monitor
25. Air cleaner clogging monitor
26. Water separator monitor
27. Clock
28. Maintenance time warning monitor
29. System condition monitor
30. Action level monitor
31. Guidance icon
Gauge
Gauge Item displayed Description Remarks
Tempera- Back- • Indicates corresponding
Range ground temperature range.
ture(°C)
color • Alarm buzzer sounds when the
(*1) W1 105 Red temperature is 105 °C or higher.
Engine coolant W2 102 Red • If the monitor background
temperature appears white, warm up the
W3 100 Blue
gauge engine.
W4 85 Blue
W5 60 Blue
W6 30 White
Tempera- Back- • Indicates corresponding
Range ground temperature range.
ture(°C)
color • Alarm buzzer sounds when the
(*1) H1 105 Red temperature is 105 °C or higher.
Hydraulic oil H2 102 Red • If the monitor background
temperature appears white, warm up the
H3 100 Blue
gauge hydraulic components.
H4 85 Blue
H5 40 Blue
H6 20 White
PC490LC-10 10-259

Back- • Indicates corresponding fuel
Range Quantity (l) ground level.
color
(*1) F1 511 Blue
Fuel level F2 381 Blue
gauge F3 295 Blue
F4 148 Blue
F5 114 Blue
F6 76 Red
Segment Load level • Indicates instantaneous fuel
Light to consumption (average of fuel
Green 1 to 8 consumption per 3 minutes) in
medium
(*2) 10 steps.
ECO gauge (It is displayed when the user
Orange 9, 10 Heavy menu's ECO guidance o
Display setting o ECO gauge
display is set.)
• Indicates accumulated engine
operating hours (the alternator is
Service meter 00000.0 h to 99999.9 h running).
(F4 switch changes it to clock
display.)
• Displays time.
• 12-hour display (AM/PM) (F4 switch changes it to service
Clock • 24-hour display meter display.)
• Indicates average fuel

(*2) consumption.
• One day (Display is switched when the user
Fuel
• Split menu's ECO guidance o Display
consumption • None
gauge setting o Average fuel consumption
display are specified.)
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer goes
off.
*2: Display item is switched with the operation of the user menu's ECO guidance o Item displayed (specify).
Caution monitor
Description
Monitor
Item Action
Symbol display Remarks
displayed Range level
(Background monitor
color)
Lights up • Background color changes
102 °C or above (Red) L02 depending on the
(*1) Min. 30 °C and Lights up temperature detected.
– • Alarm buzzer sounds when
Engine below 102 °C. (Blue)
the temperature is 105 °C or
coolant higher.
temperature Lights up • If the monitor background
Below 30 °C –
(White) appears white, warm up the
engine.
102 °C or above (Red) L02 depending on the
(*1) temperature detected.
Min. 20 °C and Lights up –
Hydraulic oil below 102 °C. (Blue) • Alarm buzzer sounds when
temperature the temperature is 105 °C or
Lights up
Below 20 °C – higher.
(White)
10-260 PC490LC-10
Description
Monitor
Item Action
(Background
monitor
color)
• If the monitor background
appears white, warm up the
hydraulic components.
Below 41 l –
(*1) (Red) depending on the remaining
Lights up fuel level.
Fuel level Min. 41 l –
(Blue)
When abnormal • When a failure is detected
Lights up (*3) with the engine stopped, the
(*1) (When below (Yellow) L01 monitor lights up.
Coolant level specified level)
When normal Off –
When charge is • The monitor lights up and
defective alarm buzzer sounds when
(*1) Lights up a failure is detected while
(Charge voltage (Red) L03
Battery < Battery the engine is running.
charge voltage)
When normal Off –
When abnormal • The monitor lights up and
(*1) Lights up alarm buzzer sounds when
(When below (Red) L03
Engine oil specified level) a failure is detected while
pressure the engine is running.
When normal Off –
(*1) Lights up (*3) when the engine is stopped,
(When below (Yellow)
Engine oil specified level) L01 the monitor lights up.
level
When normal Off –
(*1) Lights up (*3) with the engine running, the
(When above (Yellow)
Air cleaner specified level) L01 monitor lights up.
clogging
When normal Off –
When • The display changes
exceeding Lights up depending on the time to/
–
maintenance (Red) after the maintenance.
time • After the starting switch is
Maintenance turned to the ON position,
(*2)
time warning the monitor turns on if the
When Lights up
exceeding – monitor lights up conditions
(Yellow) are met, and then goes out
maintenance
noticed time in 30 seconds.
When action Lights up • The monitor lights up when
L04 and
level L04 or L03 (Red) a failure is detected in the
Condition of is detected L03
machine system.
system When action • When the background color
Lights up (*3)
level L01 is (Yellow) is red, the alarm buzzer
detected L01 sounds.
L04 and
Condition of level L04 or L03 (Red) L03
a failure is detected in the
engine is detected engine system.
system When action Lights up (*3) • When the background color
PC490LC-10 10-261
Description
Monitor
Item Action
(Background
monitor
color)
L04 and
Condition of level L04 or L03 (Red) L03
a failure is detected in the
hydraulic is detected hydraulic system.
system When action Lights up (*3) • When the background color
L04 and
level L04 or L03 (Red) a failure is detected in the
Condition of is detected L03
KDPF system.
KDPF system When action • When the background color
Lights up (*3)
level L04 or L03 (Red) L03 soot is accumulated inside
Accumulation is detected KDPF or cleaning function
of soot on is unusually degraded.
When action Lights up (*3)
KDPF • When the background color
level L01 is (Yellow) L01 is red, the alarm buzzer
detected
sounds.
• The monitor lights up and
Engine When engine Lights up alarm buzzer sounds when
overspeed overspeed is (Red) L02 engine overspeed is
detected detected.
• The monitor lights up when
When air Lights up (*3) a failure is detected in the
Condition of
conditioner is (Yellow) air conditioner system.
air conditioner L01
abnormal

level L04 is (Red) L04 a failure is detected on the
detected machine.
When action Lights up When the background color
level L03 is (Red) L03 is red, the alarm buzzer
detected sounds.
Action level
When action Lights up
level L02 is (Red) L02
detected
When action Lights up (*3)
level L01 is (Yellow)
detected L01
*1: It is included in the check before starting items. After the staring switch is turned to the ON position, the
monitor turns on for two seconds, and changes to the standard screen if no failure is found.
*2: The time of notice is changeable through the items in the maintenance mode display setting of the service
mode.
*3: Monitor goes out after lighting up for two seconds.
10-262 PC490LC-10
Pilot monitor
• It operates automatically • Indicates preheat operating
at a low temperature. condition.
(Symbol lights up for as
Automatic
long as approx. 30
preheating
seconds)
• It goes out after the
engine is started.
Elapsed time
Preheating after turning
the starting Monitor
switch to display
Manual HEAT
preheating (Preheating)
0 to 30 sec. Lights up
30 to 40 sec. Flashes
After 40 sec.
Lights out
or longer
One-touch • Indicates the operating
power max. Monitor display condition of one-touch
switch power maximizing function.
One-touch Lights up
power max.
ON (Goes out if pressed for 8.5
seconds)
OFF Lights out
Swing • Indicates swing lock
Swing lock holding Monitor operating condition.
switch brake cancel display
switch
Swing lock OFF OFF Lights out
ON OFF Lights up
OFF ON Flashes
ON ON Flashes
• Indicates front window
INT: Intermittent
wiper operating condition.
Wiper ON: Continuous
Lights out: Stopped
• Indicates air conditioner
Lights up: ON and air blower operating
Air conditioner condition.
Lights out: OFF
• Indicates whether seat belt

Lights up: Not fastened is fastened.
Seat belt
Lights out: Fastened
• Indicates the operating

Lights up: When engine is stopped condition of engine.
Engine stop
Lights out: While engine is running
• Indicates regenerating
KDPF Lights up: KDPF is being regenerated condition of KDPF.
regeneration Lights out: KDPF regeneration is finished
PC490LC-10 10-263

• Indicates regenerating
condition of KDPF.
Stop of KDPF Lights up: KDPF regeneration is stopped • KDPF soot accumulation
regeneration Lights out: KDPF regeneration is finished monitor lights up when
manual stationary
regeneration is required.
• Indicates the condition of
Message Lights up: There is unread message. message.
(Unread) Lights out: No message
Message • Indicates the condition of

Lights up: There is an already-read
(No return message.
message but return message for it is not
message, sent yet.
already-read
Lights out: No message
message)
• Indicates auto-decelerator
Auto- Lights up: Operating operating condition.
decelerator Lights out: Not operating
P: Heavy-duty operation • Displays working mode.

E: Low-fuel consumption operation
L: Fine operation
Working mode B: Breaker operation
ATT-P: Double-acting attachment
operation
ATT-E: Double-acting attachment and
low-fuel consumption operation
• Displays travel speed
Lo: Low speed
setting.
Travel speed Med: Medium speed
Hi: High speed
• Idle stop guidance • Guidance for supporting
• Guidance on deterrence of hydraulic machine operation and
relief control are indicated.
ECO guidance • E-mode recommendation guidance
• Non full speed travel recommendation
guidance
• Low fuel level guidance
10-264 PC490LC-10
Switches (PC-Q1C0-042-K-00-A)
No. Name Function Operation

Switches the auto-deceleration • When working mode is "L", this switch
Auto-deceleration function ON/OFF. is always "OFF" after engine started.
1 switch OFF io ON
Lights up: ON
[Numeric keypad: 1]
Lights out: OFF
P: Heavy-duty operation
E: Low-fuel operation
(*1) L: Fine operation
Working mode selector Displays the working mode selector B: Breaker operation
2 switch screen. ATT/P: Double-acting attachment
[Numeric keypad: 2] operation
ATT/E: Double-acting attachment and
low-fuel operation
Changes the travel speed. • Speed is sequentially changed as
Travel speed selector shown below.
Lo lights up: Low speed
3 switch Lo (Low speed) o Mi (Medium
Mi lights up: Medium speed speed) o Hi (High speed) o Lo (Low
[Numeric keypad: 3]
Hi lights up: High speed speed)
Stops the alarm buzzer. • The alarm buzzer stops sounding.
Buzzer cancel switch (Some alarm buzzer does not stop • The alarm buzzer sounds again if
4 another error worth alarming is
[Numeric keypad: 4] sounding even if the switch is
pressed.) detected.
Operates the front glass wiper. • Pressing the switch sequentially
(*2) changes the wiper operation.
INT: Intermittent operation
5 Wiper switch INT (Intermittent) o ON (Continuous)
ON: Continuous operation o OFF (Stop) o INT (Intermittent)
[Numeric keypad: 5]
Lights out: Holds in position
PC490LC-10 10-265
No. Name Function Operation

ON: Washer fluid is sprayed and
windshield wiper works continuously.
[When wiper stops]
(*2) OFF: Windshield wiper works twice
Sprays washer fluid onto the front continuously and stops after the switch is
6 Window washer switch
window glass. released.
[Numeric keypad: 6]
[When wiper operates intermittently]
OFF: Windshield wiper works twice
continuously and returns to intermittent
operation after the switch is released.
Fan switch (increase) • The air flow increases immediately
7a Controls the air flow of the air after the air conditioner adjustment
[Numeric keypad: 7] conditioner in 6 levels. screen appears.
(Low, Medium 1, Medium 2, • The air flow decreases immediately
7b Fan switch (decrease) Medium 3, Medium 4 and High) after the air conditioner adjustment
screen appears.
Temperature control • The preset temperature increases
8a switch (raise) Controls the temperature inside the immediately after the air conditioner
[Numeric keypad: 8] cab. adjustment screen appears.
Temperature control (18.0℃ to 32.0℃: Setting is • The preset temperature decreases
8b switch (lower) available in 0.5°C steps) immediately after the air conditioner
[Numeric keypad: 0] adjustment screen appears.
• The air flow, combination of vents,
(*3) Operates the air conditioner and air and selection of FRESH/RECIRC air
flow with automatic operation. are automatically selected according
9 Auto switch
AUTO lights up: Automatic to the set temperature immediately
[Numeric keypad: 9] operation after the air conditioner adjustment
screen appears.
Selects the air conditioner ON/OFF. • Switches to the air conditioner
(*4) adjustment screen, and pressing it
10 A/C ON lighted: Manual operation
Air conditioner switch again switches ON/OFF.
Not lighting: Stop OFF io ON
• Switches to the air conditioner
FRESH/RECIRC air adjustment screen, and pressing it
11 Changes the FRESH/RECIRC.
changeover switch again switches FRESH/RECIRC.
RECIRC io FRESH
Selects the air vent mode from 6
modes.
1. Front vent
• Switches to the air conditioner
2. Front and rear vents adjustment screen, and pressing it
12 Vent selector switch
3. Front, rear and foot vents again switches air vent mode.
4. Foot vent 1o2o3o4o5o6o1
5. Foot and defroster vents
6. Defroster vent
Stops the fan and air conditioner.
13 OFF switch • The fan and air conditioner stop.
Lights OFF: OFF
14a Guidance icon
See "Guidance icon and function switch"
14b Function switch
*1: When the working mode is changed, the auto-decelerator function turns "ON".
*2: When the front window is open, the wiper and washer do not operate even if the switch is pressed.
*3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to "High" and does not
change even if the set temperature is reached.
*4: Air conditioner cannot be operated while the fan stops.
10-266 PC490LC-10
Guidance icon and function switch (PC-Q1C1-042-K-00-A)

• Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
• No function is available if no guidance icon appears above the function switch.
• The following is the list of guidance icons and the functions displayed above the function switches.
Guidance
Item Function
icon
Selects user menu screen.
Background colors allow confirming the type of information
transmitted.
Selection of user mode • Gray: When the condition is normal
screen • Red: When soot accumulation abnormality (L3) is detected, or
exceeding maintenance interval
• Yellow: When soot accumulation abnormality (L1) is detected, or
exceeding maintenance interval warning
• Green: When there is unread KOMTRAX message
Switching clock/service Switches clock/service meter display.

meter
Switching to camera Switches to camera image display screen.

screen
Enters selected/setting item.

Background colors allow confirming the type of information
Enter transmitted.
• Gray: When the condition is normal
• Green: When energy saving guidance is displayed
Return Returns to the previous screen or status.
Selects the item right above the current item

Switching the select item
(To the bottom item from the top item.)
Selects the item right below the current item

(To the top item from the bottom item.)
Green arrow: Selects the item on the right side of the tab.
Switching the select item White arrow: Selects the item on the right side of the current item.
(To the leftmost item from the rightmost item.)
Green arrow: Selects the item on the left side of the tab.
Switching the select item White arrow: Selects the item on the left side of the current item.
(To the rightmost item from the leftmost item.)
Selects the page right above the current page.

(To the bottom page from the top page.)
PC490LC-10 10-267
Guidance
Item Function
icon
Selects the page right below the current page.

(To the top page from the bottom page.)
Clear Clears selected/displayed item.
Sets selected item back to default.

Restores default value
(Used for screen adjustment.)
Set Performs setting.
Starts function.
Start (Used for starting measurement of split fuel consumption on the fuel
consumption display screen.)
Stops operation.
Stop (Used for stopping measurement of split fuel consumption on fuel
consumption display screen.)
Saving Saves setting
Switching to the name

Switches the current screen to the name setting screen
setting screen
Switching to ATT1 oil flow Switching the current screen to attachment 1 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Switching to ATT2 oil flow Switching the current screen to attachment 2 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Holds the value of the target item of monitoring.

HOLD
(Used when monitoring is turned on)
Resets the currently held value of the target item of monitoring.

Resetting the hold
(Used when monitoring is turned on)
Switching the fuel

Switches the graphs on the fuel consumption record screen.
consumption record screen
Switching to oil flow setting Switches to the attachment and breaker oil flow setting screen.
screen
10-268 PC490LC-10
Guidance
Item Function
icon
Switches to the currently occurring failures list screen.
Switching to the currently Background colors allow confirming the type of information
occurring failures list transmitted.
screen • Red: When an action level of L2, L3 or L4 is displayed
• Yellow: When the action level of L1 is displayed
Display No. 1 camera Selects No. 1 camera image display screen.

screen

screen

screen
Display No. 1 and No. 2 Display both images of No. 1 and No. 2 cameras simultaneously.
camera screens
Operator mode function (PC-Q193-042-K-00-A)

• The operator can select the information to be displayed usually on the screen and the function to be used
by operating the switches.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Category Display order (*2)
Item
(*1) V W X Y Z
KOMATSU logo screen 1 1 1 1 1
Password input screen 2 — — — —
Breaker mode check screen — — 2 — —
Checks before starting screen 3 2 3 2 2
Warning screen after check before starting — — — 3 —
A — — — —
Overdue maintenance time item screen 3
Working mode and travel speed check screen 4 3 4 4 4
Standard screen 5 4 5 5 5
Engine shutdown secondary switch screen
End screen
Selecting auto-deceleration function
Selecting working mode
Selecting travel speed
Stopping alarm buzzer
Operating windshield wiper
Operating window washer
Operating air conditioner
B Operating camera mode display
Switching between clock display and service meter display
Checking maintenance information
Setting and displaying user menu
• "ECO Guidance"
• "Machine Setting"
• "KDPF Regeneration"
• "Maintenance"
PC490LC-10 10-269
Category Display order (*2)

Item
(*1) V W X Y Z
• "Monitor Setting"
• Message display (including KOMTRAX messages for user)
Displaying ECO guidance
Displaying caution monitor
C
Displaying KDPF regeneration
Displaying action level and failure code
LCD (Liquid Crystal Display) display condition checking function
D Service meter reading checking function
Access restriction setting/password changing function
*1: The items available in the operator mode are categorized as shown below.
A: Displays that appear since starting switch is turned to "ON" position until the standard screen appears, and
the displays that appear after starting switch is turned to "OFF" position .
B: Displays that appear when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied
D: Displays that require special switch operations.
*2: Display sequence from "ON" of starting switch to the standard screen varies depending on the settings
and conditions of the machine as follows:
V: When engine start lock is set effective
W: When engine start lock is disabled
X: When working mode at start is set to "Breaker Mode (B)".
Y: When a failure is detected during check before starting.
Z: When a maintenance time overdue is detected for an item.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)" section in Testing and adjusting.
a For how to set the engine start lock on/off, see " Password setting/cancel manual" .
Service mode function (PC400-Q194-042-K-00-A)

• The functions in this mode are not displayed on the standard screen. The arrangements for the
information display and various settings can be made only by the technician through the special operation
of the switches.
This function is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring/Pre-defined
Monitoring/Custom
Mechanical Systems
Abnormality Record
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Key-on Mode
Unit
Default
With/Without Attachment
Camera
Cylinder Cut-out
Diagnostic Tests Regeneration for Service
KDPF Memory Reset
Pump Absorption Torque (F)
Pump Absorption Torque (R)
Adjustment
Low Speed
Attachment Flow Adjustment
10-270 PC490LC-10
Cal F pump swash plate sensor

Cal R pump swash plate sensor
Fan Speed Mode Select
No Injection
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem Status
Service Message
a For how to operate the service mode functions, see "Service mode" section in Testing and adjusting.
PC490LC-10 10-271
KOMTRAX system
KOMTRAX system (PC-Q210-042-K-00-A)
• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
• This system transmits various machine information by use of the radio communication. This system allows
the KOMTRAX operator to refer the information and provide various services to the customers.
• Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
KOMTRAX terminal (PC220-Q220-042-K-00-A)
Type: TC330
1. GPS antenna connection

2. Machine harness connection (070-18P)
3. Machine harness connection (070-12P)
10-272 PC490LC-10
KOMTRAX system
4. Communication antenna connection
Input and output signals (PC220-Q220-03C-K-00-A)

070-18P[CN-CK01]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN (C)_H Input/Output
11 CAN (C)_L Input/Output
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P [CN-CK02]
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
Function (PC-Q220-042-K-00-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of "KOMTRAX setting" in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.
PC490LC-10 10-273
Sensor
Sensor (ALL-E700-001-P-00-A)
Ambient pressure sensor (ENG-AAP2-041-K-00-A)
1. Connector
2. Sensor
Function (ENG-AAP2-042-K-00-A)
• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.
Output characteristics
Engine oil pressure sensor (PC400-ABK5-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
10-274 PC490LC-10
Sensor
Function (PC400-ABK5-042-K-00-A)
• This oil pressure sensor, installed in the cylinder block, It detects engine oil pressure to output variable
voltage.
Charge (Boost) pressure sensor (PC400-AAM3-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC400-AAM3-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine boost pressure to output
signals as a variable voltage.
a a "Chargepressure" is the turbocharged pressure of a turbocharged engine. It is also referred to as a
"boost pressure".
Charge temperature sensor (ENG125-AAM4-041-K-00-A)
PC490LC-10 10-275
Sensor
Function (ENG125-AAM4-042-K-00-A)
• The charge temperature sensor detects the intake air temperature (boost temperature) and sends it to the
engine controller.
• The thermistor is used as a sensor of which resistance changes according to the temperature. The engine
controller applies voltage to the thermistor and senses the temperature by using the voltage divided by the
resistance in the computer and the resistance of the thermistor.
Coolant temperature sensor (ENG-BA87-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-BA87-042-K-00-A)
• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
Ne (crankshaft) speed sensor (ENG-AG42-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG-AG42-042-K-00-A)
• This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to
the gear rotation.
10-276 PC490LC-10
Sensor
Bkup (camshaft) speed sensor (ENG125-AG62-041-K-00-A)
Function (ENG125-AG62-042-K-00-A)
• Like the NE speed sensor, it utilizes 0 to 5 V pulses that result from the change in the magnetic lines
passing through the sensor.
• The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts)
around it at intervals of 120 deg.
• In addition to the above teeth, one more tooth is installed. Accordingly, seven pulses are generated every
two revolutions of the engine.
• The standard pulse of No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and
Bkup speed sensor pulse.
Common rail pressure sensor (ENG-AE28-041-K-00-A)
1. Connector
2. Sensor
PC490LC-10 10-277
Sensor
Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
EGR valve lift sensor (ENG125-A9S2-041-K-00-A)
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG125-A9S2-042-K-00-A)
• The sensor, installed to EGR valve on the engine, detects the EGR valve opening to output the
• The relation between stroke and output voltage is as shown in the following graph.
KVGT speed sensor (ENG125-AAQ4-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
10-278 PC490LC-10
Sensor
1. Sensor
2. O-ring
3. Connector
Function (ENG125-AAQ4-042-K-00-A)
• This sensor, installed to KVGT in the engine, outputs the pulse voltage by means of the rotation of KVGT
turbine.
KVGT position sensor (ENG-AAQ3-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG-AAQ3-042-K-00-A)
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
• The relation between stroke and output voltage is as shown in the following graph.
PC490LC-10 10-279
Sensor
Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)
1. Connector
2. O-ring
3. Sensor
Function (ENG-A96H-042-K-00-A)
• This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The "MAF (Mass Air Flow)" means the "intake air flow".
Dosing fuel pressure sensor (PC400-A9JC-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
10-280 PC490LC-10
Sensor
Function (PC400-A9JC-042-K-00-A)
• This sensor, which is installed to the dosing fuel solenoid valve assembly, detects the pressure of the fuel
supplied to output the corresponding variable voltage.
KDPF differential pressure and outlet pressure sensor (ENG-A9HL-041-K-00-A)
1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor
Function (ENG-A9HL-042-K-00-A)
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
• The output pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).
KDOC inlet temperature sensor (ENG-A9HG-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
PC490LC-10 10-281
Sensor
Function (ENG-A9HG-042-K-00-A)
• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDOC outlet temperature sensor (ENG-A9HH-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function (ENG-A9HH-042-K-00-A)
• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDPF outlet temperature sensor (ENG-A9HJ-041-K-00-A)
1. Sensor
2. Connector
Function (ENG-A9HJ-042-K-00-A)
• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
10-282 PC490LC-10
Sensor
Crankcase pressure sensor (ENG-A18C-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-A18C-042-K-00-A)
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
Engine oil level sensor (ENG-AB45-041-K-00-A)
1. Connector
2. Bracket
3. Float
4. Switch
Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns "OFF" by the lowered float, if the oil level
becomes lower than specified.
PC490LC-10 10-283
Sensor
Fuel level sensor (PC400-AD41-041-K-00-A)
1. Float
2. Connector
3. Cover
4. Variable resistor
Function (PC-AD41-042-K-00-A)
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
• The movement of the float activates the variable resistor through the arm. As a result, the source voltage
is changed according to the resistance change due to the arm angle change and is output as a signal.
10-284 PC490LC-10
Sensor
Coolant level sensor (PC400-B252-041-K-00-A)
1. Reservoir tank
2. Connector
3. Switch
Function (PC400-B252-042-K-00-A)
• The sensor, which is built in the reservoir tank, turns the switch OFF if the coolant level becomes lower
than the specified level.
Hydraulic oil temperature sensor (PC-PMT1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function (PC-PMT1-042-K-00-A)
• This sensor, installed on the suction pipe of main pump, senses the temperature variation as the change
in thermistor resistance, and outputs the corresponding signals.
PC490LC-10 10-285
Sensor
Front pump oil pressure sensor (PC-C3W4-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC-C3W4-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the front pump and outputs
variable voltage signal.
Rear pump oil pressure sensor (PC-C3W5-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
10-286 PC490LC-10
Sensor
Function (PC-C3W5-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the rear pump and outputs
variable voltage signal.
PPC oil pressure sensor (PC400-E720-041-P-00-A)
1. Sensor
2. Connector
Function (PC400-E720-042-P-00-A)
• Eight of this sensor are installed to the relay block.
• The sensor detects the operating condition of each actuator by the PPC pressure and transmit it to the
pump controller.
• The relation between the pressure applied to sensors (P) and output voltage (E) is shown in the figure
below.
PC490LC-10 10-287
Sensor
Operation (PC400-E720-044-P-00-A)
• The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part and
the diaphragm is deformed.
• The deformation in the diaphragm causes the resistance of the gauge to change. This causes a change in
the output voltage, which is transmitted to the amplifier (voltage amplifier).
• The amplifier magnifies the output voltage and transmits it to the pump controller.
Air cleaner clogging sensor (PC-A968-041-K-01-A)
1. Adapter
2. Hood
3. Indicator
4. Connector
Function (PC-A968-042-K-00-A)
• This sensor is installed on the air cleaner outlet side. The switch is turned to "ON" position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).
10-288 PC490LC-10
Sensor
Front pump swash plate sensor (PC-C3W9-041-K-00-A)
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
Function (PC400-C3W9-042-K-00-A)
• The senor, installed on the front pump side of the main pump, detects the stroke of the servo piston and
outputs the corresponding variable voltage.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
• The relation between the stroke and output voltage is shown in the graph below.
• The relation between the oil flow of the pump and the output voltage is shown in the graph below.
PC490LC-10 10-289
Sensor
Rear pump swash plate sensor (PC-C3WB-041-K-00-A)
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
Function (PC400-C3WB-042-K-00-A)
• The senor, installed on the rear pump side of the main pump, detects the stroke of the servo piston and
outputs the corresponding variable voltage.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
• The relation between the stroke and the output voltage is shown in the graph below.
10-290 PC490LC-10
Sensor
• The relation between the oil flow of the pump and the output voltage is shown in the graph below.
Cooling fan speed sensor (D65-B750-041-K-00-A)
1. Sensor
2. Connector
Function (D65-B750-042-K-00-A)
• This sensor is installed to the cooling fan motor.
• This sensor detects the gear speed and outputs corresponding pulse signals.
PC490LC-10 10-291
10-292 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
20 Standard value tables

4 20 Standard value tables
PC490LC-10 20-1
Table of contents

20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
20-2 PC490LC-10
Standard value table for engine
Standard service value table (ALL-A000-001-K-00-A)
Standard value table for engine (PC400_10-A000-033-K-00-A)
Machine model PC490LC–10

Engine SAA6D125E–6
Category
Standard value
Item Measurement condition Unit for new Repair limit
machine
High idle rpm 1,770 ±50 –
• Engine coolant rpm
Engine speed 1,000 ± 25 –
temperature: 60 to 100 °C Low idle
Rated speed rpm 1,900 –
• Engine coolant temperature: 60 to 100 °
C
• Hydraulic oil temperature: 45 to 55 °C kPa Min. 173
Boost pressure 140 {1,050}
• Swing lock switch: ON {mmHg} {1,300}
• Arm IN relief + One-touch power max.
ON
• Engine Engine outlet High idle Bosch – Max. 1.0
coolant (Between index
tempera- turbocharger Arm IN relief
Bosch –
ture: 60 to and KDPF swing lock Max. 1.5
index
Exhaust gas 100 °C inlet) Switch: ON
color • After kept Bosch
for 5 KDPF outlet High idle index
– Max. 0.5
seconds (Exhaust pipe Arm IN relief
Engine
at normal outlet) Bosch –

swing lock Max. 0.5
condition index
Switch: ON
Intake valve mm 0.33 –
Valve clearance • When cold Exhaust mm 0.71 –
valve
Compression • Engine oil temperature: 40 to 60 °C MPa
Min. 2.9 {30} 2.0 {20}
pressure • Engine speed: 200 to 250 rpm {kg/cm2}
• Engine coolant temperature: 60 to 100 °
C kPa
• Hydraulic oil temperature: 45 to 55 °C Max. 1.96
Blowby pressure {mmH2- 3.92 {400}
• Arm IN relief + One-touch power max. {200}
O}
ON
• When KCCV circuit is disconnected
• Engine coolant MPa 0.29 to 0.69
temperature: 60 to 100 °C High idle {kg/cm2} {3.0 to 7.0}
0.18 {1.8}
Engine oil • SAE 5W 30LA
pressure • SAE 5W 40LA MPa
• SAE 10W 30LA Low idle Min. 0.08 {0.8} 0.05 {0.5}
{kg/cm2}
• SAE 15W 40LA
PC490LC-10 20-3
Standard value table for engine

Engine SAA6D125E–6
Category
Standard value
Item Measurement condition Unit for new Repair limit
machine
• Engine coolant MPa Min. 1.43
High idle 1.43 {14.6}
EGR valve and temperature: 60 to 100 °C {kg/cm2} {14.6}
KVGT pressure • Hydraulic oil temperature: MPa
Low idle Min. 1.2 {12.0} 1.2 {12.0}
45 to 55 °C {kg/cm2}
Engine oil
Whole speed range (inside oil pan) °C 90 to 110 120
temperature
Alternator belt • Between fan pulley and alternator
mm Auto-tensioner Auto-tensioner
tension pulley
• Between compressor pulley and fan
Air conditioner pulley
Engine
compressor belt mm 14 to 16 14 to 16
• Deflection when pressed with finger
tension force of 58.8 N {6.0 kg}
MPa 0.15 to 0.3 0.15 to 0.3
Fuel pressure • Engine at high idle
{kg/cm2} {1.5 to 3.0} {1.5 to 3.0}
Leakage from • Engine at high idle
pressure limiter ml/min Max. 10 Max. 10
• Arm IN relief
1,600 960 960
1,700 1,020 1,020
Fuel return rate
• Engine speed (rpm) 1,800 ml/min 1,080 1,080
from injector
1,900 1,140 1,140
2,000 1,200 1,200
20-4 PC490LC-10
Standard value table for machine
Standard value table for machine (PC400_10-0000-033-K-00-A)

Category
Standard value Repair limit

Item Measurement condition Unit
for new machine
• Engine coolant temperature: 60 to

100 °C
• Hydraulic oil temperature: 45 to 55
Speed at 2-pump rpm 1,720 ± 100 1,720 ± 100
°C
relief
• Engine at high idle
• Power mode (P)
• Arm IN relief
• Engine coolant temperature: 60 to
Engine speed
100 °C
Speed at 2-pump
°C rpm
relief + One-touch 1,720 ± 100 1,720 ± 100
power max. ON
• Power mode (P)
• Arm IN relief + Left knob switch in
ON position
Speed when • Auto-deceleration switch in ON
auto-deceleration position rpm 1,000 ± 100 1,000 ± 100
is operated • All control levers in NEUTRAL
position
Boom control l a b l a b
valve
Travel of control valve spool
Arm control valve

Bucket control
valve
Swing control • Engine stopped
valve • For measuring point, see "Control mm 9.5 ± 9.5 ± 9.5 ± 9.5 ±
– –
valve". 0.5 0.5 0.5 0.5
Travel control
valve
Boom control mm 85 ± 10 85 ± 10
lever
Travel of control lever
Arm control lever mm 85 ± 10 85 ± 10

Bucket control • Engine stopped
• At center of control lever grip mm 85 ± 10 85 ± 10
lever
Swing control • Read value of stroke to end of
travel mm 85 ± 10 85 ± 10
lever
Travel control (excluding play at NEUTRAL)
mm 115 ± 12 115 ± 12
lever
Play of control mm Max. 10 Max. 15
lever
PC490LC-10 20-5

Category
Standard value for Repair limit

new machine
Boom control N 15.7 ± 3.9 Max. 24.5

lever {kg} {1.6 ± 0.4} {Max. 2.5}
Operating effort of control lever and pedal
N 15.7 ± 3.9 Max. 24.5

Arm control lever
{kg} {1.6 ± 0.4} {Max. 2.5}
Bucket control N 12.7 ± 2.9 Max. 21.6
• Hydraulic oil
lever temperature: 45 to 55 {kg} {1.3 ± 0.3} {Max. 2.2}
Swing control °C N 12.7 ± 2.9 Max. 21.6
lever • Engine at high idle {kg} {1.3 ± 0.3} {Max. 2.2}
• Control lever: At N 24.5 ± 5.9 Max. 39.2
center of grip Lever
• Pedal: At tip of pedal {kg} {2.5 ± 0.6} {Max. 4.0}
• Read max. value
through travel end.
Travel control
lever, pedal N 74.5 ± 18.6 Max. 107.6
Pedal
{kg} {7.6 ± 1.9} {Max. 11}

°C
• Engine at high idle MPa 4.2 ± 1.0 4.2 ± 1.0
Unload pressure • Power mode (P)
• Hydraulic pump output pressure {kg/cm2} {42 ± 10} {42 ± 10}
with all control levers in NEUTRAL
position
34.8(+1.47/-1.18) 33.2 to 36.8
{353(+15/-12)} {338 to 375}
RAISE
*37.3(+1.47/-1.18) *35.6 to 39.2
{380(+15/-12)} {363 to 400}
• Hydraulic oil LOWER
Boom relief temperature: 45 to 55 at low- 18.1 + 0.98/-1.18 16.5 to 19.6
pressure °C pressure {185 + 10/-12} {168 to 200}
• Engine at high idle setting
• Power mode (P)
Oil pressure
• Hydraulic pump LOWER

outlet pressure with at high- MPa 31.4 + 1.47/-1.67 29.2 to 33.3
all measurement pressure {kg/cm2} {320 + 15/-17} {298 to340}
circuits relieved setting
Arm relief • Values marked with 34.8(+1.47/-1.18) 33.1 to 36.8
pressure *are oil pressures {355(+15/-12)} {338 to 375}
when one-touch
Bucket relief power max. ON *37.3(+1.47/-1.18) *35.6 to 39.2
pressure (reference only) {380(+15/-12)} {363 to 400}
Swing relief 30.9(+1.47/-19.6) 28.4 to 32.9
pressure {315(+15/-20) {290 to 335}
Travel relief 37.3(+2.94/-0.98) 35.6 to 40.7
pressure {380(+30/-10)} {363 to 415}
°C
Control circuit • Engine at high idle MPa 3.24 ± 0.2 2.84 to 3.43
source pressure • Self-pressure reducing valve {kg/cm2} {33 ± 2} {29 to 35}
output pressure with all control
levers in NEUTRAL position
20-6 PC490LC-10

Category

for new machine
When all
• Hydraulic oil control
temperature: 45 to 55 MPa 4.2 ± 1.0 4.2 ± 1.0
levers in
°C NEUTRAL {kg/cm2} {42 ± 10} {42 ± 10}
• Engine at high idle position
• Power mode (P)
LS differential When
• Travel speed setting:
pressure running
Hi
• LS differential track idle off MPa 2.65 ± 0.1 2.65 ± 0.1
pressure = Pump ground
Oil pressure
(travel lever {kg/cm2} {27 ± 1} {27 ± 1}

pressure – LS
pressure at half
stroke)
PPC valve output °C MPa 2.9(+0.6/-0.2) 2.9(+0.6/-0.2)
pressure • Engine at high idle {kg/cm2} {30(+5.5/-1.5)} {30(+5.5/-1.5)}
• Control lever at travel end
OFF
• Hydraulic oil 0 0
(de-
Solenoid valve temperature: 45 to 55 energized) MPa {0} {0}
output pressure °C {kg/cm2}
• Engine at high idle ON 2.9 2.9
energized {30} {30}
°C
• Power mode (P) deg.
Overswing Max. 130 Max. 160
• Overswing of swing circle after 1 (mm)
swing
• For measuring posture, see "Swing
1"
• Hydraulic oil 90 deg. sec. 3.7 ± 0.4 Max. 4.6
temperature: 45 to 55
°C
• Power mode (P)
Swing
Time required to • Time required to pass

start swinging 90 deg. and 180 deg. 180 deg. sec. 5.4 ± 0.5 Max. 6.4
points after starting
swinging.
• For measuring
posture, see "Swing
1"
°C
Time required to • Power mode (P) Max. 38
sec. 33. 0 ± 3.3
finish swinging • Time required to complete 5
swings after 1 swing
1"
PC490LC-10 20-7

Category

for new machine

°C
• Engine stopped
• Set machine on 15 deg. slope, and
set upper structure at 90 deg. to
Swing drift on a the side mm 0 0
slope • Make matchmarks on inner and
outer races of swing circle.
Swing
• Distance that matchmarks move

apart after 5 minutes
2"
°C
swing motor l/min Max. 5.5 Max. 11
• Swing lock switch: ON
• Leakage in 1 minute during swing
relief
• Hydraulic oil Lo sec. 67.3 ± 13.5 45.0 to 84.5
temperature: 45 to 55 Mi sec. 48.1 ± 7.2 34.0 to 58.0
°C
• Power mode (P)
Travel speed (idle • Time required to
running) make 5 idle turns of
track off ground after Hi sec. 36.7 ± 3.6 32.0 to 44.0
1 idle turn
• For measuring
posture, see "Travel
1"
• Hydraulic oil Lo sec. 24.0 ± 4.8 18.9 to 31.0
temperature: 45 to 55 Mi sec. 17.1 ± 2.6 14.4 to 21.0
°C
Travel
• Power mode (P)

Travel speed • Level ground
(actual running) • Time required to
travel 20 m after Hi sec. 13.1 ± 1.3 11.7 to 15.1
running up 10 m
• For measuring
posture, see "Travel
2"
°C
• Power mode (P)
• Travel speed: Lo mm
Travel deviation Max. 200 Max. 300
• Firm and level ground
• Travel deviation (x) in travel of 20
m after running up 10 m.
• For measuring posture, see "Travel
2" and "Travel 3"
20-8 PC490LC-10

Category

for new machine

°C
• Engine stopped
Machine drift on a • Place machine on 12 deg. slope
with sprocket on uphill side. mm 0 0
slope
• Travel distance by machine drift on
a slope for 5 minutes
Travel

4"
°C
l/min Max. 20 Max. 40
travel motor • Lock sprocket with pin etc.
• Leakage in 1 minute during travel
relief
PC490LC-10 20-9

Category

for new machine
Whole work
equipment
(hydraulic Max. 600 Max. 900
drift of tooth
Hydraulic drift of work equipment
tip) • Hydraulic oil temperature: 45 to 55

°C
Boom • Level and flat ground
cylinder • Work equipment: Measuring
(Retraction posture (load: 3,060 kg) Max. 25 Max. 38
amount of • Engine stopped
cylinder) • Work equipment control lever in mm
Arm cylinder NEUTRAL position
(Extension • Fall amount for 15 minutes as
measured every 5 minutes starting Max. 85 Max. 128
amount of
cylinder) immediately after initial setting
• For measuring posture, see "Work
Bucket equipment 1"
cylinder
(Retraction Max. 30 Max. 45
amount of
cylinder)
Work equipment
• Hydraulic oil
°C
• Power mode (P)
• Time required to
Boom speed move boom between RAISE sec. 4.0 ± 0.4 Max. 4.8
RAISE stroke end
Work equipment speed
and ground touch

point of bucket
• For measuring
posture, see "Work
equipment 2"
• Hydraulic oil IN 4.3 ± 0.5 Max. 5.0
°C
• Power mode (P)
• Time required to
Arm speed sec.
move arm between OUT 3.6 ± 0.4 Max. 4.3
OUT stroke end and
IN stroke end
• For measuring
posture, see "Work
equipment 3"
20-10 PC490LC-10

Category

for new machine
• Hydraulic oil CURL 3.6 ± 0.4 Max. 4.3

Work equipment speed
°C
• Power mode (P)
Bucket • Time required to
sec.
speed move bucket between DUMP 2.9 ± 0.3 Max. 3.5
DUMP stroke end
and CURL stroke end
• For measuring
posture, see "Work
equipment 4"
°C
• Engine at low idle
• Power mode (P)
• Set boom at full RAISE position.
Move boom control lever to
Boom time
LOWER position. Measure length sec. Max. 3.0 Max. 3.6
lag
of time before front of machine
starts lifting off the ground after
work equipment touches the
Work equipment
ground.
equipment 5"
°C
• Power mode (P)
Time lag
• Set arm at full OUT position. Move

arm control lever to IN position.
Arm time lag sec. Max. 3.0 Max. 3.6
Measure length of time before arm
starts moving in IN direction again
after it stops at vertical position
momentarily.
equipment 6"
°C
• Power mode (P)
• Set bucket at full DUMP position.
Bucket time Move bucket control lever to CURL
sec. Max. 3.0 Max. 5.0
lag position. Measure length of time
before bucket starts moving in
CURL direction again after it stops
at vertical position momentarily.
equipment 7"
PC490LC-10 20-11

Category

for new machine
Cylinder cc/min 4.5 20

Internal oil leakage
Work equipment

°C
Center
• Leakage amount for 1 minute cc/min 10 50
swivel joint
during relief of cylinder to be
measured or travel motor
Performance of combined operation

°C
Travel deviation
• Power mode (P)
in combined
• Travel speed: Lo mm
operation of work Max. 400 Max. 440
• Travel deviation (x) in travel of 20
equipment and
m after running up 10 m on firm
travel
and level ground
2" and "Travel 3"
All control
Pump swash plate sensor
levers in
NEUTRAL V 1.52 ± 0.20 1.52 ± 0.63
• Hydraulic oil
position
Pump swash °C
plate sensor When
output voltage running
• Power mode (P)
track idle off
• Travel speed: Hi V 3.54 ± 0.20 3.54 ± 0.63
ground
• Run either track idle
(lever at
travel end).
Characteristics of PC flow control

°C
• Power mode (P)
Time required for • Bucket at rated load (3,060 kg)
swinging from 0 • On hard and level ground, set arm 5.0 ± 0.4
sec.
to 90 deg. with vertically and lower back of bucket (Reference value)
raising the boo, to ground
• Time required for swinging from 0
to 90 deg. with boom RAISE
equipment 8"
20-12 PC490LC-10

Category

for new machine

°C
• Engine at high idle rpm
Fan speed 1,200 ± 50 1,200 ± 50
• Fixing fan speed to maximum
(see special functions of machine
monitor)
• Hydraulic oil temperature: 45 to 55 9.8 to 15.7 9.8 to 15.7
Fan circuit oil
Fan
°C
pressure {100 to 160} {100 to 160}
• Engine at high idle MPa
Output pressure • Hydraulic oil temperature: 45 to 55 {kg/cm2} 1.13(+0.54/-0.64) 1.13(+0.54/-0.69)
of fan pump EPC °C
{11.5(+5.5/-6.5)} {11.5(+5.5/-7.0)}
solenoid valve • Engine at high idle
Fan pump EPC °C 515(+100/-125) 515(+100/-150)
mA
current • Engine at high idle
• Pump speed (rpm): 1,720 rpm
• PC-EPC current value (mA): 570
Hydraulic pump
mA
Test pump discharge pressure Q Q
Performance of
(MPa {kg/cm2}): P1 l/min
hydraulic pump (See graph) (See graph)
• Discharge pressure of another
pump (MPa {kg/cm2}): P2
• Average Discharge pressure (MPa
{kg/cm2}): Pp=(P1+P2)/2
a Bring pump Discharge pressure P1 and P2 as close as possible to the average pressure when measuring.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump Discharge and the engine speed at the time
of measurement, and use them as a base for calculating the pump Discharge at the specified speed.
PC490LC-10 20-13
20-14 PC490LC-10
Posture of machine for measuring performance and measurement

procedure (PC220_10-0000-321-K-00-A)
Control valve: Spool travel
Swing 1: Overrun when stop swinging, time required to start swinging, time required to finish swinging
Swing 2: Swing drift on a slope
PC490LC-10 20-15
Travel 1: Travel speed (idle running)
Travel 2: Travel speed (actual run), travel deviation
Travel 3: Travel deviation
Travel 4: Hydraulic drift of travel
20-16 PC490LC-10
Work equipment 1: Hydraulic drift of the work equipment
Work equipment 2: Boom speed
Work equipment 3: Arm speed
Work equipment 4: Bucket speed
PC490LC-10 20-17
Work equipment 5: Boom time lag
Work equipment 6: Arm time lag
Work equipment 7: Bucket time lag
Work equipment 8: PC flow characteristics control
20-18 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
30 Testing and adjusting

5 30 Testing and adjusting
PC490LC-10 30-1
Table of contents

30 Testing and adjusting .................................................................................................................... 30-1
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-6
Testing engine speed ........................................................................................................... 30-8
Testing boost pressure ......................................................................................................... 30-9
Testing exhaust gas color ................................................................................................... 30-11
Testing and adjusting valve clearance .................................................................................. 30-13
Testing compression pressure............................................................................................. 30-16
Testing blowby pressure ..................................................................................................... 30-18
Testing engine oil pressure ................................................................................................. 30-19
Testing EGR valve and KVGT oil pressure............................................................................ 30-20
Testing fuel pressure .......................................................................................................... 30-21
Testing fuel leakage and return............................................................................................ 30-23
Bleeding air from fuel system .............................................................................................. 30-26
Testing fuel circuit for leakage ............................................................................................. 30-28
Handling cylinder cutout mode operation.............................................................................. 30-29
Handling no-injection cranking operation.............................................................................. 30-30
Testing and adjusting air conditioner compressor belt tension ................................................ 30-31
Replacing alternator belt ..................................................................................................... 30-32
Fuel doser cleaning procedure ............................................................................................ 30-33
Writing compensation values at replacement of injector and engine controller ......................... 30-36
Power train............................................................................................................................... 30-40
Testing swing circle bearing clearance ................................................................................. 30-40
Testing and adjusting track tension ...................................................................................... 30-41
Releasing remaining pressure from hydraulic circuit .............................................................. 30-42
Testing and adjusting oil pressure in work equipment, swing and travel circuits........................ 30-43
Testing oil pressure in control circuit..................................................................................... 30-48
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-49
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-52
Testing output pressure of solenoid valve ............................................................................. 30-57
Testing PPC valve output pressure ...................................................................................... 30-61
Adjusting play of work equipment and swing PPC valves....................................................... 30-63
Testing pump swash plate sensor ........................................................................................ 30-64
Testing fan speed............................................................................................................... 30-65
Testing fan pump circuit oil pressure .................................................................................... 30-66
Checking fan pump EPC current ......................................................................................... 30-67
Testing fan pump EPC solenoid valve output pressure .......................................................... 30-68
Isolating the parts causing hydraulic drift in work equipment................................................... 30-69
Testing oil leakage ............................................................................................................. 30-71
Bleeding air from hydraulic circuit ........................................................................................ 30-74
Cab and its attachments ............................................................................................................ 30-77
Testing cab tipping stopper ................................................................................................. 30-77
Adjusting mirrors ................................................................................................................ 30-78
Electrical system ...................................................................................................................... 30-81
Special functions of machine monitor ................................................................................... 30-81
Adjusting rearview camera angle ....................................................................................... 30-150
Handling voltage circuit of engine controller........................................................................ 30-152
Handling battery disconnect switch .................................................................................... 30-153
Testing diodes ................................................................................................................. 30-154
Pm clinic ................................................................................................................................ 30-155
Check sheet .................................................................................................................... 30-159
30-2 PC490LC-10
Related information on testing and adjusting
Related information on testing and adjusting (ALL-3831-001-A-00-A)
Tools for testing and adjusting (PC400-5320-304-A-00-A)
Testing and Sym-
Q'ty
adjusting item Part No. Part name Remarks
bol
Testing boost
pressure A 799-201-2202 Boost gauge kit 1 -101 to 200 kPa {-760 to 1,500 mmHg}
Testing exhaust
gas temperature W 799-101-1502 Digital thermometer 1 -99.9 to 1,299 °C
1 799-201-9002 Handy smoke checker 1
Testing exhaust
gas color B Commercially Bosch index: 0 to 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve
C Commercially
clearance 2 Feeler gauge 1
available
1 795-502-1590 Compression gauge 1 0 to 7 MPa {0 to 70 kg/cm2}
Testing 795-471-1420 Adapter 1
compression D 2 6217-71-6112 Gasket 1
pressure Commercially
3 Hose 1 Hose inside diameter: 14 mm
available
1 799-201-1504 Blowby checker 1 0 to 5 kPa {0 to 500 mmH2O}
Testing blowby Commercially Plug
pressure E 2 available
1 Hose inside diameter: 24 mm
Commercially Cap
3 2 Pipe outside diameter: 25.4 mm
available
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1 {25, 60, 400, 600 kg/cm2}
1 • Nipple
Testing engine oil 799-101-5160 1 R1/8
pressure F
799-101-5150 • Hose 1
2 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
3 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
795T-401-1110 Plug 2
1
02896-21015 O-ring 4
Testing EGR 799-101-5002 Hydraulic tester 1 {25, 60, 400, 600 kg/cm2}
valve and KVGT G
2 799-101-5160 • Nipple 1 R1/8
oil pressure
799-101-5150 • Hose 1
799-101-5140 • Gauge 1 Pressure gauge: 2.5 MPa {25 kg/cm2}
1 • Nipple
799-101-5160 1 R1/8
Testing fuel 799-101-5150 • Hose 1
H Digital hydraulic tester
pressure 2 790-261-1204 1 Pressure gauge: 60 MPa {600 kg/cm2}
790-301-1181 Joint 1
3
07005-01212 Seal 1
4 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercially
3 Hose 1 Inside diameter: approx. 6.5 mm
Testing fuel available
leakage and J 4 Commercially
Hose 1 Inside diameter: approx. 17.5 mm
return rate available
Commercially Measuring cylinder
5 1
available
Commercially Stopwatch
6 1
available
PC490LC-10 30-3
Testing and Sym-
Q'ty
bol
Testing clearance
of swing circle Commercially Dial gauge
K 1
bearing available
Developer for dye
Testing fuel Commercially penetrant check (color
circuit for leakage L 1
available checker)
Testing and Pressure gauge: 2.5, 6, 40, 60 MPa
adjusting oil 1
pressure in work M 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
equipment, swing 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
and travel circuits 2
07002-11023 O-ring 1
Testing oil 1
pressure in N 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
control circuit 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Testing and 799-101-5002 Hydraulic tester 1 {25, 60, 400, 600 kg/cm2}
1
adjusting oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
P
pressure in pump
PC control circuit 799-101-5220 Nipple 4 Size: 10 x 1.25 mm
2
07002-11023 O-ring 4
796T-440-1101 Sensor adapter 1 Pressure gauge: 50 MPa {500 kg/cm2}
796-440-1150 • Wiring harness 1
796T-440-1160 • Nipple 1
1 799-401-2350 • Washer 1
799-401-2340 • Coupling 1
07002-61823 • O-ring 1
Testing and 7861-93-1812 • Pressure sensor 1
adjusting oil 2 799-101-5220 Nipple 1 Size: M10 × 1.25 mm
Q
pressure in pump 3 07002-11023 O-ring 1
LS control circuit 799-101-5002 Hydraulic tester 1
790-261-1150 • Hose 1
4
799-101-5110 • Pressure gauge 1 60 MPa {600 kg/cm2}
799-101-5130 • Pressure gauge 1 6 MPa {60 kg/cm2}
5 790-261-1204 Digital hydraulic tester 1
Differential pressure
6 799-401-2701 gauge 1
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
solenoid valve R 799-401-3100 Adapter 1 Size: 02
output pressure 2
02896-11008 O-ring 1
799-401-3200 Adapter 1 Size: 03
3
02896-11009 O-ring 1
799-101-5002 Hydraulic tester 1
Measuring PPC 1 {25, 60, 400, 600 kg/cm2}
valve output S 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure 790-301-1730 Joint 1 PF 1/4 x R 1/8
2
07000-12011 O-ring 1
Testing oil Commercially
T Measuring cylinder 1
leakage available
30-4 PC490LC-10
Testing and Sym-
Q'ty
bol
Testing fan pump
1 790-301-1210 • Joint 1 M 14 x 1.5 o R 1/8
circuit oil U
pressure 07002-11423 • O-ring 1
799-101-5160 • Nipple 1 R 1/8
Testing fan pump 1
EPC solenoid 799-101-5160 • Nipple 1 R 1/8
V
valve output 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure 799-101-5220 Nipple 1 M 10 x 1.25
2
07002-11023 O-ring 1
Commercially Lap top type personal
1 computer 1 Windows XP SP2, VISTA, Windows 7
available
Loading 2 Cu3886388 INSITE ver 7.4 1
compensation
795-799-5730 INLINE 5 kit 1
values of X
Commercially • Cable (USB)
injectors and 3 1 • 795-799-5740 (RS232)
controllers available
795-799-5720 • Cable 1
4 799-601-4510 Cable (12P) 1
Testing coolant
temperature and – 799-101-1502 Digital thermometer 1 -99.9 to 1,299 °C
oil temperature
Testing operating – 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
effort and
depressing effort – 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Testing stroke
– Commercially
and hydraulic Ruler 1
available
drift
Testing work Commercially Stopwatch
– 1
equipment speed available
Testing voltage – Commercially
Multimeter 1
and resistance available
Removal and
installation of
charge (boost) Commercially 3.26 mm Torx wrench
– Torx wrench 1
pressure and available (KTC Q4T15 or equivalent)
temperature
sensors
Removal and
installation of
– 795-799-6210 Socket 1 27 mm deep socket
engine oil
pressure switch
Removal and
installation of 19 mm deep socket
coolant – 795T-981-1010 Socket 1
temperature (MITOLOY 4ML-19 or equivalent)
sensor
PC490LC-10 30-5
Sketch of tools for testing and adjusting (PC400-3531-034-A-00-A)
Note) Komatsu will not be held responsible for special tools manufactured according to these sketches.
G1: Plug
Q1: Sensor adapter
30-6 PC490LC-10
Note) Komatsu will not be held responsible for special tools manufactured according to these sketches.
Q1: Nipple
-: Socket
PC490LC-10 30-7
Engine and cooling system
Testing engine speed (PC400-A000-360-K-00-A)
a Check the engine speed by using the 4) Operate the left work equipment control lever
troubleshooting support or monitoring function of to relieve the arm circuit at the IN stroke end
the machine monitor. and test the engine speed.
5. Testing speed (around rated speed) at 2-
a Measure the engine speed under the following
pump relief + one-touch power maximizing
conditions.
function
• Coolant temperature: 60 to 100°C
1) Start the engine and operate the arm cylinder
• Hydraulic oil temperature: 45 to 55°C
to “arm IN” stroke end.
Testing (PC220-A000-388-K-00-A) 2) Set the fuel control dial to the high idle (MAX)
position and set the working mode to the
1. Preparation work
Power mode (P).
Operate the machine monitor so that the engine
3) While operating the left work equipment
speed can be monitored.
control lever to relieve the arm circuit at “arm
a For the operating method of the machine IN” stroke end and pressing the one-touch
monitor, see "Special functions of machine power maximizing switch, test the engine
monitor". speed.
a Monitoring code: 01002 "Engine speed" a The one-touch power maximizing function is
reset automatically in approximately 8.5
seconds even if the switch is kept pressed.
Accordingly, test the engine speed in that
period.
a You may check with the swing lock switch
ON (In this case, you do not need to operate
the one-touch power maximizing switch.)
6. Testing auto-deceleration speed
1) Start the engine, set the fuel control dial to
high idle position (MAX), and turn the auto-
deceleration function ON.
2) Set all the control levers and pedals for work
equipment, swing, and travel to the neutral
2. Testing low idle speed position and measure the engine speed
1) Start the engine and set the fuel control dial when the auto-deceleration operates.
to the low idle (MIN) position.
2) Set all the control levers and pedals for work a The engine speed lowers to a certain level
equipment, swing, and travel to the neutral approximately 5 seconds after all the levers
position and test the engine speed. and pedals are set to NEUTRAL position.
3. Testing high idle speed This level is the auto-deceleration speed.
1) Start the engine and set the fuel control dial
to the high idle (MAX) position.
2) Set the working mode in the Power Mode (P)
and set the auto-deceleration to OFF.
3) Set the swing lock switch to ON position.
4) Set all the control levers and pedals for work
equipment, swing, and travel to the neutral
position and test the engine speed.
4. Testing 2-pump relief speed
1) Start the engine and operate the arm cylinder
to “arm IN” stroke end.
2) Set the swing lock switch to OFF position.
3) Set the fuel control dial to the high idle (MAX)
position and set the working mode to the
Power mode (P).
30-8 PC490LC-10
Testing boost pressure (PC400-A900-360-K-00-A)
a Testing tools
Sym-
Part No. Part Name
bol
A 799-201-2202 Boost gauge kit
k Park the machine on a level ground and

lower the work equipment to the ground.
a Test the boost pressure under the following

condition.
• Swing lock switch ON 2. Install nipple [1] of boost gauge kit A and
• Arm IN relief + One-touch power max. connect them to gauge [2].
Testing (PC400-A900-362-K-00-A)
Measuring with machine monitor
Testing of boost pressure is available from the
troubleshooting support or monitoring function of
the machine monitor.
a For the operating method of the machine monitor,
see “Special functions of machine monitor”.
a The boost pressure is normal when it is within
the standard value range. For standard values,
see "Standard value table", "Standard value
table related to engine".
a Monitoring code: 36500 "Charge pressure-A" 3. Run the engine at middle or higher speed and
bleed oil from the hose.
a Insert the hose connector into the gauge
halfway to open the self-seal on the hose
side repeatedly, and the oil will be purged.
a If Pm kit (A) is available, you may use the air
bleeding coupling (790-261-1130) in that kit.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to purge the oil.
4. Set the working mode to the power mode (P)
and turn the swing lock switch ON.
a If the swing lock switch is turned to ON
position, the main relief valve is set for high-
Testing by use of testing tools pressure relief.
1. Open the engine hood and remove boost 5. Measure the boost pressure when the hydraulic
pressure pickup plug (1). relief is made by arm IN operation + one-touch
power max. with engine at high idle.
a The boost pressure is normal when it is
within the standard value range. For
standard values, see "Standard value table",
"Standard value table related to engine".
PC490LC-10 30-9
6. After finishing test, remove the testing tools and

restore the machine.
Testing with machine monitor
Testing of boost pressure is available from the
troubleshooting support or monitoring function of
the machine monitor.
a For the operating method of the machine monitor,
see “Special functions of machine monitor”.
a The boost pressure is normal when it is within
the standard value range. For standard values,
see "Standard value table", "Standard value
table related to engine".
a Monitoring code: 36500 "Charge pressure-A"
30-10 PC490LC-10
Testing exhaust gas color (PC400-A900-360-K-01-A)
a Testing tools 2) Insert the exhaust gas intake pipe in port (2)
Sym- for the removed plug.
Part No. Part Name
bol a Insert the gas intake pipe so that the
1 799-201-9002 Handy smoke checker probe tip will be at the center of the piping
B Commercially in parallel with the piping.
2 Smoke meter
available 3) Start the engine and run the engine at high
k Park the machine on a level ground and idle, absorb the exhaust gas to the filter
lower the work equipment to the ground. paper by operating the handle of smoke
checker B1 with arm IN relief.
k Be careful not to touch any hot part when a Absorbing time: 1.4 ± 0.2 sec.
removing or installing the testing tools.
k After KDPF regeneration is started, high-

temperature exhaust gas spurts from the
inspection port, potentially causing burn
injury. Therefore, you must stop KDPF
regeneration from the machine monitor
before starting the inspection. (For the
stopping procedure of KDPF regeneration,
see the Operation and Maintenance Manual.)
a Test the exhaust gas color under the following

conditions.
• Coolant temperature: 60 to 100°C 4) Remove the filter paper and compare it with
• At relief with arm IN the attached scale for judgement.
• Swing lock switch ON 5) After finishing test, remove the testing tools
a If an air source and an electric power source are and restore the machine.
not available in the field, use handy smoke 3. Measuring by using smoke meter B2
checker B1. When recording official data, etc.,
use smoke meter B2.
Testing (PC400-A900-385-K-00-A)
1. Open the engine hood and remove plug (1).

3 Plug:
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug:
Seizure prevention compound (LC-G)
1) Connect the probe hose, receptacle of the

accelerator switch, and air hose to smoke
meter B2.
a Limit the supplied air pressure to 1.5 MPa
{15 kg/cm2} or below.
2) Connect the power cable to an AC 100 V
receptacle.
a Check that the smoke meter power switch
is in OFF position, before connecting the
power cable to the receptacle.
2. Measuring by using handy smoke checker
3) Insert probe [1] of the smoke meter B2 into
B1
port (2) for the removed plug.
1) Fit a sheet of filter paper to smoke checker
B1.
PC490LC-10 30-11
a Insert the gas intake pipe so that the

probe tip will be at the center of the piping
in parallel with the piping.
4) Loosen the cap nut of the suction pump and
place the filter paper.
a Place the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of smoke meter B2 to
ON position.
6) Start the engine, and perform the arm IN

relief or run the engine at high idle. Depress
the pedal of smoke meter B2 to collect the
exhaust gas on the filter paper.
7) Place the filter paper contaminated with
exhaust gas on new filter papers in the filter
paper holder, and read the indicated value.
8) After finishing test, remove the testing tools
and restore the machine.
30-12 PC490LC-10
Testing and adjusting valve clearance (ALL-A700-001-K-00-A)
a Testing tools
Sym-
Part No. Part Name
bol
1 795-799-1131 Gear
C Commercially Feeler gauge
2
available

k Turn the battery disconnect switch to OFF

position and remove the key.
a Test and adjust the valve clearance under the 5. Rotate the crankshaft in the normal direction
following condition. with gear C1 in order to bring the stamped
"1.6TOP" line (a) of the damper to pointer (5)
• Coolant temperature: Normal temperature
and set the No. 1 cylinder to the compression
Testing (PC400-A700-361-K-00-A) top dead center.
1. Open the engine hood and remove head cover a When of No. 1 cylinder is at the compression
(1) to be tested. top dead center, the rocker arm can be
a As for the No. 1 cylinder, remove air intake manually moved as much as the valve
connector (2) on top of the head cover. clearance.
2. Remove cover (3). If the rocker arm cannot be moved, the No. 1
cylinder is not at its compression top dead
a For confirming the timing mark. center. In that case, rotate the crankshaft 1
more turn.
3. Remove engine under cover (4).
4. Remove plate (13) of the engine flywheel

a Method of checking compression top dead
housing and insert gear C1.
center from underside of engine
• Align stamped line (12) of pulley (11) with
pointer (10) installed to the fan motor cover.
PC490LC-10 30-13
• Only one stamped line of "1.6 TOP" is made

on the circumference.

a Be sure to remove gear C1.
a Replace the gasket of the head cover with a
new one.
3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
6. While the No. 1 cylinder is at the compression

top dead center, check the valve clearances
marked with qin the following figure.
7. Then, rotate the crankshaft 1 turn in the normal
direction and check the valve clearance of the
remaining valves marked Q.
a It is also allowed to check the valve
clearance of No. 1 cylinder while the piston is a Be sure to remove gear C1.
at the compression top dead center, and then
check the valve clearance of other cylinders 3 Air intake connector (2) mounting
in the firing order by turning the crankshaft clamp:
120 deg. at a time. 10.5 ± 0.5 Nm {107 ± 5 kgm}
a The valve clearance is normal when it is 3 Cylinder head cover (1) mounting
within the standard value range. For bolt:
standard values, see "Standard value table", 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
Adjusting (PC400-A700-27D-K-00-A)
a If you can move the rocker arm of air intake
valves (IN) with hand by the distance of the After testing, adjust the valve clearance according
valve clearance, adjust the valves marked to the following procedure, if necessary.
with Q in the valve arrangement drawing. a After setting the No. 1 cylinder at the
a If you can move the rocker arm of exhaust compression top dead center, adjust valve
valves (EX) with hand by the distance of the clearance of No. 1 cylinder.
valve clearance, adjust the valves marked 1. While fixing adjustment screw (6), loosen
with q in the valve arrangement drawing. locknut (7).
2. Insert feeler gauge C2 in the clearance between
a Firing order: 1-5-3-6-2-4
rocker arm (8) and crosshead (9) and adjust the
valve clearance with adjustment screw (6).
30-14 PC490LC-10
a With feeler gauge C2 inserted, turn

adjustment screw (6) to a degree that you
can move feeler gauge C2 lightly.
a Adjust the valve clearance to within the
following target value.
a The valve clearance is normal when it is
3. While fixing adjustment screw (6), tighten lock
nut (7).
3 Lock nut (7):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a After tightening lock nut (7), check the valve
clearance again.

a Be sure to remove gear C1.
3 Air intake connector (2) mounting
clamp:
10.5 ± 0.5 Nm {107 ± 5 kgm}
3 Cylinder head cover (1) mounting
bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
PC490LC-10 30-15
Testing compression pressure (PC400-A000-001-K-00-A)
a Testing tools a Disconnect the terminal of the injector wiring

Sym- harness on the injector side and pull it
Part No. Part name outside the rocker housing (Loosen the 2
bol
1 795-502-1590 Compression gauge terminal nuts alternately).
795-471-1420 Adapter a Pass a wire, etc. under the fuel path
2
D 6217-71-6112 Gasket projected sideways and pull up the injector
Commercially Hose (inside diameter 14 (Do not pry the injector top up).
3 mm, length approx. 2 m)
available
a QR code tab (7) is installed to the top of
k Place the machine on a level ground and injector (5). Do not remove or damage it.

position and remove the key.
k When testing the compression pressure,

take care not to get yourself burned by
touching the exhaust manifold or KDPF, or
get caught in a rotating part.
a Measure the compression pressure under the

following conditions.
• Engine oil temperature: 40 to 60 °C
Testing (PC400-A000-36B-K-00-A)
a For the removal and installation of injectors, see

Disassembly and assembly, "Removal and
installation of fuel injector assembly".
1. Remove the cylinder head cover and set the
tested cylinder to the compression top dead
center. For details, see "Measuring and
adjusting valve clearance".
a When the cylinder is at the compression top
dead center, the both rocker arms (intake
and exhaust side) of the cylinder can be
moved as much as the valve clearance with 4. Install adapter D2 to the injector mounting hole
the hand. and connect compression gauge D1.
2. Remove common rail cover (1) and remove a Be sure to install the gasket to the end of the
high-pressure fuel tube (2) to be tested. adapter.
a Fix the adapter by using the injector holder.
3 Injector holder mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a If a small amount of oil is applied to the
connecting portions of the adapter and
gauge, air will not leak easily.
5. Install rocker arm assembly (3).
3 Rocker arm assembly mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
6. Adjust the valve clearances.
3. Remove rocker arm assembly (3), disconnect See "Measuring and adjusting valve clearance".
injector wire harness (4), and remove injector 7. Install the removed air intake connector (6)
(5). referring to "Measuring and adjusting valve
clearance".
30-16 PC490LC-10
3 Air intake connector (6) mounting 12.After finishing test, remove the testing tools and
clamp: restore the machine.
10.5 ± 0.5 Nm {107 ± 5 kgm} a Install the injector, injector wiring harness,
and high-pressure fuel tube according to the
following procedure.
1) Install O-rings (8) and (9) and gasket (10) to
injector (5).
2) Fit holder (11) to injector (5) to temporarily
assemble them as a unit to the cylinder
head.
3) Fit spherical washer (13) to mounting bolt
(12) and tighten them to the cylinder head.
2 Spherical part of washer:
Engine oil (SAE30DH)
8. Install hose D3 to the common rail at where the 3 Mounting bolt:

tube is disconnected to let injected fuel drain to a 58.8 to 73.5 Nm {6.0 to 7.5 kgm}
container. 4) Install wiring harness (14) to the rocker arm
9. Restore the engine parts disconnected when housing and fix it with mounting bolt (15).
removing high-pressure fuel tube (2), and make 5) Insert wiring harness (14) into holder (16).
the engine possible to be cranked. 6) Alternately tighten two nuts at wiring harness
10.Select the "no injection cranking mode" by (14) end to injector (5).
operating the machine monitor.
3 Nut:
a Turn the battery disconnect switch to ON 2.0 to 2.4 Nm {0.2 to 0.24 kgm}
position, and then turn the starting switch to 7) Tighten tube (17) to injector (5).
ON position.
3 Sleeve nut:
a To select the "No injection cranking" mode,
39.2 to 44.1 Nm {4 to 4.5 kgm}
see "Special functions of machine monitor".
8) Tighten the clamping bolt of the fuel piping.
k If the engine is not set in the no injection 3 Clamping bolt:
cranking mode, it will start and will be 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
dangerous. Accordingly, be sure to set
the engine in this mode.
3 Rocker arm assembly mounting

11.Rotate the crankshaft by the starting motor and bolt:
measure the compression pressure. 58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a Read the pressure when the gauge pointer is a Adjust the valve clearance. For details,
stabilized. see “Adjusting valve clearance”.
a The compression pressure is normal when it 3 Cylinder head cover mounting
is within the standard value range. For bolt:
standard values, see "Standard value table", 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
PC490LC-10 30-17
Testing blowby pressure (PC400-A000-001-K-01-A)
a Testing tools 5. Install tool and adapter [1] of blowby checker E1

Sym- to inlet side hose (2) and connect gauge [2].
Part No. Part name
bol
1 799-201-1504 Blowby checker
Commercially Plug (hose inside
2 diameter: 24 mm)
E available
Commercially Cap (tube outside
3 diameter: 25.4 mm)
available
k Place the machine on a level ground and

a Test the blowby pressure under the following

conditions.
• Hydraulic oil temperature: 45 to 55°C 6. Start the engine, set the work equipment mode
• Arm IN relief + One-touch power max. ON to power mode (P), and turn the swing lock
• Perform at regeneration disable switch ON.
Testing (PC400-A000-36C-K-00-A) a If the swing lock switch is turned to ON

position, the main relief valve is set for high-
1. Open engine hood (1) (center). pressure relief.
7. While running the engine at high idle, relieve the
arm circuit, turn on the power maximizing
function, and measure the blowby pressure.
a Read the gauge for blowby pressure when
the pointer is stabilized.
2. Disconnect the KCCV side of KCCV blowby gas

inlet hose (2) and outlet hose (3).
3 Clamp:
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

3. Install plug E2 to disconnected outlet side hose

(3).
4. Install cap E3 to KCCV (4) outlet and the inlet
side tube.
30-18 PC490LC-10
Testing engine oil pressure (PC400-AB00-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1 799-101-5160 • Nipple
F 799-101-5150 • Hose
2 790-261-1204 Digital hydraulic tester
3 799-401-2320 Gauge

a Measure the engine oil pressure under the 4. Install nipple [1] and hose [2] of hydraulic tester
following condition. F1 and connect them to gauge F3.
a The nipple and hose for digital hydraulic
a The engine oil pressure can also be checked by tester F2 can also be used.
using troubleshooting support or monitoring
function of machine monitor.
For operating method, see "Special functions of
machine monitor".
a Monitoring code: 37200 "Engine oil pressure
sensor"
Testing (PC400-AB00-362-K-00-A)
1. Open engine hoods (1) and (2).
5. Start the engine and turn the auto-decelerator

OFF.
6. Run the engine and measure the engine oil
pressure at high idle and low idle.
a The engine oil pressure is normal when it is
2. Remove covers (3) and (4), and remove radiator

sub tank (5).

3. Remove oil pressure pickup port plug (6) from

the cylinder block.
PC490LC-10 30-19
Testing EGR valve and KVGT oil pressure (PC400-A9K1-001-K-00-A)
a Testing tools a The nipple and hose for digital hydraulic

Sym- tester G3 can also be used.
Part No. Part name
bol
795T-401-1110 Plug
1
02896-21015 O-ring
G 799-101-5160 • Nipple
2
799-101-5150 • Hose
799-101-5140 • Gauge

a Measure oil pressure under the following 4. Start the engine and measure the oil pressure at
condition. high idle and low idle.
• Hydraulic oil temperature: 45 to 55°C a The EGR valve and KVGT oil pressure is
normal when it is within the standard value
Testing (PC400-A9K1-362-K-00-A) range. For standard values, see "Standard
1. Open engine hood (1). value table", "Standard value table related to
engine".
2. Remove plug (2) (drive pressure).

3 Plug (2):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3. Install plug G1, install nipple [1] and hose [2] of

hydraulic tester G2, and connect them to gauge
[3].
3 Plug G1:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a Use gauge [3] of 2.5 MPa {25 kg/cm2}.
30-20 PC490LC-10
Testing fuel pressure (PC400-AE20-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5160 • Nipple
799-101-5150 • Hose
H 2 799-261-1204 Digital hydraulic tester
790-301-1181 Joint
3
07005-01212 Seal
4 799-401-2320 Gauge

lower the work equipment to the ground. 3. Install joint H3, install nipple [1] and hose [2] of
hydraulic tester H1, and then connect them to
k When checking the fuel system and gauge H4.
removing or installing testing tools, stop the
a When installing joint H3, be sure to install the
engine and wait for at least 30 seconds until
seal.
the remaining pressure is released from the
fuel circuit. (Do not start the work 3 Joint:
immediately after the engine is stopped since 14.7 to 19.6 Nm {1.5 to 2.0 kgm}
there is remaining pressure.)
a The nipple and hose of digital hydraulic tester
a Measure only the fuel pressure in the low- H2 can also be used.
pressure circuit from the feed pump through the
main fuel filter to the supply pump.
k The pressure in the high-pressure circuit
from the supply pump through the common
rail to the injectors is very high, so it cannot
be measured.
Testing (PC400-AE20-362-K-00-A)
1. Open engine hood (1) (center).
4. Start the engine and measure the fuel pressure

at high idle.
a The fuel pressure is normal when it is within
the standard value range. For standard
values, see "Standard value table",
2. Remove fuel pressure pickup port plug (1) (inlet

side) from the fuel filter head.
PC490LC-10 30-21

30-22 PC490LC-10
Testing fuel leakage and return (PC400-AE20-001-K-01-A)
a Testing tools
Sym-
Part No. Part name
bol
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially Hose (inside diameter:
3 approx. 6.5 mm)
available
J Commercially Hose (inside diameter:
4 approx. 17.5 mm)
available
Commercially Measuring cylinder
5
available
Commercially Stopwatch
6
available

k When checking the fuel system and

removing or installing testing tools, stop the
engine and wait for at least 30 seconds until
the remaining pressure is released from the
fuel circuit. (Do not start the work
immediately after the engine is stopped since
there is remaining pressure.)
a Prepare the container of about 20 l to receive

the fuel flowing out during measurement.
PC490LC-10 30-23
Testing (PC400-AE20-363-K-00-A)
Testing leakage from pressure limiter 3 Joint bolt:

1. Open engine hood (center). 17.7 to 22.6 Nm {1.8 to 2.3 kgm}
2. Remove the engine undercover.
a Be sure to fit the gaskets to both ends of the
3. Disconnect hose (5).
joint.
7. Connect inspection hose J3 to the tip of joint J2.
a Bind the connecting part of the test hose with
a wire, etc. to prevent it from coming off.
a Adjust the route of the test hose so that it
does not slacken and put its end in a
container.
4. Remove engine controller covers (6) and (7).

Remove tube (3) between common rail (1) and
return block (2).
8. Start the engine and run it at the rated output

speed.
9. When the engine speed is stabilized, measure
the leakage amount per minute with measuring
cylinder J5.
a You may test for 20 seconds and judge by
multiplying the result by 3.
a The leakage from the pressure limiter is
5. Insert spacer J1 to return block (2) side and normal when it is within the standard value
retighten it with the currently removed joint bolt. range. For standard values, see "Standard
3 Joint bolt: value table", "Standard value table related to
24.5 to 34.3 Nm {2.5 to 3.5 kgm} engine".
a Be sure to fit the gaskets to both ends of the

spacer.
10.After finishing measuring, stop the engine.

Measuring return rate from injector
6. Insert joint J2 to common rail (1) side and tighten a Keep the hose on the pressure limiter side
the currently removed joint bolt again. connected and keep its end in the conainer
while measuring the return rate from the injector.
30-24 PC490LC-10
1. Disconnect fuel return hose (4) of return block

(2).
a Plug the fuel hose side.
Plug part number: 07376-70315

3 Joint bolt at block side:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
2. Connect inspection hose J4 to return block (2) 3 Joint bolt at common rail side:
side. 17.7 to 22.6 Nm {1.8 to 2.3 kgm}
a Bind the connecting part of the test hose with
a wire, etc. to prevent it from coming off.
a Adjust the route of the test hose so that it
does not slacken and put its end in a
container.
3. Start the engine and run it at the rated output

speed.
4. When the engine speed is stabilized, measure
the return amount per minute with measuring
cylinder J5.
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the supply pump is not supplying fuel, the
engine speed may not rise. In this case,
record the engine speed, too, during the test.
a The return rate (spill) from the injector is
normal when it is within the standard value
range. For standard values, see "Standard
value table", "Standard value table related to
engine".
PC490LC-10 30-25
Bleeding air from fuel system (PC400-AD00-001-K-00-A)
Low-pressure fuel circuit
1. Fuel tank a In the following cases, bleed air according to this

2. Fuel connector procedure.
3. Pre-filter • When a fuel filter is replaced
• When run out of fuel occurs
4. Fuel feed pump
• When starting the engine for the first time
5. Doser after replacing fuel piping or supply pump
6. Supply pump
k Place the machine on a level ground, and
7. Feed pump lower the work equipment to the ground.
8. Cooling plate
9. Main fuel filter k While the fuel feed pump is in operation,
pressure is applied to the fuel circuit. Do not
10. Common rail pressure
loosen the air bleeding plug at this time,
11. Injector since the fuel may spout out.
12. Pressure limiter valve
30-26 PC490LC-10
Bleeding air (PC400-AD00-231-K-01-A)
1. Fill the fuel tank up with fuel. a Shifting the switch to the OFF position while
the lamp is flashing turns off the lamp and
a Add fuel until the fuel level gauge reaches
stops the fuel feed pump, too.
green range.
(Check on the machine monitor)
2. Set the starting switch to OFF position.
3. Open engine hood (1) (center).
5. After the specified time (approx. 6 minutes 30

seconds), lamp (3) goes off and the fuel feed
pump stops automatically.
4. Set fuel feed pump switch (2) inside the engine a When the fuel filter alone was replaced,
compartment to the "ON" position. above completes bleeding air..
a Lamp (3) will start flashing and operation of 6. When fuel is not provided in the fuel circuit such
the fuel feed pump will be started. as when run out of fuel occurred or when
replacement of the fuel pipe or supply pump was
done, set switch (2) to the ON position again
after the fuel feed pump is automatically
stopped.
7. Bleeding air, in this case, completes as lamp (3)
goes out.
8. Crank the engine by using the starting motor to
start the engine.
k Before starting the engine, check that

there is no person around the engine.
a Do not rotate the starting motor continuously
for more than 20 seconds.
a The built-in timer of this switch automatically a The air in the high-pressure circuit is bled
starts or stops operation of the fuel feed automatically by cranking the engine.
pump. (See the figure below)
a When the engine starts, run it at low idle for 5
a Operation of the fuel feed pump is stopped minutes to bleed all air from the fuel circuit.
as long as flashing of the lamp is continued.
It is not an error. a If the engine does not start, the air may have
not been bled from the low-pressure circuit.
In this case, try to start the engine again
according to the following procedure.
1) Set fuel feed pump switch (2) to the "ON"
position.
2) Rotate the engine with the starting motor to
start it while the fuel feed pump is in
operation. If the engine does not start, wait
for about 2 minutes, and then repeat steps 1)
and 2).
PC490LC-10 30-27
Testing fuel circuit for leakage (ALL-AD00-001-K-01-A)
a Testing tools a Relieve the arm circuit at the arm IN stroke

Sym- end.
Part No. Part name 9. Check the fuel piping and devices for fuel
bol
Developer leakage.
Commercially
L for dye penetrant check a Check the high-pressure circuit for fuel
available
(color checker) leakage focusing on the area to which color
checker L is sprayed.
k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel a If any fuel leakage is detected, repair it and
leaks while the engine is running, it presents perform the checks from step 1 again.
a serious danger that could result in a fire. a If no fuel leakage is detected, check is
After testing the fuel system and removing or complete.
installing the tools for the test, test it for fuel
leakage according to the following procedure.

a Clean the engine and the parts around it and

degrease them in advance so that you can
check easily for fuel leakage.
Testing (PC-AD00-364-K-00-A)
1. Spray color checker (developer) L to the fuel

supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep it at low idle , and stop it
when the engine speed is stabilized.
3. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
a If any fuel leakage is detected, repair it and
perform the checks from step 1 again.
4. Start the engine, and keep it running at low idle.
leakage.
6. Start the engine, and keep it running at high idle.
leakage.
8. Start the engine and keep it running at high idle,
then apply a load to the engine.
30-28 PC490LC-10
Handling cylinder cutout mode operation (PC400-AD00-34F-K-00-A)
a The cylinder cut-out test mode operation means

to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for Cylinder Cut-out
Mode operation, if the engine speed and output
do not change from the normal operation (all-
cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.
PC490LC-10 30-29
Handling no-injection cranking operation (PC-A000-25L-K-00-A)
a No-injection cranking means to crank the engine

by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
No-injection cranking is performed to lubricate
the engine parts and to protect them from
seizure. It is performed before the engine is
started, or after the machine has been stored for
a long period.
a When performing no-injection cranking operation,
see "Special functions of machine monitor".
30-30 PC490LC-10
Testing and adjusting air conditioner compressor belt tension (ALL-K5A0-001-K-00-

A)
k Park the machine on a level ground and 1. Loosen mounting bolt (5) and fixing bolt (6).
lower the work equipment to the ground. 2. Loosen lock nut (7), and slide compressor (9) by
rotating adjustment nut (8) to adjust V-belt (10)
Testing (PC400-K5A0-285-K-01-A) tension, and then tighten lock nut (7).
1. Open engine hoods (1) and (2). 3 Lock nut (7):
156.8 to 196 Nm {16 to 20 kgm}
a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt with V-
groove.
a If the V-belt is elongated exceeding the
adjustment allowance or it has a cut or a
crack, replace it with a new one.
3. Tighten mounting bolt (5) and fixing bolt (6).
a After tightening the bolts, check the belt
tension again according to the above
procedure.
2. Remove guards (3) and (4).
a If the V-belt is replaced, adjust and check the
tension again after operating the machine for
one hour.
3. Press the intermediate point of the belt between

fan pulley and compressor pulley with a finger
and measure deflection (a) of the belt. 4. After finishing adjustment, restore the machine.
• Belt depressing force: 58.8 N {6 kg}
• Belt deflection (a): 14 to 16 mm
4. After finishing testing, restore the machine.

Adjusting (PC400-K5A0-27C-K-01-A)
a If the belt deflection is improper, adjust it

PC490LC-10 30-31
Replacing alternator belt (PC400-AKM4-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
Commercially Adapter
1
available
U
Commercially
2 Ratchet wrench
available
a The auto-tensioner is provided for the alternator

belt. Thus, checking and adjusting the belt is
usually not necessary.
a When replacing the alternator belt, remove the
air conditioner compressor belt beforehand. 3. Replace alternator belt (4).
k Place the machine on a level ground and • Check each pulley for breakage and crack.
lower the work equipment to the ground. • Check that each alternator belt is fitted
securely to the corresponding pulley groove.
Replacing (PC400-AKM4-923-K-00-A)
1. Open engine hoods (1) and (2).
2. Insert a wrench to the portion( A) (width across

flats: 12.7 mm) of tensioner assembly (3), and
rotate it to the opposite to the winding-up
direction to decrease the alternator belt (4)
tension.
k Firmly set the wrench on tensioner

assembly (3) at portion (A) before
applying turning force to the wrench. (If
you try to rotate the wrench before it is
fully inserted, it can disengage and cause
serious physical injuries, due to strong
spring force of tensioner assembly (3).)
k After removing the alternator belt (4),

slowly and carefully restore tensioner
assembly (3).
k Be careful not to get your fingers caught

between the pulley and alternator belt (4)
during work.
30-32 PC490LC-10
Fuel doser cleaning procedure (PC400-A9H6-001-K-00-A)
a If the KDPF unit has trouble and

• if the trouble corresponds to "S-22 Forced
regeneration time is long" in Troubleshooting for
engine or if the fuel doser needs to be cleaned
for 4500-hour service, follow the procedure
below.
k Install or remove the cleaning devices after

the exhaust manifold and pipe temperature
has lowered.
Removal (PC400-A9H6-520-K-00-A) Cleaning (PC400-A9H6-255-K-00-A)
1. Open engine hood (1) (center). 1. Perform the following cleaning work to remove
soot (14) form fuel doser (8).
2. Remove bolt (2) and disconnect wiring harness

clamp (3). 2. Wet cloth (15) with a generous amount of diesel
3. Remove bolt (4) and nut (5) to remove bracket fuel, and press the cloth against the soot
(6). accumulated at the fuel doser injection port end
4. Remove two bolts (7) (width across flats: 8 mm) to let the fuel soak into the soot.
and remove fuel doser (8).
5. With the mounting face of fuel doser (8) up, 3. Wipe off the soot soaked with fuel with cloth
remove gasket (9) and heat insulator (10), and (15).
clean fuel doser (8).
PC490LC-10 30-33
a Cleaned injection port end

Cleaning complete (A: no soot remaining)
Cleaning incomplete (B: soot remaining)
4. Remove soot from the injection port end by

using nylon brush (16).
• Remove all soot from the injection port by
using nylon brush (16) and cloth (15).
a Be sure to use a nylon brush. Do not use a
wire brush as it may scratch the injection
port.
a Use only diesel fuel for cleaning.
Installation (PC400-A9H6-720-K-00-A)
1. Install heat insulator (10) to fuel doser (8).

2. Insert bolts (11) in fuel doser (8), fit gasket (9),
and install them to the exhaust connector.
3 Bolt (10) (width across flats 8 mm):
8.5 to 9.5 Nm {0.87 to 0.97 kgm}
30-34 PC490LC-10
a Replace bolts (11), gasket (9), and heat

insulator (10) with new ones.
a When installing gasket (9), direct its

shouldered side (convex side) toward the
exhaust connector.
3. Install the bracket and wiring harness clamp in

the reverse order to removal.
4. After the fuel doser is installed, run the engine at
low idle for about 3 minutes and then stop the
engine. Check the water and fuel circuits of the
fuel doser for leaks.
PC490LC-10 30-35
Writing compensation values at replacement of injector and engine

controller (PC400-AP70-001-K-00-A)
a Equipment needed for writing compensation a Service connector (1) (CN-N08) is installed
values inside the right rear panel of the cab.
Sym-
Part No. Part name
bol
Laptop computer:
Commercially
1 Windows XP SP2/ VISTA/
available
Windows 7
2 Cu3886388 INSITE ver 7.4
Cu4919416 INLINE 5 kit
X Commercially
available • Cable (USB)
3 • Cable (RS232)
or
795-799-5740
795-799-5720 • Cable
4 799-601-4510 Cable (12P)
a To install the INSITE program to the computer, Starting INSITE

insert the software DVD-ROM into the DVD 1. Start the computer.
drive of the computer and follow the menu. 2. Turn the starting switch to the ON position to
supply battery power to the engine controller.
a For writing, use INSITE v7.4 Feature Pack 1 or
3. On the personal computer screen, double-click
after.
on the icon shown below.
a If a problem (shutdown or open circuit) occurs in
the computer or cables, a serious error may
arise in the engine controller. Be careful when
connecting the cables.
a When connecting the INSITE system to the
engine controller, do not interrupt the battery
power supply to the engine controller. A power
loss breaks the connection with the INSITE
system.
Connection of PC (PC400-AP70-270-K-00-A)
1. Make sure that starting switch is in the OFF

position. 4. Establish communication with the engine
controller.
k When connecting and disconnecting the
1) Select "Connect to ECM".
PC, be sure to turn the starting switch to
the OFF position. • A: Confirm that "INLINE5 USB(J1939)
Connection" is displayed.
2. Connect INLINE 5 kit X3 and cables X4, to
personal computer X1. Connect these to service
connector (CN-N08).
2) Select "Connect".
• B: Confirm that "None" is displayed.
30-36 PC490LC-10
3) Input new data to "New Barcode" field.

a C: Establishing connection screen
D: Connection established screen a Writing for injector replacement or engine
(illustration does not move) controller replacement can be carried out.
Injector replacement
E: Communication status is displayed
• When replacing injectors, write the
(illustration moves during communication)
injector compensation value indicated on
the new injector to the engine controller.
• If the compensation values are not written
correctly, the engine may not operate
normally.
• Read the string of characters indicated on
top of the injector.
Read from left to right, starting with the
top line.
5. Write injector trim control behaviors and data.

1) Select "Advanced ECM Data".
• F: Confirm that "Advanced ECM Data" is
displayed.
Engine controller replacement

• When replacing engine controller, write
the injector compensation values
indicated on the old engine controller into
the new engine controller.
• If the compensation values are not written
correctly, the engine may not operate
normally.
• Compensation values on the back side of
engine controller
2) Select "Highpressure Common Rail Injector a: String of characters
Setup". b: QR codes
• G: Confirm that "Highpressure Common
Rail Injector Setup" is displayed.
PC490LC-10 30-37
• H: "New Barcode" field • Data processing screen (wait for 30

seconds)
4) Execute writing to the engine controller.

When all injector data are input, select 6) When data writing is completed, turn the
"Apply". starting switch to the ON position and then
• I: Data input for injectors select "OK".
Examples)
• L: Select OK.
Input the injector data of cylinder No. 1,
corresponding to "Cylinder 1".
• J: Select "Apply".
7) On the writing complete screen, select "OK".

• M: Select OK.
5) To execute writing, turn the starting switch to
the OFF position and then select "OK".
• K: Select OK.
30-38 PC490LC-10
8) "success" is displayed on the data writing 7. Turn the starting switch to OFF position and then
normal ending screen. turn ON again. Confirm that no errors are
• Check that "success" is displayed in present on the monitor.
portion N. a Related error codes:
CA2765: Injector trim data mismatch
8. When an injector is replaced, delete the
compensation value for that injector from the
label on back side of the engine controller.
a Delete the compensation value for the
replaced injector from the label on back side
of the engine controller.
a Record the data of the replaced injector in
the maintenance log book.
9. When replacing the engine controller, the values
indicated on the back side label of the old
controller may be void if any of the injectors
a Data writing failed screen have been replaced at an earlier time. Use the
• P: A message indicating failure of latest data recorded in the maintenance log
writing book, or read off the compensation value from
• If the following screen appears after the top of all existing injectors as described
step 7 instead of the screen shown in above in "Injector replacement".
step 8, a newly entered data may be
invalid. (Confirm the data and redo the
procedure)
6. Terminate communication with the engine

controller and exit.
• Q: Select "Disconnect from ECM".
PC490LC-10 30-39
Power train
Power train (ALL-C100-001-K-30-A)
Testing swing circle bearing clearance (ALL-J117-001-K-00-A)
a Testing tools 5. From this state, read the dial gauge K value.
Sym- a The value indicated by dial gauge K is the
Part No. Part Name
bol clearance of the bearing.
Commercially Dial gauge
K
available
k Be careful not to put a hand or foot under the

undercarriage, while taking measurement.
Testing (PC-J117-365-K-00-A)
1. Fasten dial gauge K to swing circle outer race

(1) or inner race (2), and touch the probe to the
end surface of inner race (2) or outer race (1) on
the opposite side.
a Set dial gauge K in the front side or rear side
of the machine.
6. Return the machine to the condition of step 2
and check that dial gauge K indicates 0 point.
a If 0 value is not indicated, repeat the steps 3
through 5.
2. Set the work equipment to the maximum reach

posture and set the bucket tip to the height of the
underside of the revolving frame.
a At this time, the front side of the upper
structure rises and the rear side lowers.
3. Set the reading of dial gauge K to the 0 point.
4. Set the arm almost perpendicular to the ground

and lower the boom until the front part of the
tracks float by 150 to 200 mm.
a At this time the front of the upper structure
rises and the rear lowers.
30-40 PC490LC-10
Undercarriage and frame
Testing and adjusting track tension (ALL-DTL0-001-K-00-A)
Testing (PC220-DTL0-285-K-00-A) a You can add grease until dimension (b)

between the idler guide and the track
1. Run the engine at low idle and move the
machine forward by the length of track on frame end becomes 0 mm. If the tension
is still low, the pins and bushings will
ground, and then stop slowly.
become excessively worn. In this case,
2. Place square bar [1] on the track shoes between
turn 180 deg. , or replace the pins and
the idler and the 1st carrier roller.
bushings.
a As the square bar [1], use an angle steel, etc.
which deflects less.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
• Standard maximum clearance (a): 10 to 30
mm
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.
k Do not loosen the valve more than 1

turn. Otherwise, the valve jumps out
Adjusting (PC220-DTL0-27C-K-00-A) because of the high-pressure grease
inside.
a If the track tension is improper, adjust it
according to the following procedure. 2) To check that the tension is proper, run the
1. Increasing tension engine at low idle and move the machine
forward by the length of track on ground,
1) Add grease through grease fitting (1) by
then stop slowly.
using a grease gun.
3) After adjusting, check the track tension again
2) To check that the tension is proper, run the
according to the above procedure.
engine at low idle and move the machine
forward by the length of track on ground,
then stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.
PC490LC-10 30-41
Hydraulic system
Releasing remaining pressure from hydraulic circuit (ALL-C000-001-P-02-A)
Releasing remaining pressure (PC400- a The engine does not start unless the lock
C000-22A-K-00-A) lever is set to LOCK position.
1. Releasing remaining pressure from hydraulic 4) Repeat steps 2) and 3) above 2 or 3 times,
tank and the remaining pressure in the piping is
released completely.
k Since the hydraulic tank is enclosed and 3. Releasing remaining pressure from swing
pressurized, release the remaining motor circuit
pressure from it when removing a hose or The remaining pressure in the swing motor
a plug connected to it. circuit can be released by performing the same
operation for “Releasing residual pressure from
1) Lower the work equipment to the ground in a hydraulic cylinder circuit" (Operate the lever to
stable position and stop the engine. SWING only, however).
2) Loosen oil filler cap (1) of the hydraulic tank 4. Releasing remaining pressure from travel
gradually to release the air in the tank. motor circuit
Since the control valve spool of the travel motor
circuit is open, the pressure in this circuit can be
released by performing “Releasing remaining
pressure from hydraulic tank”.
2. Releasing remaining pressure from hydraulic

cylinder circuit
k When disconnecting a pipe between a

hydraulic cylinder and the control valve,
release the remaining pressure from the
piping according to the following
procedure.
1) Lower the work equipment to the ground and
hydraulic tank. For details, see " Releasing
remaining pressure from hydraulic tank" .
a Keep the oil filler cap of the hydraulic tank
removed.
2) Turn the starting switch to ON position and
set the lock lever to FREE position, and then
operate the right and left work equipment
control levers forward, backward, to the right,
and to the left.
a The control valve is operated by the
pressure in the accumulator. The
pressure in the accumulator is used up,
however, after the work equipment
control levers are operated 2 to 3 times.
3) Start the engine and run it at low idle for 5
seconds to raise the pressure in the
accumulator.
30-42 PC490LC-10
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing and travel
circuits (PC400-C000-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
790-261-1204 Digital hydraulic tester
M
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
k Place the machine on level ground and lower

the work equipment to the ground. Then,
hydraulic system. For details, see "Releasing
remaining pressure from hydraulic system".
2. Increase the hydraulic oil temperature to 45 to
a Measure the oil pressure in the work equipment, 55°C and measure the pump discharge
swing, and travel circuits under the following pressure.
condition.
Measuring method by using oil pressure gauge
• Hydraulic oil temperature: 45 to 55°C 1. Open the side cover on the left side of the
Testing (PC400-C000-362-K-00-A) machine and remove oil pressure gauge [1] of
hydraulic tester M1 to ports (1) and (2).
a The oil pressure in the work equipment, swing,
and travel circuits (pump discharge pressure) a Use an oil pressure gauge of 60 MPa {600
can be checked from the "Monitoring Pre- kg/cm2}.
defined" or "Monitoring" screen of the machine • (1): Front pump discharge pressure pickup
monitor. port (rear of machine)
• (2): Rear pump delivery pressure pickup port
Measuring method by using machine monitor (front of machine)
1. Start the engine and set the machine monitor to
"Monitoring/Pre-defined" or "Monitoring" screen.
a For the setting method, see "Special
functions of machine monitor".
• Monitoring code: 01100 "F Pump Pressure"
• Monitoring code: 01101 "R Pump Pressure"
• "Monitoring/Pre-defined (8/16)" screen
• "Monitoring" screen
PC490LC-10 30-43
Hydraulic system
Start the engine and keep it running until the 2. Set all control levers and pedals to the
hydraulic oil temperature rises to the operating NEUTRAL and measure the oil pressure while
range. running the engine at high idle.
a Hydraulic oil pressure when the unload valve
unloads is displayed.
Combination of pump, actuator, and valve

a When the oil from the pumps is divided, the front
pump and rear pump act independently on each Testing work equipment relief pressure
actuator as shown in the table. Note that the 1. Start the engine and operate the cylinder to be
relieved valve varies depending on the actuator. measured to the stroke end.
2. Set the working mode to Power Mode (P).
a When the work equipment circuit or swing circuit
3. Measure the hydraulic oil pressure when the
is relieved singly, the oil flows of the pumps are
cylinder is relieved while the engine is running at
merged. When the travel circuit is relieved singly,
high idle.
the oil flows of the pumps are divided.
a The pressure at the time when the main relief
a The actuators in the table are arranged in the
valve is relieved is displayed.
order when the control valve is viewed from the
front of the machine (As for the service valve, a If the one-touch power maximizing switch is
the table shows a case for the machine with one pressed, the main relief valve is relieved at
attachment installed). low pressure. If the former is pressed, the
latter is relieved at high pressure.
Pump
Actuator Valve relieved a If the swing lock switch is set to the ON

position, the 2-stage relief valve is kept ON
(F unload valve) (F main relief valve)
and the relief valve is relieved at high
Service Safety valve for service pressure. Therefore, keep the swing lock
Boom Hi switch at the OFF position.
F main relief valve
Arm Hi
Front
bucket F main relief valve Testing swing relief pressure

L.H. 1. Start the engine, set the working mode to the
F main relief valve
travel Power Mode (P), and turn the swing lock switch
Raise: F main relief valve ON.
Boom
Lower: Safety-suction valve 2. Measure the hydraulic oil pressure when the
(Pump merge-divider valve) (Travel junction valve) engine is running at high idle and the swing
(Self-pressure reducing valve) circuit is relieved.
Swing Swing motor safety valve a The swing motor safety valve relief pressure
Rear
R.H. is indicated.
R main relief valve
travel
Arm Lo R main relief valve a The swing motor relief pressure is lower than
(R unload valve) (R main relief valve) the main relief pressure.
(Centralized safety valve) (Back pressure valve) Testing travel relief pressure
1. Start the engine and lock the travel mechanism.
Measuring unload pressure
1. Start the engine, set the working mode to Power
k Put pin [2] between the sprocket and
Mode (P), and turn the auto-decelerator OFF.
track frame to lock the travel mechanism
securely.
30-44 PC490LC-10
Hydraulic system
2. Set the working mode to Power Mode (P). 1) Disconnect pilot hose (5).
3. Measure the pressure when the engine is 2) While fixing holder (6), loosen locknut (7).
running at high idle speed and the travel circuit 3) Turn holder (6) to adjust the pressure.
is relieved.
a If the holder is
k Before operating the travel lever (pedal), • turned clockwise, the pressure is
check the pin position and locked increased.
direction of the travel again. • turned counterclockwise, the pressure
is decreased.
a The pressure at the time when the main relief
valve is relieved is displayed. The travel a Pressure of adjustment per turn of holder:
circuit is always relieved at high pressure. Approximately 20.5 MPa {Approximately
209 kg/cm2}
Work after finishing measurement
4) While fixing holder (6), tighten locknut (7).
After finishing test, remove the testing tools and
restore the machine. 3 Locknut:
Adjusting (PC400-C000-270-K-00-A) 49 to 58.8 Nm {5 to 6 kgm}
The figure shows the front main relief valve.
a The unload valve cannot be adjusted.
1. Adjusting work equipment and travel relief
pressure
a When the relief pressure of the work
equipment circuit or travel circuit is abnormal,
adjust main relief valves (3) and (4)
• (3): Front main relief valve
• (4): Rear main relief valve
a When adjusting the main relief valve on the
front pump side, remove the top cover of the
control valve.
a When adjusting the main relief valve on the
rear pump side, remove the undercover of
the control valve.
a Adjust only the low relief pressure of the
main relief valve. (When the low relief
pressure is adjusted, the high relief pressure
is set automatically.)
a The low relief pressure is the pressure under
the following condition: the 2-stage relief
solenoid valve is not energized and the pilot
pressure is not applied to the selector port.
5) Connect pilot hose (5).
PC490LC-10 30-45
Hydraulic system
6) After finishing adjustment, check the oil 5) Connect pilot hose (9).
pressure again according to the above 6) After finishing adjustment, check the oil
measurement procedure. pressure again according to the above
2. Adjustment of boom LOWER relief pressure measurement procedure.
(on the side where high pressure is set)
a Adjusting the high-pressure setting side
a If the high-pressure relief pressure for boom changes the setting of the low-pressure
LOWER is improper, adjust the high side. Thus, low-pressure setting side
pressure set side of safety-suction valve (8) requires adjustment, as well.
for boom LOWER according to the following 3. Adjusting boom LOWER relief pressure (on
procedure. the side where low pressure is set)
a The high-pressure relief pressure mode a When the low relief pressure for boom
denotes the state in which the machine push- LOWER is improper or when the high
up switch is turned on, disabling to apply the pressure set side is adjusted, adjust the low
pilot pressure to the selector port. pressure side of safety-suction valve (8) for
boom LOWER according to the following
procedure.
a The low-pressure relief pressure mode
denotes the state in which the machine push-
up switch is turned off, disabling to apply the
pilot pressure to the selector port.
1) Disconnect pilot hose (9).
2) While fixing holder (12), loosen locknut (13).
3) Turn holder (10) to adjust the pressure.
a If the holder is
• turned clockwise, the pressure is
increased.
1) Disconnect pilot hose (9). • turned counterclockwise, the pressure
2) While fixing holder (10), loosen locknut (11). is decreased.
3) Turn holder (10) to adjust the pressure. a Pressure of adjustment per turn of holder:
a If the holder is Approximately 25.3 MPa {Approximately
• turned clockwise, the pressure is 258 kg/cm2}
increased. 4) While fixing holder (12), tighten locknut (13).
• turned counterclockwise, the pressure 3 Locknut:
is decreased.
78 to 93 Nm {8.0 to 9.5 kgm}
a Pressure of adjustment per turn of holder:
Approximately 25.3 MPa {Approximately
258 kg/cm2}
4) While fixing holder (10), tighten locknut (11).
3 Locknut:
93 to 123 Nm {9.5 to 12.5 kgm}
5) Connect pilot hose (9).

6) After finishing adjustment, check the oil
pressure again according to the above
measurement procedure.
4. Adjusting swing relief pressure
30-46 PC490LC-10
Hydraulic system
1) If the swing relief pressure is improper, adjust

swing 2-stage relief valve (14) according to
the following procedure.

3) While fixing pressure adjustment screw (16),
loosen locknut (17).
4) Turn adjustment screw (16) to adjust the
pressure.
a If the pressure adjustment screw is
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure
is decreased.
a Pressure of adjustment per turn of
pressure adjustment screw:
7.68 MPa {78.3 kg/cm2}
5) While fixing pressure adjustment screw (16),
tighten locknut (17).
3 Locknut:
58.8 to 78.4 Nm {6 to 8 kgm}

7) After finishing adjustment, check the oil
pressure again according to the above
measurement procedure.
PC490LC-10 30-47
Hydraulic system
Testing oil pressure in control circuit (ALL-C010-001-K-00-A)
a Testing tools
Sym-
Part No. Part Name
bol
1
N
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
k Lower the work equipment to the ground and

stop the engine. After the engine stops,
operate the control lever several times to
release the remaining pressure in the piping.
Then loosen the oil filler cap slowly to 5. After finishing test, remove the testing tools and
release the pressure inside the hydraulic restore the machine.
tank.
a The control circuit source pressure may be
a Measure the control circuit oil pressure under tested at oil pressure pickup port plug (2) on
the following condition. the hydraulic pump.
Testing (PC400-C010-362-K-00-A)
1. Remove the control valve top cover and oil

pressure pickup port plug (1).
2. Install nipple N2 and connect it to oil pressure

gauge [1] of hydraulic tester N1.
a Use an oil pressure gauge of 6.0 MPa {60 kg/
cm2}.
3. Start the engine and keep it running until the
hydraulic oil temperature increases to 45 to 55°
C.
• Set the working mode in Power Mode (P)
a Do not adjust the relief valve for the control
and set the auto-deceleration to OFF.
circuit source pressure.
4. Measure the hydraulic oil pressure, when the
engine is running at full speed and all the control
levers are set to NEUTRAL.
30-48 PC490LC-10
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit (ALL-C2A3-001-K-00-A)
a Testing tools 2) Install nipple P2 and connect it to oil

Sym- pressure gauge [1] of hydraulic tester P1
Part No. Part Name
bol a Use an oil pressure gauge of 60 MPa
799-101-5002 Hydraulic tester {600 kg/cm2}.
1
P • The figure shows the rear side.
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
a Before testing the oil pressure in the pump PC

control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
3) Start the engine and keep it running until the
the source pressure of the control circuit are
hydraulic oil temperature rises to 45 to 55°C.
proper.
Measure the PC valve output pressure (servo
piston inlet pressure) under the following
conditions.
Testing (PC400-C2A3-362-K-00-A)
1. Testing PC valve output pressure (servo

piston inlet pressure)
a Measure the PC valve output pressure
(servo piston inlet pressure) and pump
discharge pressure simultaneously and
compare them.
4) Measure the pump discharge pressure and
1) Open the side cover on the left side of the PC valve output pressure (pressure at servo
machine and remove oil pressure pickup piston inlet) at the same time after setting the
plugs (1), (2), (3), and (4). machine to the following conditions with the
• (1): Front pump discharge pressure engine running at high idle.
pickup port • Working mode: P mode
• (2): Rear pump discharge pressure • Swing lock switch: ON
pickup port (Turning 2-stage relief ON switches to
• (3): Front control pressure pickup port high-pressure relief)
• (4): Rear control pressure pickup port • Work equipment, swing and travel: Arm
IN relief
PC490LC-10 30-49
Hydraulic system
a Judgment method:
When the ratio between the pump
discharge pressure and the PC valve
output pressure (servo piston output
pressure) reaches the following value, the
pressures are proper.
Oil pressure to be Oil pressure ratio
checked
Pump discharge
pressure 1
PC valve output Approx. 0.6 (Approx. 3/
pressure 5)
3) Start the engine and keep it running until the
a If the PC valve or the servo piston is hydraulic oil temperature rises to 45 to 55°C.
defective, the PC valve output pressure
(servo piston output pressure) comes to
the same pressure as the pump
discharge pressure, or almost 0.
2. Testing PC-EPC valve output pressure
1) Open the side cover on the left side of the
machine body and remove oil pressure
pickup plugs (5) and (6).
• (5): Front PC mode selector pressure
pickup port
• (6): Rear PC mode selector pressure
pickup port 4) Measure the hydraulic oil pressure with all
the control levers set to the NEUTRAL and
the engine running at high idle and at low
idle.
a When the PC-EPC valve output pressure
changes as shown below, it is normal.
Engine Control lever Pressure
2.9 MPa
Low idle {30 kg/cm2}
NEUTRAL
0.98 MPa
High idle
{10 kg/cm2}
2) Install nipple P2 and connect it to oil Adjusting (PC400-C2A3-270-K-00-A)
pressure gauge [1] of hydraulic tester P1. a If either of the following problem occurs and the
a Use an oil pressure gauge of 6.0 MPa {60 PC valve seems to be defective, adjust PC
kg/cm2}. valves (7) and (8) according to the procedure
• The figure shows the rear side pump. shown below.
• As the work load increases, the engine
speed decreases remarkably.
• The engine speed is normal but the work
equipment speed is low.
• (7): Front pump PC valve
• (8): Rear pump PC valve
30-50 PC490LC-10
Hydraulic system
a The width across flats of the PC valve locknut is 4. After the adjustment, make sure that the PC
13 mm and that (inside width) of the adjusting valve output pressure (servo piston inlet
screw is 4 mm. pressure) is normal according to the
Do not turn any locknuts and adjustment screws measurement steps explained earlier.
other than the above because doing so affects
the hydraulic pump performance.
1. Loosen locknut (9).

a Before loosening the locknut, make a match
mark on the end face of the adjustment
screw to indicate the original position of the
adjustment screw (so that you can return the
adjustment screw to the original position if
you turn it in the opposite direction).
2. Adjust the pressure by rotating adjustment
screw (10) to the right or left.
a Turn the adjustment screw
• To clockwise when the work equipment
speed is low (to increase pump
absorption torque).
• To counterclockwise when the engine
speed lowers (to decrease pump
absorption torque).
a Following indicates the range of adjustment
available from the adjustment screw.
• Counterclockwise: Within 1 turn
• Clockwise: Within 1 turn
3. Tighten lock nut (9).
3 Locknut:
27 to 34 Nm {2.8 to 3.5kgm}
PC490LC-10 30-51
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit (PC400-C2A4-360-K-00-

A)
a Testing tools
Sym-
Part No. Part name
bol
Sensor adapter
796T-440-1101 (50 MPa {500 kg/cm2})
796-440-1150 • Wiring harness
796T-440-1160 • Nipple
1
799-401-2350 • Washer
799-401-2340 • Coupling
07002-61823 • O-ring
7861-93-1812 • Pressure sensor
2 799-101-5220 Nipple (M10 × 1.25 mm)
Q 3 07002-11023 O-ring a To measure the LS pressure (actuator load
799-101-5002 Hydraulic tester pressure), measure the front and rear pump
790-261-1150 • Hose discharge pressures simultaneously and
• Pressure gauge (60 calculate the difference.
4 799-101-5110 MPa {600 kg/cm2}) 1. Remove oil pressure pickup plugs (1) and (2) of
• Pressure gauge (6 the main pump.
799-101-5130 MPa {60 kg/cm2}) • (1): Front pump LS pressure pickup port (rear
5 790-261-1204 Digital hydraulic tester of machine)
Differential pressure • (2): Rear pump LS pressure pickup port (rear
6 799-401-2701 gauge
of machine)
stop the engine. Operate the control levers
several times to release the remaining
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the pressure in the hydraulic tank.
a Before measuring the oil pressure in the LS

control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the oil pressure of the control circuit are normal.
a Measure the LS valve output pressure (servo
piston inlet pressure) under the following
2. Install nipple Q2 to each pressure pickup port.
conditions.
• Hydraulic oil temperature: 45 to 55 °C a When installing nipple Q2, be sure to install
O-ring Q3.
Testing (PC400-C2A4-362-K-00-A) 3. Connect sensor adapter assembly Q1 to front
Measuring LS differential pressure with the LS pressure pickup port (1).
machine monitor
a Front pump discharge pressure and rear pump
discharge pressure can be checked on the
"Monitoring/Pre-defined" or "Monitoring" screen
of the machine monitor.
a LS pressure (actuator load pressure) can be
checked on the "Monitoring/Pre-defined" or
"Monitoring" screen of the machine monitor by
using service oil pressure connector (11) (CN-
P49).
30-52 PC490LC-10
Hydraulic system
4. Start the engine and set the machine monitor to discharge pressure and LS pressure (actuator
"Monitoring/Pre-defined" or "Monitoring" screen. load pressure) simultaneously.
a For the setting method, see "Special • Working mode: power mode (P)
functions of machine monitor". • Travel speed: Hi
• Work equipment, swing, and travel: Measure
• Monitoring code: 01141 "Service Pressure
when all of these levers are in NEUTRAL
Sensor"
and when the travel lever is moved halfway
(to run the raised track shoe idle).
k Run the raised track idle, paying enough

attention to the surroundings for safety.
a Calculation of LS differential pressure:
LS differential pressure See standard value table
7. After finishing test remove the testing tools and
a Perform testing of LS differential pressure on
front pump side similarly to rear pump side
described previously.
• "Monitoring" screen Testing LS valve output pressure (servo piston

inlet pressure)
a Measure the LS valve output pressure (servo
piston inlet pressure) and the pump discharge
pressure simultaneously and compare them.
1. Open the side cover on the left side of the
machine and remove oil pressure pickup plugs
(1), (2), (3), and (4).
• (1): Front pump discharge pressure pickup
port
• (2): Rear pump discharge pressure pickup
port
• (3): Front LS valve output pressure pickup
port
5. Increase the hydraulic oil temperature to 45 to • (4): Rear LS valve output pressure pickup
55°C and raise the track of the measured side. port
• When measuring the front circuit: left track
shoe
k Provide a enough work space to run the

track idle off the ground.
2. Install nipple Q2 to the pressure pickup port and

connect it to oil pressure gauge [1] of hydraulic
tester Q1.
a Use an oil pressure gauge of 60 MPa {600
kg/cm2}.
6. While running the engine at high idle under the
• The figure shows the rear side.
following condition, measure the pump
PC490LC-10 30-53
Hydraulic system
Operation of lever
Travel lever at
All control levers half stroke
in NEUTRAL (Runs truck idle
off ground)
Pump Actual measure
Oil pressure to
discharge value is
be checked
pressure regarded as 1
Almost same
LS valve pressure Approx. 0.6 (3/5)
out put of above
pressure pressure
3. Start the engine and raise the hydraulic oil
temperature to the operating range and raise up 5. After finishing test, remove the testing tools and
the track to be tested. restore the machine.
• When measuring the front circuit: left track Testing LS differential pressure with oil
• When measuring the rear circuit: right track pressure gauge
a To obtain the LS differential pressure, measure
k Provide a enough work space to run the the pump discharge pressure and LS pressure
track idle off the ground. (actuator load pressure) at the same time and
calculate the difference.
machine and remove oil pressure pickup plugs
(5) and (6).
• (1): Front pump discharge pressure pickup
port
• (2): Rear pump discharge pressure pickup
port
• (5): Front load pressure pickup port
• (6): Rear load pressure pickup port
4. Measure the pump discharge pressure and LS

valve output pressure (pressure at servo piston
inlet) at the same time after setting following
conditions with the engine running at full speed.
• Working mode: P mode
• Work equipment, swing and travel: When all
levers are at NEUTRAL and when travel
lever is at half stroke (to run a track idle off
ground)
a Run the raised track idle, paying enough
attention to the surroundings for safety. 2. Install nipple Q2 to the pressure pickup port and
a Measurement conditions and judgment connect it to oil pressure gauge [1] of differential
method: pressure gauge Q3 or hydraulic tester Q1.
When the ratio between the pump discharge a When using differential pressure gauge:
pressure and LS valve output pressure Connect the pump discharge pressure hose
(servo piston input pressure) reaches the to the high pressure side (back side) and
following value, the pressures are correct. connect the LS pressure hose to the low
pressure side (lower side).
As the differential pressure gauge needs DC
12V power supply, connect it to one battery.
30-54 PC490LC-10
Hydraulic system
a When using the oil pressure gauge: a Run the raised track idle, paying enough
Use the oil pressure gauge of 60 MPa {600 attention to the surroundings for safety.
kg/cm2} with the graduation by 1 MPa {10 kg/ a Calculating LS differential pressure (when
cm2}. the pressure gauge is used):
The differential pressure is approximately 2.9 LS differential pressure = pump discharge
MPa {30 kg/cm2} at the maximum, so pressure – LS pressure
perform the measurement by using the same
gauge alternately. a When the LS differential pressure is as
follows, it is normal.
• The figure shows the pump rear side
discharge pressure and load pressure pickup LS differential
Operation of lever
port. pressure
4.2 ± 1.0 MPa
All control levers in NEUTRAL {42 ± 10 kg/cm2}
Travel lever at half stroke (Runs 2.65 ± 0.1
truck idle off ground) 27 ± 1
Testing LS-EPC valve output pressure
1. Remove pressure pickup port plug (7).
3. Start the engine and raise the hydraulic oil

temperature to the operating range and raise up
the track to be tested.
• When measuring the front circuit: left track
• When measuring the rear circuit: right track
k Provide a enough work space to run the

2. Install nipple Q2 and connect it to oil pressure

gauge [1] of hydraulic tester Q1.
cm2}.
4. While running the engine at full speed under the

following condition, measure the pump
discharge pressure and LS pressure (actuator
load pressure) simultaneously.
3. Start the engine and keep it running until the
• Travel speed: Hi
hydraulic oil temperature rises to the operating
• Work equipment, swing and travel: When all
range.
levers are at NEUTRAL and when travel
4. Measure the oil pressure when the engine is
lever is at half stroke (to run a track idle off
running at full speed and the travel speed switch
ground)
and travel control lever are operated.
PC490LC-10 30-55
Hydraulic system
a When the LS-EPC valve output pressure

changes as follows, it is normal.
Travel Operation of Output pressure
speed lever
Approx. 2.9 MPa

Lo NEUTRAL
{Approx. 30 kg/cm2}
Fine control 0 MPa

Hi (Note) {0 kg/cm2}
Note: Operate the travel lever to a degree that
the PPC oil pressure switch is just turned on
(position before the machine starts moving).
4. After finishing adjustment, check that the LS
valve output pressure (servo piston inlet
pressure) is correct according to the testing
Adjusting (PC400-TA11-270-P-00-A) procedure described above.
a If the LS differential pressure is improper, adjust

LS valves (8) and (9) according to the following
procedure.
• (8): Front LS valve
• (9): Rear LS valve
1. While fixing adjustment screw (10), loosen

locknut (11).
2. Turn adjustment screw (10) to adjust the
differential pressure.
a If the adjustment screw is
• turned to clockwise, the differential
pressure is increased.
• turned to counterclockwise, the
differential pressure is decreased.
a Pressure of adjustment (LS differential
pressure) per turn of adjustment screw:
1.3 MPa {13.3 kg/cm2 }
3. While fixing adjustment screw (10), tighten
locknut (11).
3 Locknut:
49 to 68.6 Nm {5 to 7 kgm}
30-56 PC490LC-10
Hydraulic system
Testing output pressure of solenoid valve (ALL-PQPT-001-K-00-A)
a Testing tools
Sym-
Part No. Part Name
bol
1
799-401-3100 Adapter (size: 02)
R 2
02896-11008 O-ring
799-401-3200 Adapter (size: 03)
3
02896-11009 O-ring

Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
a Before testing the solenoid valve output

pressure, check that the control circuit source
pressure is normal.
a Measure the solenoid valve outlet pressure
under the following conditions:
PC490LC-10 30-57
Hydraulic system
Testing (PC400-PQPT-001-K-00-A)
1. Remove the control valve top cover and

disconnect outlet hoses (1) to (8) of the solenoid
valve to be measured.
No. Solenoid valve to be measured
1 2-stage relief solenoid valve
Attachment selector solenoid valve
2 (for the machine with the attachment)
3 Machine push-up solenoid valve
4 Swing holding brake solenoid valve
5 Travel speed increase solenoid valve
6 Travel junction solenoid valve
7 Swing 2-stage relief solenoid valve
4. Start the engine.
8 PPC lock solenoid valve
5. Run the engine at high idle, operate the control
a Use adapter R3 for outlet hoses (4), (5), and levers and switches to energize or de-energize
(8). Use adapter R2 for other hoses. the solenoid valve, and measure the outlet
pressure.
a For the conditions for turning ON or OFF, see
the operation table of each solenoid valve.
a The operating status of each solenoid valve
can be checked by using monitoring function
of the machine monitor. (For details, see
"Special functions of the machine monitor".)
• Monitoring code: 02300 Solenoid 1
Solenoid valve outlet
pressure See standard value table
2. Install adapter R2 or R3 and reconnect the
hoses. a When the output pressure is as shown in the
3. Install nipple [2] and connect it to pressure table, the solenoid valve is normal.
gauge [3]. 6. After finishing test, remove the testing tools and
a Use an oil pressure gauge of 6.0 MPa {60 kg/ restore the machine.
cm2}.
a The figure shows the testing tools connected
to outlet hose (1) of the 2-stage solenoid
valve.
30-58 PC490LC-10
Hydraulic system
Operating condition (PC400-PQPT-04C-K-00-A)

(1) Operation table of 2-stage relief solenoid valve
Overheat 1st setting is ON.
Overheat 2nd setting is ON. OFF
When all the signals for work equipment, swing and travel are OFF.
Swing lock switch is ON.
Travel signal is ON.
When L mode is selected ON
When the boom LOWER signal is ON
Signals other than the "swing only"
When one-touch power max. are ON.
In P or E mode
switch is ON. "Swing only " is ON.
OFF
Other than the above conditions
(2) Operation table of attachment selector solenoid valve (for the machine equipped with attachment)
Working mode: Other than B OFF
Working mode: B ON
(3) Operation table of machine push up solenoid valve

OFF ON
Machine push-up switch
ON OFF
(4) Operation table of swing holding brake solenoid valve

Signals of work equipment and swing (Work All are OFF. OFF
equipment includes attachment.) Any one is ON. ON
(5) Operation table of travel speed increase solenoid valve

Overheat 2nd setting is ON.
Fuel control dial is at 1,200 rpm or below
Travel speed switch is at Lo.
OFF
Travel signal is OFF.
When F or R pump pressure is 32.3
Travel speed switch is at Mi or MPa {330 kg/cm2 } or above.
Hi Travel signal is ON.
When F or R pump pressure is 18.6
MPa {190 kg/cm2} or below. ON
Other than the above conditions
(6) Operation table of travel junction solenoid valve

Travel steering signal is ON.
When " travel only" When F or R pump pressure is 34.3 ON
Travel steering signal is OFF. signal is ON. MPa {350 kg/cm2} or above.
Other than the above conditions OFF
PC490LC-10 30-59
Hydraulic system
(7) Operation table of swing 2-stage relief solenoid valve

When boom When F pump
When boom RAISE PPC pressure is rising
RAISE pressure is 2.2 and 20.6 MPa
When the swing signal is signal is ON MPa {22 kg/cm2 } {210 kg/cm2 } or
ON but except when the or below When arm above
signal is OFF When F pump ON
swing back operation is
turned on pressure is
When pump flow is divided dropping and
25.5 MPa {260
kg/cm2 } or above
Other than the above conditions OFF
(8) Operation table of PPC lock solenoid valve

at LOCK position OFF
PPC lock lever
at FREE position ON
30-60 PC490LC-10
Hydraulic system
Testing PPC valve output pressure (PC400-PW11-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
S
790-301-1730 Joint (PF 1/4 x R 1/8)
2
07000-12011 O-ring
a Measure PPC valve output pressure after

confirming that control circuit original pressure is
normal.
a Measure the PPC valve output pressure under
the following conditions.
Measuring with oil pressure gauge
• Hydraulic oil temperature: 45 to 55°C 1. Remove the control valve top cover and the
Testing (PC400-PW11-362-K-00-A) operator cab under cover (front side).
2. Disconnect pressure sensor of the tested PPC
Measuring with machine monitor
circuit and install joint S2.
a PPC valve output pressure can be checked on 3. Install nipple [1] of hydraulic tester S1 to joint S2
the "Monitoring/Pre-defined" or "Monitoring" and connect oil pressure gauge [2].
screen of the machine monitor.
1. Start the engine and set the machine monitor to cm2}.
"Monitoring/Pre-defined" or "Monitoring" screen.
a The figure shows the testing tools installed to
a For the setting method, see "Special the hydraulic hoses of the bucket CURL PPC
functions of machine monitor". circuit.
• Monitoring code: 07400 "Boom RAISE PPC
pressure"
• Monitoring code: 07500 "Boom LOWER PPC
pressure"
• Monitoring code: 07200 "Arm IN PPC
pressure"
• Monitoring code: 07600 "Arm OUT PPC
pressure"
• Monitoring code: 07300 "Bucket CURL PPC
pressure"
• Monitoring code: 07301 "Bucket DUMP PPC
pressure"
• Monitoring code: 09001 "Swing LEFT PPC
pressure" a Remove PPC oil pressure sensors (1) to (12)
• Monitoring code: 09002 "Swing RIGHT PPC of the circuit to be measured.
pressure"
• Monitoring code: 07102 "Travel FORWARD
L.H. PPC pressure"
• Monitoring code: 07103 "Travel FORWARD
R.H. PPC pressure"
• Monitoring code: 07104 "Travel REVERSE L.
H. PPC pressure"
• Monitoring code: 07105 "Travel REVERSE R.
H. PPC pressure"
PC490LC-10 30-61
Hydraulic system
Circuit to be Circuit to be
No. No.
measured measured
1 Boom RAISE (green) 7 Swing LEFT (red)
Boom LOWER
2 8 Swing right (–)
(brown)
L.H. travel
3 Arm IN (blue) 9
FORWARD (red)
R.H. travel
4 Arm OUT (yellow) 10
FORWARD (green)
L.H. travel
5 Bucket CURL (white) 11 REVERSE (–)
Bucket DUMP R.H. travel
6 (black) 12 REVERSE (blue)
• The colors in ( ) are the colors of the bands

installed for piping identification.
4. Start the engine and set the working mode to
Power Mode (P).
5. Measure the pressure when the engine is

running at high idle and the control lever of the
circuit to be measured is kept at NEUTRAL
position and at the full stroke.
a When PPC valve output pressure is at the
level shown below, it is correct.
Operation of lever Output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Nearly equal to control
at stroke end circuit source pressure
(See standard value table)
30-62 PC490LC-10
Hydraulic system
Adjusting play of work equipment and swing PPC valves (ALL-PL28-001-K-00-A)
a If the right and left work equipment levers have

large play, adjust them according to the following
procedure.
a The play of the lever measured at a position of
200 mm from the pivot must be 0.5 to 3 mm.
Adjusting (PC400-PL28-270-K-00-A)
1. Remove boot (1).

2. Loosen locknut (2) and tighten disc (3) until it
touches the heads of 4 pistons (4).
a Do not move the piston at this time.
3. Fix the position of disc (3) and tighten locknut (2)
to the specified torque.
3 Locknut:
69 to 88 Nm {7 to 9 kgm}
4. Install boot (1).
PC490LC-10 30-63
Hydraulic system
Testing pump swash plate sensor (ALL-C3WG-001-K-00-A)
a Before testing pump swash plate sensor, check a Testing condition and judgment: When the
that oil pressure in work equipment, swing, and voltages are as shown in the table, pump swash
travel circuits, control circuit source pressure, plate sensor is correct.
and no-load travel speed are correct. Pump swash plate
Operation of lever
a Test pump swash plate sensor under the sensor voltage
following conditions. Control levers and pedals
1.52 ± 0.63 V
in NEUTRAL
• Hydraulic oil temperature: 45 to 55 °C
Travel lever at stroke end.
• Working mode: P mode (Runs track idle off ground) 3.54 ± 0.63 V
Testing output voltage of pump swash plate

sensor
a Output voltage of pump swash plate sensor can
be checked by using monitoring function of
machine monitor.
(For the operating method, see "Special
functions of machine monitor".)
• Monitoring code:
01138 "F pump sw plate sensor volt"
01140 "R pump sw plate sensor volt"
Testing (PC400-C3WG-36J-K-00-A)
1. Start the engine, and raise the track on the side

to be tested by using the work equipment, and
prepare for running the track idle.
• When testing front pump: left track
• When testing rear pump: right track
k Provide an enough work space to run the

2. Set the working mode to Power Mode (P) and
set the travel speed to Hi.
3. Set the swing lock switch to the ON position.
4. While running the engine at high idle, set all the
levers and pedals for work equipment, swing,
and travel to the NEUTRAL, and then set the
travel lever to stroke end in order to run a track
idle, and measure the voltage during each
operation.
k Be careful about safety around the machine
while running the track idle off the ground.
30-64 PC490LC-10
Hydraulic system
Testing fan speed (PC400-B400-360-K-00-A)

lower the work equipment and set firmly on
the ground, then stop the engine and work
equipment lock lever to LOCK position.
a Test the fan motor speed under the following

condition.
• Hydraulic oil temperature: Min. 45 °C
Testing (PC400-B400-388-K-00-A)
1. Start the engine and switch the machine monitor

to "Monitoring/Pre-defined" or "Monitoring"
screen.
a For the operating method, see "Special
functions of machine monitor".
• Monitoring code: 10007 "Fan speed"
• "Monitoring" screen
2. While running the engine at low idle and high

idle, measure the fan speed
PC490LC-10 30-65
Hydraulic system
Testing fan pump circuit oil pressure (PC400-B450-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
790-301-1210 • Joint
1
U 07002-11423 • O-ring
799-101-5160 • Nipple

pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
a Measure the fan pump circuit oil pressure under

the following condition.
Testing (PC400-B450-362-K-00-A)

machine and remove oil pressure pickup plug
(1).
3. Start the engine and measure the fan circuit oil

pressure while running the engine at high idle.
2. Install joint [2], O-ring [3] and nipple [4] to

hydraulic tester U1, and connect them to oil
pressure gauge [1].
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.
a The nipple and joint for the digital hydraulic
tester U2 can also be used.
30-66 PC490LC-10
Hydraulic system
Checking fan pump EPC current (PC400-B720-001-K-00-A)
a The fan pump EPC current can be checked by

using Monitoring/Pre-defined or Monitoring
function of machine monitor.
a Measure the fan pump EPC current under the
following condition.
Testing (PC400-B720-36K-K-00-A)
1. Operate the machine monitor so that the fan

pump EPC current can be monitored.
a For the operating method of the machine
monitor, see “Special functions of machine
monitor”.
a Monitoring code:
31623 "Fan Pump EPC Sol. Curr."
2. Start the engine and measure the EPC solenoid

current while running the engine at high idle.
PC490LC-10 30-67
Hydraulic system
Testing fan pump EPC solenoid valve output pressure (PC400-B721-001-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5160 • Nipple
V 790-261-1204 Digital hydraulic tester
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

pressure in the piping, and then loosen the 3. Start the engine and measure the solenoid valve
oil filler cap of the hydraulic tank slowly to output pressure while running the engine at high
release the pressure in the hydraulic tank. idle.
a Measure the fan pump EPC solenoid valve restore the machine.
output pressure under the following condition.
Testing (PC400-B721-362-K-00-A)

machine and remove oil pressure pickup plug
(1).
2. Install nipple V2, install nipple [1] of hydraulic

tester V1, and connect them to oil pressure
gauge [2].
a Use the oil pressure gauge of 5.9 MPa {60
kg/cm2}.
30-68 PC490LC-10
Hydraulic system
Isolating the parts causing hydraulic drift in work equipment (ALL-L410-001-K-00-A)
a If the work equipment (cylinder) drifts

hydraulically, perform check to see if the
problem is in the cylinder seal or control valve
Testing (PC-L410-360-K-00-A)
1. Testing boom cylinder and bucket cylinder

1) Stop the engine with the same posture as the
hydraulic drift measurement.
a Apply rated load to the bucket inside or fill
the bucket with soil or sand.
2) Operate the arm control lever to IN again to

determine the test results.
• When the lowering speed is increased at
this time, the cylinder packing is
defective.
• If the lowering speed does not change at
this time, the control valve is defective.
a The control lever can be operated when
the starting switch is set to ON position.
a If the accumulator pressure is reduced,
run the engine for approximately 10
2) For boom, move the boom control lever to seconds to accumulate the pressure.
"RAISE" side. For bucket, move the bucket [Reference] Reasons why the lowering speed is
control lever to "CURL" side. increased by the above operation when the
• When the lowering speed is increased at cylinder packing causes the hydraulic drift:
this time, the cylinder packing is 1) When the machine is set in the above
defective. posture (where the holding pressure is
• If the lowering speed does not change at applied to the bottom side), the oil leaks from
this time, the control valve is defective. the bottom side to the head side. Since the
Determine the test results as described volume on the head side is less than that on
above. the bottom side by the volume of the rod, the
pressure in the head side is increased by the
a The control lever can be operated when
oil flowing in from the bottom side.
the starting switch is set to ON position.
2) As the internal pressure on the head side
a If the accumulator pressure is reduced, increases, both pressures come to balance
run the engine for approximately 10 at a certain level of pressure (depending on
seconds to accumulate the pressure. leakage), and the lowering speed becomes
2. Testing arm cylinder slower.
1) Operate the arm control lever to IN, and stop 3) If the circuit on the head side is opened to
the engine at the time when the arm cylinder the drain circuit by the above operation of the
extends to approximately 100 mm front of the lever (the bottom side is closed by the check
stroke end. valve at this time), the oil in the head side
flows in the drain circuit. As a result, the
pressure is imbalanced and the lowering
speed is increased.
3. Testing PPC valve
Test the lowering volume of the work equipment
when the work equipment lock lever is set to the
LOCK position and FREE position with the
pressure accumulated in the accumulator.
a The control lever can be operated when the
starting switch is set to ON position.
PC490LC-10 30-69
Hydraulic system
a If the accumulator pressure is reduced, run

the engine for approximately 10 seconds to
accumulate the pressure.
a In case of a difference of lowering volume
between the LOCK and FREE positions, the
PPC valve is defective (internal defect).
30-70 PC490LC-10
Hydraulic system
Testing oil leakage (ALL-C000-001-P-03-A)
a Component to be checked 1) Move the arm cylinder to the arm IN stroke

Sym- end and stop the engine.
Part No Part Name
bol
Available on k Release the remaining pressure from
T Measuring cylinder
the market the piping on the arm cylinder head
side. For details, see “Releasing
a Measure the oil leakage under the following remaining pressure from hydraulic
condition. circuit” (Operate the lever in the arm
• Hydraulic oil temperature: 45 to 55 °C IN direction only, however).
Testing (PC400-C000-364-K-00-A) 2) Disconnect hose (2) on the cylinder head
1. Measuring oil leakage from boom cylinder side and block the hose end by a flange.
1) Extend the boom cylinder to the boom
k Take care not to disconnect the hose
RAISE stroke end and stop the engine.
on the cylinder bottom side.
k Release the remaining pressure from a Use the following part to block on the
the piping on the boom cylinder head hose end.
side. For details, see “Releasing 07379-01044 (Flange #10)
remaining pressure from hydraulic
circuit”. (Operate the lever in the boom
RAISE direction only, however).
2) Disconnect hoses (1) on the cylinder head
side and block the hose end by a flange.

a Use the following part to block on the
hose end.
07379-01044 (Flange #10)
3) Start the engine and run it at high idle and

perform arm IN relief.
k Take care not to operate "arm OUT".

4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the
leak for 1 minute.
3. Measuring oil leakage from bucket cylinder
1) Move the bucket cylinder to the bucket
3) Start the engine and run it at high idle and CURL stroke end and stop the engine.
perform boom RAISE relief.
k Referring to Release of remaining
k Takecare not to operate "boom pressure from hydraulic circuit,
LOWER". release the remaining pressure from
the piping on the bucket cylinder head
4) Start measuring the oil leakage 30 seconds side (Operate the lever only in the
after relieving is started, and measure the CURL direction, however).
leak for 1 minute.
5) After finishing test, remove the testing tools 2) Disconnect hose (3) on the cylinder head
and restore the machine. side and block the hose end by a flange.
2. Measuring oil leakage from arm cylinder
PC490LC-10 30-71
Hydraulic system
a Use the following part to block on the 1) Remove the travel motor cover.
hose end. 2) Start the engine, lock the travel mechanism,
07379-01044 (Flange #10) and stop the engine.
k Insert pin [1] between the sprocket

and the track frame to securely lock
the track.

perform bucket CURL relief.
k Takecare not to operate "bucket

DUMP". 3) Disconnect drain hose (5) of the travel motor
and block the hose end by a plug.
4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the a Use the following part to block on the
leak for 1 minute. hose end.
5) After finishing test, remove the testing tools 07376-70522 (Plug #05)
4. Measuring oil leakage from swing motor
1) Disconnect drain hose (4) and block the
hose end with plugs.
a Use the following part to block on the
hose end.
07376-70522 (Plug #05)
4) Start the engine and run it at high idle, relieve

the travel circuit, and measure the oil
leakage.
k Before operating the travel lever,

check the pin position and locked
direction of the travel again.
2) Set the swing lock switch to ON position.
k Wrong operation of the lever can
cause an accident. Accordingly, make
perform swing relief.
signals and checks securely.
a Start measuring the oil leakage 30
a Start measuring the oil leakage 30
seconds after relieving is started, and
seconds after relieving is started, and
measure the leak t for 1 minute.
measure the leak t for 1 minute.
a After Measuring one time, swing 180 deg.,
a Measure several times, moving the motor
and then measure again.
a little (changing the position of the valve
plate and cylinder, and that of the cylinder
and piston) each time.
5. Measuring oil leakage from travel motor
30-72 PC490LC-10
Hydraulic system

PC490LC-10 30-73
Hydraulic system
Bleeding air from hydraulic circuit (ALL-C000-001-P-04-A)
q: Execution of work
o: Go to next procedure
Air bleeding procedure and item
1 2 3 4 5 6
Bleeding air Checking oil
from Starting the Bleeding air Bleeding air Bleeding air
level and
hydraulic engine from cylinder from swing from travel
operating
pump motor motor
machine
• Replacement of
hydraulic oil q q
q q q q
• Cleaning (See note) (See note)
strainer
• Replacing
return oil filter q o o o q
element
• Replacing or
repairing
hydraulic pump q q q o o q
• Removal of
suction piping
• Replacing or
repairing
control valve
q q o o q
• Removal of
Detail of work, remarks
control valve
piping
• Replacement
or repair of
cylinder q q o o q
• Removal of
cylinder piping
• Replacing or
repairing swing
motor
q o q o q
• Removal of
swing motor
piping
• Replacing or
repairing travel
motor
q o o q q
• Removal of
travel motor
piping
• Replacing or
repairing swivel
joint q o o o q
• Installing swivel
joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
Bleeding air (PC400-C000-231-P-01-A)
1. Bleeding air from hydraulic pump check that oil oozes out from the air
bleeders.
a Keep the oil filler cap of the hydraulic tank
loosened while the air is bled from the
hydraulic pump.
1) Loosen air bleeder (1) on work equipment
pump and air bleeder (2) on fan pump and
30-74 PC490LC-10
Hydraulic system
1) Start the engine and run it at low idle for

approximately 5 minutes.
2) While running the engine at low idle, raise
and lower the boom 4 to 5 times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not
cause the relief.
3) While running the engine at high idle,
perform step 2).
4) While running the engine at low idle speed,
move the piston rod to the stroke end and
relieve the oil.
2) When oil does not flow out, disconnect drain 5) Bleed air from the arm cylinder and bucket
hose (3) and then fill up the pump case with cylinder according to steps 2) to 4).
oil fed from the drain port. 4. Bleeding air from swing motor
1) Start the engine and run it at low idle.
a Fix the drain hose fitting in a position 2) Loosen S port hose (4) slowly to make sure
higher than the oil level in the hydraulic oil oozes out through the S port hose.
tank.
a Continue supplying oil until the bubble- k In this case, do not perform the swing
free oil flows out. operation.
3) When oil does not flow out, stop the engine
once, disconnect S port hose and then fill up
the motor case with oil.
a As the motor case is filled up with oil,
connect S port hose once and then
repeat steps 1) and 2).
4) After bubble-free oil flows out, tighten the S
port hose.
5) Swing slowly right and left more than 2 times
each.
3) After bubble-free oil flows out, tighten air

bleeders (1) and (2).
3 Air bleeder:
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
2. Starting engine
When running the engine after performing step 1,
let it low-idle for 10 minutes.
a When the automatic warm-up operation
starts due to low engine coolant temperature,
stop the engine and cancel the warm-up
operation by using the fuel control dial. (With 5. Bleeding air from travel motor
the starting switch at ON position, hold the 1) Remove travel motor cover.
fuel control dial at MAX position for 3 2) Start the engine and run it at low idle.
seconds or more, and the automatic warm- 3) Loosen bleeder (5) and check that oil oozes
up operation is canceled) out.
3. Bleeding air from cylinder 4) bubble-free oil flows out, tighten bleeder (5).
a When a cylinder is replaced, bleed air from it
before connection to the work equipment. In
particular, the boom cylinder rod does not
move to the lowering stroke end, if it is
installed to the work equipment.
PC490LC-10 30-75
Hydraulic system
3 Bleeder: a When the oil level is between lines H and

27.4 to 35.3 Nm {2.8 to 3.6 kgm} L, it is normal.
a When the oil level is below line L, add
new oil.
5) Raise one track by using the work

equipment.
6) Run the lifted track idle slowly for
approximately 2 minutes.
a Repeat the same for the opposite side
track.
6. Checking oil level and operating machine

1)
2) Start the engine, retract the arm cylinder and
bucket cylinder to the stroke ends, lower the
work equipment to the ground, and stop the
engine.
3) Check the oil level by using sight gauge (6)

on the rear side of the hydraulic tank.
30-76 PC490LC-10
Cab and its attachments
Testing cab tipping stopper (ALL-K138-001-K-00-A)
a Check the cab tipping stopper according to the following procedure.

Testing (PC-K138-280-K-00-A)
1. Check the tightening torque of the mounting bolt

(2) of the lock plate (1).
3 Bolt (2):
98 to 123 Nm {10 to 12.5kgm}
[Reference]
• Note that the tightening torque for mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4):
245 to 309 Nm {25 to 31.5kgm}
PC490LC-10 30-77
Adjusting mirrors (PC400-K810-001-K-00-A)
1. Mirror installation positions 3 Mounting bolt (4):

6.0 to 7.0 Nm {0.61 to 0.71 kgm}
2. Adjusting mirror (a)

Adjust mirror (a) so that the operator can see a
person in the rear left end of the machine.
• Adjust the mirror so that the side of the
machine is reflected in it as shown below.
a Tighten bolts for the brackets alternately

while keeping the left and right clearances
(L) and (R) equal.
a Install the mirror and stay to dimensions as
shown below.
• Stay (1)
(D): 59 mm, (E): 81 deg.
3 Mounting bolt (2):
34 to 74 Nm {3.5 to 7.5 kgm}
• Mirror (3)
(F): 89 mm, (G): 110 deg.
3. Adjusting mirror (b)

Adjust mirror (b) so that the operator can see a
person at the right rear end of the machine.
• Adjust the mirror so that the side of the
machine is reflected in it as shown below.
30-78 PC490LC-10
4. Adjusting mirror (c)

a Install the mirror and stay to dimensions as
Adjust the mirror (c) so that the operator can see
shown below.
persons on the ground at around the machine
• Stay (5) (W).
(H): 420 mm, (J): 87 deg. (W): 1 m
34 to 74 Nm {3.5 to 7.5 kgm}
• Mirror (7)
(K): 10 mm, (M): 27 deg., (Q): 9 deg.
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
a Install the mirror to dimension as shown

below.
• Mirror (9)
(N): 28 mm, (P): 25 deg.
a Tighten bolts for the brackets alternately

while keeping the left and right clearances
(L) and (R) equal.
PC490LC-10 30-79

6.0 to 7.0 Nm {0.61 to 0.71 kgm}
30-80 PC490LC-10
Electrical system
Special functions of machine monitor (PC220-Q170-042-K-01-A)
PC490LC-10 30-81
Electrical system
Upper part of machine monitor (display portion)

(a): Multi-information display
a When the engine is started, the battery voltage
may drop suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the screen display of the machine
monitor may go off for a moment. This
phenomenon is not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated
by the icon which is displayed just above the
function switch on the screen of the multi-
information display panel (a).
a If the icon for a function switch is not displayed,
that function switch is not working.
Lower part of machine monitor (switch portion)

[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer stop
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals : Air conditioner switch
a Each switch has the function indicated by the
icon on it and the function of inputting a numeral.
a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of the multi-
information display panel (a).
30-82 PC490LC-10
Electrical system
Ordinary functions and special functions of machine monitor (PC400-Q170-042-K-00-A)
The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-display.
Some items are displayed automatically according to the internal setting of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This function is used for special setting, testing, adjusting, or troubleshooting.
Operator mode (outline) Service mode

A Display of KOMATSU logo(PAGE 30-85) Troubleshooting support(PAGE 30-102)
A Password input(PAGE 30-85) Monitoring(PAGE 30-107)
Abnormality record (mechanical systems)(PAGE
A Display of check of breaker mode(PAGE 30-86) 30-114)
Abnormality record (electrical systems)(PAGE 30-
A Display of check before starting(PAGE 30-86) 115)
Display of warning after check before starting
A (PAGE 30-86) Maintenance record(PAGE 30-117)
Display of maintenance due time over(PAGE 30-
A 87) Maintenance mode setting(PAGE 30-118)
Display of check of working mode and travel
A speed(PAGE 30-87) Phone number entry(PAGE 30-120)
A Display of standard screen(PAGE 30-87) Default (Key-on Mode)(PAGE 30-121)
A Display of end screen(PAGE 30-87) Default value setting (Unit)(PAGE 30-122)
(Special operation)
Display of operation screen for engine shutdown

A secondary switch(PAGE 30-88) Default (With/Without Attachment)(PAGE 30-123)
B Selection of auto-deceleration(PAGE 30-88) Default (Camera)(PAGE 30-123)
Testing (Cylinder Cut-out operation)(PAGE 30-
B Selection of working mode(PAGE 30-88)
125)
B Selection of travel speed(PAGE 30-89) Testing (Regeneration for Service)(PAGE 30-126)
B Operation to cancel alarm buzzer(PAGE 30-89) Testing (KDPF Memory Reset)(PAGE 30-128)
o Adjustment (Pump Absorption Torque (F))(PAGE
B Operation of windshield wiper(PAGE 30-89)
30-129)
Adjustment (Pump Absorption Torque (R))(PAGE
B Operation of window washer(PAGE 30-90)
30-129)
Operation to display air conditioner settings Adjustment (Attachment Flow Adjustment)(PAGE
B (PAGE 30-90) 30-131)
Adjustment (Attachment Flow Adjustment)(PAGE
B Operation to display camera mode(PAGE 30-90)
30-131)
Operation to display clock and service meter Adjustment (F pump swash plate sensor
B (PAGE 30-90) calibration)(PAGE 30-132)
Adjustment (R pump swash plate sensor
B Check of maintenance information(PAGE 30-91)
calibration)(PAGE 30-137)
Setting and display of user mode (including Adjustment (Pump calibration: Matching speed
B KOMTRAX messages for user)(PAGE 30-91) check)(PAGE 30-138)
Adjustment (Pump calibration: Matching speed
C Display of ECO guidance(PAGE 30-91)
calibration)(PAGE 30-143)
Adjustment (Fan Rotation Mode Selection)(PAGE
C Display of caution monitor(PAGE 30-93)
30-145)
C Display of KDPF regeneration(PAGE 30-93) No-Injection(PAGE 30-145)
Display of action level and failure code(PAGE 30- KOMTRAX Settings (Terminal Status)(PAGE 30-
C 96) 146)
KOMTRAX Settings (GPS and Communication
O (Special operation) Status)(PAGE 30-147)
PC490LC-10 30-83
Electrical system
Operator mode (outline) Service mode

Function of checking display of LCD (Liquid KOMTRAX Settings screen (Modem Status)
D Crystal Display)(PAGE 30-98) (PAGE 30-148)
D Function of checking service meter(PAGE 30-98) Service Message(PAGE 30-148)
Function of Usage Limitation Setting/ Change
D Password(PAGE 30-98)
a Classification of operator mode

A: Display or function that is indicated or enabled from the time when the starting switch is turned to the
ON position to the time when screen changes to the standard screen, and screen after starting switch is
turned to the OFF position
B: Display or function when the switch of machine monitor is operated
C: Display or function when certain condition is satisfied
D: Display or function when the special operation of switches is required
30-84 PC490LC-10
Electrical system
Operator mode (outline) (PC400-Q193-042-K-00-A) a Display pattern of operator mode

a Only outline of the operator mode is described in The contents of display from the time when
this section. starting switch is turned ON to time when screen
changes to standard screen depends on the
For details of contents and operations of each
setting and condition of the machine.
function and display, see "Structure and function
", or the "Operation and Maintenance Manual". A: When the engine start lock is set effective
B: When the engine start lock is set ineffective
a The following are the displays or functions of the
operator mode explained in this section C: When working mode at start is set to breaker
(including some items which need special mode (B)
operations). D: When there is abnormal item in "check before
starting" items
E: When there is maintenance time overdue
Display pattern item
A B C D E
Display of KOMATSU logo(PAGE Display of KOMATSU logo (PC220-Q180-044-K-01-A)
30-85) 1 1 1 1 1 When starting switch is turned to ON position,
Password input(PAGE 30-85) 2 KOMATSU logo is displayed for 2 seconds.
Display of check of breaker mode
2 a After the KOMATSU logo screen is displayed for
(PAGE 30-86)
Display of check before starting 2 seconds, the screen changes to "Password
(PAGE 30-86) 3 2 3 2 2 input" screen, or "Check before starting" screen.
Display of warning after check
before starting(PAGE 30-86) 3
Display of maintenance due time
over(PAGE 30-87) 3
Display of check of working mode
and travel speed(PAGE 30-87) 4 3 4 4 4
Display of standard screen(PAGE
30-87) 5 4 5 5 5
Display of end screen(PAGE 30-87)
Display of operation screen for engine shutdown
secondary switch(PAGE 30-88)
Selection of auto-deceleration(PAGE 30-88)
Selection of working mode(PAGE 30-88)
Selection of travel speed(PAGE 30-89)
Operation to cancel alarm buzzer(PAGE 30-89) Password input (PC220-Q180-044-K-02-A)
Operation of windshield wiper(PAGE 30-89) After the KOMATSU logo is displayed, the screen to
Operation of window washer(PAGE 30-90) input the engine start lock password is displayed.
Operation to display air conditioner settings(PAGE
a This screen is displayed only when the engine
30-90)
start lock function is enabled.
Operation to display camera mode(PAGE 30-90)
Operation to display clock and service meter(PAGE a When correct password is input, the screen
30-90) changes to "Check before starting" screen.
Check of maintenance information(PAGE 30-91)
Setting and display of user mode (including
KOMTRAX messages for user)(PAGE 30-91)
Display of ECO guidance(PAGE 30-91)
Display of caution monitor(PAGE 30-93)
Display of KDPF regeneration(PAGE 30-93)
Display of action level and failure code(PAGE 30-
96)
O (Special operation)
Function of checking display of LCD (Liquid Crystal
Display)(PAGE 30-98)
Function of checking service meter(PAGE 30-98)
Function of Usage Limitation Setting/ Change
Password(PAGE 30-98)
PC490LC-10 30-85
Electrical system
a The machine monitor has some password

functions other than the engine start lock. Those
functions are independent from one another.
Display of check before starting (PC220-Q180-044-K-

04-A)
When the screen changes to the check before
starting screen, the check before starting is
a The following screen may sometimes be
performed for 2 seconds.
displayed instead of the above "Password input"
screen. a If any abnormalities are detected in the check
before starting, the screen changes to "Warning
a If this screen is displayed, call the person
after the check before starting" screen or
responsible for the operation of KOMTRAX in
"Overdue Maintenance" screen.
your Komatsu distributor and ask for remedy.
a If no abnormalities were detected in the check
before starting, display changes to "Working
Mode and Travel Speed Check" screen.
a The monitors (6 monitors) on the screen shows
the items currently subjected to the check before
starting.
Display of check of breaker mode (PC220-Q180-

044-K-03-A)
When the starting switch is turned ON, if the
working mode is set to the breaker mode [B], a
message to inform the operator of starting in the
breaker mode is displayed on the screen.
k If an attachment other than the breaker is Display of warning after check before
used while the working mode is set to the starting (PC220-Q180-044-K-05-A)
breaker mode [B], the machine may move If any abnormalities are detected in the check
unexpectedly or may not operate normally or before starting, the alarm monitor is displayed on
the hydraulic components may be damaged. the screen.
a After operation to check of the breaker mode is a The figure shows how air cleaner clogging
finished, the screen changes to "Display of monitor (a) warns of clogging on air cleaner.
check before starting".
If [No] is selected: Working mode is set to
economy mode [E]
If [Yes] is selected: Working mode is set to
breaker mode [B]
30-86 PC490LC-10
Electrical system
Display of maintenance due time over (PC220- Display of standard screen (PC220-Q180-044-K-08-A)
Q180-044-K-06-A) If the machine monitor starts normally, the standard
If the check before starting detected a maintenance screen is displayed.
item that is near or overdue the set interval, the
maintenance monitor is displayed for 30 seconds to a Service meter (a) or clock is displayed in the top
urge the operator to perform maintenance. center area of the screen (use [F4] to switch the
display of the service meter and clock).
a This screen is displayed only when the
maintenance reminder function is enabled. If the a Right end of the screen displays ECO gauge (b)
remaining time of any item is 30 hours or less, (turn on or off the display in the operator mode).
the yellow icon is displayed. If the remaining
time of any item is 0 hour or less, the red icon is
displayed.
a The maintenance reminder function is enabled
or disabled by using the machine monitor in the
service mode.
Display of end screen (PC220-Q180-044-K-09-A)

When starting switch is turned to OFF position, the
end screen is displayed for 5 seconds.
a Other messages may appear on the end screen
due to KOMTRAX message display function.
Display of check of working mode and travel

speed (PC220-Q180-044-K-07-A)
If the check before starting is finished normally, the
screen for checking the working mode and travel
speed is displayed for 2 seconds.
a After the "Working mode and travel speed
check" screen is finished, the screen changes to
the "Standard" screen.
PC490LC-10 30-87
Electrical system
Display of operation screen for engine Selection of working mode (PC400-PT5W-100-K-00-A)

shutdown secondary switch (PC220-AKHL-100-K-00-A) Select desired working mode according to the
When you turn the engine shutdown secondary following procedure.
switch to ON position, the "Engine Shutdown 1. While the standard screen is displayed, press
Secondary Switch Activated" screen is displayed on the working mode selector switch, and the
every screen except the end screen. working mode selection screen is displayed.
a The engine shutdown secondary switch is a Following figure shows the working mode
provided on the lower left side of the operator's selection screen when "with attachment" is
seat. It is used to stop the engine when you set. (If "with attachment" is not set in service
cannot stop the engine by turning the starting mode, attachment mode "ATT/P", "ATT/E"
switch to OFF position. are not displayed.)
If you turn the engine shutdown secondary switch to 2. Operate the function switches or working mode
OFF position, the KOMATSU logo appears once, selector switch to select the desired working
and then the display changes to the standard mode and enter the selection.
screen. Function switch
• [F3]: Moves to lower item
Selection of auto-deceleration (PC220-AF6C-100-K-
00-A) • [F4]: Moves to upper item
While the ordinary screen is displayed, if the auto- • [F5]: Cancels selection and returns to
deceleration switch is pressed, large auto- standard screen
deceleration monitor (a) is displayed for 2 seconds • [F6]: Enters selection and returns to standard
and the setting of the auto-deceleration is changed. screen
Working mode selector switch
a Each time the auto-deceleration switch is • Pressed: Moves to lower item
pressed, the auto-deceleration is changed in the • Kept pressed: Enters selection and returns to
order of [ON] o [OFF] o [ON]. standard screen
a If the auto-deceleration is set to ON, large a If you do not touch any of the function
monitor (a) and auto-deceleration monitor (b) are switches and working mode selector switch
displayed simultaneously. for 5 seconds, the selection is determined
a If the auto-deceleration is set to OFF, auto- and the screen changes to the standard
deceleration monitor (b) goes off. screen.
30-88 PC490LC-10
Electrical system
3. When the ordinary screen is displayed again, a Travel speed setting sequentially changes
large working mode monitor (a) is displayed for 2 between [Lo] o [Mi] o [Hi] o [Lo] in this order
seconds, and then the setting of the working every time the switch is pressed.
mode is changed to the selected mode.
a When large monitor (a) is displayed, the display
a When large monitor (a) is displayed, the of travel speed monitor (b) is changed, too.
display of working mode monitor (b) is
changed, too.
Operation to cancel alarm buzzer (PC220-Q576-100-

K-00-A)
<Precautions for selecting breaker mode [B]> Press the buzzer cancel switch while the alarm
• If breaker mode [B] is selected, both of the buzzer is sounding, then the alarm buzzer stops.
control of the hydraulic pump and the setting
of the hydraulic circuit are changed. a Even if the buzzer cancel switch is pressed, the
• If an attachment other than the breaker is display on the screen does not change.
used, the machine may move unexpectedly
or may not operate normally or the hydraulic Operation of windshield wiper (PC220-K751-100-K-00-
A)
components may be damaged.
While the ordinary screen is displayed, if the wiper
• After the breaker mode is selected, the
switch is pressed, large wiper monitor (a) is
screen to confirm the selection of the breaker
displayed for 2 seconds and the wiper starts or
mode is displayed (The buzzer sounds
stops.
intermittently while this screen is displayed).
• If the setting is confirmed on this screen, the a The window washer does not operate if the
screen changes to the standard screen. window limit switch is "ON".
If "No" is selected: Screen returns to working
a The wiper setting changes sequentially between
mode selecting screen
[INT] o [ON] o [OFF] o [INT] every time you
If [Yes] is selected: Working mode is set to
press the switch.
breaker mode [B]
a When the wiper is set to INT or ON, large
monitor (a) is displayed and the display of wiper
monitor (b) is changed at the same time.
a If the wiper is set to OFF, large monitor (a) is not
displayed and the wiper monitor disappears.
Selection of travel speed (PC220-C6T7-100-K-00-A)

While the standard screen is displayed, if the travel
speed selector switch is pressed, large travel speed
monitor (a) is displayed for 2 seconds and the
setting of the travel speed is changed.
PC490LC-10 30-89
Electrical system
Operation of window washer (PC220-K7DA-100-K-00-

A)
While the ordinary screen is displayed, if the
window washer switch is pressed, the washer fluid
is splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation to display air conditioner

settings (PC220-K500-100-K-00-A)
Operate the air conditioner switch while the
standard screen is displayed, and the air
conditioner setting screen will appear.
a If the switch is not operated for 5 seconds or a If any caution occurs in the camera mode, the
longer while the air conditioner setting screen is corresponding caution monitor is displayed at
displayed, the screen changes to the standard the left top of the screen (excluding the low
screen. hydraulic oil temperature caution).
a If no control lever is operated for 10 seconds

Operation to display camera mode (PC220-Q16A-
100-K-00-A) while a failure enough to display user code is
When [F3] is pressed, the multi-display changes to occurring in the camera mode, the screen
the camera image (Set the connection of the returns to the standard screen and displays
camera in the service mode). information about that failure.
a When 2 or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
a As 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side
of the screen and the image of camera 2 is
displayed on the right side.
The image of camera 3 is displayed only singly.
a If 2-camera image display operation is made, the
images are displayed frame by frame at intervals
of approximately 1 second on the right and left
side of the screen.
a Up to 3 cameras can be connected. However, if Operation to display clock and service
the camera mode is selected, only the image of meter (PC220-Q1MA-100-K-00-A)
camera 1 is always displayed. While the standard screen is displayed, if [F4] is
pressed, the service meter and the clock are
displayed alternately in section (a).
30-90 PC490LC-10
Electrical system
a When selecting the clock display, perform the Setting and display of user mode (including
time adjustment, 12-hour or 24-hour display KOMTRAX messages for user) (PC220-Q1C3-100-K-
02-A)
setting, and summer time setting by using the
user mode functions. To enter and display the user mode, press [F6] to
display the "User Menu" screen while the standard
screen is displayed.
Check of maintenance information (PC220-Q1C2-

100-K-00-A)
You can check the maintenance information on a There are following items in the user menu.
"Maintenance" screen displayed by pressing [F6] "ECO Guidance"
while the maintenance monitor is displayed. "Machine Setting"
You can check the maintenance information on "KDPF Regeneration"
"Maintenance" displayed by pressing [F6] and then "Maintenance"
[F1] or [F2] when maintenance monitor is not "Monitor Setting"
displayed.
"Check Mail"
[KOMTRAX message]
• There are two types of KOMTRAX message;
one is for the user and the other is for the
technician.
• For user:
It denotes the messages transmitted from the
KOMTRAX base station to users. Upon
receiving a message, the message monitor is
displayed on the standard screen. Operate this
"Check Mail" when viewing contents of a
message.
• For technician:
It denotes the messages transmitted from the
a To reset the remaining time after finishing the KOMTRAX base station to users. Upon
maintenance, further operations are required. receiving a message, nothing is displayed on the
standard screen. Operate "Service Massage" of
the service mode when viewing contents of a
message.
Display of ECO guidance (PC220-Q1L3-100-K-00-A)

When the machine is set in a certain operating
condition, the ECO Guidance screen is displayed
automatically to urge the operator to perform the
energy-saving operation.
a "ECO Guidance" screen is displayed when the
following conditions are met while this display
function is set to enabled in operator mode.
a Conditions for display:
• Idle stop guidance
PC490LC-10 30-91
Electrical system
If no lever is operated for a period of at least 5 a The lamp for the E-mode recommendation
minutes and the engine keeps running at idle guidance goes out automatically after 10
speed during this period, the guidance on idle seconds has passed since it appeared, or if
stop is displayed on the monitor. This function the function switch [F5] is pressed.
helps reduce unnecessary fuel consumption by
alerting the operator to stop the engine while
waiting for the next operation, or during a break.
a The lamp for the idle stop guidance goes out
automatically when the lever operation is
resumed, or if the function switch [F5] is
pressed.
• Travel partial recommendation guidance

If machine travel in the travel mode Hi and the
fuel control dial at MAX continues for 2 or more
minutes, the travel partial recommendation
guidance is displayed. When traveling the
machine for a long period of time, moving the
fuel control dial from MAX to a lower position
helps reduce fuel consumption.
• Guidance on deterrence of hydraulic relief
If relieving lasts for 3 or more seconds during a The lamp for the travel partial
operation, guidance on deterrence of hydraulic recommendation guidance goes out
relief is displayed on the monitor. automatically after 10 seconds has passed
since it appeared, or if the function switch
a The lamp for the guidance on deterrence of
[F5] is pressed.
hydraulic relief goes out automatically after
10 seconds has passed since it appeared, or
if the function switch [F5] is pressed.
• Low fuel level guidance

If the amount of time the machine can be
operated that is projected from the remaining
• E-mode recommendation guidance
fuel level and the latest average fuel
If light-load work continues for 10 or more
consumption drops to less than 8 hours, the low
minutes in P- or ATT/P-mode, E-mode
fuel level guidance is displayed.
recommendation guidance is displayed. This
function helps reduce unnecessary fuel
consumption by alerting the operator to turn on
E-mode.
30-92 PC490LC-10
Electrical system
a The lamp for the low fuel level guidance goes Display of KDPF regeneration (PC400-A9H0-251-K-01-
out automatically after 10 seconds has A)
passed since it appeared, or if the function 1. KDPF regeneration
switch [F5] is pressed.
k During the KDPF regeneration, the
exhaust temperature may become higher
than that of the former models. To prevent
being burnt, do not stand near the
exhaust pipe. In addition, to prevent a fire,
do not bring any combustible matter near
the exhaust pipe outlet.
k If there is a thatched roof, dead leaves,

paper, or other combustible matter near
the machine, set KDPF regeneration to
stop to prevent a fire caused by the high-
temperature exhaust gas during the KDPF
regeneration. For the setting procedure,
Display of caution monitor (PC220-Q1FC-044-K-00-A) see the Operation and Maintenance
If an error that is serious enough to display Action Manual.
Level "L01" alarm monitor on the standard screen or KDPF (Komatsu Diesel Particulate Filter) is a
camera mode screen occurs, a large alarm monitor device used to capture soot in exhaust gas and
is displayed on the screen once and is continuously purify the gas. If any soot has accumulated to a
shown in window (a). certain level inside the filter, it is burnt
a On the camera mode screen, the alarm monitor automatically to keep the KDPF performance
flashes at the left upper of the screen when a high. This purification process is called
caution is issued. "regeneration".
If an operation that may lower the filtering
function of the KDPF has continued for a long
period of time, the regeneration may be
performed to protect the KDPF system,
regardless of the accumulated soot.
If an error serious enough to display a alarm monitor

of Action Level [L02], [L03] or [L04] occurs, the
alarm monitor is displayed at the center of the
monitor screen until the error is eliminated.
During the KDPF regeneration, KDPF

regeneration monitor (1) lights up on the
standard screen.
a Even if KDPF regeneration monitor (1) lights
up, the machine does not need to be stopped
but can continue work unless the alarm
monitor is displayed at the center of the
standard screen.
PC490LC-10 30-93
Electrical system
The KDPF regeneration is performed The action level monitor goes out after 2
automatically in the normal state, but the soot seconds, and then the following standard
may not be burnt or the filtering function may not screen is displayed.
be recovered sufficiently, depending on the
operating condition. Since KDPF soot
accumulation monitor (2) lights up in this case,
stop the machine in a safe place and perform
the manual stationary regeneration process. For
the execution procedure, see the Operation and
Maintenance Manual.
When the lock lever is set to the LOCK

position or all the work equipment control
levers are set in NEUTRAL, the "KDPF
Regeneration" screen is displayed after 3
seconds for only the first time. However, if
the manual stationary regeneration operation
is not performed, the screen returns to the
2. Manual stationary regeneration standard screen after 30 seconds.
There are 2 levels of monitor displays to request
the manual stationary regeneration, depending
on the degree of emergency.
k If the work is continued while the red

KDPF soot accumulation monitor (2) is
displayed, the KDPF or engine may
encounter a problem. If KDPF soot
accumulation monitor (2) lights up, be
sure to perform the manual stationary
regeneration process.
1) When degree of urgency is low
When KDPF soot accumulation monitor (2) is
yellow (action level (3): L01), the following a If KDPF soot accumulation monitor (2) is
screen is displayed first. yellow, stop the work, and then stop the
machine in a safe place and perform the
manual stationary regeneration process.
2) When the degree of emergency is high
30-94 PC490LC-10
Electrical system
k If the work is continued without

performing the manual stationary
regeneration and the soot quantity
exceeds the allowable limit, action
level monitor "L04" lights up and the
machine needs to be repaired.
a If KDPF soot accumulation monitor (2)

becomes red, immediately stop the
machine in a safe place and perform the
manual stationary regeneration process.
a If KDPF soot accumulation monitor (2) is

red, the maximum output and maximum
speed of the engine are limited to protect
the engine and KDPF system.
When KDPF accumulation monitor (2) is red
(action level (3): L03), the following screen is
displayed.
When the lock lever is set to the LOCK

position or all the work equipment control
levers are set in NEUTRAL, the "KDPF
Regeneration" screen is displayed after 3
seconds. Then, until the manual stationary
regeneration process is performed, the
"KDPF Regeneration" screen or the standard
screen with the alarm monitor lighted is
displayed automatically according to the
position of the lever.
PC490LC-10 30-95
Electrical system
Display of action level and failure code (PC220-

Q1FC-100-K-00-A)
If an abnormality that displays an action level and a
failure code occurs on the standard screen or
camera mode screen, the alarm monitor lights up.
If the alarm monitor lights up, press function switch

[F5], then "Error List" is displayed.
• [F1]: Moves to next page (screen) (when
displayed)
• [F2] Moves to previous page (screen) (when
displayed)
• [F5]: Returns to the standard screen
On the "Error List" screen, the following information
is displayed.
(a): Alarm monitor
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a This screen appears when trouble (failure code)
occurs only if its action level is set.
a The telephone number is displayed only when
the telephone number is registered in Service
Mode.
a If multiple troubles occur simultaneously, all the
codes are displayed repeatedly in order.
a As the information of the displayed failure code
is recorded in "Abnormality Record" in the
service mode, check the details in service mode.
a "Error List" is replaced with the standard screen
automatically after 30 seconds.
a Since "Error List" cannot be displayed from the
screen on which the camera mode is displayed,
move to "Error List" from the standard screen
side.
30-96 PC490LC-10
Electrical system
a Remedies that displayed action levels require

operator to do (The following table is an excerpt
from the Operation and Maintenance Manual)
Degree of Alarm Remedy
urgency Action level Buzzer
monitor
Stop immediately and perform checking and
High Q maintenance.
L04 Q
(Continuous) Ask your Komatsu distributor for testing and repair
services.
Stop the work, move machine to safe place, stop it, and
Q perform checking and maintenance.
L03 Q
(Intermittent) Ask your Komatsu distributor for testing and repair
I
services.
Stop the work once, and run the engine at medium
O Q speed with no load or stop the engine. If the symptom is
L02 Q not resolved, ask your Komatsu distributor for checking
(Intermittent)
and repair services.
L01 Some functions may be limited. However, you can
(For 2 perform the work. Perform the inspection and
- Q maintenance after completion of the work.
Low seconds
only) Please contact your KOMATSU distributor as needed.
PC490LC-10 30-97
Electrical system
Function of checking display of LCD (Liquid

Crystal Display) (PC-Q1LE-100-K-00-A)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
• Switch operations (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a To return to the former screen, press any one of
the function switches. Function of Usage Limitation Setting/ Change
Reference: An LCD panel, as one of its
Password (PC220-Q19X-100-K-00-A)
Selecting the Usage Limitation Setting displays the
characteristics, sometimes shows black spots
password input screen when you proceed to
(spots that remain unlit) and bright spots (spots that
breaker setting, attachment setting and
do not go off).
maintenance resetting. Observe the following
If the number of the bright points and black points procedure when using the Usage Limitation Setting.
does not exceed 10, the LCD panel is not faulty or
1. While the standard screen is displayed, perform
defective.
the following operation by using the numeral
input switches.
• Switch operation (Press the switches in order
while pressing [4])
[4] + [5] o [5] o [5]
a This operation of the switches is not
accepted until 10 minutes elapse after the
starting switch is turned to ON position.
Function of checking service meter (PC-Q1MB-

100-K-00-A)
When checking the service meter with the starting
switch in OFF position, operate the numeral input
switches as follows to display only the service meter
section.
• Switch operations (simultaneous): [4] + [1]
a There is some time lag in start of the LCD, so 2. After the "Usage Limitation Password" screen is
hold down the switches until the service meter is displayed, input the current password by using
displayed. the numeral input switches and confirm it by
a If you release one of the switches, the monitor using the function switch.
goes off. • [F5]: Deletes input numbers/Returns to
Reference: After the machine monitor is used standard screen.
continuously over a long period of time, blue points • [F6]: Enters input password.
(points that remain lit) may appear on this screen. It a Default password: [000000]
does not indicate that the LCD panel is faulty or
defective. a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
screen displays message to request inputting
the password again.
30-98 PC490LC-10
Electrical system
3. After the "Usage Limitation Setting" screen is

a The password for the Usage Limitation and
displayed, select a setting by using the function
the engine start lock password are not
switch.
identical.
• [F3]: Moves selection downward 4. Changing a password
• [F4]: Moves selection upward After the "Usage Limitation New Password
• [F5]: Cancels the selection and returns the Input" screen is displayed, input the new
display to the previous screen password by using the numeral input switches
• [F6]: Enters selection and confirm it by using the function switch.
• [F5]: Deletes input numbers/Returns the
display to the preceding screen.
• [F6]: Enters input password.
a Default password: [000000]
a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
screen displays message to request inputting
the password again.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
Selection of use/non-use of Usage Limitation is not accepted).
After the "Usage Limitation ON/OFF" screen is
displayed, select a setting by using the function
switch.
• "Enable": Password input screen is not
displayed
• "Disable": The password input screen
appears for setting of the circuit breaker or
attachment, or maintenance resetting.
• [F3]: Moves selection downward
• [F4]: Moves selection upward
• [F5]: Cancels the selection and returns the
display to the previous screen
• [F6]: Enters selection
After the "Usage Limitation New Password
Input" screen is displayed once more, input the
new password for the second time by using the
numeral input switches and confirm it by using
the function switch.
• [F5]: Deletes input numbers/Returns to
standard screen.
• [F6]: Enters input password.
PC490LC-10 30-99
Electrical system
a If the input password is different from the one

input before, the message to request
inputting again is displayed.
If the standard screen is displayed after the

screen to notify completion of setting is
displayed, the password is changed successfully.
30-100 PC490LC-10
Electrical system
Service mode (PC400-Q194-100-K-00-A) a The menu items which can be selected in the
To change the mode of the machine monitor to the service menu are as follows (including some
service mode from the operator mode, perform the items which need special operations).
following operation.
01 Troubleshooting support(PAGE 30-102)
This operation is always required when you use the 02 Monitoring(PAGE 30-107)
service mode. Abnormality record (mechanical systems)
1. Check of screen display and operation of (PAGE 30-114)
03
switches Abnormality record (electrical systems)(PAGE
While the standard screen is displayed, perform 30-115)
the following operation by using the numeral 04 Maintenance record(PAGE 30-117)
input switches. 05 Maintenance mode setting(PAGE 30-118)
• Operation of switches (While pressing [4], 06 Phone number entry(PAGE 30-120)
press the switches in order): Default (Key-on Mode)(PAGE 30-121)
[4] + [1] o [2] o [3] Default value setting (Unit)(PAGE 30-122)
a This operation of the switches is accepted 07 Default (With/Without Attachment)(PAGE 30-
only while the standard screen is displayed. 123)
Default (Camera)(PAGE 30-123)
Testing (Cylinder Cut-out operation)(PAGE 30-
125)
08 Testing (Regeneration for Service)(PAGE 30-
126)
Testing (KDPF Memory Reset)(PAGE 30-128)
Adjustment (Pump Absorption Torque (F))
(PAGE 30-129)
Adjustment (Pump Absorption Torque (R))
(PAGE 30-129)
Adjustment (Attachment Flow Adjustment)
(PAGE 30-131)
Adjustment (Attachment Flow Adjustment)
(PAGE 30-131)
2. Selection of service menu Adjustment (F pump swash plate sensor
When the "Service Menu" screen is displayed, 09 calibration)(PAGE 30-132)
the service mode is selected. Select the desired Adjustment (R pump swash plate sensor
service menu by using the function switches or calibration)(PAGE 30-137)
numeral input switches. Adjustment (Pump calibration: Matching speed
• [F3]: Moves to lower item check)(PAGE 30-138)
• [F4]: Moves to lower item Adjustment (Pump calibration: Matching speed
• [F5]: Return the display to the standard calibration)(PAGE 30-143)
screen (operator mode) Adjustment (Fan Rotation Mode Selection)
• [F6]: Validate the selection (PAGE 30-145)
10 No-Injection(PAGE 30-145)
a If you input a 2-digit code by using the KOMTRAX Settings (Terminal Status)(PAGE
numeral input switches, the corresponding 30-146)
menu is directly selected. This will allow you KOMTRAX Settings (GPS and Communication
to validate the selection using [F6]. 11 Status)(PAGE 30-147)
KOMTRAX Settings screen (Modem Status)
(PAGE 30-148)
12 Service Message(PAGE 30-148)
PC490LC-10 30-101
Electrical system
Troubleshooting support (PC400-Q1S1-100-K-00-A)

The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which control them. In the
troubleshooting support, monitoring items that are
used frequently in daily work are selected
beforehand.
1. Selecting the menu
Select "Troubleshooting support" on the
"Service Menu" screen.
2. Checking monitoring / pre-defined information

After the "Monitoring / Pre-defined" screen is
displayed, you can check the items displayed in
the troubleshooting support by using the function
switches.
• [F1]: Moves to next page (screen)
• [F2]: Moves to previous page (screen)
• [F4]: Selects hold or releasing hold (If hold is
selected, a diagonal line is displayed on the
HOLD portion)
• [F5]: Returns to Service Menu screen
a You can select and check any items not
displayed in "Troubleshooting support" from
the "Monitoring items."
a If the working mode is changed to breaker

mode [B], the screen to confirm the change
of the setting is displayed as in changing the
working mode on the standard screen.
30-102 PC490LC-10
Electrical system
List of troubleshooting support items (SI unit is default)

Support screen (1/16) Machine basic items
Unit (Default: SI) Applicable
No. ID Item name component
SI Metric Imperial
1 01002 Engine speed r/min rpm rpm ENG
2 04107 Engine coolant temperature °C °C °F ENG
3 37200 Engine oil pressure sensor kPa kg/cm 2 psi ENG
4 18400 Intake temperature °C °C °F ENG
5 04401 Hydraulic oil temperature °C °C °F PUMP
6 03203 Battery power supply V V V ENG
Support screen (2/16) Fuel injection
SI Metric Imperial
2 47300 KDOC inlet temperature 1 °C °C °F ENG
3 36400 Common rail pressure MPa kg/cm2 psi ENG
4 36200 Last rail press command MPa kg/cm2 psi ENG
5 17201 PCV opening timing (TDC base) CA CA CA ENG
Support screen (3/16) EGR, KVGT actuator
SI Metric Imperial
2 48100 Turbo speed r/min rpm rpm ENG
3 18100 EGR valve position mm mm in ENG
4 48600 EGR solenoid current mA mA mA ENG
5 48700 KVGT position mm mm in ENG
6 48800 KVGT solenoid current mA mA mA ENG
Support screen (4/16) Engine temperature-related items
SI Metric Imperial
5 18500 Charge temperature °C °C °F ENG
Support screen (5/16) Air intake/exhaust pressure, etc.
SI Metric Imperial
2 37400 Ambient pressure kPa kg/cm 2 psi ENG
3 36500 Boost pressure kPa kg/cm2 psi ENG
5 48200 Intake air flow rate kg/min kg/min kg/min ENG
PC490LC-10 30-103
Electrical system
Support screen (6/16) Post treatment-related items

SI Metric Imperial
1 47000 KDPF outlet pressure kPa kg/cm2 psi ENG
2 47100 KDPF differential pressure kPa kg/cm 2 psi ENG
3 47200 KDPF outlet temperature 1 °C °C °F ENG
5 47400 KDOC outlet temperature 1 °C °C °F ENG
6 47600 Dozer fuel pressure kPa kg/cm2 psi ENG
Support screen (7/16) Engine-related items
SI Metric Imperial
2 37200 Engine oil pressure sensor kPa kg/cm 2 psi ENG
3 48400 Crank case pressure kPa kg/cm2 psi ENG
5 36500 Boost Pressure kPa kg/cm 2 psi ENG
Support screen (8/16) F & R pumps basic items
SI Metric Imperial
2 01100 F pump pressure MPa kg/cm2 psi PUMP
3 01101 R pump pressure MPa kg/cm 2 psi PUMP
4 01300 PC-EPC sol. current (F) mA mA mA PUMP
5 01302 PC-EPC sol. current (R) mA mA mA PUMP
Support screen (9/16) F & R pumps application items
SI Metric Imperial
4 01137 F pump capacity cc/rev cc/rev cc/rev PUMP
5 01139 R pump capacity cc/rev cc/rev cc/rev PUMP
Support screen (10/16) F pump application items
SI Metric Imperial
3 01141 Service pressure MPa kg/cm2 psi PUMP
4 01300 PC-EPC sol. current (F) mA mA mA PUMP
5 01137 F pump capacity cc/rev cc/rev cc/rev PUMP
6 01500 LS-EPC sol. current mA mA mA PUMP
30-104 PC490LC-10
Electrical system
Support screen (11/16) R pump application items

SI Metric Imperial
4 01302 PC-EPC sol. current (R) mA mA mA PUMP
5 01139 R pump capacity cc/rev cc/rev cc/rev PUMP
6 01500 LS-EPC sol. current mA mA mA PUMP
Support screen (12/16) PPC pressure
SI Metric Imperial
2 07400 Boom RAISE PPC pressure MPa kg/cm 2 psi PUMP
3 07500 Boom LOWER PPC pressure MPa kg/cm2 psi PUMP
4 07200 Arm CURL PPC pressure MPa kg/cm2 psi PUMP
5 07600 Arm OUT PPC pressure MPa kg/cm2 psi PUMP
SI Metric Imperial
2 09002 Swing RIGHT PPC pressure MPa kg/cm2 psi PUMP
3 09001 Swing LEFT PPC pressure MPa kg/cm 2 psi PUMP
4 07300 Bucket CURL PPC pressure MPa kg/cm2 psi PUMP
5 07301 Bucket DUMP PPC pressure MPa kg/cm2 psi PUMP
SI Metric Imperial
2 07102 Travel Fwd L.H. PPC pressure MPa kg/cm2 psi PUMP
3 07103 Travel Fwd R.H. PPC pressure MPa kg/cm 2 psi PUMP
4 07104 Travel Rev L.H. PPC pressure MPa kg/cm2 psi PUMP
5 07105 Travel Rev R.H. PPC pressure MPa kg/cm2 psi PUMP
Support screen (15/16) Hydraulic fan (1)
SI Metric Imperial
5 10010 Fan speed command r/min rpm rpm PUMP
6 10007 Fan speed r/min rpm rpm PUMP
PC490LC-10 30-105
Electrical system
Support screen (16/16) Hydraulic fan (2)

SI Metric Imperial
2 10010 Fan speed command r/min rpm rpm PUMP
3 10007 Fan speed r/min rpm rpm PUMP
4 31623 Fan pump EPC sol. current mA mA mA PUMP
30-106 PC490LC-10
Electrical system
Monitoring (PC220-Q19L-100-K-00-A)
The machine monitor can monitor the condition of a Up to 6 monitoring items are selectable at a
the machine in real time by receiving signals from time. However, the items may not be set up
various switches, sensors, and actuators installed to to 6 depending on the form of display of the
various parts of the machine and the information selected item.
from the controllers which is controlling switches,
etc. The monitoring function allows you to select a
desired monitoring item.
1. Selecting menu
Select "Monitoring/Custom" on "Service Menu"
screen.
3. Deciding monitoring items

After selecting monitoring items, execute
monitoring with the function switch or numeral
input switch.
a Execution with function switch: Double click
or keep pressing [F6] (for approximately 2
2. Selecting monitoring item seconds).
After the "Monitoring Selection Menu" screen is
displayed, select items to be monitored by using a Execution with numeral input switch: Input
the function switches or numeral input switches. [99999] and press [F6].
• [F1]: Moves selection to the left item a When monitoring only 2 items, for example,
• [F2]: Moves selection to the right item select them and confirm with [F6]. If [F6] is
• [F3]: Moves selection to the below item pressed once more at this time, monitoring is
• [F4]: Moves selection to the above item executed.
• [F5]: Clears input numbers/ Returns the
display to the service menu screen a If monitoring items are selected up to the limit
• [F6]: Enters selection number, monitoring is executed
automatically.
a In setting of the monitoring, each time
function switch [F2] is pressed, sequential
switching among [ENG] o [KDPF] o
[PUMP] o [MON] o [ENG] takes place in
this order. (Pressing [F1] induces the
sequential switching in the reverse order.)
a Selection with function switches: Select an
applicable equipment by using [F1] or [F2],
select an item by using [F3] or [F4], and then
enter it by using [F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is
selected directly. Enter that item by using
[F6]. 4. Performing monitoring
After the "Monitoring" screen is displayed,
a If the color of the selected box changes from perform the necessary operation of the machine
yellow to red, the selection of the item of that and check the monitoring information.
box is entered.
a Monitoring information is indicated by value,
ON/OFF, or special display.
PC490LC-10 30-107
Electrical system
a The unit of display can be selected in SI unit,

metric unit, or inch unit with the Default
function in the service mode.
a When the working mode is changed to

breaker mode [B], the screen to confirm the
change of the setting is displayed as in
5. Holding monitoring information changing the working mode on the standard
You can hold and release holding of the screen.
monitoring information by using the function
switches.
• [F4]: Selects hold or releasing hold
(If the Hold is selected, the HOLD portion is
hatched.)
• [F5]: Returns the display to monitoring
selection menu screen
7. Saving of monitoring item

A function switch lets you save and delete the
selected monitoring item.
• [F1]: MEMORY
• [F2]: CLEAR
6. Changing machine setting mode

To change the setting of the working mode,
travel speed, or auto-deceleration during
monitoring, operate the corresponding switch
under the current condition, and the
corresponding mode is selected.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after
monitoring is finished.
a When you saved a monitoring item, selecting

"Monitoring" again displays the screen that
confirms whether you want to display the
once saved item.
a When an item is saved, it can be displayed
as many times as required unless it is
cleared.
30-108 PC490LC-10
Electrical system
a If another item is saved while having the

previous item saved, the previously saved
item is overwritten by the latest one.
a The saved monitoring item is cleared by
using [F2]. It is also cleared when the
selection is entered by using [F6] in the
following screen.
• KOMTRAX terminal screen
• "With/Without Attachment" screen
• Functional specification screen
• Air conditioner setting screen
PC490LC-10 30-109
Electrical system
Monitoring items list (PC400-Q19L-208-K-00-A)
Code Monitoring item Unit (Default: SI) Applicable

(Display on screen) Remarks
No. SI meter inch component
01002 Engine speed r/min rpm rpm ENG
04107 Engine coolant temperature ℃ °C deg.F ENG
03203 Battery power supply V V V ENG
37200 Engine oil pressure sensor kPa kg/cm2 psi ENG
36400 Common rail pressure MPa kg/cm 2 psi ENG
37400 Ambient pressure kPa kg/cm2 psi ENG
18400 Intake Temperature °C ℃ deg.F ENG
18500 Boost temperature °C °C deg.F ENG
Absolute value
indication (including
36500 Boost Pressure kPa kg/cm2 psi ENG atmospheric
pressure)
48100 Turbo Speed r/min rpm rpm ENG
48200 Mass Air Flow kg/min kg/min lb/min ENG
48400 Crankcase Pressure kPa mmAg psi ENG
18100 EGR Valve Position mm mm in ENG
48600 EGR Solenoid Current mA mA mA ENG
48700 KVGT Position mm mm in ENG
48800 KVGT Solenoid Current mA mA mA ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Fuel Dial Pos Sens Volt V V V ENG
04105 Eng. Water Temp. Volt V V V ENG
37201 Eng Oil Press Sens Volt V V V ENG
37401 Ambient Press Sens Volt V V V ENG
18401 Intake Temp Sens Volt V V V ENG
18501 Boost Temp Sens Volt V V V ENG
36501 Boost press Sens volt V V V ENG
36401 Rail Pressure Sens Volt V V V ENG
48401 Crankcase Press Sens Volt V V V ENG
18101 EGR Valve Pos Sens Volt V V V ENG
48701 KVGT Pos Sensor Volt V V V ENG
17201 PCV opening timing (based on TDC) CA CA CA ENG
17500 Engine Power Mode — ENG
48900 Engine Operation Mode — ENG
08402 Droop switch — ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Last rail press command MPa kg/cm2 psi ENG
37300 Fuel rate (Note 1) l/h l/h gal/h ENG
20216 ECM Build Version — ENG
20217 ECM CAL Data Ver — ENG
18900 ECM Internal Temp °C ℃ deg.F ENG
20400 ECM Serial No — ENG
47000 KDPF Outlet Pressure kPa kg/cm2 psi KDPF
47001 KDPF Out Pressure Sensor Volt V V V KDPF
47100 KDPF Delta Pressure kPa kg/cm 2 psi KDPF
47101 KDPF Delta Press. Sensor Volt V V V KDPF
47300 KDOC 1 Inlet Temperature °C ℃ deg.F KDPF
30-110 PC490LC-10
Electrical system

(Display on screen) Remarks
No. SI meter inch component
47301 KDOC 1 Inlet Temp Sens Volt V V V KDPF
47400 KDOC 1 Outlet Temperature °C ℃ deg.F KDPF
47401 KDOC 1 Outlet Temp Sens Volt V V V KDPF
47200 KDPF 1 Outlet Temperature °C ℃ deg.F KDPF
47201 KDPF 1 Outlet Temp Sens Volt V V V KDPF
47500 Dozing Fuel Rate l/h l/h gal/h KDPF
47600 Dozer Fuel pressure kPa kg/cm2 psi KDPF
47601 Dosing Fuel P Sens Volt V V V KDPF
47700 Soot Accumulation Level g/L g/L g/gal KDPF
47800 Ash Accumulation Level g/L g/L g/gal KDPF
01601 2nd Eng. Speed Command r/min rpm rpm PUMP
01100 F Pump Pressure MPa kg/cm 2 psi PUMP
01101 R Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom RAISE PPC Pressure MPa kg/cm2 psi PUMP
07500 Boom Lower PPC Pressure MPa kg/cm 2 psi PUMP
07200 Arm IN PPC Pressure MPa kg/cm2 psi PUMP
07600 Arm OUT PPC pressure MPa kg/cm2 psi PUMP
07300 Bucket CURL PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket DUMP PPC pressure MPa kg/cm 2 psi PUMP
09001 Swing LEFT PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing RIGHT PPC Pressure MPa kg/cm2 psi PUMP
07102 Travel Fwd L.H. PPC pressure MPa kg/cm 2 psi PUMP
07103 Travel Fwd R.H. PPC pressure MPa kg/cm2 psi PUMP
07104 Travel Rev L.H. PPC pressure MPa kg/cm2 psi PUMP
07105 Travel Rev R.H. PPC pressure MPa kg/cm 2 psi PUMP
01137 F Pump Displacement cc/rev cc/rev cc/rev PUMP
01138 F Pump Sw Plate Sensor Volt V V V PUMP
01139 R Pump Displacement cc/rev cc/rev cc/rev PUMP
01140 R Pump Sw Plate Sensor Volt V V V PUMP
04401 Hydraulic oil temperature °C ℃ deg.F PUMP
10007 Fan Speed r/min rpm rpm PUMP
10010 Fan Speed Command r/min rpm rpm PUMP
01300 PC-EPC Sol. Curr.(F) mA mA mA PUMP
01302 PC-EPC Sol. Curr. (R) mA mA mA PUMP
01500 LS-EPC Sol. Curr. mA mA mA PUMP
31623 Fan Pump EPC Sol. Curr. mA mA mA PUMP
08000 Merge-divide Sol Current Main mA mA mA PUMP
08001 Merge-divide Sol Current LS mA mA mA PUMP
01700 Attachment Sol. Curr. mA mA mA PUMP
03200 Battery Voltage V V V PUMP
04402 Hydr. Temp. Sensor Vol. V V V PUMP
01602 2nd Eng. Speed Command % % % PUMP
17301 Dynamic Torque Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
13114 Fan Pump Absorb Torque Nm kgm lbft PUMP
13112 Total Pump Absorb Torque Nm kgm lbft PUMP
01141 Service Pressure MPa kg/cm2 psi PUMP
PC490LC-10 30-111
Electrical system

(Display on screen) component Remarks
No. SI meter inch
Swing ON, OFF PUMP
Travel ON, OFF PUMP
Pressure Switch Boom LOWER ON, OFF PUMP
01900
1 Boom RAISE ON, OFF PUMP
Arm IN ON, OFF PUMP
Arm OUT ON, OFF PUMP
Bucket CURL ON, OFF PUMP
Pressure Switch Bucket DUMP ON, OFF PUMP
01901
2 Attachment ON, OFF PUMP
Travel steering ON, OFF PUMP
Travel Junction ON, OFF PUMP
Swing holding brake ON, OFF PUMP
Solenoid Valve Merge-divider ON, OFF
02300 PUMP
1
2-stage Relief ON, OFF PUMP
Travel Speed ON, OFF PUMP
Swing cutoff ON, OFF PUMP
Solenoid Valve Attachment Return ON, OFF PUMP
02301
2 Variable back
ON, OFF PUMP
pressure
Solenoid Valve ON, OFF
02302 Fan reverse rotation PUMP
3
Controller
03700 Battery relay drive ON, OFF PUMP
Output 1
Knob Sw. ON, OFF PUMP
02200 Switch Input 1 Swing Release SW. ON, OFF PUMP
Swing holding brake ON, OFF PUMP
SW.
Model Select 1 ON, OFF PUMP
02201 Switch Input 2
Overload Alarm ON, OFF PUMP
02202 Switch Input 3 Key Switch (ACC) ON, OFF PUMP
02203 Switch Input 4 Lock lever ON, OFF PUMP
Window limit switch ON, OFF PUMP
02204 Switch Input 5 P Limit SW. ON, OFF PUMP
W Limit SW. ON, OFF PUMP
20229 Pump Con. Ass'y P/N — PUMP
20403 Pump Con. Serial No — PUMP
20230 Pump Con. Prog. P/N — PUMP
20212 Program version (pump controller) — PUMP
04300 Battery Charge V V V MON
04200 Fuel Level Sensor Vol. V V V MON
Key Switch ON, OFF MON
Start ON, OFF MON
04500 Monitor Input 1 Preheating ON, OFF MON
Light ON, OFF MON
Coolant level ON, OFF MON
Air cleaner ON, OFF MON
04501 Monitor Input 2 Engine oil level ON, OFF MON
Battery Charge ON, OFF MON
30-112 PC490LC-10
Electrical system

(Display on screen) component Remarks
No. SI meter inch
Swing holding brake ON, OFF MON
SW.
04502 Monitor Input 3 Engine Shutdown ON, OFF
Secondary SW. MON
Seat Belt SW. ON, OFF MON
F1 ON, OFF MON
F2 ON, OFF MON
Monitor F3 ON, OFF MON
04503 Function
F4 ON, OFF MON
Switches
F5 ON, OFF MON
F6 ON, OFF MON
SW1 ON, OFF MON
SW2 ON, OFF MON
Monitor 1st & SW3 ON, OFF MON
04504 2nd Row
SW4 ON, OFF MON
Switches
SW5 ON, OFF MON
SW6 ON, OFF MON
SW7 ON, OFF MON
SW8 ON, OFF MON
Monitor 3rd & SW9 ON, OFF MON
04505 4th Row
SW10 ON, OFF MON
Switches
SW11 ON, OFF MON
SW12 ON, OFF MON
SW13 ON, OFF MON
Monitor 5th Row ON, OFF
04506 SW14 MON
Switches
SW15 ON, OFF MON
20227 Monitor Ass'y P/N — MON
20402 Monitor Serial No — MON
20228 Monitor Prog. P/N — MON
20200 Monitor Prog. Version — MON
55300 Aircon Compressor Status ON, OFF MON
55000 Aircon Outside Temp. Code — MON
55100 Aircon Inside Temp. Code — MON
55200 Aircon Mode Data (Mon) — MON
55201 Aircon Mode Data (Aircon ECU) — MON
Only when
20260 KOMTRAX Ass'y P/N — MON
KOMTRAX is used
— Only when
20418 KOMTRAX Serial No MON
KOMTRAX is used
Only when
20261 KOMTRAX Prog. P/N — MON
KOMTRAX is used
Only when ID key is
20262 ID Key Controller Ass'y P/N — MON
used
Only when ID key is
20419 ID key controller Serial No. — MON
used
Only when ID key is
20263 ID Key Controller Prog. P/N — MON
used
a Listing order of items in table

The items are listed in the order of display on the monitoring item selection menu screen.
a Unit
The display unit can be set to SI, meter, or inch as required (select a desired unit from "Unit" of "Default").
"mg/st" in the display unit is an abbreviation for milligram/stroke.
PC490LC-10 30-113
Electrical system
a Applicable component
ENG: The engine controller detects monitoring information.
KDPF: KDPF detects monitoring information.
PUMP: The pump controller detects monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: The instantaneous fuel consumption (monitoring code: 37300) is the theoretical fuel consumption
(because it is a theoretical value, it is a little different from the actual fuel consumption).
Abnormality record (mechanical

systems) (PC220-Q1S2-100-K-00-A)
The machine monitor logs the past and currently
occurring failures classifying them into the
mechanical system abnormality and electrical
system abnormality.
To check the mechanical system abnormality record,
perform the following procedures.
a For the failure code list, see "(Chapter 40)
Failure code list for troubleshooting".
1. Selecting a menu
Select "Abnormality Record" on "Service Menu"
screen. 3. Information displayed on "Abnormality Record"
screen
On the "Mechanical Systems" screen, the
following information is displayed.
(a): Occurrence order from latest one/Total
number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at the first occurrence
(f): Service meter reading at the last occurrence
• [F1]: Moves to next page (screen) (This
function key is available when more than 1
2. Selecting a sub menu page is needed for display.)
After the "Abnormality Record" screen is • [F2]: Returns to previous page (screen) (This
displayed, select "Mechanical Systems" by function key is available when more than 1
using the function switch or numeral input page is needed for display.)
switches. • [F5]: Returns to the "Abnormality Record"
• [F3]: Moves selection downward. screen.
• [F4]: Moves selection upward. a If no abnormality is recorded, "No Error" is
• [F5]: Returns to "Service Menu" screen. displayed.
• [F6]: Enters selection.
a In the mechanical systems abnormality
a When you input a 2-digit code by using the record screen, up to 50 cases currently
numeral input switches, the corresponding stored are displayed.
item is directly selected. Accordingly, you
may enter the selection by using [F6]. a If the number of occurrence is 1 (first
occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
When the latest service meter reading is
recovered, the value at the recovery time is
displayed, thus the above readings may not
be the same.
30-114 PC490LC-10
Electrical system
a If [E] is displayed on the left of a failure code, Abnormality record (electrical

the abnormality is still occurring or correction systems) (PC220-Q1S3-100-K-00-A)
of it is not confirmed. The machine monitor records the past and currently
occurring failures classifying them into the
a For all of the failure codes that the machine mechanical system abnormality and electrical
monitor can record, see the failure code list. system abnormality.
To check the electrical system abnormality record,
perform the following procedures.
a For the failure code list, see "40 Failure code list
for troubleshooting".
1. Selecting a menu
Select "Abnormality Record" on "Service Menu"
screen.
4. Clearing abnormality record

The contents of an abnormality record of the
mechanical system cannot be deleted.
2. Selecting a sub menu

Select "Electrical Systems" by using the function
switch or numeral input switches on
"Abnormality Record" screen displayed.
• [F5]: Returns the screen to "Service Menu"
screen
a When you input a 2-digit code by using the
numeral input switches, the corresponding
item is directly selected. Accordingly, you
may enter the selection by using [F6].
3. Information displayed on "Abnormality Record"

screen
After "Electrical Systems" screen is displayed,
the following information is displayed.
PC490LC-10 30-115
Electrical system
(a) Occurrence order of abnormalities from latest

one/ Total number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at the first occurrence
(f): Service meter reading at the last occurrence
• [F1]: Moves to next page (screen) (when
displayed)
• [F2] Moves to previous page (screen) (when
displayed)
• [F4]: Moves selection upward 2) Check that the display on the screen
• [F5]: Returns screen to "Abnormality Record" becomes the clear mode, then clear the
screen individual information one by one or all
together by using the function switches.
a If no abnormality is recorded, "No Error" is
displayed. a If the screen is set in the clear mode,
graphic mark [CLEAR] is indicated above
a On the electrical systems abnormality record [F2].
screen, up to 20 cases currently stored are
displayed. • [F2]: Clears all items
If the number of abnormality records • [F4]: Moves selection upward
increases to 21 or beyond, the latest • [F5]: Returns screen to "Abnormality
occurrence code is displayed and the oldest Record" screen
one is deleted. • [F6]: Clears items one by one
a If the number of occurrence is 1 (first a To clear items one by one: Select the item
occurrence), the service meter reading at the to be cleared with [F3] or [F4] and press
first occurrence and that at the last [F6].
occurrence are the same.
a To clear all items together: Press [F2],
a If [E] is displayed on the left of a failure code, and all the items are cleared, regardless
the abnormality is still occurring or correction of selection of the items.
of it is not confirmed.
a If [E] is displayed on the left of a failure
a For all of the failure codes that the machine code, the clearing operation is accepted
monitor can record, see the failure code list. but the item is not cleared.
4. Clearing abnormality record 3) Operate the function switches on "Electrical

1) While the "Electrical Systems" screen is Sys. Error Reset" screen displayed.
displayed, perform the following operation by • [F5]: Returns the screen to "Electrical
using the numeral input switches. Systems" screen (clear mode)
• Switch operation (Press the switches in • [F6]: Executes clearing
order while pressing [4])
[4] + [1] o [2] o [3]
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Electrical system
a The following figure shows the screen

when an individual item is cleared (it is
slightly different from the screen when all
the item are cleared at once).
2. Selecting maintenance record item

After the "Maintenance Record" screen is
displayed, select an item to be checked by using
the function switches or numeral input switches.
4) If the screen to notify completion of clearing
is displayed and then "Electrical Sys. Error
Reset" screen (clear mode) is displayed, the
• [F4]: Moves to upper item
clearing of the abnormality record is
complete.
a You may enter a 2-digit code with the
a After a while, the screen returns to the
numeral input switches to select the item of
"Electrical Systems" abnormality record
that code.
screen.
a The following items can be selected in the

Maintenance record (PC400-Q19Z-100-K-00-A) maintenance record.
The machine monitor records the maintenance
49 Cleaning and replacement of cleaner
information of the filters, oils, etc., which are
displayed and checked by the following operations. 01 Engine oil change
02 Engine oil filter change
When maintenance is performed, if the remaining
time is reset in the operator mode, the number of 03 Fuel main filter change
maintenance times is recorded in this record. 41 Fuel pre filter change
04 Hydraulic oil filter change
Select "Maintenance Record" on the "Service 05 Hydraulic tank breather change
Menu" screen. 07 Checking and adding oil in damper case
08 Final drive case oil change int.
09 Machinery case oil change
10 Hydraulic oil change
47. Replacement of KCCV filter
48 Cleaning of KDPF filter
52 Cleaning of fuel doser
3. Items displayed on maintenance record screen
PC490LC-10 30-117
Electrical system
The following items are displayed.

(a): Maintenance items
(b): Number of times of replacement up to now
(c): Service meter reading (SMR) at previous
replacement
a The following items can be selected on the

“Maintenance Mode Setting” screen.
00 Maintenance Mode Change
49 Air cleaner cleaning and change int.
01 Engine oil change int.
Maintenance mode setting (PC400-Q1F1-100-K-00-A) 02 Engine oil filter change int.
The actuating condition of the maintenance 03 Fuel main filter change int.
reminder function in the operation mode can be set 41 Fuel pre-filter change int.
and changed by using this menu. 04 Hyd. oil filter change int.
• To enable or disable the function 05 Hyd. tank breather change int.
• To change set replacement interval (by item) 07 Damper case service int.
• To initialize all set replacement intervals 08 Final drive case oil change int.
1. Selecting the menu 09 Machinery case oil change int.
Select "Set maintenance" on the "Service Menu" 10 Hydraulic oil change int.
screen.
99 Initialize all items
3. Contents of setting of maintenance mode
change
After selecting "Maintenance Mode Change", if
the screen is displayed, set with the function
switches.
• ON: Function of all maintenance items are
enabled in operator mode
• OFF: Function of all maintenance items are
disabled in operator mode
• [F5]: Cancels selection and returns to
Maintenance Mode Change screen
2. Selecting sub menu
• [F6]: Enters selection and returns to
After the "Maintenance Mode Setting" screen is
Maintenance Mode Change screen
displayed, select an item the setting of which is
to be changed by using the function switches or a This setting overrides ON/OFF setting of
numeral input switches. each item.
a You may enter a 2-digit code with the
numeral input switches to select the item of
that code and enter it with [F6].
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Electrical system
4. Contents of maintenance notice time setting 5. Setting of each maintenance item

After selecting "Maintenance Notice Time After selecting each maintenance item, if the
Setting", if the screen is displayed, set with the screen is displayed, set the item with the
function switches. function switches.
• ON: Function of all maintenance items are
enabled in operator mode
• OFF: Function of all maintenance items are
disabled in operator mode
• [F3]: Moves to lower set value
• [F4]: Moves to upper set value
• [F5]: Cancels selection and returns to
Maintenance mode change screen
• [F6]: Enters selection and returns to
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
• Default: Maintenance notice time set in
machine monitor (Recommended by
manufacturer and not changeable).
• Set value: Maintenance interval which can
be set freely. Maintenance functions in
operator mode operate on basis of this set
time (which is increased or decreased by 10
hours).
• [F3]: Decreases set value
• [F4]: Increases set value
• [F5]: Cancels setting before entering setting
and return to Maintenance mode change
screen.
• [F6]: Enters setting and returns to 6. Setting of each maintenance item value
Maintenance mode setting screen Select a set value of a maintenance item. After
a After entering with [F6], press [F5] to return to the screen is displayed, set with the function
the Maintenance mode setting screen, and switches.
then the setting is effective.
a If the set value of an item of which
maintenance reminder function is set to "ON"
is changed after one operating hour or more
from the setup, the change is recognized as
a reset of the remaining time.
PC490LC-10 30-119
Electrical system
• Default: Maintenance notice time set in • If this function is executed, the set values of
machine monitor (Recommended by all the maintenance items are initialized.
manufacturer and not changeable). • [F5]: Returns to Maintenance mode setting
• Set value: Maintenance interval which can screen
be set freely. Maintenance functions in • [F6]: Enters initialization
operator mode operate on basis of this set
a A while after [F6] is pressed, the message to
time (which is increased or decreased by 25
notify of initialization completion is displayed.
hours).
Then, if the "Maintenance Mode Setting"
• [F3]: Decreases set value
screen is displayed, the initialization is
completed.
• [F5]: Cancels setting before confirmation and
returns to “Maintenance Mode Change”
screen.
• [F6]: Enters setting and returns to
a After entering with [F6], press [F5] to return to
the Maintenance mode setting screen, and
then the setting is effective.
a If the set value of an item of which
maintenance reminder function is set to "ON"
is changed after one operating hour or more
from the setup, the change is recognized as
a reset of the remaining time.
Phone number entry (PC220-Q19A-110-K-00-A)
The telephone number displayed together with the
"Error List" in operator mode can be input and
changed according to the following procedure.
If no telephone number is inputted with this function,
no telephone number is displayed in operator mode.
1. Selecting a menu
Select "Phone Number Entry" on "Service
Menu" screen.
7. Function of initializing all items

After selecting "All Default Value" to display the
screen, initialize the set values by using the
function switches.
30-120 PC490LC-10
Electrical system
2. Registering and changing phone number

After the "Phone Number Entry" screen is Default (Key-on Mode) (PC220-Q1F2-100-K-00-A)
displayed, register or change the phone number Use the menu of "Default" to check or change
by using the function switch or numeral input various settings of the machine monitor and
switches. machine.
• [F2]: Deletes all input digits Use the sub menu of "Key-on Mode" to set the
• [F3]: Moves the input position to the next left working mode selected and displayed on the
place (if not blank) machine monitor when the starting switch is turned
• [F4]: Moves the input position to the next to ON position.
right place (if not blank) 1. Selecting a menu
• [F5]: Deletes input numbers or returns the Select "Default" on "Service Menu" screen.
screen to the "Service Menu" screen
• [F6]: Validates the entry

After the "Default" screen is displayed, select
"Key-on Mode" by using the function switch or
a Up to 14 digits can be input from the left.
numeral input switches.
Leave the surplus places without inputting.
a Selecting method is the same as on the
a If an input numeral is wrong, move the cursor
(orange background) to that digit and
overwrite it with the correct numeral.
a If [F6] is pressed without inputting a digit,
there is no information of telephone number
for display in operator mode.
3. Selecting a mode
PC490LC-10 30-121
Electrical system
After the "Key-on Mode" screen is displayed, Default value setting (Unit) (PC220-Q1F3-100-K-00-A)
select the mode by using the function switches Use the menu of "Default" to check or change
to set it. various settings of the machine monitor and
• "Power Mode": [P] is displayed when the machine.
starting switch is set to ON position The unit selecting function is used to select the unit
• "Economy Mode": [E] is displayed when the of the data to be displayed in monitoring, etc.
starting switch is set to ON position
1. Selecting a menu
• "Lifting Mode": [L] is displayed when the
Select "Default" on "Service Menu" screen.
• "Breaker Mode": [B] is displayed when the
• "Attachment / P Mode": [ATT / P] is displayed
when the starting switch is set to ON position
• "Attachment / E Mode": [ATT / E] is displayed
• "Mode at Previous Key-off Mode": Final
mode in previous operation is displayed
screen to the "Default" screen
• [F6]: Enters selection and returns the screen 2. Selecting a sub menu
to the "Default "screen After the "Default" screen is displayed, select
"Unit" by using the function switch or numeral
a Factory default is, "Mode at Previous Key- input switches.
off".
a "Attachment / P Mode" and "Attachment / E "Service Menu" screen.
Mode" cannot be selected when "With
Attachment" is not set.
a If the setting is changed to "Without
Attachment" with "Attachment / P
Mode"[ATT/P] and "Attachment / E
Mode"[ATT / E], "Power Mode" [P] is
displayed when selecting [ATT/P], and
"Economy Mode"[E] is displayed when
selecting [ATT / E] while the starting switch is
set to ON position.
a If the engine is stopped with "Breaker Mode"
[B] selected in the operator mode, "Breaker
Mode" [B]] is always displayed regardless of
3. Selecting an unit
the above setting.
After the "Unit" screen is displayed, select the
unit to be set by using the function switches.
• [F6]: Enters selection and returns the screen
to the "Default "screen
a Factory default is SI Unit.
30-122 PC490LC-10
Electrical system
After the "With/Without Attachment" screen is

displayed, select the setting by using the
function switch.
• Without Attachment: When attachment is not
installed
• With Attachment: When attachment is not
installed
• [F6]: Enters selection and returns the screen
to the "Default "screen
Default (With/Without Attachment) (PC220-Q1F4- a The attachment setting in the operator
100-K-00-A) mode cannot be performed without
Use the menu of "Default" to check or change performing this setting correctly when
various settings of the machine monitor and attachment is installed. As a result, the
machine. attachment may not work normally or the
Use the sub menu of "With/Without Attachment" to hydraulic components may be damaged.
configure attachment setting when the attachment
is installed or removed.
1. Selecting a menu
Default (Camera) (PC220-Q1F6-100-K-00-A)

Use the menu of "Default" to check or change
various settings of the machine monitor and
machine.
After the "Default" screen is displayed, select Camera setting is for setting of camera when the
"With/Without Attachment" by using the function camera is installed or removed.
switch or numeral input switches. 1. Selecting menu

3. Selecting With/Without
PC490LC-10 30-123
Electrical system
After "Default" screen is displayed, select

"Camera" by using the function switch or
numeral input switches.
a Selecting method is the same as on "Service
Menu" screen.
3. Selecting camera setting

After "Camera" screen is displayed, select a
setting by using the function switch.
• Not Use: Camera is not used
• "Use": Images from connected camera are
displayed as a normal image.
• [Я]: Reverse images (mirror images if it is
used for rear view monitor) are displayed.
• [R]: Normal images (visual images if it is
used for front or side monitor) are displayed.
• [F5] Cancels contents of setting before entry
and returns to "Default" screen
• [F6]: Enters selection in each line
a You cannot switch camera 1 between [Я] and
[R].
a Enter selection in each line with [F6], and
return to "Default" screen with [F5], and then
your setting is validated.
a Unless setting is normally set with this a If 2 or more cameras are connected, be sure
function when the camera is connected, the to set the use of them from camera 1 in
graphic mark of camera is not displayed at order.
[F3] in the operator mode. Accordingly, the a The simultaneous display function of 2
image of the camera cannot be used. images becomes effective when camera 1
a When the camera is installed, check that the and camera 2 are set for use.
right and left portions of the displayed image
are correct.
30-124 PC490LC-10
Electrical system
After the "Diagnostic Tests" screen is displayed,

select "Cylinder Cut-out" by using the function
switch or numeral input switches.
• "2 Cameras Display Setting"
3. Selecting a cylinder to be cut out

After the "Cylinder Cut-out" screen is displayed,
select a cylinder to be cut out by using the
function switches.
• [F1]: Moves selection leftward
• [F2]: Moves selection rightward
• [F4]: Selects hold or releasing hold
(If the Hold is selected, a diagonal line is
drawn on the HOLD portion.)
• [F5]: Returns the screen to "Diagnostic
Testing (Cylinder Cut-out operation) (PC220-
AD00-34F-K-00-A) Tests" screen
On the machine monitor, the cylinder cutout mode • [F6]: Enters selection
operation and KDPF regeneration operation can be a This operation can be performed while the
executed as well as their cancellation. engine is running.
Cylinder cutout mode operation means to run the
a If background (a) of the selected cylinder
engine with one or more fuel injectors disabled
number becomes white after you press [F6],
electrically to reduce the number of effective
the cylinder is cut out.
cylinders. This operation is used to identify a
cylinder that does not output power normally a If the machine monitor cuts out a cylinder but
(combustion in it is abnormal). the engine controller cannot cutout that
1. Selecting a menu cylinder, the background (a) of the cylinder
Select "Diagnostic Tests" on "Service Menu" number becomes yellow.
screen. a One or more cylinders can be cut out.
a Auto-deceleration function can be selected in
the cylinder cutout mode operation. When
turning auto-deceleration ON, auto-
deceleration monitor (b)) is displayed.
PC490LC-10 30-125
Electrical system
[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur.
1) Lowering of engine speed
2) Fuel Inject Command (quantity) increases.
• If the engine is running at near high idle,
however, the engine speed may not lower for
the reason of engine control.
• In this case, lower the engine speed with the
fuel control dial and judge by increase of the
injection rate command.
Testing (Regeneration for Service) (PC400-A9H0-

4. Releasing cut out cylinder 252-K-00-A)
When changing a cylinder to be cut out or when In the machine monitor, the cylinder cut-out mode
cylinder cutout operation is finished, select a cut operation and the KDPF regeneration operation can
out cylinder to be reset with the function be executed as well as their cancellation.
switches. Active regeneration for service refers to the method
of burning soot by performing the KDPF
a This operation can be performed while the
regeneration, regardless of the soot accumulation.
engine is running.
1. Selecting menu
a When [F6] is pressed, if background (a) of Select "Diagnostic Tests" on "Service Menu"
the selected cylinder No. becomes blue, the screen.
cylinder is reset.
a If the machine monitor releases a cutout
cylinder but the engine controller cannot
release the cutout cylinder, the background
(a) of the cylinder number becomes red.
a The cutout cylinder mode operation is not
automatically released after the screen
returns to the operator mode. Accordingly, be
sure to perform the releasing operation after
the cylinder cutout mode operation is
finished.
5. Holding displayed data
Each time [F4] is pressed during the cylinder
cutout operation, the displayed data is newly
held (c) (the real-time data is kept displayed on
select "Regeneration for Service" by using the
the left side).
function switch or numeral input switches.
While the data is held, if [F4] is pressed, the data
holding function is reset. a Select this item similarly to an item on the
a The holding function is available for a
cylinder, regardless of whether it is cut out or a While the KDPF regeneration status is in the
not. manual stationary regeneration or stopped,
"Regeneration for Service" cannot be
selected.
30-126 PC490LC-10
Electrical system
a The active regeneration for service

automatically stops in 40 minutes.
However, if the regeneration is started
with the soot accumulation of
approximately 4 g/liter and if the soot
accumulation still remains at above 1.9 g/
liter after 40 minutes from the start, the
operation is switched to the automatic
regeneration. The regeneration is
continued until the soot accumulation
decreases to 1.9 g/liter.
3. Setting regeneration for service

When "Regeneration for Service" screen is
displayed, the following informations are
displayed corresponding to the KDPF
regeneration condition. Set the KDPF
regeneration according to the given messages.
(a): Soot accumulation level
(b): Regenerating condition of KDPF
(c): Selectable items
(d): Message
a The screen displays "Monitoring

Selection Menu" screen by the following
switch operations while the regeneration
for service is in progress.
• Switch operation (While pressing [4],
press other switches in order): [4] + [1]
o [2] o [3]
To return to the regeneration for
service screen from the monitoring
screen, press [F5].
For the monitoring procedures, see
1) KDPF active regeneration (manual stationary "Monitoring" of "Service mode".
regeneration) 2) Finishing regeneration
Select "Manual Stationary Regeneration" on After the active regeneration for service is
"Regeneration for Service" screen. completed, "Regeneration completed" is
• [F5]: Returns the display to "Diagnostic displayed on the screen.
Tests" screen
• [F6]: Executes manual stationary
regeneration
a Active regeneration for service can be
performed only when the lock lever is in
LOCK position and the fuel control dial is
the low idle (MIN) position.
a Before performing the manual stationary
regeneration, be sure the surrounding
environment is safe, no people and no
combustibles are in the area. When you
have to move the machine again for the
sake of security, move it to a safe place
3) Stopping of regeneration
and repeat the operation from the start.
If [F6] is pressed during manual stationary
regeneration, "Stop manual stationary
PC490LC-10 30-127
Electrical system
regeneration?" is displayed on the screen.

Validate the stop by using the function switch.
• [F5]: Does not disable regeneration
(Continue manual stationary
regeneration)
• [F6]: Stops regeneration
3. Setting KDPF Memory Reset

Select an item to be reset, on the "KDPF
Memory Reset" screen.
• [F5] Returns the screen to "Diagnostic Tests"
screen
Testing (KDPF Memory Reset) (PC220-A9H0-271-K- • [F6]: Enters selection
00-A)
On the machine monitor, the cylinder cutout mode
operation and KDPF regeneration operation can be
executed as well as their cancellation.
KDPF memory reset means to reset the KDPF
information saved in the machine. It is performed
when cleaning or replacement of KDPF is done, or
when the engine controller is replaced.
1. Selecting a menu
Select "Diagnostic Tests" on "Service Menu"
screen.
After "Do you want to reset?" is displayed,

validate the reset by using the function
switch.
• [F5]: Returns the screen to the previous
screen
• [F6]: Executes reset

select "KDPF Memory Reset" by using the
When the reset is finished properly, "Reset

completed" is displayed on the screen. If the
reset is not finished properly, "Reset failed" is
displayed on the screen.
30-128 PC490LC-10
Electrical system
a Perform "KDPF Change" after replacing • [F6]: Checks and enters setting. Returns the
the KDPF. screen to "Adjustment" screen
a Perform "KDPF Cleaning" after cleaning a The 3-digit number in the left column does
the KDPF. not change since it is the code of this
function.
a Perform "KDOC Change" after replacing
the KDOC.
Adjustment (Pump Absorption Torque

(F)) (PC220-C201-27E-K-00-A)
You can perform various adjustments related to the
machine with the machine monitor.
The sub menu of Pump Absorption Torque is used
to finely adjust the absorption torque of the
hydraulic pump.
1. Selecting a menu
Select "Adjustment" on "Service Menu" screen.
a Relationship between set value and torque

adjustment value
Torque adjustment
Code Set Value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
2. Selecting a sub menu 006 -19.6 N {-2 kgm}
After the "Adjustment" screen is displayed, 007 -29.4 Nm {-3 kgm}
select "Pump Absorption Torque (F)" by using 008 -39.2 Nm {-4 kgm}
the function switch or numeral input switches.
Adjustment (Pump Absorption Torque
a Selecting method is the same as on the (R)) (PC220-C202-27E-K-00-A)
"Service Menu" screen. You can perform various adjustments related to the
The sub menu of Pump Absorption Torque (R) is
used to finely adjust the absorption torque of the
rear hydraulic pump.
1. Selecting a menu
3. Selecting a pump absorption torque setting

After the "Pump Absorption Torque (F)" screen
is displayed, select the desired value at the right
side by using the function switches.
• Set value: For actual torque adjustment
value, see table
• [F4]: Decreases set value 2. Selecting a sub menu
PC490LC-10 30-129
Electrical system
After the "Adjustment" screen is displayed, Torque adjustment

Code Set Value
select "Pump Absorption Torque (R)" by using value
the function switch or numeral input switches. 008 -39.2 Nm {-4 kgm}
a Selecting method is the same as on the Adjustment (Low Speed) (PC400-Q1F8-100-K-00-A)

"Service Menu" screen. You can make various adjustments related to the
The sub menu of Low Speed is used to finely adjust
the travel speed at Low setting.
1. Selecting menu
3. Selecting a pump absorption torque setting

After the "Pump Absorption Torque (R)" screen
side by using the function switches.
• Set value: For actual torque adjustment
value, see table
• [F3]: Increases set value 2. Selecting sub menu
• [F4]: Decreases set value After the "Adjustment" screen is displayed,
• [F6]: Checks and enters setting. Returns to select "Low Speed" by using the function switch
"Adjustment" screen. or numeral input switches.
a The 3-digit number in the left column does a Select this item similarly to an item on the
not change since it is the code of this "Service Menu" screen.
function.
3. Selecting travel Low Speed

After the "Low Speed" screen is displayed,
a Relationship between set value and torque
select the desired value at the right side by using
adjustment value
the function switches.
Torque adjustment • Set value: For actual travel Low speed value,
Code Set Value
value see table
000 +39.2 Nm {+4 kgm} • [F3]: Increases set value
001 +29.4 Nm {+3 kgm} • [F4]: Decreases set value
002 +19.6 Nm {+2 kgm} • [F6]: Confirms setting and returns to
003 +9.8 Nm {+1 kgm} Adjustment screen
022
004 0 Nm {0 kgm} a The 3-digit number in the left column does
005 -9.8 Nm {-1 kgm} not change since it is the code of this
006 -19.6 Nm {-2 kgm} function.
007 -29.4 Nm {-3 kgm}
30-130 PC490LC-10
Electrical system
3. Selecting distribution of oil flow

a Relationship between set value and travel
After the "Attachment Flow Adjustment" screen
Low speed value
Travel speed at side by using the function switches.
Code Set Value
Low • Set value: For actual distribution of oil flow,
000 3.0 km/h see table
001 2.8 km/h • [F3]: Increases set value
020
002 3.2 km/h • [F4]: Decreases set value
003 3.4 km/h • [F6]: Confirms setting and returns to
Adjustment screen
Adjustment (Attachment Flow
Adjustment) (PC400-Q1F9-100-K-00-A) a The 3-digit number in the left column does
You can make various adjustments related to the not change since it is the code of this
machine with the machine monitor. function.
The sub menu of "Attachment Flow Adjustment" is
used to finely adjust the oil flow rate to the
attachment in combined operations.
1. Selecting menu
a Relationship between set value and

distribution of oil flow to attachment
Distribution of flow to
Code Set Value
attachment
000 50%
2. Selecting sub menu 001 70%
044
After the "Adjustment" screen is displayed, 002 100%
select "Attachment Flow Adjustment" by using 003 40%
a Select this item similarly to an item on the
PC490LC-10 30-131
Electrical system
Adjustment (F pump swash plate sensor calibration) (PC400-C3W9-273-K-00-A)

The machine monitor allows for adjustment of
various items related to the machine.
The F pump swash plate sensor calibration sub
menu is used to calibrate the sensor installed on the
actual machine to eliminate deviation of the sensor
signal made when the front pump swash plate
sensor is removed and installed or replaced with
new one.
a The pump swash plate sensor needs to be
adjusted in the following cases.
Calibration Calibration
of front of rear pump
pump swash swash
platesensor platesensor
Removal and
installation or
replacement of front Necessary —
pump swash plate
sensor
Removal and
installation or
replacement of rear — Necessary
pump swash plate
sensor
Replacement of main
Necessary Necessary
pump assembly 1. Preparation for calibration
Replacement of pump Necessary Necessary Before starting calibration, set the machine
controller under the following condition.
Adjustment and • Hydraulic oil temperature: 50 °C
disassembly of front Necessary — • Working mode: P mode
pump PC valve • Travel speed: Hi
Adjustment and 2. Selecting the menu
disassembly of rear — Necessary Select "Adjustment" on the "Service Menu"
pump PC valve
screen.
a Before calibrating the pump swash plate sensor,

check the pump swash plate sensor to confirm
that the pump swash plate sensor is normal.
a A rough flow of calibration of the pump swash
plate sensor is as follows.
In adjustment menu of service menu

After the "Adjustment" screen is displayed,
select "F pump swash plate sensor calibration"
by using the function switches or numeral input
switches.
30-132 PC490LC-10
Electrical system

3) When the idle run speed is stabilized, hold

down [F1] of the machine monitor to start
4. Calibration of front pump swash plate sensor for calibration. During calibration, a bar is
the maximum angle displayed on the screen. Keep running the
track idle until calibration is finished.
1) After the "Calib F pump swash plate sensor
max" is displayed, calibrate the front pump
swash plate sensor for the maximum angle
by running track idle off the ground and
operating the function switches.
[F1]: START
[F2]: CLEAR
[F5]: Returns to the adjustment screen
[F6]: Enters setting
4) Calibration is finished successfully, "OK" is

displayed for the State of Adjustment to show
that calibration for the maximum angle is
completed.
Press [F6] to go to calibration for the
maximum angle.
2) Raise the left track off ground by using the

work equipment and move the left travel
lever to the stroke end to run the left track
idle off the ground.
• Fuel control dial: MAX position
• Left travel lever: Full stroke
Travel direction may be set in either of
forward and reverse.
• Swing lock switch may be set in either of
ON and OFF.
If calibration is finished unsuccessfully, "NG"
k Provide a enough work space to run is displayed for the State of Adjustment and
the track idle off the ground. the failure cause code is displayed. Referring
to the failure cause codes in Table 1, find out
k Be careful about safety around the and remove the cause and repeat calibration.
machine while running the track idle
off the ground.
PC490LC-10 30-133
Electrical system
4) Calibration is finished successfully, "OK" is

a The calibration value can be initialized by
displayed for the State of Adjustment to show
holding down CLEAR button [F2].
that calibration for the minimum angle is
If the calibration value is initialized, completed.
"READY" is displayed for the State of Press [F6] to return to the Adjustment screen.
Adjustment on the screen.
5. Calibration of front pump swash plate sensor for
the minimum angle
1) After the "Calib F pump swash plate sensor
min" is displayed, set all the levers in
NEUTRAL and perform calibration the front
pump swash plate sensor for the minimum
angle with the function switches.
[F1]: START
[F2]: CLEAR
[F5]: Returns to the adjustment screen
[F6]: Enters setting
If calibration is finished unsuccessfully, "NG"

is displayed for the State of Adjustment and
the failure cause code is displayed. Referring
to the failure cause codes in Table 1, find out
and remove the cause and press [F6] to
repeat the calibration for the minimum angle.
2) Wait under the following conditions:

• All levers: NEUTRAL
Fuel control dial may be at any position.
3) Hold down [F1] of the machine monitor to
start calibration.
During calibration, a bar is displayed on the
screen. Keep all the lever in neutral until
calibration is finished.
a The calibration value can be initialized by
holding down CLEAR button [F2].
If the calibration value is initialized,
"READY" is displayed for the State of
Adjustment on the screen.
30-134 PC490LC-10
Electrical system
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
Cause MIN MAX
swash swash Pump IT Content Remedy
code
plate plate calibration
calibration calibration
A-1 q q q Engine speed signal is 0 rpm Check that engine is started
Check hydraulic oil
A-2 q q q Hydraulic oil temperature is low
temperature (Min. 45 °C )
Check hydraulic oil
A-3 q q q Hydraulic oil temperature is high
temperature: (Max. 55 °C )
A-4 q q q Engine overheats Check for overheat
Pump pressure sensor (F, R) is Perform troubleshooting for
A-6 q q q pump pressure sensor
defective
— Pump swash plate (F, R) sensor is Perform troubleshooting for
A-7 q q pump swash plate sensor
defective
Arm IN PPC pressure sensor is Perform troubleshooting for
A-8 — — q
defective arm IN PPC pressure sensor
— — PC-EPC abnormality Perform troubleshooting for
A-9 q
PC-EPC
CAN communication is defective Perform troubleshooting for
A-A — — q (Engine, monitor, pump) CAN
Perform troubleshooting for
— — Bucket CURL PPC pressure
A-B q bucket CURL PPC pressure
sensor is defective
sensor
— — Pump pressure of calibrated pump Perform troubleshooting for
B-1 q relief valve and pump
is above standard value
B-3 q — — Lever is not in NEUTRAL Set lever in NEUTRAL
C-1 q relief valve and pump
is below standard value
— — Travel speed setting is not Hi Set travel speed to Hi on
C-2 q
monitor
Fuel control dial is not set to MAX Check that fuel control dial is
C-3 — q q position at MAX position
Check that travel lever is at
— — Both tracks are running Max. position and work
C-4 q
equipment control lever is in
NEUTRAL
Check adjustment of service
Oil flow from two pumps are not (Oil flow is normally divided
C-5 — q —
divided during travel single
operation)
Travel PPC pressure sensor Perform troubleshooting for
C-6 — q —
abnormality travel PPC
Travel PPC pressure is below Check that travel lever is at
C-7 — q —
standard value Max. position
When arm IN circuit is relieved,
arm IN PPC pressure is below
Check that arm lever is at
E-1 — — q standard value or arm IN PPC
Max. position
pressure sensor is in normal range
(*1)
Pump pressure (F, R) is out of Perform troubleshooting for
E-2 — — q standard range relief valve and pump
Engine speed is out of standard Check that engine speed is at
E-3 — — q range Hi idle
Engine torque is out of standard Perform troubleshooting for
E-4 — — q range engine and pump
PC490LC-10 30-135
Electrical system
Object
Cause MIN MAX
code
PC-EPC current is out of standard Perform troubleshooting for
E-5 — — q range PC-EPC current
When bucket CURL circuit is
relieved, bucket CURL PPC
Check that bucket lever is at
E-6 — — q pressure is below standard value
Max. position
or bucket CURL PPC pressure
sensor is in normal range (*1)
— — Working mode is not P or ATT/P Set working mode to P or
E-7 q
ATT/P
— — Check that air conditioner is
E-A q Air conditioner is ON
OFF
Output voltage of pump swash
FF q q — plate sensor is out of calibration
swash plate sensor
range
G-1 — — q KDPF is being regenerated Finish regeneration of KDPF
(*1) When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the
relief pressure to be 0 MPa {0 kg/cm2}. Accordingly, perform troubleshooting, referring to Troubleshooting
(Failure code "DHPAMA and DHPBMA).
30-136 PC490LC-10
Electrical system
Adjustment (R pump swash plate sensor

calibration) (PC220-C3WB-273-K-00-A)
1. Preparation for calibration
Before starting calibration, set the machine
under the following condition
• Travel speed: Hi
2. Selecting a menu

After the "Adjustment" screen is displayed,
select "Cal R pump swash plate sensor" by
using the function switch or numeral input
switches.
4. Perform the subsequent calibration procedure

according to "Cal F pump swash plate sensor".
PC490LC-10 30-137
Electrical system
Adjustment (Pump calibration: Matching speed check) (PC400-C200-280-K-00-A)

The pump calibration function is used to check the
matching speed for arm IN relief and bucket CURL
relief and to set the matching speed to the engine
properly when the pump or pump controller is
replaced.
a The pump calibration (matching speed
calibration) is required in the following cases.
Calibration of front
pump swash plate
sensor
Replacement of engine –
Replacement of main
Necessary
pump assembly
Replacement of pump Necessary
controller
Disassembly of front
Necessary
pump PC valve
Disassembly of rear
Necessary
pump PC valve
Replacement of main –
valve
Adjustment or
replacement of main –
relief valve 1. Preparation for calibration
Before starting calibration, set the machine
• A rough flow of calibration of the pump is as under the following condition.
follows. • Perform warm-up operation for at least 30
In adjustment menu of service menu minutes
• Hydraulic oil temperature: 50 °C
• Swing emergency stop switch: ON
• Air conditioner: OFF
Select "Adjustment" on the "Service Menu"
screen.
30-138 PC490LC-10
Electrical system
If the "Adjustment" screen is displayed, input [F1]: START

"40" with the numeral input switches and press [F5]: Returns to pump calibration screen
"F6".
a Since this function is required only when the
pump is replaced, the PC valve is adjusted or
disassembled, or the pump controller is
replaced, it is not displayed in the menu list.
2) Operate the arm control lever or bucket

control lever under the following condition to
check the relief matching.
(Operation)
Operate according to the arm IN relief and
bucket curl relief screen.
4. Selection of matching speed check menu
After the "Pump Calibration" screen is displayed, a Set bucket CURL relief matching after
select "Matching Speed Check" by using the completing arm IN relief matching.
function switches or numeral input switches. Arm lever: IN max. (Operate during arm
a Select this when it is require to check IN relief matching)
abnormality or current condition of the Bucket lever: CURL max. (Operate during
machine. bucket CURL relief matching)
Select this sub menu as in the case of (Condition)
selecting a menu on the "Service Menu" • Hydraulic oil temperature: 50 °C
screen. • Working mode: P mode
k Secure sufficient area for operation of

the work equipment during testing.
k When operating the work equipment,

secure full safety around the machine.
[Reference]
• The alphabet letter at the right top of the
screen indicates the following condition.
D: Default
F: Adjustment value at shipment from factory
(Factory shipment state (Normal))
U: User calibration value
5. Matching speed check (arm IN relief)
1) When the "Matching Speed Check" screen is
displayed, check the matching speed by 3) Perform arm IN relief operation. When the
performing arm IN relief operation and using engine speed is stabilized, hold down [F1] on
the function switches. the machine monitor to start checking.
PC490LC-10 30-139
Electrical system
During matching speed check, a bar is

displayed on the screen. Keep relief
operation until the is finished.
• It takes 10 seconds for the bar graph to
start moving.
6. Matching speed check (Bucket CURL relief)

1) When the "Matching Speed Check" screen is
displayed, check the matching speed by
performing bucket CURL relief operation and
using the function switches.
4) If the check is normally completed, the result [F1]: START
is displayed. [F5]: Returns to arm IN relief screen
Press [F6] to go to the bucket CURL relief.
2) Wait under the following conditions.

Standard value of matching speed result • Hydraulic oil temperature: 50 °C
Item Unit • Working mode: P mode
Standard value
Engine Matching
speed rpm 1,720 ± 50 • Fuel control dial: MAX position
speed • Swing lock switch: ON
check
F Pump 34.8 + 1.47/- • Air conditioner: OFF
Pump MPa 3) Hold down [F1] of the machine monitor to
Pressure 1.18
pressure R Pump start check.
MPa 4.12 ± 1.0
Pressure During matching speed check, a bar is
If check is finished unsuccessfully, "NG" is displayed on the screen. Keep relief
displayed for the State of check and the operation until the is finished.
failure cause code is displayed. Referring to
the failure cause codes in Table 1, find out
and remove the cause and repeat matching
speed check.
30-140 PC490LC-10
Electrical system
4) If the check is normally completed, the result

is displayed.
Press [F6] to return to the "pump calibration"
screen.
Standard value of matching speed result

Item Unit Standard value
Engine Matching
speed rpm 1,720 ± 50
speed
check
F Pump 34.8 + 1.47/-
Pump MPa
Pressure 1.18
pressure R Pump
MPa 4.12 ± 1.0
Pressure
If check is finished unsuccessfully, "NG" is
displayed for the State of check and the failure
cause code is displayed. Referring to the failure
cause codes in Table 1, find out and remove the
cause and repeat matching speed check.
PC490LC-10 30-141
Electrical system
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
Cause MIN MAX
code
A-1 q q q Engine speed signal is 0 rpm Check that engine is started
Check hydraulic oil
A-2 q q q Hydraulic oil temperature is low
temperature (Min. 45 °C )
Check hydraulic oil
A-3 q q q Hydraulic oil temperature is high
temperature: (Max. 55 °C )
A-4 q q q Engine overheats Check for overheat
Pump pressure sensor (F, R) is Perform troubleshooting for
A-6 q q q pump pressure sensor
defective
— Pump swash plate (F, R) sensor is Perform troubleshooting for
A-7 q q pump swash plate sensor
defective
Arm IN PPC pressure sensor is Perform troubleshooting for
A-8 — — q
defective arm IN PPC pressure sensor
— — PC-EPC abnormality Perform troubleshooting for
A-9 q
PC-EPC
CAN communication is defective Perform troubleshooting for
A-A — — q (Engine, monitor, pump) CAN
— — Bucket CURL PPC pressure
A-B q bucket CURL PPC pressure
sensor is defective
sensor
B-1 q relief valve and pump
is above standard value
B-3 q — — Lever is not in NEUTRAL Set lever in NEUTRAL
C-1 q relief valve and pump
is below standard value
— — Travel speed setting is not Hi Set travel speed to Hi on
C-2 q
monitor
Fuel control dial is not set to MAX Check that fuel control dial is
C-3 — q q position at MAX position
Check that travel lever is at
— — Both tracks are running Max. position and work
C-4 q
equipment control lever is in
NEUTRAL
Check adjustment of service
Oil flow from two pumps are not (Oil flow is normally divided
C-5 — q —
divided during travel single
operation)
Travel PPC pressure sensor Perform troubleshooting for
C-6 — q —
abnormality travel PPC
Travel PPC pressure is below Check that travel lever is at
C-7 — q —
standard value Max. position
When arm IN circuit is relieved,
arm IN PPC pressure is below
Check that arm lever is at
E-1 — — q standard value or arm IN PPC
Max. position
pressure sensor is in normal range
(*1)
Pump pressure (F, R) is out of Perform troubleshooting for
E-2 — — q standard range relief valve and pump
Engine speed is out of standard Check that engine speed is at
E-3 — — q range Hi idle
Engine torque is out of standard Perform troubleshooting for
E-4 — — q range engine and pump
30-142 PC490LC-10
Electrical system
Object
Cause MIN MAX
code
PC-EPC current is out of standard Perform troubleshooting for
E-5 — — q range PC-EPC current
When bucket CURL circuit is
relieved, bucket CURL PPC
Check that bucket lever is at
E-6 — — q pressure is below standard value
Max. position
or bucket CURL PPC pressure
sensor is in normal range (*1)
— — Working mode is not P or ATT/P Set working mode to P or
E-7 q
ATT/P
— — Check that air conditioner is
E-A q Air conditioner is ON
OFF
Output voltage of pump swash
FF q q — plate sensor is out of calibration
swash plate sensor
range
G-1 — — q kDPF is being regenerated Finish regeneration of kDPF
(*1) When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the
relief pressure to be 0 MPa {0 kg/cm2}. Accordingly, perform troubleshooting, referring to Troubleshooting
(Failure code "DHPAMA" and "DHPBMA").
Adjustment (Pump calibration: Matching a Since this function is required only when the
speed calibration) (PC400-C200-270-K-00-A) pump is replaced, the PC valve is adjusted or
1. Preparation for calibration disassembled, or the pump controller is
Before starting calibration, set the machine replaced, it is not displayed in the menu list.
under the following condition
• Perform warm-up operation for at least 30
minutes
• Hydraulic oil temperature: 50°C
2. Selecting menu
4. Selecting matching speed calibration menu

After the "Pump Calibration" screen is displayed,
select "Matching Speed Calibration" by using

After the "Adjustment" screen is displayed, input
"40" by using the numeral input switches and
press "F6".
PC490LC-10 30-143
Electrical system
5. Perform the subsequent calibration procedure

according to "Matching Speed Calibration".
30-144 PC490LC-10
Electrical system
Adjustment (Fan Rotation Mode

Selection) (PC400-Q1GA-270-K-00-A)
In fan rotation mode selection, the maximum speed
of the hydraulic fan is set to 100% speed mode or
70% speed mode.
Select "Adjustment" on the "Service Menu"
screen.
a Relationship between set value and mode

Code Set value Mode (Speed)
001 Max (1200 rpm)
055
002 70% (840 rpm)
a For the method of selection forward or

reverse operation of the hydraulic fan, see
the "Operation and Maintenance Manual".
No-Injection (PC220-AD00-25L-K-00-A)
2. Selecting sub menu If the engine is operated after long storage of the
After the "Adjustment" screen is displayed, machine, it may be worn or damaged because of
select "Fan Speed Mode Select" by using the insufficient lubrication with oil. To prevent this, the
function switches or numeral input switches. machine monitor has a function to crank the engine
without injecting fuel to lubricate the engine before
starting it.
Set no-injection cranking while the engine is
stopped.
1. Selecting a menu
Select "No Injection" on "Service Menu" screen.
3. Selecting mode
After the screen of "Fan Speed Mode Select" is
displayed, select a set value on the right by
using the function switches.
• Set value: For the actual fan speed, see the 2. Displaying check screen
table. When the "No Injection" screen is displayed, the
• [F3]: Increases set value message to ask if "Begin Injectionless
• [F4]: Decreases set value Cranking?" appears. Select the answer by using
• [F6]: Enters setting and return to the the function switch.
adjustment menu screen • [F5]: Does not implement (returns the screen
a The 3-digit number in the left column do not to "Service Menu")
change since it is the code of this function. • [F6]: Executes
PC490LC-10 30-145
Electrical system
3. Starting no-injection cranking Also, if no-injection cranking is operated when

If no-injection cranking (no fuel injection to every "Check" screen is displayed, the function does
cylinder) is enabled, a message "No-injection is not become effective in the following case.
possible" is displayed on the screen. Under this • The communication between the monitor and
condition, crank the engine with the starting engine controller is not normal.
motor. • Perform an engine start operation before the
message "No injection is possible" is
a While the screen is changing to the following
displayed.
screen, the screen of "Getting Ready" is
displayed.
a Do not crank the engine for 20 seconds or
longer to protect the starting motor.
KOMTRAX Settings (Terminal Status) (PC220-

Q210-110-K-00-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of KOMTRAX
4. Finishing no-injection cranking
Settings.
After the cranking is over, turn the starting switch
to OFF position. Terminal setting status is used for checking the
setting condition of the KOMTRAX terminal.
a You cannot change the screen described
1. Selecting a menu
above to another screen.
Select "KOMTRAX Settings" on "Service Menu"
5. Prohibiting no-injection cranking
screen.
Even if the operator tries to perform the no-
injection cranking while the engine is running,
the message "The engine is operating" is
displayed and the no-injection cranking does not
become effective.
a This function can be selected even when the
engine is running. However, if you execute
no-injection cranking, a message "The
engine is operating. Please turn the key off
once." is displayed on the screen.
30-146 PC490LC-10
Electrical system

After the "KOMTRAX Settings" screen is
displayed, select "Terminal Status" by using the
a Selecting method is the same as ot on the

displayed, select "GPS & Communication
Status" by using the function switch or numeral
input switches.
a Selecting method is the same as it on the
3. Contents displayed on Terminal Status screen "Service Menu" screen.
On "Terminal Status" screen, the following items
of information are displayed.
• "Terminal Type": Model name of the
KOMTRAX communication modem
• "KOMTRAX Communication": Status of radio
station establishment underway
• "GMT Time": Greenwich Mean Time (add 9
hours to it for Japan time)
• [F5]: Returns the screen to "KOMTRAX
Settings" screen
3. Contents of display of GPS & Communication

Status
On "GPS & Communication Status" screen, the
following items of information are displayed.
• "Positioning": GPS positioning status
• "Communication": Communication
environment and connecting condition of the
communication modem
• "Number of message not yet sent": Number
of message(s) not yet sent: Number of
unsent mails existing in the machine monitor
KOMTRAX Settings (GPS and Communication • [F5]: Returns the screen to "KOMTRAX
Status) (PC220-Q210-110-K-01-A) Settings" screen
Settings.
GPS & Communication Status is for checking the
positioning and communication condition of the
KOMTRAX terminal.
1. Selecting a menu
screen.
PC490LC-10 30-147
Electrical system
IP addresses (2 systems) of the modem are

displayed.
• [F5]: Returns the screen to "KOMTRAX
Settings" screen
a IP address is a unique number assigned to
each modem that is used when
communication between the modem and
server is established.
KOMTRAX Settings screen (Modem

Status) (PC220-Q210-110-K-02-A)
Settings.
Modem information is used to check the IP address
of the KOMTRAX communication modem.
1. Selecting a menu
Service Message (PC220-Q210-100-K-00-A)
screen.
Special messages for the technician sent from
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If a received message includes a setting operation,
a return mail can be sent by using the numeral input
switches as well.
1. Selecting a menu
Select "Service Message" on "Service Menu"
screen.

displayed, select "Modem Status" by using the
2. Displaying message (read only)

If there is a message, the contents are displayed.
If there is no message, "No message." is
displayed.
• [F5]: Returns to "Service Menu" screen
a This message is different from that sent to
the operator in the operator mode.
a Since this message is special for the
technician, the message monitor is not
displayed when it is received with the
3. Details displayed on Modem Status screen machine monitor in the operator mode.
30-148 PC490LC-10
Electrical system
3. Display of message (with return mail function)

If Numeric Input is displayed under the message,
input a proper number by using the numeral
input switches and enter it by using the function
switch, and the information is returned to the
KOMTRAX base station.
• [F5]: Returns to "KOMTRAX Settings" screen
• [F6]: Enters input value and sends it back
a This message is different from that sent to
the operator in the operator mode.
a Since this message is special for the
technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
PC490LC-10 30-149
Electrical system
Adjusting rearview camera angle (ALL-Q162-001-K-00-A)
a Adjust the camera so that persons in the area a The claw of cover (2) is made of plastic, so
(W) of 1 meter around the rear of the machine is be careful not to break it when removing.
displayed on the machine monitor in the
operator's cab.
2. Remove bolts (3) (2 places).

3. Remove cover (1).
a Check where and how many shims (6) have
been used.
If the image displayed on the machine monitor is out
of position, remove cover (1) and adjust installation Shims (6) are put on cover (1). Be careful not
angle (A) of the rearview camera. to drop them.
a Angle (A) can be adjusted in the range shown in

the following figure.
Adjusting (PC220-Q162-270-K-01-A)
1. Remove cover (1) by inserting flat-head

screwdriver [1], etc. in the hole in cover (2) and
then pressing the internal claw.
4. Loosen camera mounting bolts (4) (at 3 places)

and adjust camera mounting angle (A) so that
corner (B) of mounting bracket (5) is aligned with
horizontal line (C) of the camera.
30-150 PC490LC-10
Electrical system
a By using shims (6), adjust the difference

between the upper and lower clearances
between the counterweight and cover (1) to 2
mm or less.
a Since shim (6) may be caught in cover (1),

insert it from outside to the cover after
inserting the bolt temporarily.
a Machine is displayed partially on the

machine monitor screen.
5. After adjusting, tighten bolts (4).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install cover (1) with bolt (3) to install cover (2).
PC490LC-10 30-151
Electrical system
Handling voltage circuit of engine controller (PC220-AP40-2A4-K-00-A)
1. Disconnecting or connecting work of the

connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in OFF
position and the system operating lamp goes
out.
k Before connecting the wiring harness

connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
2. If the T-adapter is inserted in or connected to the
connector between the engine controller and
engine harness for troubleshooting, do not start
the engine.
a You may turn the starting switch to OFF or
ON position but must not turn it to START
position.
30-152 PC490LC-10
Electrical system
Handling battery disconnect switch (PC400-AW1P-100-K-00-A)
1. Pull out switch key (1) whenever you have

turned the battery disconnect switch OFF.
kA serious accident can result if someone

turns switch key (1) ON inadvertently.
2. Check the operating condition of each controller
with system operating lamp (2) to prevent
abnormal stop by cutting out the battery power
supply circuit while the controllers are in
operation.
1) When cutting out the battery power supply
circuit, turn the starting switch to OFF
position and check that the system operating
lamp has gone out, and then turn the battery
disconnect switch to OFF position.
2) If the battery disconnect switch is turned to
OFF position (to cut out the battery power
supply circuit) while the system operating
lamp is lighting up, the data loss error may
occur in the controllers. Do not operate the
battery disconnect switch while the system
operating lamp is lighting up.
3) The system operating lamp goes out within 2
minutes after the starting switch is turned to
OFF position.
4) Even if the starting switch is in OFF position,
the system operating lamp may light up since
the KOMTRAX terminal may perform
communication.
5) Even if the system operating lamp is off, it
may seem to be lighting slightly because of a
very little current inside the controller. This
phenomenon does not indicate abnormality.
• The KOMTRAX terminal performs
communication periodically even if the
starting switch is kept in OFF position,
thus it starts and stops repeatedly.
• The starting and stopping period (sleep
cycle) of the KOMTRAX terminal varies
with the communication condition,
operation stop time, etc., and the terminal
may keep lighting up for a maximum of
approximately 1 hour.
6) To cut out the battery circuit for maintenance
while the system operating lamp is lighting
up, turn the starting switch to ON position
and then return to OFF position, and the
lamp goes out within 2 minutes.
After the system operating lamp goes out,
turn the battery disconnect switch to OFF
position immediately.
PC490LC-10 30-153
Electrical system
Testing diodes (ALL-E300-001-P-00-A)
a Test the diode array (8-pin) and the single diode

(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.
2. When using analog tester

1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to
a The continuity direction of the single diode is the anode (P) side of the diode and apply
indicated on the surface of the diode. the black (-) lead to the cathode (N) side.
Testing (PC220-E300-36J-P-00-A) 2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
1. When using a digital tester apply the black (-) lead to the anode (P)
1) Select the diode range screen to check the side.
displayed values. 3) Evaluate the condition of the diode by the
a When an ordinary circuit tester is used, movement of the pointer.
the voltage of the internal battery is • The pointer does not move by the above
indicated. 1] connection, but it does by the 2]
2) Apply the red (+) lead of the multimeter to the connection: Normal (however, the
anode (P) side of the diode and apply the movement of the pointer (resistance)
black (-) lead to the cathode (N) side and varies by type of tester, or selection of
check the indicated value. measuring range).
3) Evaluate the condition of the diode by the • The pointer moves by either connection
indicated value. of the above 1], and 2]:
• Indicated value does not change: No Defective (internal short circuit)
continuity (defective) • The pointer moves by neither connection
• Indicated value changes: Continuity the above 1], nor 2]: Defective (internal
(normal) (note) open circuit)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
• The indicated value is 0 or approximate
0:
The diode has internal short circuit
(defective).
30-154 PC490LC-10
Pm clinic
Pm clinic (PC400-2160-209-A-00-A)
Pm Clinic service
Model Serial No. Service meter reading
T PC490LC-10 h
User name Date of inspection Inspector
/ /
Specification
Main component Attachment Shoe width
Boom TStandard T ( ) TBreaker T 600 mm
Arm T Standard T( ) T( ) T 700 mm T( )
BucketT Standard T( ) T( ) T 800 mm
Check of oil and coolant level
TRadiator coolant When necessary
T Engine oil T Damper case oil T Machinery case oil
T Hydraulic oil T Final drive case oil T( )
Ambient temperature Height above sea level
°C m
Operator's comment
Result of visual inspection
Mechanical system abnormality record Electrical system abnormality record

_____- _____-
AA10- ____ ____
times/1st as hrs./latest at times/1st as hrs./latest at
NX hrs. hrs.
_____- _____-
AB00- ____ ____
KE hrs. hrs.
_____- _____-
B@BA- ____ ____
ZG hrs. hrs.
_____- _____-
B@BA- ____ ____
ZK hrs. hrs.
_____- _____-
B@BC- ____ ____
NS hrs. hrs.
_____- _____-
B@BC- ____ ____
ZK hrs. hrs.
_____- _____-
B@HA- ____ ____
NS hrs. hrs.
_____- _____-
CA234 times/1st as hrs./latest at ____ times/1st as hrs./latest at ____
hrs. hrs.
PC490LC-10 30-155
Pm clinic
Max. range of engine coolant temperature gauge
Coolant
Engine coolant Color of monitor
temperature
temperature light (a)
gauge level
6 105 °C
Red
5 102 °C
4 100 °C
3 85 °C Blue
2 60 °C
1 30 °C White
Max. range of hydraulic oil temperature gauge
Hydraulic oil
Hydraulic oil Color of monitor
temperature
temperature light (a)
gauge level
6 105 °C
Red
5 102 °C
4 100 °C
3 85 °C Blue
2 40 °C
1 20 °C White
30-156 PC490LC-10
Pm clinic
Check items related to engine
PC490LC-10 30-157
Pm clinic
Check items related to hydraulic oil pressure
30-158 PC490LC-10
Pm clinic
Check sheet (PC400_10-2160-033-A-00-A)

Check sheet (PC490LC-10)
Service meter Date of
Model Serial No. User name Inspector
reading inspection
/ /
1. Engine
Testing conditions
Standard
deceleration
Fuel control
No good
L.H. knob
Good
Working
Auto-
Operation value for Repair limit Measured
switch
mode
No. Check item Unit
dial
of work new value

equipment machine
rpm 1,720 to
1 Engine speed 1,830
—
All levers in
MAX
Engine oil NEUTRAL MPa 0.29 to 0.69 0.18
2 pressure {kg/cm2} {3.0 to 7.0} {1.8}
OFF
rpm 975 to
3 Engine speed 1,025
—
All levers in
MIN OFF
Engine oil NEUTRAL MPa Min. 0.08
4 pressure P 0.05 {0.5}
{kg/cm2} {0.8}
rpm 1,620 to 1,620 to
5 Engine speed 1,820 1,820
Arm IN
ON
Blowby relief kPa Max. 1.96
6 pressure MAX 3.92 {400}
{mmH2O} {200}
All levers in rpm 900 to 900 to
7 Engine speed ON OFF 1,100 1,100
NEUTRAL
2. Work equipment speed
Testing conditions
Standard
Fuel control
No good
Good
Working
value for Repair limit Measured

mode
No. Check item Work equipment Unit

dial
new value
posture, etc.
machine
Work equipment
1 Boom RAISE extended fully 3.6 to 4.4 Max. 4.8
P
2 Arm OUT 3.2 to 4.0 Max. 4.3
3 Boom top face 3.8 to 4.8 Max. 5.0
4 Arm IN E horizontal 3.8 to 4.8 Max. 5.0
5 L 4.6 to 5.8 Max. 6.0
Boom top face
6 Bucket CURL horizontal, Arm 3.2 to 4.0 Max. 4.3
MAX cylinder retracted fully sec.
Work equipment
Swing
7 (5 swing) extended fully, Swing 29.7 to 36.3 Max. 38
P right and left
Travel speed One track LO 53.8 to 80.8 45.0 to 84.5
(5 idle turns raised off MI 40.9 to 55.3 34.0 to 58.0
8 of track off ground and run
ground) idle forward and HI 33.1 to 40.3 32.0 to 44.0
reverse
PC490LC-10 30-159
Pm clinic
3. Hydraulic drift of work equipment

Testing conditions
Standard
Fuel control
No good
Good
Working
value for Repair limit Measured
mode
No. Check item Work equipment Unit
dial
new value
posture, etc.
machine
Hydraulic drift Boom top face

Engine horizontal, Arm mm/15
1 of bucket stopped cylinder retracted fully, Max. 600 Max. 900
tooth tip min
Bucket loaded
4. Hydraulic circuit
Testing conditions [1] [2] [3] [4] [5]
60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
Fuel control
No good
L.H. knob
{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/
Good
Working
Operation of
switch
mode
No. Check item cm2} cm2} cm2} cm2} cm2}

dial
work
equipment F pump R pump F pump R pump
Control
main main LS LS
Self-pressure
All levers in – – – –
1 reducing A
NEUTRAL
valve
Main relief OFF
2 valve (low B B B B –
pressure)
Arm OUT relief
Main relief
3 valve (high ON C C C C –
pressure)
All levers in –
4 Unload valve D D D D
NEUTRAL
Run right track
idle off ground,
– E – E –
Lever moved
5 LS valve halfway
Run left track idle
off ground, Lever E – E – –
moved halfway
MAX P Swing locked,
Swing RIGHT F F – – –
Swing motor relief
6 safety valve
Swing locked,
Swing LEFT F F – – –
OFF relief
Right track
locked, Right – – – –
G
track forward
relief
Main relief Right track
valve, travel locked, Right – – – –
G
track reverse
7 motor safety
valve, travel relief
junction valve Left track locked,
Left track forward G – – – –
relief
Left track locked,
Left track reverse G – – – –
relief
30-160 PC490LC-10
Pm clinic
Oil pressure to be checked Standard value for new Repair limit

Unit
machine
A (Control source pressure) 3.04 to 3.44 {31 to 35} 2.84 to 3.43 {29 to 35}
B (Work equipment relief pressure,
33.6 to 36.3 {343 to 370} 33.1 to 36.8 {338 to 375}
low)
Standard
C (Work equipment relief pressure,

MPa 36.1 to 38.8 {368 to 395} 35.6 to 39.2 {363 to 400}
value
high)
D (Unload pressure) {kg/cm }
2
3.2 to 5.2 {33 to 53} 3.2 to 5.2 {33 to 53}
E (LS differential pressure) 2.55 to 2.75 {26 to 28} 2.55 to 2.75 {26 to 28}
F (Swing relief pressure) 28.9 to 32.4 {295 to 330} 28.4 to 32.9 {290 to 335}
G (Travel relief pressure) 36.1 to 40.2 {370 to 410} 35.6 to 40.7 {363 to 415}
* Gauge connection changing work: Exchange hoses of gauges [3] and [4].
Testing conditions [1] [2] [3] [4] [5]
Fuel control
No good
L.H. knob
{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/
Good
Working
Operation of
switch
mode
No. Check item cm2} cm2} cm2} cm2} cm2}

dial
work
equipment F pump R pump F pump R pump
Control
main main LS LS
8 Servo piston MAX P OFF Arm OUT relief H1 H1 H2 H2 –

Unit
machine
Standard
H1: H2 = 1: 0.6
value
H (Servo control pressure) –

(Oil pressure ratio)
* Gauge connection changing work: Change gauges [3] and [4] to 60 MPa {60 kg/cm 2} and exchange hoses
of gauges [3], [4], and [5].
Testing conditions [1] [2] [3b] [4b] [5a]
Fuel control
No good
L.H. knob
{600 {600 {600 {600 {60 kg/
Good
Working
Operation of
switch
mode
No. Check item kg/cm 2} kg/cm2} kg/cm2} kg/cm2} cm2}

dial
work
equipment F pump R pump F pump R pump LS-
main main (LS) (LS) EPC
MIN – – J1 J1 –
PC-EPC(F) P
– – J2 J2 –
valve PC- All levers in – – –
9 E J3 J3
EPC (R) NEUTRAL
valve L – – J4 J4 –
B – – J5 J5 –
Travel speed:
Lo, Travel – – – –
OFF K1
MAX lever in
NEUTRAL
LS-EPC Travel speed:
10 P Mi, Travel – – – – K2
valve
lever operated
Travel speed:
Hi, Travel – – – – K3
lever operated
PC490LC-10 30-161
Pm clinic

Unit
machine
J1 (PC-EPC valve output pressure 1) Approx. 2.09 {Approx. 21.3}
Standard
MPa
value

J5 (PC-EPC valve output pressure 5) {kg/cm2} Approx. 2.30 {Approx. 23.5}
K1 (LS-EPC valve output pressure 1) Approx. 2.9 {Approx. 30}
K2 (LS-EPC valve output pressure 2) Approx. 2.6 {Approx. 26.5}
K3 (LS-EPC valve output pressure 3) 0 {0}
30-162 PC490LC-10
Pm clinic
Visual check of welded structures

a If any crack is found, draw its shape below.
Arm Boom Revolving frame

1. Arm cylinder bracket 4. Boom top bracket 9. Boom bracket
TLeft TRight TLeft TRight TLeft TRight
2. Arm foot 5. Boom cylinder bracket
TLeft TRight TLeft TRight Track frame
T End plate 6. Arm cylinder bracket 10. Circle bracket
3. Arm top boss TLeft TRight TFront TRear
TLeft TRight 7. Boom lower plate TLeft TRight
TLeft TRight
8. Boom foot
TLeft TRight
PC490LC-10 30-163
Pm clinic
UNDERCARRIAGE INSPECTION REPORT
30-164 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
40 Troubleshooting
6 40 Troubleshooting
PC490LC-10 40-1
40 Troubleshooting
Table of contents

40 Troubleshooting............................................................................................................................ 40-1
Related information on troubleshooting......................................................................................... 40-9
Troubleshooting points ......................................................................................................... 40-9
Sequence of events in troubleshooting................................................................................. 40-11
Checks before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation for troubleshooting of electrical system............................................................... 40-32
Classification and procedure for troubleshooting ................................................................... 40-38
Symptom and troubleshooting numbers ............................................................................... 40-41
Connector list and layout .................................................................................................... 40-46
Connector contact identification........................................................................................... 40-57
T-branch box and T-branch adapter table ............................................................................. 40-96
Connection table of fuse box ............................................................................................. 40-101
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-103
Preparation of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-106
Preparation of short circuit electrical connector (for failure codes [CA1883] and
[CA3135]) .......................................................................................................... 40-107
Failure codes table........................................................................................................... 40-108
Troubleshooting by failure code (Display of code) ...................................................................... 40-117
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-117
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-118
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-119
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-120
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-121
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-122
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-123
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-124
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-125
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-126
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-127
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-128
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-129
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-134
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-136
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-138
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-139
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-140
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-141
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-143
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-144
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-145
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-147
Failure code [CA131] Throttle Sensor High Error................................................................. 40-149
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-151
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-153
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-155
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-157
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-159
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-161
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-163
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-167
40-2 PC490LC-10
40 Troubleshooting
Table of contents
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-169
Failure code [CA234] Eng Overspeed ................................................................................ 40-172
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-173
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-174
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-175
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-176
Failure code [CA273] PCV2 Short Error ............................................................................. 40-177
Failure code [CA274] PCV2 Open Error ............................................................................. 40-178
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-191
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-192
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-195
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-197
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-200
Failure code [CA442] Battery Voltage High Error................................................................. 40-202
Failure code [CA449] Rail Press Very High Error................................................................. 40-203
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-204
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-206
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-208
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-210
Failure code [CA553] Rail Press High Error ........................................................................ 40-212
Failure code [CA559] Rail Press Low Error......................................................................... 40-215
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-219
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-220
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-222
Failure code [CA691] Intake Temperature Sensor High Error ............................................... 40-224
Failure code [CA692] Intake Temperature Sensor Low Error ................................................ 40-226
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-228
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-229
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-230
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-231
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-233
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-234
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-237
Failure code [CA1695] Sens supply 5 volt high error ........................................................... 40-240
Failure code [CA1696] Sens supply 5 volt low error............................................................. 40-241
Failure code [CA1843] Crankcase Pressure Sensor High Error ............................................ 40-243
Failure code [CA1844] Crankcase Press Sensor Low Error ................................................. 40-245
Failure code [CA1879] KDPF Delta Pressure Sensor High Error .......................................... 40-247
Failure code [CA1881] KDPF Delta Pressure Sensor Low Error ........................................... 40-249
Failure code [CA1883] KDPF Delta Pressure Sensor In Range Error.................................... 40-251
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-266
Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-268
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-270
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-272
PC490LC-10 40-3
40 Troubleshooting
Table of contents
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-276
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-278
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-280
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-282
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-284
Failure code [CA2265] Fuel feed pump open circuit error..................................................... 40-285
Failure code [CA2266] Fuel feed pump short circuit error..................................................... 40-287
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-289
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-291
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-293
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-295
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-297
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-298
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-300
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-302
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-304
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-306
Failure code [CA2555] Grid Htr Relay Open Circuit Error ..................................................... 40-307
Failure code [CA2556] Grid Htr Relay Short Circuit Error ..................................................... 40-309
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-311
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-313
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-320
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-321
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-325
Failure code [CA3133] KDPF Outlet Pressure Sensor High Error ......................................... 40-330
Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error .......................................... 40-332
Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error................................... 40-334
Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-338
Failure code [CA3251] KDOC Inlet Temperature High Error ................................................. 40-341
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-344
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-347
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-350
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-357
Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error....................................... 40-363
Failure code [CA3314] KDOC Inlet Temperature Sensor High Error ...................................... 40-366
Failure code [CA3315] KDOC Intlet Temperature Sensor In Range Error .............................. 40-370
Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error .................................... 40-375
Failure code [CA3317] KDOC Outlet Temperature Sensor High Error ................................... 40-378
Failure code [CA3318] KDOC Outlet Temp Sensor In Range Error ....................................... 40-382
Failure code [CA3319] KDPF Outlet Temperature Sensor High Error .................................... 40-387
Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error..................................... 40-391
Failure code [CA3322] KDPF Outlet Temp Sensor In Range Error ........................................ 40-394
Failure code [CA3419] Mass Air Flow Sensor Power Supply High Error ................................ 40-399
Failure code [CA3421] Mass Air Flow Sensor Power Supply Low Error................................. 40-401
Failure code [D110KB] Battery Relay Drive S/C .................................................................. 40-403
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-405
Failure code [D811MC] KOMTRAX Error............................................................................ 40-408
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-409
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-410
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-412
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-413
Failure code [DA20MC] Pump Controller Malfunction .......................................................... 40-414
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-415
40-4 PC490LC-10
40 Troubleshooting
Table of contents
Failure code [DA25KP] 5V Sensor1 Power Abnormality ...................................................... 40-417

Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-419
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-422
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-424
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-425
Failure code [DA2RKR] CAN1 Discon ( Pump Con) ............................................................ 40-428
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-429
Failure code [DAF0MC] Monitor Error ................................................................................ 40-430
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-431
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-433
Failure code [DAFGMC] GPS Module Error........................................................................ 40-434
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-435
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-437
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-438
Failure code [DAZ9KQ] AC Model Selection Abnormality .................................................... 40-439
Failure code [DAZQKR] CAN2 Discon (AC)........................................................................ 40-440
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-445
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-450
Failure code [DGH2KA] Hyd Oil Temp Sensor Open ........................................................... 40-455
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-457
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ....................................... 40-459
Failure code [DHPAMA] Pump Press Sensor Abnormality ................................................... 40-461
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-464
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....................................................... 40-467
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ................................ 40-469
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality ................................. 40-472
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality....................................... 40-475
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality....................................... 40-478
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality ....................................... 40-481
Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality ...................................... 40-484
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-487
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality................................... 40-490
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ................................. 40-493
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality .................................. 40-496
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality .................................. 40-499
Failure code [DKR0MA] F pump S/P sensor Abnormality..................................................... 40-502
Failure code [DKR1MA] R pump S/P sensor Abnormality .................................................... 40-504
Failure code [DLM3KA] Fan speed sensor: Open circuit ...................................................... 40-506
Failure code [DLM3KB] Fan Speed Sensor Short Circuit ..................................................... 40-507
Failure code [DLM3MB] Fan Control Mismatch ................................................................... 40-508
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-513
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-515
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-517
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-519
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-522
Failure code [DW7BKA] Fan Reverse Sol Open Circuit ....................................................... 40-524
Failure code [DW7BKB] Fan Reverse Sol Short Circuit ....................................................... 40-526
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-528
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-530
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-532
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-534
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ...................................................... 40-536
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ...................................................... 40-538
Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit ........................................ 40-540
Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit ........................................ 40-542
Failure code [DWK8KA] Swing C/O Solenoid Open Circuit .................................................. 40-544
Failure code [DWK8KB] Swing C/O Solenoid Short Circuit................................................... 40-546
PC490LC-10 40-5
40 Troubleshooting
Table of contents
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit..................................................... 40-548
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit..................................................... 40-550
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-552
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-554
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-556
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-558
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-560
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-562
Failure code [DXE4KA] Service Current EPC Disc. ............................................................. 40-564
Failure code [DXE4KB] Service Current EPC S/C ............................................................... 40-565
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ............................................... 40-566
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ............................................... 40-568
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit .................................................. 40-570
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit .................................................. 40-572
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-574
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-576
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-578
Failure code [DY2DKB] Wiper Drive (For) Short .................................................................. 40-580
Failure code [DY2EKB] Wiper Drive (Rev) Short ................................................................. 40-582
Troubleshooting of electrical system (E-mode) .......................................................................... 40-584
E-1 Engine does not start (Engine does not crank) .............................................................. 40-584
E-2 Manual preheater does not operate ............................................................................. 40-590
E-3 Automatic preheater does not operate ......................................................................... 40-593
E-4 While preheater is operating, engine preheating monitor does not light up....................... 40-595
E-5 While starting switch is turned ON, machine monitor displays nothing............................. 40-597
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level
E-8 Engine coolant temperature monitor lights up in white while engine is running ................. 40-602
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-603
E-10 Charge level monitor lights up in red while engine is running ........................................ 40-604
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-605
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-606
E-13 Engine coolant temperature monitor lights up in red while engine is running .................. 40-607
E-14 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-608
E-15 Engine oil pressure monitor lights up in red while engine is running .............................. 40-609
E-16 Fuel gauge display does not move from minimum or maximum .................................... 40-610
E-17 Display of fuel gauge differs from actual fuel level ....................................................... 40-611
E-18 Engine coolant temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-612
E-19 Display of engine coolant temperature gauge differs from actual coolant
temperature ....................................................................................................... 40-613
E-20 Hydraulic oil temperature gauge display does not move from minimum or
maximum ........................................................................................................... 40-614
E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature ................ 40-616
E-22 Machine monitor does not display partially.................................................................. 40-617
E-23 Function switch does not operate............................................................................... 40-618
E-24 Automatic warm-up system does not work (in cold weather)......................................... 40-619
E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or
does not go off.................................................................................................... 40-620
E-26 Auto-decelerator is not operated or canceled with lever ............................................... 40-621
E-27 When working mode switch is operated, working mode selection screen is not
displayed ........................................................................................................... 40-622
E-28 When working mode is changed, setting of engine and hydraulic pump is not
changed............................................................................................................. 40-623
E-29 When travel speed switch is operated, travel speed monitor does not change ............... 40-624
E-30 When travel speed selection is changed, actual travel speed does not change .............. 40-625
E-31 Alarm buzzer cannot be canceled .............................................................................. 40-626
40-6 PC490LC-10
40 Troubleshooting
Table of contents
E-32 When starting switch is turned OFF, service meter is not displayed ............................... 40-627
E-33 Machine monitor cannot be set in service mode .......................................................... 40-628
E-34 All of work equipments, swing, and travel mechanism do not move............................... 40-629
E-35 All of work equipment, swing, and travel mechanism do not lock................................... 40-631
E-36 When swing brake cancel switch is set to CANCEL position, machine cannot
swing................................................................................................................. 40-632
E-37 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL
position .............................................................................................................. 40-634
E-38 One-touch power maximizing function does not operate properly, or indicator not
displayed on monitor ........................................................................................... 40-636
E-39 One-touch power maximizing function is not cancelled ................................................ 40-638
E-40 Alarm does not sound during travel ............................................................................ 40-639
E-41 Alarm does not stop sounding while machine is stopped.............................................. 40-641
E-42 Horn does not sound ................................................................................................ 40-642
E-43 Horn does not stop sounding..................................................................................... 40-644
E-44 When wiper switch is operated, wiper monitor does not light up or go off ....................... 40-645
E-45 When wiper switch is operated, windshield wiper does not operate............................... 40-646
E-46 When window washer switch is operated, window washer does not operate.................. 40-648
E-47 Boom LOWER indicator is not displayed properly with monitoring function .................... 40-649
E-48 Arm OUT indicator is not displayed properly with monitoring function ............................ 40-650
E-49 Arm IN indicator is not displayed properly with monitoring function................................ 40-651
E-50 Boom RAISE indicator is not displayed properly with monitoring function ...................... 40-652
E-51 Bucket CURL indicator is not displayed properly with monitoring function...................... 40-653
E-52 Bucket DUMP indicator is not displayed properly with monitoring function ..................... 40-654
E-53 Swing indicator is not displayed properly with monitoring function................................. 40-655
E-54 Travel indicator is not displayed properly with monitoring function................................. 40-656
E-55 Service indicator is not displayed properly with monitoring function............................... 40-657
E-56 Attachment hydraulic circuit cannot be changed.......................................................... 40-659
E-57 KOMTRAX system does not operate properly............................................................. 40-660
E-58 Machine push-up function cannot be canceled............................................................ 40-662
E-59 Machine push-up function does not operate................................................................ 40-664
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-665
Information described in troubleshooting table (H-mode) ..................................................... 40-665
System diagram of hydraulic equipment system ................................................................. 40-666
Failure mode and cause table ........................................................................................... 40-668
H-1 Speed or power of all work equipment, swing, and travel is low. ..................................... 40-674
H-2 Engine speed lowers significantly or engine stalls ......................................................... 40-676
H-3 Any of work equipment, swing and travel does not work ................................................ 40-678
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-679
H-5 Fine control performance or response is poor ............................................................... 40-680
H-6 Speed or power of boom is low.................................................................................... 40-681
H-7 Speed or power of arm is low ...................................................................................... 40-685
H-8 Speed or power of bucket is low .................................................................................. 40-689
H-9 Work equipment does not move in single operation....................................................... 40-692
H-10 Hydraulic drift of work equipment is large ................................................................... 40-693
H-11 Time lag of work equipment is large ........................................................................... 40-697
H-12 Other work equipment moves when one of work equipment is relieved ......................... 40-698
H-13 One-touch power maximizing function does not work .................................................. 40-699
H-14 Machine push-up function does not work.................................................................... 40-700
H-15 In combined operation of work equipment , equipment having heavier load moves
slower. ............................................................................................................... 40-701
H-16 In combined operation of swing and boom RAISE, boom rising speed is low ................. 40-702
H-17 Travel speed drops largely in combined operation of swing and trave ........................... 40-703
H-18 Machine does not travel straight ................................................................................ 40-704
H-19 Travel speed is low................................................................................................... 40-706
H-20 Machine is hard to steer or travel power is low ............................................................ 40-708
H-21 Travel speed does not change, or travel speed is too low or high.................................. 40-710
H-22 One of tracks does not run ........................................................................................ 40-711
H-23 Upper structure does not swing ................................................................................. 40-712
PC490LC-10 40-7
40 Troubleshooting
Table of contents
H-24 Swing acceleration is poor or swing speed is low ........................................................ 40-714

H-25 Upper structure overruns excessively when it stops swinging....................................... 40-716
H-26 Shock is large when upper structure stops swinging.................................................... 40-718
H-27 Large unusual noise is heard when upper structure stops swinging .............................. 40-719
H-28 Swing drift on a slope is large .................................................................................... 40-720
H-29 Attachment circuit cannot be changed........................................................................ 40-722
H-30 Oil flow in attachment circuit cannot be controlled ....................................................... 40-723
H-31 Fan speed is abnormal (high, low, or 0 rpm)................................................................ 40-724
H-32 Unusual noise is heard from around fan ..................................................................... 40-725
Troubleshooting of engine (S-mode)......................................................................................... 40-726
Information mentioned in troubleshooting table (S mode)..................................................... 40-726
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-727
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-728
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) ...................................................................................................... 40-729
S-4 Engine startability is poor ............................................................................................ 40-730
S-5 Engine does not pick-up smoothly ............................................................................... 40-732
S-6 Engine stops during operation ..................................................................................... 40-734
S-7 Engine runs rough or is unstable ................................................................................. 40-736
S-8 Engine lacks power .................................................................................................... 40-737
S-9 KDPF gets clogged in a short time ............................................................................... 40-739
S-10 Engine oil consumption is excessive .......................................................................... 40-741
S-11 Engine oil becomes contaminated early...................................................................... 40-742
S-12 Fuel consumption is excessive .................................................................................. 40-743
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-744
S-14 Oil pressure drops .................................................................................................... 40-745
S-15 Fuel mixes into engine oil.......................................................................................... 40-746
S-16 Water mixes into engine oil (milky) ............................................................................. 40-747
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-748
S-18 Unusual noise is heard ............................................................................................. 40-749
S-19 Vibration is excessive ............................................................................................... 40-750
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-751
S-21 Active regeneration is executed frequently ................................................................. 40-752
S-22 Active regeneration takes a long time......................................................................... 40-753
S-23 White smoke is exhausted during active regeneration ................................................. 40-754
40-8 PC490LC-10
40 Troubleshooting
Related information on troubleshooting
Related information on troubleshooting (ALL-5100-001-A-00-A)
Troubleshooting points (ALL-5130-42A-A-00-A)
(Rev. 2012/11)
k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.
k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.
k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
k Drain approximately 10l

l of coolant beforehand, because you may get scalded by hot water
spurting out from mounting location of coolant temperature sensor when removing radiator cap
during checking and replacing coolant temperature sensor.
k When performing checking and replacement of engine oil pressure sensor (switch), open oil filler
port, and check that engine oil temperature cools down enough not to get scalded.
k Loosen the oil filler cap of the hydraulic tank to release the pressure in the hydraulic tank. For
details, see Testing and adjusting "Releasing remaining pressure in hydraulic circuit" when
checking and replacing oil temperature sensor and oil pressure sensor. Check the code with
monitoring function and display the hydraulic oil temperature, then check that the temperature is
40°C or lower and cool enough not to burn.
Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Is there any sign of irregularities of the machine?
2) Make checks before starting day's work.
PC490LC-10 40-9
40 Troubleshooting
3) Make checks of other items.

4) Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is
eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.
40-10 PC490LC-10
40 Troubleshooting
Sequence of events in troubleshooting (ALL-5140-42A-A-00-A)
(Rev. 2011. 7)
PC490LC-10 40-11
40 Troubleshooting
40-12 PC490LC-10
40 Troubleshooting
Checks before troubleshooting (PC400-5150-208-A-00-A)
No. Item Criterion Remedy

1 Check for abnormal sounds and smells – Repair
2 Check for dirt around engine – Remove
3 Check for water leakage around engine – Repair
4 Check for oil leakage around engine – Repair
5 Check for leakage from fuel line – Repair
a: Engine, lubricating oil and coolant
6 Check of radiator for clogging – Remove

7 Check of level and type of fuel – Refilling with fuel
8 Check for foreign matter in fuel – Clean and drain
9 Check of fuel pre-filter – Replace
10 Check of fuel main filter – Replace
Between
11 Check of level (in oil pan) and type of engine oil Refilling with oil
H and L
Between Refilling with
12 Check of coolant level (in sub tank)
H and L coolant
Air
cleaner
clogging
monitor is
13 Check of air cleaner for clogging not Clean or replace
displayed
on
machine
monitor
1 Check for abnormal sounds and smells – Repair
Check for oil leakage – Repair
b: Hydraulic and mechanical equipment
2
Check of hydraulic oil level Between Refilling with oil
3
H and L
4 Check of hydraulic oil strainer – Clean or replace
5 Check of hydraulic oil filter – Replace
Check of swing machinery case oil level Between Refilling with oil
6
H and L
7 Check of damper case oil level – Refilling with oil
8 Check of final drive case oil level – Refilling with oil
9 Performing air bleeding operation – Bleeding air
Retighten or
1 Check of battery terminal for looseness and corrosion –
replace
Retighten or
c: Electrical equipment
2 Check of alternator terminal for looseness and corrosion –

replace
Retighten or
3 Check of starting motor terminal for looseness and corrosion –
replace
4 Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
Check of battery electrolyte level Between Add or replace
5
H and L
6 Check of wiring harness for discoloration, burn and cover peeling – Repair or replace
7 Check of wiring harness for release from clamp and sagging – Repair
8 Check of grounding – Repair
9 Check for loose connector and damaged lock – Repair or replace
PC490LC-10 40-13
40 Troubleshooting
No. Item Criterion Remedy

10 Check of connector pin for corrosion, bends and deformation – Repair or replace
Dry, clean or
11 Check for water and foreign matter in connector –
replace
c: Electrical equipment
12 Check of wiring harness for open or short circuit – Repair or replace

13 Check of fuse for blowing out and corrosion – Replace
After
several
Check of alternator voltage (When engine speed is medium or minutes
14 higher) Replace
operation:
27.5 –
29.5 V
Check of battery relay operation sound (when starting switch is
15 turned to ON or OFF position) – Replace
16 Check and cleaning of camera – Clean or repair
1 Check of undercarriage – Repair
d: Exterior parts
2 Check of handrails and steps – Repair
3 Check of mirrors – Clean or repair
1 Check of gauges and monitors – Clean or replace

e: Interior parts
2 Check of seat belt – Repair
40-14 PC490LC-10
40 Troubleshooting
Inspection procedure before troubleshooting (ALL-5150-001-A-00-A)
Walk-around check (PC400-5150-289-A-00-A)
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Any accumulation of flammable materials, or leakage of fuel or oil, around the battery, engine itself,
KDPF, turbocharger, or other high temperature engine parts can cause the machine to catch fire.
Check carefully, and if any problem is found, repair it.
a a1, a2, ... b1, b2, ... , etc. correspond to the symbol in the table of the previous page.
a1. and b1. Check for unusual sounds and smells c17. Check and cleaning of rearview camera
Check if there is unusual sounds or smells. Check the rearview camera for failure. If any, repair
If the machine is operated under the unusual it.
sounds or smells, the cause of it may damage the d1. Check of wheels (Undercarrage) for abnormality,
machine, so stop the operation immediately after wear and loose bolts
the check. If any abnormality is found, repair it.
a2. Check around engine and dirt removal d2. Check of handrails and steps for abnormality
Check and remove any accumulated dirt around the and loose bolts
engine and any combustibles (dead leaves, twigs, If any abnormality is found, repair it and retighten
etc.) on hot engine parts such as the KDPF, loose bolts.
turbocharger, etc.
d3. Check and cleaning of rearview mirrors
a3. Check for water leakage around engine
Check rearview mirror for failure. If any, repair it.
a4. Check for oil leakage around engine
Clean the mirror surface and adjust the mirror angle
Check for oil leakage from engine and water so that the rear of the machine can be seen from
leakage from cooling system. If any, repair it. the operator's seat.
a5. Check for leakage from fuel line e1. Check of gauges and monitors for abnormality
Check for fuel leakage, check hoses and pipes for Check gauges and monitors in the operator's cab
damage. If any, repair it. for abnormality. If any, replace it with new one.
a6. Check of radiator and dirt removal Clean up the surfaces.
Check and remove any accumulated dirt and any e2. Check of seat belt and mounting hardware
combustibles (dead leaves, twigs, etc.) around the
Check hook, lock and hook mounting part for
radiator.
damage. If any, repair it.
For removal of dirt from the radiator, see the
Operation and Maintenance Manual, "Cleaning and
testing of radiator fins, oil cooler fins, aftercooler fins,
fuel cooler fins and air conditioner condenser fins
(machine with the air conditioner)".
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage and
hoses for breakage, wear and clearance. If any
abnormality is found, repair it.
b2. Check of hydraulic equipment, hydraulic tank,
hoses and joints for oil leakage
Check and repair any oil leaks.
b9. Bleeding air
For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel
circuit".)
For the bleeding air from the hydraulic system, see
Testing and adjusting, "Bleeding air from each
part".)
PC490LC-10 40-15
40 Troubleshooting
Checks according to checking procedure (PC400-5150-280-A-00-A)
a7. Check of fuel level and type

k Fuel is highly flammable and dangerous.
Never bring flames near fuel.
k When adding fuel, never spill it or let it

overflow.
k Wipe off any spilled fuel. If fuel spills over

soil or sand, remove all the fuel and soil or
sand together.
1. Turn the starting switch to ON position and

check the fuel level with fuel level gauge (1) on
the monitor panel. • If breather hole (3) in the oil filler cap is
After checking, turn the switch back to OFF clogged, the pressure in the tank decreases
position. and fuel may not be supplied. To prevent this,
clean the breather hole.
2. If the fuel level is low, open fuel filler cap (F) of

the fuel tank and add fuel through the oil filler a8. Check of foreign material in fuel
port to the necessary level, referring to the 1. Open the side cover on the rear right of the
position of float gauge (G). machine.
3. After adding fuel, push float gauge (G) straight 2. Prepare a container below drain hose (1) to
down with fuel filler cap (F), and tighten fuel filler receive the fuel.
cap (F) securely while taking care the float 3. Turn drain valve (1) to "OPEN" position (O) to
gauge (G) is not caught in tab (2) of fuel filler cap discharge the sediment and water in the bottom
(F). together with the fuel.
4. When only the clean fuel flows out, turn drain
valve (2) to "CLOSE" position (S).
5. Close the side cover.
a9. Check of fuel prefilter
40-16 PC490LC-10
40 Troubleshooting
k Immediately after the engine is stopped, its a This machine is equipped with sensor which
parts and oil are still very hot, and may cause detects water accumulated in the transparent
burn injury. Accordingly, wait until all parts cap (2).
have cooled down before starting the work.
a Water separator monitor may not light up if
the water accumulated in transparent cap (2)
k High pressure is generated inside the engine
is frozen. Or, water separator monitor (5)
fuel piping system when the engine is
may suddenly light up when the frozen water
running. Stop the engine and wait at least 30
is melted after engine is started due to
seconds until the inner pressure is released
temperature raised around fuel prefilter (1).
and then replace the filter .
Drain water frequently at cold weather even
when water separator monitor (5) is not lit.
k Never bring flames near fuel.
a If water in transparent cap (2) is frozen, drain
a A special filter with high-efficiency filtering water only after confirming that it has
properties is adopted for Komatsu genuine fuel completely melted.
filter cartridges. Be sure to use Komatsu
genuine parts when replacing. a If you cannot visually identify the presence of
water due to stains on transparent cap (2),
a The common rail fuel injection system used on clean transparent cap (2) when replacing fuel
this machine consists of more precise parts than prefilter cartridge (1).
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu a When you have removed drain valve (4) for
genuine fuel filter cartridge is used, foreign the above cleaning process, coat the O-ring
material may enter and it may cause problems in with grease and tighten drain valve until it
the injection system. Do no use substitute parts. touches the bottom.
Replace fuel prefilter cartridge
a During testing or maintenance of the fuel system,
1. Turn valve (1) at the bottom of the fuel tank to
take extreme care not to allow any foreign
the "CLOSE" (S) position.
material to enter the fuel system. If any dust or
other material sticks to any part, wash the part
thoroughly with clean fuel.
• Prepare a container to receive drained oil.
• Prepare a filter wrench.
Check of water separator, and drainage of water
and sediments
1. Open the engine hood.
• The water separator is integrated with fuel
prefilter (1).
2. It is possible to judge the water level and amount
of sediment by looking through transparent cap
(2). If there is any water or sediment collected at
the bottom, place a container to catch the drain 2. Open the engine hood.
water under drain hose (3). 3. Place a container under the fuel prefilter
3. Loosen drain valve (4) to drain the water. cartridge (2) to receive the fuel.
4. If drain hose (3) starts to discharge fuel, close 4. Loosen drain valve (3) and drain water and
drain valve (4) immediately. sediments from transparent cup (4), and also
drain all the fuel from filter cartridge (2).
5. Remove drain hose.
6. Turn transparent cap (4) by using the filter
wrench, and remove it. (This cap is reused.)
7. Turn filter cartridge (2) by using the filter wrench,
and remove it.
8. Install currently removed transparent cap (4) to
the bottom of the new filter cartridge.
PC490LC-10 40-17
40 Troubleshooting
k Immediately after the engine is stopped, its

parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
k High pressure is generated inside the engine

fuel piping system when the engine is
running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter .
k Never bring flames near fuel.
9. Clean the filter holder, fill the new filter cartridge a A special filter with high-efficiency filtering
with clean fuel, apply thin film of oil to the properties is adopted for Komatsu genuine fuel
packing surface, then install it to the filter holder. filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a Be sure to add fuel through 8 small holes (A)
on the dirty side without removing center cap a The common rail fuel injection system used on
(B). this machine consists of more precise parts than
those in the conventional injection pump and
a After adding fuel, remove cap (B) and install nozzles. If any cartridge other than a Komatsu
the fuel filter. genuine fuel filter cartridge is used, foreign
a Always fill with clean fuel. Be careful not to let material may enter and it may cause problems in
any dirt or dust get into the fuel. In particular, the injection system. Do no use substitute parts.
center part is the clean side, so do not a During testing or maintenance of the fuel system,
remove cap (B) when adding fuel. Be careful take extreme care not to allow any foreign
not to let dirt or dust get into the center clean material to enter the fuel system. If any dust or
side part. other material sticks to any part, wash the part
thoroughly with clean fuel.
• Prepare a container to receive drained oil.
• Prepare a filter wrench.
1. Turn valve (1) at the bottom of the fuel tank to
the "CLOSE" (S) position.
10.When installing the cartridge, tighten it until the

packing surface contacts the sealing surface of
the filter holder, then tighten it 3/4 of a turn.
a If the filter cartridge is fastened too much, the
packing will be damaged and this leads to
leakage of fuel. If the filter cartridge is too 2. Open the engine hood.
loose, fuel will also leak from the packing. 3. Place a container under the filter cartridge to
Therefore, be sure to observe the fastening receive the fuel.
angle. 4. Turn filter cartridge (2) by using the filter wrench,
a When using a filter wrench for tightening, and remove it.
take care not to leave flaws or dents on the a After removing the filter cartridge, fuel falls in
filter. drops from the filter head.
11.Install drain hose.
12.Turn valve (1) at the fuel tank bottom to "OPEN" In order to prevent fuel from flowing out, be
(O) position. sure not to leave the machine without the
a10. Check of main filter filter cartridge.
40-18 PC490LC-10
40 Troubleshooting
5. Clean the filter holder. Apply a thin film of oil to 11.After the specified time (approximately 7
the packing of the new filter cartridge and install minutes), the fuel feed pump automatically stops
the cartridge to the filter holder. and the air bleeding is complete. At that time,
lamp (4) goes out.
a Do not fill the new filter cartridge with fuel.
a When no fuel is in the fuel circuit (when the
a Remove cap (A) at the center, and then
fuel feed pump stops from running out of fuel,
install the filter cartridge.
or when fuel hoses and tubes are repaired,
or when supply pump is replaced), the fuel
feed pump automatically stops and the lamp
goes out. At that time, tilt switch (3) for the
fuel feed pump to ON position again.
12.Start the engine. If the engine is not started, the
air bleeding may not be complete. Start the
engine again in the following procedure.
1) Tilt switch (3) for the fuel feed pump to ON
position.
2) Start the engine while the fuel feed pump is
in operation. If the engine is not started,
repeat steps 1) and 2).
• Keep away from the engine while it is
6. When installing the cartridge, tighten it until the
being started and running.
packing surface contacts the sealing surface of
the filter holder, then tighten it 3/4 of a turn. 3) After the engine starts, run it for
approximately 5 minutes to bleed all air from
a If the filter cartridge is over tightened, fuel will the fuel circuit.
leak because the O-ring is damaged. If the 4) After approximately 5 minutes, stop the
filter cartridge is not tightened sufficiently, engine. Then, start the engine as usual.
fuel will also leak through the clearance of a11. Check of engine oil level (in oil pan) and
the O-ring. Therefore, observe the tightening type
angle.
7. Turn valve (1) at the fuel tank bottom to "OPEN" k Immediately after the engine is stopped, its
(O) position. parts and oil are still very hot, and may cause
8. Bleed air according to the following procedure. burn injury. Accordingly, wait until all parts
9. Turn the starting switch to OFF position, and have cooled down before starting the work.
stop the engine.
a When checking the oil level after the engine has
10.Tilt switch (3) for the fuel feed pump to ON
been operated, wait for at least 15 minutes after
position. Lamp (4) starts flashing and the fuel
stopping the engine.
feed pump operates.
a If the machine is at an angle, make it level
before checking.
PC490LC-10 40-19
40 Troubleshooting
a When the ambient temperature is low, water or

emulsified matter may stick to the dipstick, oil
filler cap, etc. or the drained oil may be milky
white because of water vapor in the blowby gas.
However, if the coolant level is normal, it is not a
problem.
1. Stop the engine.
2. Open the engine hood.
3. Remove dipstick (G) and wipe off oil on it with a
cloth.
4. Insert dipstick (G) fully and pull it out.
5. If the oil level is between lines H and L on

dipstick (G), it is at the correct level.
If the oil level is below the L mark, add oil a12. Check of coolant level (in reservoir tank)
through oil filler port (F).
k The radiator cap does not need to be opened
for standard checks. When checking the
coolant level, check it in reservoir tank when
the engine is cooled down.
k Immediately after the engine is stopped, the

coolant is still very hot and the pressure is
accumulated in the radiator.
If the cap is opened under these conditions,
6. If the oil level is above line H, drain the extra you may be scalded. If you need to remove
engine oil through drain valve (P) at the bottom the radiator cap, wait until the temperature
of the engine oil pan and check the oil level drops before you do. Then turn the cap
again. slowly to release the pressure and remove it
7. If the oil is at the correct level, tighten the oil filler with care.
cap securely and close the engine hood.
1. Open the engine hood, check the coolant level is
within "FULL - LOW" range at reservoir tank (1)
(shown in the figure below). If coolant is
insufficient, add coolant up to FULL level
through water filler port at reservoir tank (1).
2. After refilling with coolant, tighten the cap
securely.
3. If the reservoir tank is vacant, coolant may have
leaked.
If any abnormality is found in the check for
leakage, repair it immediately. If no abnormality
is found, check the level of the coolant in the
radiator. If it is low, add coolant to the radiator
and then to the reservoir tank.
40-20 PC490LC-10
40 Troubleshooting
4. If reservoir tank (1) is dirty and it is difficult to

check the coolant level, clean it.
a Until air cleaner clogging monitor (1) on monitor

panel lights up, do not clean the air cleaner
element. If you clean the element frequently
before the air cleaner clogging monitor on
machine monitor lights up, the air cleaner will not
deliver optimum performance and the cleaning
efficiency will be reduced.
a Inspection, cleaning or servicing while the
engine is running allows entry of dusts and can
damage the engine since dusts attached to the
element drop into the inner cylinder element
more frequently during the cleaning process. Be
sure to stop the engine before cleaning.
Cleaning of outer element
a13 Check of air cleaner for clogging a Before and after cleaning, be careful not to leave
or store the element being exposed to the direct
k When using compressed air for cleaning, put
sunlight.
on personal protective items such as
protective eyeglasses, gloves, dust mask, a Replace the outer element after you have
etc. to protect yourself from dirt that will fly cleaned 6 times or it has been used for a year.
out. When replacing it, replace the inner element at
the same time, too.
k When removing the outer element from the
air cleaner body, do not forcibly pull it out, a Even when the number of cleanings of the outer
otherwise it can be dangerous. element is less than 6 times, it must be replaced
along with the inner element if air cleaner
Be careful not to fall from a high location on clogging monitor (1) indicates the red zone
unsafe scaffolding as a reaction when pulling immediately after cleaning.
out the outer element.
1. Open side cover on the rear left of the machine,
Testing remove hook (2) (6 places), and remove the
cover (3).
If air cleaner clogging monitor (1) on monitor panel
lights up on the machine monitor, clean the air
cleaner element.
PC490LC-10 40-21
40 Troubleshooting
2. When removing outer element (5), hold it and

pull it out while gently moving it up and down,
right and left.
a Never remove inner element (6). Removing
the inner element allows entry of dusts,
leading to failure of the engine.
a Do not use tools like a screwdriver.
a After removing outer element (5), check the
inner element for disengagement and tilting.
If tilted, push it back fully with your hands.
3. After removing outer element (5), cover inner a After clearing the element, throw light on its
element (6) with a clean cloth or tape to protect inside by using a light bulb to check it. If it
from dusts. has a small hole or thin part, replace it.
4. Clean dusts in inside and on cover (3) of air
cleaner body (7) by using a clean cloth or brush.
a Do not hit the element or bump it against
nearby things when cleaning it.
8. Remove the cover of cloth or tape attached to

inner element (6).
9. Check the seal of the cleaned or new element
for adhesion of dusts and oil and wipe them of, if
any.
a Do not use an element or O-ring that has
5. If any dust is attached to vacuator valve (4) been in service for a year since trying to use
installed to cover (3), remove it. them after cleaning most probably induces
troubles.
a Do not use the element if its folds or gasket
or seal are damaged.
10.Push the outer element straight backward into
the air cleaner body with your hands while
moving it up and down, right and left.
a When installing the air cleaner element, set it
so that its cylinder bottoms (side without a
hole) (B) and (C) come to cover (3) side.
If they are installed in the opposite direction,
serious troubles including damage on the air
cleaner elements and engine may occur.
6. Blow dry compressed air (less than 0.2 MPa
{2.1kg/cm2}) from the inside of the outer element
along the folds.
7. Then blow it from outside along the folds, and
finally blow it from the inside again.
40-22 PC490LC-10
40 Troubleshooting
2. Remove inner element (6), and immediately

install inner element (6) to air cleaner body (7).
a Do not clean or reuse the inner element.
Replace the inner element with a new one
when replacing the outer element.
11.Install cover (3) according to the following

procedure.
1) Align cover (3) with the element.
a Install cover (3) so that vacuator (4) faces
down (A) .

so that its cylinder bottoms (side without a
hole) (B) and (C) come to cover (3) side.
If they are installed in the opposite direction,
serious troubles including damage on the air
cleaner elements and engine may occur.
a If the outer element and cover are installed
when the inner element is securely installed,
the outer element can be damaged. Be sure
to install it securely.
2) Lock the tip of hook (2) on the protrusion of

the air cleaner body.
a Lock the tip of hooks (2) diagonally (top
and bottom, and right and left).
a After installing cover (3), check presence
of clearance between the air cleaner
body and cover (3). If any, install the
cover again.
3. Push the outer element straight backward into

the air cleaner body with your hands while
moving it up and down, right and left.
in such that its cylinder bottom (side without
a hole) C comes to cover (3) side.
Installing it in an opposite direction can
induce serious troubles including damage on
the air cleaner elements and engine.
4. Replace O-ring (8) of cover (3) with a new one.
Replacement of element
1. Referring to "Cleaning of outer element", remove
outer element (5).
PC490LC-10 40-23
40 Troubleshooting
5. Referring to "Cleaning of outer element", install 3. Open the door at the left of the machine, then
cover (3). check sight gauge (G). The oil level should be
b. Hydraulic and mechanical equipment between H and L lines.
b3. Check of hydraulic oil level a If the oil level is below line L, add oil through
k Immediately after the engine is stopped, its oil filter port (F).
parts and oil are still very hot, and may cause a Do not add oil above the H mark since it can
burn injury. Accordingly, wait until all parts damage the hydraulic circuit or allow spurt of
have cooled down before starting the work. oil.
k When removing the oil filler cap, the oil may

spout out. Turn it slowly to release the
internal pressure, then remove it.
1. Set the work equipment in the posture as shown

below and, after stopping the engine, check the
oil level and add new oil if necessary.
a If the work equipment posture is not as
shown below, start the engine, fully retract
the cylinder rods for arm and bucket at
engine low idle. Then lower the boom until
bucket teeth touch the ground, then stop the
engine. Since the oil level varies according to the oil
temperature, use the followings as a guide.
• Between of H and L before start of operation
(oil temperature 10 to 30°C)
• During normal operation (oil temperature: 50
to 80°C), the oil level should be near line H.
b4. Check of hydraulic oil strainer

2. Turn the starting switch to ON position within 15 internal pressure, then remove it.
seconds from the engine stop and operate
control levers (work equipment and travel) to the 1. Stop the engine and remove oil filler cap (F) of
travel end in each direction to release internal the hydraulic tank to release the internal
pressure. pressure.
40-24 PC490LC-10
40 Troubleshooting
2. Remove oil filler cap (F) of the hydraulic tank to

k When removing the cover, it may jump release the internal pressure.
out under the reaction force of spring (4).
Loosen bolts evenly while holding cover
down, and remove it.
2. Remove the bolts, and remove cover (1).
3. Pull out rod (3) from the top, and take out spring
(2) and strainer (4).
4. Remove any dirt stuck to strainer (4), then wash
it in flushing oil. If strainer (4) is damaged,
replace it with a new one.
5. Insert and set strainer (4) in projected portion (5)
of the tank.
6. While pressing down spring (2) with the
projection at the bottom of cover (1), install the
bolts. Tighten the mounting bolts.
k When removing the cover, it may jump
out under the reaction force of spring (4).
Loosen bolts evenly while holding cover
down, and remove it.
3. Remove the bolts, and remove cover (1).
4. Remove spring (2), valve (3) and strainer (4),
and then remove element (5).
• Check the bottom of the filter case for dirt or
other material, and remove any if found. At
that time, take extreme care for any dirt or
other material not to drop into the hydraulic
tank.
5. Clean the removed parts by using cleaning oil.
b.5 Check of hydraulic oil filter 6. Install new element (5).
k Immediately after the engine is stopped, its 7. Place strainer (4), valve (3) and spring (2) onto
parts and oil are still very hot, and may cause the element.

internal pressure, then remove it.
1. Set the work equipment in the posture on a level

and firm ground as shown below, and stop the
engine.
PC490LC-10 40-25
40 Troubleshooting
8. Set cover (1) and install it with the mounting

bolts while pressing it by hand.
9. Tighten the mounting bolts.
10.Install oil filler cap (F).
11.To bleed air, run the engine at low idle for 10
minutes.
12.Stop the engine.
b6. Check of swing machinery case oil level
b7. Check of damper case oil level
1. Remove dipstick (G) and wipe off oil on it with a
cloth. k Perform oil level check more than 30 minutes
2. Insert dipstick (G) fully into the guide. after placing the machine on a level place.
3. Pull out dipstick (G) and check the oil level. If the
oil level is between stamped lines (H) and (L) on 1. Open the cover on the left side of the machine.
the dipstick, it is correct. 2. Remove plug (G) and check if the oil level is
4. If the oil does not reach the (L) mark on dipstick near the bottom line of the plug hole, it is correct.
(G), add oil through oil filler (F). If it is not, remove cap (F), and refill the oil until it
5. If the oil level is above line (H) of dipstick (G), reaches to the bottom of plug (P) through oil filler
loosen drain valve (B) to drain the excessive oil. port.
• When draining the oil, place an oil container a If the oil level is too high, it may cause
under drain valve (PB). overheating. Drain oil until it becomes
6. After checking the oil level and adding oil, install specified level.
dipstick (G) and oil filler cap (F). 3. Install plug (P) and cap (F).
4. Close the side cover.
b8. Check of final drive case oil level
40-26 PC490LC-10
40 Troubleshooting
k Since the oil may spurt out due to internal

pressure, rotate the plug gradually from its
side to release the internal pressure and then
remove it carefully.

• Refill capacity (right and left): 5.0 l

• Prepare a handle for the work.
1. Set the TOP mark at the top, and the line
running on TOP mark and plug (P)
perpendicular to the ground.
2. Place the oil container to receive oil under plug
(P).
3. Remove plugs (P) and (F) by using the handle,
and drain oil.
a Check for damages on O-ring attached to the
plugs. Replace it if necessary.
4. Tighten plug (P) to the specified torque.
5. Refill oil through plug (F) hole.
6. If oil flows out of the plug (F) hole, install the plug
(F).
3 Tightening torque of plugs (P) and (F):
b9. Bleeding air
68.6 ± 9.8 Nm {7 ± 1 kgm}
• For the bleeding air from the fuel system, see
k There are 2 plug (f)s. For refilling, use the
circuit".
one which is easier for refilling and inner
• For bleeding air from the hydraulic system, see
gear is not seen through.
Testing and adjusting, "Bleeding air from
hydraulic circuit".
c. Electric equipment
c1. Check of battery terminal for looseness and
corrosion
• Check battery terminals for looseness and
corrosion.
• Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the batteries.
c2. Check of alternator terminal for looseness and
corrosion
• Remove the engine undercover.
• Check alternator terminals B, R and E for open
circuit, loosening and corrosion.
c3. Check of starting motor terminal for looseness
and corrosion
• Check starting motor terminals B, C and R for
open circuit, loosening and corrosion.
c4. Check of battery voltage (with engine stopped)
Check the battery voltage by using the battery tester
while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
PC490LC-10 40-27
40 Troubleshooting
k Do not use the battery if the battery a If the fluid exceeds the U.L. line, remove the
electrolyte level is below LOWER LEVEL line. fluid using a dropping pipette or others until
This will accelerate deterioration of the the fluid drops to the U.L. line. When you
inside of the battery and reduce the service have removed the fluid from the battery,
life of the battery. In addition, it may cause an neutralize it with the baking soda (sodium
explosion. bicarbonate) and wash it away with a large
quantity of water.
k Since the battery produces combustible gas • When electrolyte level cannot be checked
that can explode, do not bring any open through the side face of the battery
flame near it. 1. Remove caps (2) from the top of battery. (As
described previously)
k Battery electrolyte is dangerous. Be careful 2. Observe fluid level port (3), and check the fluid
that it does not come in contact with your level. If the fluid level is below sleeve (4), always
eyes or skin. If it does, wash it away with add the purified water (such as a commercial
water and contact your doctor. battery fluid) until it reaches the bottom of sleeve
(the UPPER LEVEL).
a Do not add the battery fluid above the UPPER
LEVEL line. If done, the fluid may leak and the • (A) Correct level: Since the electrolyte level
coating surface may be damaged or the parts reaches to the sleeve bottom, the shape of
may be corroded. the electrode plates will appear distorted due
to the surface tension.
a To avoid freezing, add the purified water (such • (B) Low: Since the electrolyte level does not
as a commercial battery fluid) before starting the reach the sleeve bottom, the shape of the
work in the next day. electrode plates will appear straight.
• When checking the electrolyte level through the 3. After refilling, tighten cap (2).
side face of the battery
1. Wipe and clean the battery surface, especially
around the battery level lines with a wet cloth,
and check to see that the battery fluid is
between the UPPER LEVEL (U.L.) and LOWER
LEVEL (L.L.) lines.
a Do not clean the battery with a dry cloth
since static electricity may cause an
explosion.
a If the fluid exceeds the U.L. line, remove the

fluid using a dropping pipette or others until
the fluid drops to the U.L. line. When you
have removed the fluid from the battery,
neutralize it with the baking soda (sodium
bicarbonate) and wash it away with a large
quantity of water.
2. If the electrolyte level is below the middle of the c6. Check of wiring harness for discoloration, burn
U.L. and L.L. lines, remove cap (2) and add the and cover peeling
purified water (such as a commercial battery • Check the wiring harness and cables for
fluid) to the U.L. line immediately. discoloration and burn.
a After adding the refined water, tighten the a If discolored or burnt, the circuit may be shorted
cap securely. or grounded.
• Check the wiring harnesses and cables for
damage and peeling of the covers.
• If any abnormality is found, repair or replace the
wiring harness or cables.
c7. Check for coming off of wiring harness clamp
and sagging of wiring harness
40-28 PC490LC-10
40 Troubleshooting
• Check wiring harness for sagging and looseness a Check the connection of engine ground strap
due to coming off of harness clamp from the bottom of engine.
a In particular, carefully check the wiring harness • Remove the engine undercover.
around the hot and movable parts. • Check the connection of ground strap (2) of
engine controller (1).
• If removed from the clamp, secure it with the
clamp.
• Check engine ground strap (3).

c8. Check of grounding
a Take special care not to cause a loose cable
connection and corrosion.
• Open the battery cover.
• Check the connection of ground terminal (T08).
• Cab ground T02

a Since (T02) is situated at the bottom on the rear
left side of the cab and connected to (T01), it is
not particularly necessary to be checked.
• Remove cab rear cover.
• Check the connection of ground terminal (T01).
• Remove the cab undercover.
(Rear left of air conditioner unit (4))
• Check the connection of ground terminals (T04)
to (T07), (T09), and (T10).
c9. Check for loose connector and damaged lock.

• Open the engine hood. • Check the connection of male and female
connectors by pulling them by hand.
• If the connection is loose, secure it.
PC490LC-10 40-29
40 Troubleshooting
• Check the connectors for unlocking, and check

a If any water or foreign materials are found, the
the lock and connector housing for cracking.
seals may be defective. Check the seals for
• Check lock screws (2) to (4) of engine controller
damage.
(1) for looseness.
• If the seal is defective, repair or replace it.
a Use a hexagonal wrench with 4 mm width • Dry the inside of the connector with a dryer.
across flats.
• Wipe and remove any foreign material with a

c10. Check the connector pins for corrosion, cloth or others, and blow the air to clean the
bending and deformation. connector.
• Disconnect the connectors, and check their pins
for corrosion, bending, sinking than other pins,
and extension of female pins.
• If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for water and foreign
material insertion.
• Disconnect connectors, and check them for
insertion of water or foreign materials.
c12. Check of wiring harness for open or short
circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.
40-30 PC490LC-10
40 Troubleshooting
Open the inspection cover, and fusible links F04

and F05 are seen.
• Visually check wiring harnesses for peeling of

harness covers and the pins for contact with
adjacent pins due to defective crimping.
c14. Check of alternator voltage (when engine
c13. Check of fuse for blowing out and corrosion speed is medium or higher)
a When replacing a fuse, be sure to turn off the 1. Open the engine hood.
power (turn the starting switch to OFF position) 2. Connect the positive (+) lead of the multimeter to
and turn the battery disconnect switch to OFF alternator terminal (B) and connect the negative
position. (-) lead to the chassis ground.
• A fusible link is a large-capacity fuse. 3. Start and warm up the engine and measure the
• If a fuse is corroded and coated with white voltage while running the engine at a medium or
powder, or there is any play between the fuse a higher speed.
and fuse holder, replace the fuse. • If the voltage is abnormal, repair or replace
• Replace each fuse with the one of the same the alternator.
capacity. c15. Check of battery relay operation sound
Remove the cover at the right rear of the operator's 1. Open the battery cover.
cab, and fuse holder (F01) is seen. 2. Turn the starting switch to ON and OFF
positions, and check whether the battery relay
operation sound is heard or not.
• If the operation sound is not heard, check the
related circuits, referring to the description of
troubleshooting for E-1 described in the E
mode troubleshooting.
• If the relating circuit is normal, replace the
battery relay.
PC490LC-10 40-31
40 Troubleshooting
Preparation for troubleshooting of electrical system (PC400-C050-42C-K-00-A)
a When performing troubleshooting of electric circuits of machine monitor, pump controller, engine controller,
and KOMTRAX terminal, expose the applicable connector part according to the following procedure.
a For connectors whose lock method is special, perform disconnection and connection in the following
procedure.
Preparation
1. Machine monitor 4) Insert or connect troubleshooting T-adapters
1) Remove 3 mounting screws of cover (1). to connectors CM01, CM02, and CM04 on
machine monitor (7).
a One of the 3 screws is covered with cap
(2).
a Disconnect connector P31 of sunlight
sensor and remove cover (1).
2. Pump controller
1) Slide the operator's seat and seat stand to
the forward end.
2) Remove 5 mounting bolts to remove cool
2) Remove a mounting bolt and duct (6). and hot box (9).
3) Insert a flat-head screwdriver in slit (3) and
a While removing it, disconnect the drain
pull it upward to remove cover (5) while
hose.
releasing lug (4).
3) Remove 2 mounting bolts and 1 fastener to
remove magazine box (10).
4) Remove 3 mounting bolts to remove cover
(11).
(14).
6) Connect test adapters to connectors CP01

and CP02 of pump controller (15).
a The operating voltage cannot be
measured by inserting T-adapter because
it is not designed to accept T-adapter.
40-32 PC490LC-10
40 Troubleshooting
a How to disconnect connectors CP01 and a Connector without connector cover

CP02 (1).
• While pressing lock (L1), turn lock
(L2) inward.
a Bar (B) comes out and the lock is
released.
• Procedure for installing connector cover

1) Push in right and left sliders (4) as far as
they go.
3. Reference
• Procedure for removing connector cover (1)
1) Cut and remove cable tie (2).
2) Move lever (3) upward.
a Right and left sliders (4) pushed in as

far as they go (left in the following
figure)
2) Move lever (3) on connector cover (1)
from the top position to the left position
3) Lightly press part (A) on both sides of (locked position) as shown in the
connector cover (1) to release tabs (B). following figure.
4) Remove connector cover (1) around tab a (B), (C): Tab
(C).
PC490LC-10 40-33
40 Troubleshooting
a If the sliders and lever are not set as 2) Remove 5 mounting bolts to remove cool
shown in the following figure, the and hot box (9).
connector is not disconnected or
a While removing it, disconnect the drain
locked securely with the lever.
hose.
Accordingly, check their positions
3) Remove 2 mounting bolts and 1 fastener to
again.
remove magazine box (10).
(11).
(14).
3) Set tab (C) to the connector and place

connector cover (1).
a Take care that wiring harness (5) is
not caught.
6) Connect T-adapters for troubleshooting to
connectors CK01 and CK02 of KOMTRAX
terminal (15).
4) Put tabs (B) in to install connector cover

(1).
1) Open the engine hood.
2) Remove cover (1).
5) Replace the cut cable ties with new ones

to bind connector cover (1) and the wiring
harness together.
4. KOMTRAX terminal
1) Slide the operator's seat and seat stand to 3) Connect or insert T-adapters for
the forward end. troubleshooting to engine controller (2)
connectors J1, J2, and CE03.
40-34 PC490LC-10
40 Troubleshooting
a Use a hexagonal wrench with 4 mm width a Disconnection and connection of

across flats for lock screws (L1) and (L2). connectors
3 Lock screw: Since the connectors of ambient pressure
sensor and engine Ne speed sensor
3 ± 1 Nm {0.3 ± 0.1 kgm}
have a special lock mechanism,
a For details of engine intermediate disconnect them in the order of (a) to (c),
connector (3), see step 7. and connect them in the order of (d) to (f)
as shown in the following figure.
Disconnection: (a) Slide the lever, (b)
unlock, and (c) disconnect the connectors.
Connection: (d) Connect the connectors,
(e) engage the lock, and (f) slide the lever.
2) Bkup (camshaft) speed sensor (G)

Supply pump PCV1 (PCV1)
Supply pump PCV2 (PCV2)
a Disconnection and connection of
connectors
Since the connectors of Bkup speed
6. Engine-related connectors sensor and supply pump PCV have a
1) Ambient pressure sensor (PAMB) special lock mechanism, disconnect them
Engine Ne speed sensor (NE) in the order of (a) to (b), and connect
Crankcase pressure sensor (PC57) them in the order of (c) to (d) as shown in
Engine oil pressure sensor (POIL) the following figure.
Charge (Boost) pressure sensor (PIM) Disconnection: (a) Unlock and (b)
Fuel dosing pressure sensor (PDOSER) disconnect the connectors.
Mass air flow and temperature sensor (P55) Connection: (c) Connect the connectors
Shut off valve solenoid #1 (SOV1) and (d) engage the lock.
Shut off valve solenoid #2 (SOV2)
Fuel dosing solenoid (DOSER)
KDPF differential pressure and outlet
pressure sensor (PDPF)
KDPF temperature sensor (E26, TEMP1,
TEMP2, TEMP3)
3) Common rail pressure sensor (PFUEL)
PC490LC-10 40-35
40 Troubleshooting
a Disconnection and connection of a Precautions for connecting connectors

connectors When connecting connectors, pay
Since the connectors of common rail attention not to connect the connectors
pressure sensor have a special lock reverse.
mechanism, disconnect them in the order Engage lock portion (e) on the harness
of (a) to (b), and connect them in the side to triangle notch portion (f). (Pay
order of (c) to (d) as shown in the attention not to take square guide portion
following figure. (g) on the opposite side of triangle notch
Disconnection: (a) Unlock and (b) portion (f) by mistake.)
disconnect the connectors.
Connection: (c) Connect the connectors
and (d) engage the lock.
4) Engine coolant temperature sensor (TWTR)

Charge (Boost) temperature sensor (TIM)
a Disconnection and connection of
a Precautions for disconnection of connectors
connectors Since the connectors of engine coolant
The direction of the lock for connector temperature sensor have a special lock
may be changed toward the difficult mechanism, disconnect them in the order
direction (facing to the bottom or to the of (a) to (b), and connect them in the
engine side) for unlocking depending on order of (c) to (d) as shown in the
the position where the sensor is screwed following figure.
in. Disconnection: (a) Unlock and (b)
In such a case, turn the lock to the disconnect the connectors.
direction (a) by using the needle nose Connection: (c) Connect the connectors
pliers with curved tip (commercially and (d) engage the lock.
available) [1], then the lock can be
canceled easily.
Since the lock is canceled with "click"
sound, listen to the sound and disconnect
the connectors.
a Removal and installation of sensor body

Since a deep socket is necessary when
removing and installing the engine coolant
temperature sensor, see "Tools for testing,
adjusting, and troubleshooting".
7. Engine intermediate connector
40-36 PC490LC-10
40 Troubleshooting
a Disconnecting connectors
1) Take connector cover (1) off.
6) Grab the intermediate connector body (black

part on both male and female sides) to
disconnect the connector.
2) Remove clip (2) to release intermediate
connector BREAKOUT/E24 (3).
a Photo shows the state of bare engine.
3) Lower the red lock (L1).

4) Confirm lock (L2) at the side.
a A slit is provided on one side only. (Back
side)
5) While pinching lock (L2), lower side cover (4)

until it touches lock (L1).
PC490LC-10 40-37
40 Troubleshooting
Classification and procedure for troubleshooting (PC220-5160-40D-A-00-A)

Classification of troubleshooting
Mode Content
Display of Troubleshooting by failure code
code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
S-mode Troubleshooting engine
Procedure for troubleshooting

If a problem occurs in the machine, go to the corresponding troubleshooting section according to the following
procedure.
1. Troubleshooting procedure to be taken when action level and failure code are displayed on
machine monitor:
If an action level and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding [Display of code] according to the displayed failure code.
a If multiple problems occur simultaneously, all the failure codes for the problems are displayed
repeatedly in order. Record all the failure codes.
2. Troubleshooting procedure to be taken when action level and failure code are not displayed on
normal screen of machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1])
1) If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and
then see if the trouble is still detected. (See [*2])
a A failure code of the mechanical system cannot be deleted.
a If abnormality related to air conditioner is displayed in electrical system abnormality record, perform
"Check with self-diagnosis" in "Air conditioner".
2) If no failure code is recorded in the abnormality record, a failure that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the problem which seems to be a failure again and select the same problem from
the table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out
troubleshooting corresponding to that problem in the [E-mode], [H-mode], or [S-mode].
3. Actions to take after failure is repaired
Referring to following page, delete all failure codes in electrical system abnormality record.
[*1],[*2]
1. On the normal operation screen, while pressing number key [4] in the panel switch section, press [1], [2],
and [3] in this order.
2. On the service menu screen, press switch [F3] (R) in the panel switch section twice, and then select "03
Abnormality Record".
3. Press switch [F6] in the panel switch section to confirm, and then enter the "Abnormality record" screen.
40-38 PC490LC-10
40 Troubleshooting
4. Press switch [F6] in the panel switch section to confirm, and then enter the "Mechanical system failure
record" screen.
5. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a A failure code of the mechanical system cannot be deleted.
6. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
7. Similarly to 2 and 3, enter the "Electrical system abnormality record" screen.
8. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a If [E] is displayed on the left of a failure code, that failure code is "active" (the failure is still occurring or
normal resetting is not confirmed yet). If [E] is not displayed on the left of a failure code, that failure
code is "non-active" and disappears in the following clearing step. Accordingly be sure to take record
of that failure code.
9. While pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order to enter the
"Clearing mode". (Same as 1)
10.Press switch [F2] (CLEAR) in the panel switch section.
11.Press switch [F6] in the panel switch section to clear all failure codes temporarily.
PC490LC-10 40-39
40 Troubleshooting
12.Press switch [F5] (return) in the panel switch section to return to the "Electrical system abnormality record"
screen. Check if there is any failure code still displayed and take record.
13.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
14.Take record of information of all columns.

a Similarly to the electrical system abnormality record, if "E" is displayed on the left of a failure code, that
failure code is "active"
(the failure is still occurring or normal resetting is not confirmed yet).
15.Press switch [F2] (CLEAR) in the panel switch section to clear all codes temporarily. Check if "Abnormal"
is still displayed and take record. (Same as 10 in [*1] and [*2])
16.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
40-40 PC490LC-10
40 Troubleshooting
Symptom and troubleshooting numbers (PC400-5540-441-A-00-A)
Troubleshooting
No. Symptom of failure
Index
User code and failure code
Action level is displayed on the machine monitor. Press function switch [F5] to
1 display the "Occurred error list". Follow the
The failure code is displayed on the mechanical system abnormality record troubleshooting
2 procedure for the
screen
The failure code is displayed on the electrical system abnormality record failure code.
3
screen
Check items related to engine
4 Engine does not start E-1, S-1
When the starting switch is turned to the "START" position, the engine is not
5 E-1, S-1
cranked, or started
6 Engine cranks but no exhaust smoke comes out S-2
7 Fuel is being injected but engine does not start S-3
8 Engine starting performance becomes deteriorated S-4
9 Engine does not pick up smoothly S-5
10 Engine stops during operation S-6
11 Engine runs rough or is unstable S-7
12 Engine lacks power S-8
13 Exhaust smoke is black (KDPF gets clogged in a short time) S-9
14 Oil is consumed much S-10
15 Oil becomes contaminated quickly S-11
16 Fuel consumption is excessive S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Oil pressure drops S-14
19 Fuel is in oil S-15
20 Coolant is in oil (milky) S-16
21 Coolant temperature rises too high (overheating) S-17
22 Unusual noise is heard S-18
23 Vibration is excessive S-19
24 Air cannot be bled from fuel circuit S-20
25 Automatic regeneration is frequent S-21
26 Active regeneration is long S-22
27 White smoke is exhausted during active regeneration S-23
28 Manual preheater does not operate E-2
29 Automatic preheater does not operate E-3
30 While preheater is operating, preheating monitor does not light up E-4
31 Automatic warm-up system does not operate (in cold weather) E-24
When auto-decelerator switch is operated, auto-decelerator monitor does not
32 light up or does not go out E-25
33 Auto-deceleration does not operate or released with lever E-26
Symptom related to work equipment, swing and travel
34 All work equipment, swing, and travel do not work E-34, H-3
35 Any of work equipment, swing, and travel can not be locked E-35
36 All of work equipment, swing and travel work slow or lack power H-1
37 Engine speed lowers extremely or engine stalls H-2, S-6
When working mode switch is operated, working mode selection screen is
38 not displayed E-27
When working mode is changed, setting of engine and hydraulic pump is not
39 changed E-28
40 Unusual sound is heard from around hydraulic pump H-4
41 Fine control performance or response is poor H-5
Symptom related to work equipment
PC490LC-10 40-41
40 Troubleshooting
Troubleshooting
Index
42 Speed or power of boom is low H-6
43 Speed or power of arm is low H-7
44 Speed or power of bucket is low H-8
45 Work equipment does not move in single operation H-9
46 Hydraulic drift of boom is large H-10
47 Hydraulic drift of arm is large H-10
48 Hydraulic drift of bucket is large H-10
49 Time lag of work equipment is large H-11
50 Other wok equipment moves when one of work equipment is relieved H-12
51 One-touch power maximizing function does not operate H-13, E-38
52 One-touch power maximizing function cannot be canceled E-39
53 When additional attachment is installed, attachment circuit is not switched H-29, E-56
54 Oil flow in attachment circuit cannot be changed H-30
55 Machine push-up function cannot be canceled E-58
56 Machine push-up function does not operate H-14, E-59
Symptom related to combined operation
57 Work equipment loaded more is slower during combined operation H-15
58 In combined operations of swing and boom RAISE, boom rising speed is low H-16
59 Travel speed drops largely in combined operation of swing and travel H-17
Symptom related to travel
60 Machine deviates during travel H-18
61 Travel speed is low H-19
62 Machine is not steered well or steering power is low H-20
63 Travel speed does not change or travel speed is too low or high H-21, E-29, E-30
64 Travel system does not operate (only one side) H-22
65 Alarm does not sound during travel E-40
66 When the machine stops traveling, the travel alarm does not stop sounding E-41
Symptom related to swing
67 Upper structure swings neither to the right nor left H-23
68 Upper structure does not swing in only one direction H-23
69 Swing acceleration or swing speed is low in both directions (right and left) H-24
Swing acceleration performance is poor or swing speed is slow in only one
70 H-24
direction
Upper structure overruns remarkably when it stops swinging in both
71 directions (right and left) H-25
Upper structure overruns excessively when it stops swinging in only one
72 H-25
direction
73 Large shock is made when upper structure stops swinging H-26
74 Large unsual noise is heard when upper structure stops swinging H-27
75 When the swing parking brake is applied, hydraulic drift of swing is large H-28
76 When the swing parking brake is released, hydraulic drift of swing is large H-28
When swing parking brake cancel switch is set to the CANCEL position,
77 machine cannot swing E-36
When swing parking brake cancel switch is set to the NORMAL position,
78 swing holding brake does not operate E-37
Symptom is related to machine monitor
When starting switch is turned to ON position, machine monitor displays
79 nothing E-5
When starting switch is turned to the ON position (with engine stopped),
80 engine oil level monitor lights up yellow E-6
When starting switch is turned to the ON position (with engine stopped),
81 radiator coolant level monitor lights up yellow E-7
82 Engine coolant temperature monitor lights up white while engine is running E-8
40-42 PC490LC-10
40 Troubleshooting
Troubleshooting
Index
83 Hydraulic oil temperature monitor lights up white while engine is running E-9
84 Charge level monitor lights up while engine is running E-10
85 Fuel level monitor lights up red while engine is running E-11
86 Air cleaner clogging monitor lights up yellow while engine is running E-12
87 Engine coolant temperature monitor lights up red while engine is running E-13
88 Hydraulic oil temperature monitor lights up red while engine is running E-14
89 Engine oil pressure monitor lights up red while engine is running E-15
90 Fuel level gauge does not move from "E" or "F" position E-16
Fuel level gauge displays the different level from the actual fuel level
91 (displays other than "E" or "F") E-17
92 Engine coolant temperature gauge does not move from "C" or "H" position E-18
Engine coolant temperature gauge displays the different temperature from
93 the actual coolant temperature (displays other than "C" or "H") E-19
94 Hydraulic oil temperature gauge does not move from "C" or "H" position E-20
Hydraulic oil temperature gauge displays the different temperature from the
95 actual oil temperature (displays other than "C" or "H") E-21
96 Machine monitor does not display some items E-22
97 Function switch does not work E-23
98 Alarm buzzer cannot be canceled E-31
99 When starting switch is at OFF position, service meter is not displayed E-32
100 Machine monitor cannot be set in service mode E-33
101 The horn does not sound E-42
102 Horn does not stop sounding E-43
103 When wiper switch is operated, wiper monitor does not light up or go out E-44
104 When wiper switch is operated, windshield wiper does not operate E-45
105 When window washer switch is operated, window washer does not operate E-46
"Testing and
Air conditioner does not operate normally (including failure codes related to troubleshooting
106 air conditioner)
procedure" in Chapter
80
107 Monitoring function does not display lever control signal normally E-47 – E-55
Others
108 KOMTRAX system does not operate properly. E-57
109 Fan speed is abnormal (high, low, or 0 rpm) H-31
110 Abnormal sound is heard around the fan. H-32
PC490LC-10 40-43
40 Troubleshooting
Information in troubleshooting table (ALL-5170-421-A-01-A)
(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit head bolt or bolt hole which has no rust, etc.
• Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
6 • Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power circuit comes into
contact with the power circuit accidentally.
• Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)
40-44 PC490LC-10
40 Troubleshooting

<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
• When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
• When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
7 Defective controller female connector.
• "Male and female" means male and female of connector pins, not
connector housings.
• Male and female of connector pins and housing in DT series, etc, are
opposite to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to
troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The "/" in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• The arrow (io) indicates a rough installation
position on the given machine.
• NO: Normally Open
• NC: Normally Closed
• Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
• Except for GND and 24 V, a signal name indicated
at a junction, etc. shows that the wire is connected
to another junction or controller at where the same
signal name is indicated.
PC490LC-10 40-45
40 Troubleshooting
Connector list and layout (PC400-C050-055-K-00-A)
Num-
Connector No. Connector type ber of Location Address
pins
A13 DT 2 Intermediate connector G1
A15 DT 2 Intermediate connector L4
A16 DT 4 Intermediate connector J9
A40 DT 4 Intermediate connector L5
A41 DT 4 Camera 1 S1
A42 DT 4 Camera 2 S1
A45 DT 4 Camera K9
AC01 YAZAKI 10 Air conditioner unit X4
AC02 SUMITOMO 4 Air conditioner unit X6
AC03 x 1 Air conditioner compressor solenoid clutch I9
BREAKOUT FRAMATOME 24 BREAKOUT AE7
B-RES DT 3 Resistance AJ3
CC01 070 14 ID key authorization controller
CE03 DRC 60 Engine controller AI1
CK01 070 18 KOMTRAX controller X7
CK02 070 12 KOMTRAX controller X6
CM01 070 18 Monitor O5
CP01 AMP 81 Pump controller V9
CP02 AMP 40 Pump controller W9
D01 SWP 8 Diode M8
D02 SWP 8 Diode M9
D03 SWP 8 Diode N9
DOSER FRAMATOME 2 HC dosing solenoid AF8
E01 Terminal 1 Electrical intake air heater (ribbon heater) I9
E24 FRAMATOME 24 Intermediate connector AJ3
E25 FRAMATOME 4 Intermediate connector AE8
E26 FRAMATOME 4 KDPF temperature sensors consolidating box AF7
E27 DT 8 Intermediate connector AJ3
EGR-SOL DT 2 EGR valve solenoid AG1
F01 ― - Fuse T9
F04 Liters 2 Fusible link D9
F05 M 2 Fusible link B8
F11 Terminal 1 Holder E1
F12 Terminal 1 Fuse E9
G SUMITOMO 3 G sensor AH1
G-RES DT 2 Resistance AJ2
H08 M 4 Intermediate connector AD2
H09 M 8 Intermediate connector X5
H14 090 22 Intermediate connector S9
H15 090 22 Intermediate connector S9
H16 090 22 Intermediate connector X3
INJ DT 12 Intermediate connector AJ5
INJ#1 DT 2 Injector #1 AF3
INJ#4 DT 2 Injector #4 AG4
INJ#5 DT 2 Injector #5 AH5
INJ#6 DT 2 Injector #6 AJ4
40-46 PC490LC-10
40 Troubleshooting
Num-
pins
J01 20 Junction connector (black) X3
J02 20 Junction connector (pink) W3
J03 20 Junction connector (orange) W2
J04 20 Junction connector (pink)
J05 20 Junction connector (pink)
J06 20 Junction connector (orange) X6
J1 [CE01] DRC 60 Engine controller AJ2
J1939 DT 3 CAN_C AI5
J2 [CE02] DRC 60 Engine controller AJ2
JC01 Terminal 8 Junction connector AJ4
JC02 Terminal 8 Junction connector AJ3
JM03 Terminal 3 Junction connector ―
K01 M 2 Pump (PC) resistor O8
K02 DT 3 CAN terminating resistor AI2
L01 DT 2 Working lamp (boom) E9
L02 DT 2 Working lamp (right) D1
L03 M 2 Room lamp T9
L05 SWP 2 Intermediate connector AC8
L09 DT 2 Working lamp (rear) (if equipped) L9
L15 DT 2 Revolving warning lamp (if equipped) AB9
L19 DT 2 System operating lamp F1
M01 PA 10 Radio V1
M01A ― 3 Cable, AUX V2
M02 M 2 L.H. speaker AD8
M03 M 2 R.H speaker AC9
M04 Terminal 2 Cigarette lighter S9
M05 M 6 Wiper motor O4
M06 YAZAKI 2 Washer motor L3
M07 090 2 Horn (treble tone) G1
M08 090 2 Horn (bass tone) G9
M09 M 2 Power supply (1) (if equipped) M5
M10 M 2 Power supply (2) (if equipped) N5
M11 DT 6 DC/DC converter X5
M12 M 2 12V power supply (if equipped) X5
M13A M 2 12V socket (if equipped) X7
M13B M 2 12V socket (if equipped) X7
M14 DT 2 Travel alarm J2
M17 DT 2 Starting motor AG5
M18 Terminal 1 Alternator AI8
M1A M 2 Power supply (3) (if equipped) M5
M24 DT 2 Intermediate connector G9
M25 DT 2 Fuel refill pump (if equipped) ―
M35 DT 2 Heated seat V2
PC490LC-10 40-47
40 Troubleshooting
Num-
pins
M36 DT 2 Air suspension system U1
M37 DT 2 Fuel feed pump AE5
M40 x 2 Head lamp (if equipped) AB1
M41 x 2 Head lamp (if equipped) Y8
M80 x 3 Bucket quick coupler control box (if equipped) O4
M81 x 2 - J2
N08 DT 12 Service connector T9
NE FRAMATOME 3 NE sensor AE6
P01 AMP 3 Bucket CURL pressure sensor A7
P02 AMP 3 Boom LOWER pressure sensor C7
P03 AMP 3 Swing (left) pressure sensor A6
P04 AMP 3 Arm IN pressure sensor C6
P05 AMP 3 Bucket DUMP pressure sensor A6
P06 AMP 3 Boom RAISE pressure sensor C6
P07 AMP 3 Swing (right) pressure sensor A6
P08 AMP 3 Arm OUT pressure sensor C6
P09 AMP 3 L.H. travel FORWARDpressure sensor Q1
P10 AMP 3 L.H. travel REVERSE pressure sensor Q1
P11 AMP 3 R.H. travel FORWARD pressure sensor P1
P12 AMP 3 R.H. travel REVERSE pressure sensor P1
P13 x 2 Pressure switch (if equipped) O3
P17 S090 2 Air conditioner high- and low-pressure switch W2
P18 090 2 Air conditioner outside air temperature sensor H9
P20 M 3 Fuel control dial P8
P21 DT 2 Fuel level sensor F9
P22 DT 2 Hydraulic oil temperature sensor L3
P23 DT 2 Air cleaner clogging sensor G9
P24 x 2 Radiator coolant level sensor I9
P25 AMP 3 Front pump pressure sensor K2
P26 AMP 3 Rear pump pressure sensor L3
P27 DT 3 Front pump swash plate sensor L5
P28 DT 3 Rear pump swash plate sensor L5
P31 Terminal 2 Sunlight sensor O6
P44 DT 2 Engine oil level sensor AI1
P49 AMP 3 Service pressure sensor L3
P50 DT 2 Fan speed sensor AH9
P55 FRAMATOME 4 MAF sensor H9
P57 FRAMATOME 3 Crankcase pressure sensor J9
PAMB FRAMATOME 3 Ambient pressure sensor AF9
PCCV FRAMATOME 3 CCV pressure sensor ―
PCV1 SUMITOMO 2 Supply pump #1 AH1
PCV2 SUMITOMO 2 Supply pump #2 AI1
PDOSER FRAMATOME 3 Shut off valve pressure sensor AH5
PDPF FRAMATOME 4 KDPF pressure sensor AE8
PFUEL AMP 3 Common rail pressure sensor AJ4
PIM FRAMATOME 3 Boost pressure sensor AI5
POIL FRAMATOME 3 Engine oil pressure sensor AH1
R01 Terminal 1 Battery relay B9
R02 Terminal 1 Battery relay B9
R03 Terminal 1 Battery relay D9
R04 Terminal 1 Battery relay D9
40-48 PC490LC-10
40 Troubleshooting
Num-
pins
R05 Relay 5 Battery relay T9
R06 Relay 5 Starting motor cut-off relay (PPC lock) V9
R07 Relay 5 Starting motor cut-off relay (personal code) W9
R08 Relay 5 Horn relay U9
R10 Relay 5 Rear light relay (if equipped) U9
R12 Relay 5 CAB light relay (if equipped) T9
R15 Terminal 1 electrical intake air heater (ribbon heater) relay D8
R16 Terminal 1 Electrical intake air heater (ribbon heater) relay B8
R17 Terminal 1 Electrical intake air heater (ribbon heater) relay D8
R18 Relay 5 Auto preheat relay W9
R21 Relay 5 Compressor clutch relay X8
S01 Terminal 5 Starter switch P7
S02 SWP 6 Daytime light switch Q8
S04 SWP 6 Swing lock switch Q8
S05 SWP 6 Machine push-up switch Q9
S07 SWP 6 Revolving warning lamp switch (if equipped) R9
S10 Y090 2 R.H. knob switch (horn) P8
S11 Y090 2 L.H. knob switch (one-touch power max.) T1
S14 M 3 PPC oil pressure lock switch U1
S18 SWP 6 Engine shutdown secondary switch T1
S19 DT 2 Seat belt monitor switch T1
S21 Terminal 12 Emergency pump drive switch N9
S22 Terminal 6 Parking brake emergency release switch N9
S25 090 16 Intermediate connector O9
S30 S 8 Machine model selection U9
S41 DT 2 Switch box (if equipped)
S50 DT 12 Pump timer switch H9
SB Terminal 1 Starting motor K9
SEGR DT 4 EGR valve position sensor AG1
SOV1[AFT
SOV1] FRAMATOME 2 Shut off valve solenoid #1 AG5
SOV2[AFT
SOV2] FRAMATOME 2 Shut off valve solenoid #2 AH5
SVGT DT 3 VGT position sensor AF9
T01 Terminal 1 Ground W2
T02 Terminal 1 CAB ground AD2
T03 M 1 Radio body ground U1
T04 Terminal 1 Revolving frame J1
T05 Terminal 1 Revolving frame I1
T08 Terminal 1 Frame E1
T09 Terminal 1 Revolving frame H1
T10 Terminal 1 Revolving frame G1
T11 Terminal 1 Engine body ground AH5
T12 Terminal 1 Engine cylinder block AF5
T18 Terminal 1 Floor frame T1
T19 Terminal 1 Right console frame R9
TDOC_IN FRAMATOME 2 KDOC inlet temperature sensor AE8
TDOC_OUT FRAMATOME 2 KDOC outlet temperature sensor AE8
TDPF_OUT FRAMATOME 2 KDPF outlet temperature sensor AE8
PC490LC-10 40-49
40 Troubleshooting
Num-
pins
TIM PACKARD 2 Boost temperature sensor AJ4
TWTR PACKARD 2 Coolant temperature sensor AF5
V01 DT 2 PPC source pressure solenoid valve A2
V02 DT 2 Swing pressure cut off solenoid valve C2
V03 DT 2 Travel junction valve solenoid valve A2
V04 DT 2 Travel Hi/Lo selecting solenoid C2
V05 DT 2 Swing parking brake A2
V06 DT 2 Machine push-up solenoid valve C2
V07 DT 2 Service return solenoid valve (if equipped) C1
V08 DT 2 2-stage relief solenoid valve A1
V11 DT 2 F-PC-EPC valve K9
V12 DT 2 R-PC-EPC valve L4
V13 DT 2 Fan pump L6
V17 DT 2 Fan reverse solenoid valve AG9
V19 DT 2 LS-EPC valve K9
V23 DT 2 Merge-divider EPC valve (main) J9
V24 DT 2 Merge-divider LS valve (main) K2
V25 DT 2 Variable back pressure solenoid valve K2
V30 DT 2 ATT flow adjustment EPC (if equipped) O3
VGT REV DT 2 VGT speed sensor AF9
VGT-SOL DT 2 VGT solenoid AF2
W03 x 2 Rear limit switch AB9
40-50 PC490LC-10
40 Troubleshooting
PC490LC-10 40-51
40 Troubleshooting
40-52 PC490LC-10
40 Troubleshooting
PC490LC-10 40-53
40 Troubleshooting
40-54 PC490LC-10
40 Troubleshooting
PC490LC-10 40-55
40 Troubleshooting
40-56 PC490LC-10
40 Troubleshooting
Connector contact identification (ALL-5310-030-A-00-A)
(Rev. 2014. 08)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
PC490LC-10 40-57
40 Troubleshooting
40-58 PC490LC-10
40 Troubleshooting
PC490LC-10 40-59
40 Troubleshooting
40-60 PC490LC-10
40 Troubleshooting
PC490LC-10 40-61
40 Troubleshooting
40-62 PC490LC-10
40 Troubleshooting
PC490LC-10 40-63
40 Troubleshooting
40-64 PC490LC-10
40 Troubleshooting
PC490LC-10 40-65
40 Troubleshooting
40-66 PC490LC-10
40 Troubleshooting
PC490LC-10 40-67
40 Troubleshooting
40-68 PC490LC-10
40 Troubleshooting
PC490LC-10 40-69
40 Troubleshooting
40-70 PC490LC-10
40 Troubleshooting
PC490LC-10 40-71
40 Troubleshooting
40-72 PC490LC-10
40 Troubleshooting
PC490LC-10 40-73
40 Troubleshooting
40-74 PC490LC-10
40 Troubleshooting
PC490LC-10 40-75
40 Troubleshooting
40-76 PC490LC-10
40 Troubleshooting
PC490LC-10 40-77
40 Troubleshooting
40-78 PC490LC-10
40 Troubleshooting
PC490LC-10 40-79
40 Troubleshooting
40-80 PC490LC-10
40 Troubleshooting
PC490LC-10 40-81
40 Troubleshooting
40-82 PC490LC-10
40 Troubleshooting
PC490LC-10 40-83
40 Troubleshooting
40-84 PC490LC-10
40 Troubleshooting
PC490LC-10 40-85
40 Troubleshooting
40-86 PC490LC-10
40 Troubleshooting
PC490LC-10 40-87
40 Troubleshooting
40-88 PC490LC-10
40 Troubleshooting
PC490LC-10 40-89
40 Troubleshooting
40-90 PC490LC-10
40 Troubleshooting
PC490LC-10 40-91
40 Troubleshooting
40-92 PC490LC-10
40 Troubleshooting
PC490LC-10 40-93
40 Troubleshooting
40-94 PC490LC-10
40 Troubleshooting
PC490LC-10 40-95
40 Troubleshooting
T-branch box and T-branch adapter table (ALL-5330-305-A-00-A)
(Rev. 2014. 05)
a The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of
harness checker assemblies are listed in the horizontal line.
T-adapter kit
Not included in kit

Number of pins
Identifi-
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name cation
Symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14 pins) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
ECON-
799-601-2750 Adapter for ECONO 2 q q
O2P
ECON-
O3P
ECON-
O4P
ECON-
O8P
ECON-
O12P
799-601-2810 Adapter for DLI 8 DLI-8P q q
Extension cable (ECONO ECON-
799-601-2840 type) 12 q q q
O12P
799-601-2850 Case q
T-box (for DRC60,
799-601-4350 ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
40-96 PC490LC-10
40 Troubleshooting
T-adapter kit
Not included in kit

Number of pins
Identifi-
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Symbol

799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (white) 10 S10P q q q q
799-601-7160 Adapter for S (blue) 12 S12P q q q
799-601-7170 Adapter for S (blue) 16 S16P q q q q
799-601-7330 Adapter for S (white) 16 S16PW q
799-601-7350 Adapter for S (white) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short socket adapter for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (gray) 8 DT8GR q q
799-601-9070 Adapter for DT (black) 8 DT8B q q
799-601-9080 Adapter for DT (green) 8 DT8G q q
799-601-9090 Adapter for DT (brown) 8 DT8BR q q
799-601-9110 Adapter for DT (gray) 12 DT12GR q q
799-601-9120 Adapter for DT (black) 12 DT12B q q
799-601-9130 Adapter for DT (green) 12 DT12G q q
PC490LC-10 40-97
40 Troubleshooting
T-adapter kit
Not included in kit

Number of pins
Identifi-
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Symbol
799-601-9140 Adapter for DT (brown) 12 DT12BR q q

799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24 pins) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-
T2)
799-601-9420 Adapter PFUEL for engine 3 A3 q q
(CRI-T3)
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* Socket PCV for engine 2 P q q
(CRI-T3)
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* Socket TIM for engine 2 A q q
(CRI-T3)
795-799-5460 Cable for engine (HPI-T2) 3 q
Adapter PIM for engine
799-601-4110 (140-T3) 4 ITT3N q q
Adapter NE, CAM for
799-601-4130 engine (CRI-T3) 3 FCIN q q
799-601-4140 T3) 3 FCIG q q
Ambient pressure
Adapter POIL for engine
799-601-4150 (CRI-T3) 3 FCIB q q
799-601-4160 T3) 2 4160 q q
40-98 PC490LC-10
40 Troubleshooting
T-adapter kit
Not included in kit

Number of pins
Identifi-
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Symbol
Oil pressure switch

Adapter PEVA for engine
799-601-4180 (CRI-T3) 3 4180 q q
799-601-4190* 3 1, 2, 3 L q q
Common rail pressure
1, 2, 3, 4
799-601-4230* Intake pressure/ 4 q q
C
temperature
Socket PAMB for engine
799-601-4240* 3 1, 2, 3A q q
(CRI-T3)
Socket PIM for engine
799-601-4250* 3 1, 2, 3B q q
(CRI-T3)
Socket G for engine (CRI- 1, 2, 3,
799-601-4330* T3) 3 q q
G
799-601-4340* 2 2, PA q q
Pump actuator
(95) 1, 2, 3,
799-601-4380* 4 q
Intake pressure/ 4T
temperature
Adapter for controller
799-601-4260 (ENG) 4 DTP4 q q
799-601-4211 (ENG) 50 DRC50 q
799-601-4220 (ENG) 60 DRC60 q
Socket for controller
799-601-4390* (95ENG) 60 q
12-
799-601-4280* Box for controller (PUMP) q
1
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for DT 2 to 4,
799-601-9890 DTM 2 pins 3, q
4
T-adapter for ICT control
799-902-9600 26 q
box
799-902-9700 T-box 26 q
*: These are not T-adapters but sockets.
PC490LC-10 40-99
40 Troubleshooting
T-adapter kit
Not included in kit

Number of pins
799-A65-4600
Identification
799-902-9300
Part No. Part name
Symbol
799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 q

799-902-9310 Adapter for control box 19 799-902-9310 q
799-902-9320 Adapter for IMU 10 799-902-9320 q
799-902-9330 Adapter for MS cylinder 6 799-902-9330 q
KDPF differential pressure sensor
799T-601-4611 short socket adapter 4 799T-601-4611 q
KDPF outlet pressure sensor short
799T-601-4670 socket adapter 4 799T-601-4670 q
799T-601-4680 KDPF dummy temperature sensor 4 799T-601-4680 q
40-100 PC490LC-10
40 Troubleshooting
Connection table of fuse box (PC400-5530-04D-A-00-A)
a This connection table shows the fuse box and the devices which receive the power from the fuse box ( A
switched power supply is the power source which supplies power while the starting switch is in ON
position and a continuous power supply is the power source which supplies power while the starting
switch is in OFF and ON positions).
a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see
if the power is supplied properly.
Type of
Fuse Fuse
power Fusible link Destination of power
No. capacity
supply
1 5A Working lamp relay, emergency switch
2 30 A Solenoid valve
3 5A PPC oil pressure lock solenoid
4 10 A Window washer, cigarette lighter
5 10 A Horn
6 5A Auto preheater
Fusible link
F04 7 10 A Revolving warning lamp
Switched
(65 A) 8 10 A Radio, Speaker, L.H. knob switch
power
supply 9 20 A Working lamp, rearlamp
10 20 A Air conditioner unit
11 10 A Headlamp
12 10 A Optional power supply (1)
Optional power supply (2), travel alarm, 12 V power supply,
13 30 A Heated air suspension seat
Starting 14 5A Engine controller
switch ACC 15 5A Engine controller KOMTRAX
16 10 A Radio backup, room lamp, system operating lamp
Machine monitor (continuous power supply), pump
Continuous Fusible link 17 20 A
controller
power F05
18 30 A Engine controller
supply (30 A)
19 5A Engine controller backup
20 25 A Electric priming pump
Locations of fusible link
* The two fusible links (F04) and (F05) are accessible when the battery cover is lifted.
PC490LC-10 40-101
40 Troubleshooting
Location of fuse box and fuse number
40-102 PC490LC-10
40 Troubleshooting
Precautions for KDPF (KCSF and KDOC) Cleaning and

Replacement (PC220-A9H0-2A4-K-00-A)
1. Related information From service menu of machine monitor,
display the "Diagnostic Tests" screen, open
k Since KDPF and KDOC are heated to 500° "KDPF Memory Reset", and then perform
C or above, take care not to get burn "KDOC Cleaning" (reset after KDOC
injury. cleaning).
• Resetting after KDPF (KCSF) change
• Soot accumulation at KCSF inside the KDPF
From service menu of machine monitor,
is classified into 8 levels. The current soot
level can be checked on the machine
"KDPF Memory Reset", and then perform
monitor by selecting the "Diagnostic Test"
"KDPF Change" (resetting after KDPF
screen from the service menu, and then
change).
selecting the "Regeneration for Service"
screen. a When KCSF in KDPF is replaced, always
perform resetting procedures for KDPF
a If the soot accumulation reaches level 4 or 5,
cleaning and KDPF change, and then
failure code [CA2639] is displayed.
perform manual stationary regeneration from
a If the soot accumulation reaches level 6 or 7, "Regeneration for Service" to eliminate
failure code [CA1921] is displayed. moisture from KCSF.
a If the soot accumulation reaches level 8, • Resetting after KDOC change
failure code [CA1922] is displayed. From service menu of machine monitor,
• If the soot accumulation reaches level 8, the
"KDPF Memory Reset", and then perform
KDPF is completely clogged with soot, and
"KDOC Change" (reset after KDOC change).
inspection, cleaning, or replacement is
required. a When KDOC in KDPF is changed, resetting
• Manual stationary regeneration can be procedure for KDOC change must be
performed to burn away soot in the KCSF performed though manual stationary
when the soot accumulation is up to level 7. regeneration is not necessary.
2. When cleaning and replacing KCSF
a At soot accumulation levels 4 to 7, manual
stationary regeneration can also be 1) Regular cleaning at 4500H
performed from the user mode. 1] Check the soot accumulation level. If the
• Procedure of performing manual stationary level is not zero, repeat "Regeneration for
regeneration from Regeneration for Service Service" until the level returns to zero.
2] Stop the engine and wait until the
a When soot accumulation is at level 3 or lower, temperature of piping around the engine
the manual stationary regeneration can be cools down. Remove the KDPF, and then
performed only from "Regeneration for remove the KCSF.
Service". 3] Clean the KCSF by using an ash cleaner,
1) Start the engine. which is equipped at certain workshops.
2) Make sure that machine is in safe condition. (when the removed KCSF is cleaned and
3) From the service menu of the machine reused)
monitor, display the "Diagnostic Tests" 4] Install the cleaned KCSF to the machine.
screen, open "Regeneration for service", and (when the removed KCSF is cleaned and
then perform the "Manual Stationary reused)
Regeneration". 5] Install the replacement KCSF to the
machine (when the KCSF is replaced
a Time required for manual stationary
with a new one).
regeneration depends on the accumulated
6] Turn the starting switch to the ON
soot in KCSF, however, it is estimated as
position. From the KDPF reset screen,
follows.
perform resetting after KDPF cleaning.
• If soot accumulation is level 4: Approx. 40 7] Start the engine and run at low idle to
minutes to 1 hour warm up.
• If soot accumulation is level 5: Approx. 1 to 2 8] Perform regeneration for service.
hours 2) If cracks or damages are found during
• Resetting after KDPF (KCSF) cleaning inspection
PC490LC-10 40-103
40 Troubleshooting
1] Stop the engine and wait until the Case 1-4] From the KDPF reset screen, perform
temperature of piping around the engine resetting after KDPF change.
cools down. Remove the KDPF, and then Case 1-5] Start the engine and run at low idle to
remove the KCSF. warm up.
2] Install the replacement KCSF (new or Case 1-6] Perform Regeneration for Service.
reused) to the machine. (In this case, Regeneration for Service may
3] Turn the starting switch to the ON continue for about 2 hours, since it is set to
position. From the KDPF reset screen, terminate when the soot accumulation drops to 2
perform resetting after KDPF cleaning. g/l.)
4] From the KDPF reset screen, perform Case 1-7] When Regeneration for Service is
resetting after KDPF change. completed, check that failure codes (CA1922,
5] Start the engine and run at low idle to CA1921, and CA2639) are not displayed.
warm up. <Case 2> When Regeneration for Service is
6] Perform regeneration for service. performed (KDPF removal unnecessary)
3) If Soot Level High Error 2 (CA1922) is
a If the following conditions are met, the total
displayed
soot sediment is not beyond the limit (9 g/l),
1] Stop the machine and check that failure but the differential pressure has increased
code (CA1922) is displayed on the due to clogging caused by uneven
machine monitor. accumulation of soot. In this case, actual
2] Check the abnormality record for failure regeneration will not result in abnormal
codes "CA2639: Manual Stationary burning. Regeneration for Service can be
Regeneration Request", "CA1921: KDPF performed safely without replacing the KCSF,
Soot Level High Error 1", and "CA1922: and the KCSF can be continuously used
KDPF Soot Level High Error 2"on the after the regeneration.
machine monitor.
• After checking that no sensor related failures
<Case 1> When KDPF is removed and KCSF is
are present, perform this work if any of the
replaced
following is met.
a If the following conditions are met, soot • Time between activation of "CA2639: Manual
accumulation is beyond the limit to burn Stationary Regeneration Request (L01)" and
away by regeneration. The KDPF must be "CA1921: KDPF Soot Level High Error 1
removed to change the KCSF. (L03)" < 360 sec. (KOMTRAX history) or <
• Time between activation of "CA2639: Manual 0.1 h (Abnormality record screen on monitor)
Stationary Regeneration Request (L01)" and • "Time between activation of "CA1921: KDPF
"CA1921: KDPF Soot Level High Error 1 Soot Level High Error 1 (L03)" and "CA1922:
(L03)" X 360 sec. (KOMTRAX history) or X KDPF Soot Level High Error 2 (L04)" <
0.1 h (Abnormality record screen on monitor) 360sec. (KOMTRAX history) or < 0.1 h
and (Abnormality record screen on monitor)
• Time between activation of "CA1921: KDPF [Contents of work]
Soot Level High Error 1 (L03)" and "CA1922: Case 2-1] Start the engine and run at low idle to
KDPF Soot Level High Error 2 (L04)" X360 warm up. From the KDPF reset screen, perform
sec. (KOMTRAX history) or X 0.1 h resetting after KDPF cleaning.
(Abnormality record screen on monitor) Case 2-2] Perform Regeneration for Service.
[Contents of work] (In this case, Regeneration for Service may
Case 1-1] Stop the engine and wait until the continue for about 2 hours, since it is set to
temperature of piping around the engine cools terminate when the soot accumulation drops to 2
down, then remove KCSF. g/l.)
Case 1-2] Install the replacement KCSF (new or Case 2-3] When Regeneration for Service is
reused). completed, check that failure codes (CA1922,
Case 1-3] Turn the starting switch to the ON CA1921, and CA2639) are not displayed.
position. From the KDPF reset screen, perform 3. When cleaning and replacing KDOC
resetting after KDPF cleaning. 1) If cracks or damages are found during
inspection
a When resetting after KDPF cleaning is
performed, changes in ( ) are reflected. 1] If cracks or damages are found in the
(Soot accumulation amount: 9 g/lo8.1 g/l; KDOC, replace it with a new one.
Action level: L04oL03; Failure code: 2] From the KDPF reset screen, perform
CA1922oCA1921) resetting after KDOC change.
40-104 PC490LC-10
40 Troubleshooting
2) When Regeneration Ineffective (CA1691) is

displayed
1] Stop the machine and check that failure
code (CA1691) is displayed on the
machine monitor.
(CA2637 may be displayed at the same
time.)
2] Check the exhaust gas color.
3] With CA1691 displayed, perform
Regeneration for Service for 40 minutes.
(Since this is done for drying the KDOC,
fuel is not injected during the
regeneration)
4] Stop the engine and wait until the
temperature of piping around the engine
cools down. Remove the KDOC and
check it for cracks or damages.
<Case 1> If cracks or damages are found in
KDOC
Case 1-1] Replace KDOC with a new one.
Case 1-2] From the KDPF reset screen,
perform resetting after KDOC change.
<Case 2> If cracks or damages are not found
in KDOC
Case 2-1] Clean KDOC and reinstall it.
Case 2-2] From the KDPF reset screen,
perform resetting after KDOC cleaning.
Case 2-3] Perform Regeneration for Service
twice for 40 minutes each. (Fuel is injected
during regeneration)
*When performing Regeneration for Service
several times, stop the engine each time
before repeating the regeneration.
Case 2-4] If failure code "CA2637: KDOC
Face Plugging" is displayed after
Regeneration for Service is completed, the
catalyst performance of KDOC is
deteriorated. Replace KDOC with a new one.
PC490LC-10 40-105
40 Troubleshooting
Preparation of dummy temperature sensor (for KDOC and KDPF

temperature sensors) (HM300-A9J2-304-K-00-A)
• It is included in kit part number: 799-A65-4600.
• This dummy temperature sensor is used for KDPF related failure codes.
• Remove KDPF temperature sensor consolidating box which is installed to KDPF and install a dummy
temperature sensor instead. Dummy temperature sensor simulates the temperatures at KDOC inlet,
KDOC outlet, and KDPF outlet to approximately 560°C to 590°C by only setting the starting switch to ON
position in order to reduce stresses applied to engine and machine.
• Dummy temperature sensor
40-106 PC490LC-10
40 Troubleshooting
Preparation of short circuit electrical connector (for failure codes

[CA1883] and [CA3135]) (HM300-A9J2-304-K-01-A)
a The connector of KDPF differential pressure sensor is the same as that of KDPF outlet pressure sensor.
• It is included in the kit part number: 799-A65-4600.
• Short socket adapter for KDPF differential pressure sensor used for failure code [CA1883].
• Short socket adapter for KDPF outlet pressure sensor used for failure code [CA3135].
PC490LC-10 40-107
40 Troubleshooting
Failure codes table (PC400-5520-441-A-00-A)
Failure Applicable Action Category of

Failure (Displayed on screen) Remarks
code component level history
Failure code [879AKA] A/C Inner Sensor Open Electrical See Chapter
879AKA Circuit(PAGE 40-117) MON —
system 80, Appendix
Failure code [879AKB] A/C Inner Sensor Short Electrical See Chapter
879AKB Circuit(PAGE 40-118) MON —
system 80, Appendix
Failure code [879BKA] A/C Outer Sensor Electrical See Chapter
879BKA Open Circuit(PAGE 40-119) MON —
system 80, Appendix
Failure code [879BKB] A/C Outer Sensor Electrical See Chapter
879BKB Short Circuit(PAGE 40-120) MON —
system 80, Appendix
Failure code [879CKA] Ventilating Sensor Electrical See Chapter
879CKA Open Circuit(PAGE 40-121) MON —
system 80, Appendix
Failure code [879CKB] Ventilating Sensor Electrical See Chapter
879CKB Short Circuit(PAGE 40-122) MON —
system 80, Appendix
Failure code [879DKZ] Sunlight Sensor Open Electrical See Chapter
879DKZ Or Short Circuit(PAGE 40-123) MON —
system 80, Appendix
Failure code [879EMC] Ventilation Damper Electrical See Chapter
879EMC Abnormality(PAGE 40-124) MON L01 system 80, Appendix
Failure code [879FMC] Air Mix Damper Electrical See Chapter
879FMC Abnormality(PAGE 40-125) MON L01 system 80, Appendix
Failure code [879GKX] Refrigerant Electrical See Chapter
879GKX Abnormality(PAGE 40-126) MON L01 system 80, Appendix
Failure code [989L00] Engine Controller Lock Electrical
989L00 Caution 1(PAGE 40-127) MON —
system
Failure code [989M00] Engine Controller Lock Electrical
989M00 Caution 2(PAGE 40-128) MON —
system
Failure code [989N00] Engine Controller Lock Electrical
989N00 Caution 3(PAGE 40-129) MON —
system
Failure code [A1U0N3] HC Desorb Request 1 Electrical
A1U0N3 (PAGE 40-130) ENG L01 system
Failure code [A1U0N4] HC Desorb Request 2 Electrical
A1U0N4 (PAGE 40-132) ENG L03 system
Failure code [AA10NX] Air Cleaner Clogging Mechanical
AA10NX (PAGE 40-134) MON L01 system
Failure code [AB00KE] Charge Voltage Low Mechanical
AB00KE (PAGE 40-136) MON L03 system
Failure code [B@BAZG] Eng Oil Press Low Mechanical
B@BAZG ENG L03
(PAGE 40-138) system
Failure code [B@BAZK] Eng Oil Level Low Mechanical
B@BAZK MON L01
Failure code [B@BCNS] Eng Water Overheat Mechanical
B@BCNS ENG L02
Failure code [B@BCZK] Eng Water Level Low Mechanical
B@BCZK MON L01
Failure code [B@HANS] Hyd Oil Overheat Mechanical
B@HANS PUMP L02
Failure code [CA115] Eng Ne and Bkup Speed Electrical
CA115 Sens Error(PAGE 40-144) ENG L04 system
Failure code [CA122] Chg Air Press Sensor Electrical
CA122 High Error(PAGE 40-145) ENG L03 system
Failure code [CA123] Chg Air Press Sensor Electrical
CA123 Low Error(PAGE 40-147) ENG L03 system
Failure code [CA131] Throttle Sensor High Electrical
CA131 Error(PAGE 40-149) ENG L03 system
Failure code [CA132] Throttle Sensor Low Electrical
40-108 PC490LC-10
40 Troubleshooting

Failure code [CA135] Eng Oil Press Sensor Electrical
Failure code [CA141] Eng Oil Press Sensor Electrical
Failure code [CA144] Coolant Temp Sens High Electrical
Failure code [CA145] Coolant Temp Sens Low Electrical
Failure code [CA153] Chg Air Temp Sensor Electrical
Failure code [CA154] Chg Air Temp Sensor Electrical
Failure code [CA187] Sensor 2 Supply Volt Electrical
Failure code [CA221] Ambient Press Sensor Electrical
Failure code [CA222] Ambient Press Sensor Electrical
Failure code [CA234] Eng Overspeed(PAGE Mechanical
CA234 40-172) ENG L02 system
Failure code [CA238] Ne Speed Sensor Electrical
CA238 Supply Volt Error(PAGE 40-173) ENG L01 system
Failure code [CA239] Ne Speed Sens Supply Electrical
CA239 Volt High Error(PAGE 40-174) ENG L01 system
Failure code [CA271] IMV/PCV1 Short Error Electrical
CA271 (PAGE 40-175) ENG L03 system
Failure code [CA272] IMV/PCV1 Open Error Electrical
Failure code [CA273] PCV2 Short Error(PAGE Electrical
Failure code [CA274] PCV2 Open Error(PAGE Electrical
Failure code [CA322] Inj #1(L#1) Open/Short Electrical
Failure code [CA343] ECM Critical Internal Electrical
CA343 Failure(PAGE 40-191) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
Failure code [CA356] Mass Air Flow Sensor Electrical
PC490LC-10 40-109
40 Troubleshooting

Failure code [CA441] Battery Voltage Low Electrical
Failure code [CA442] Battery Voltage High Electrical
Failure code [CA449] Rail Press Very High Electrical
Failure code [CA451] Rail Press Sensor High Electrical
Failure code [CA452] Rail Press Sensor Low Electrical
Failure code [CA515] Rail Press Sens Sup Electrical
CA515 Volt High Error(PAGE 40-208) ENG L03 system
Failure code [CA516] Rail Press Sens Sup Electrical
CA516 Volt Low Error(PAGE 40-210) ENG L03 system
Failure code [CA553] Rail Press High Error Electrical
Failure code [CA555] Crankcase Press High Electrical
CA555 Error 1(PAGE 40-213) ENG L01 system
Failure code [CA556] Crankcase Press High Electrical
Failure code [CA559] Rail Press Low Error Electrical
Failure code [CA595] Turbo Speed High Error Electrical
CA595 2(PAGE 40-219) ENG L01 system
Failure code [CA687] Turbo Speed Low Error Electrical
Failure code [CA689] Eng Ne Speed Sensor Electrical
Failure code [CA691] Intake Temperature Electrical
CA691 Sensor High Error(PAGE 40-224) ENG L01 system
Failure code [CA692] Intake Temperature Electrical
CA692 Sensor Low Error(PAGE 40-226) ENG L01 system
Failure code [CA697] ECM Internal Temp Electrical
Failure code [CA698] ECM Int Temp Sensor Electrical
Failure code [CA731] Eng Bkup Speed Sens Electrical
CA731 Phase Error(PAGE 40-230) ENG L01 system
Failure code [CA778] Eng Bkup Speed Sensor Electrical
Failure code [CA1117] Persistent Data Lost Electrical
Failure code [CA1664] KDOC Malfunction Electrical
Failure code [CA1691] Regeneration Electrical
CA1691 Ineffective(PAGE 40-237) ENG L03 system
Failure code [CA1695] Sens supply 5 volt high Electrical
CA1695 error(PAGE 40-240) ENG L03 system
Failure code [CA1696] Sens supply 5 volt low Electrical
CA1696 error(PAGE 40-241) ENG L03 system
Failure code [CA1843] Crankcase Pressure Electrical
Failure code [CA1844] Crankcase Press Electrical
40-110 PC490LC-10
40 Troubleshooting

Failure code [CA1879] KDPF Delta Pressure Electrical
CA1883 Sensor In Range Error(PAGE 40-251) ENG L03 system
Failure code [CA1921] KDPF Soot Load High Electrical
Failure code [CA1922] KDPF Soot Load High Electrical
Failure code [CA1923] Dosing Fuel Valve 1 Electrical
Failure code [CA1925] Dosing Fuel Valve 1 In Electrical
CA1925 Range Error(PAGE 40-266) ENG L03 system
Failure code [CA1927] Dosing Fuel Press Electrical
CA1927 Sens High Error(PAGE 40-268) ENG L01 system
Failure code [CA1928] Dosing Fuel Press Electrical
CA1928 Sens Low Error(PAGE 40-270) ENG L01 system
Failure code [CA1942] Crankcase Press Sens Electrical
CA1942 In Range Error(PAGE 40-272) ENG L01 system
CA1963 Servo Error(PAGE 40-273) ENG L03 system
Failure code [CA1977] Fuel Doser Open/Short Electrical
Failure code [CA2185] Throt Sensor Sup Volt Electrical
Failure code [CA2186] Throt Sensor Sup Volt Electrical
Failure code [CA2249] Rail Press Very Low Electrical
Failure code [CA2265] Fuel feed pump open Electrical
CA2265 circuit error(PAGE 40-285) ENG L01 system
Failure code [CA2266] Fuel feed pump short Electrical
CA2266 circuit error(PAGE 40-287) ENG L01 system
Failure code [CA2271] EGR Valve Pos Sens Electrical
Failure code [CA2272] EGR Valve Pos Sens Electrical
Failure code [CA2349] EGR Valve Solenoid Electrical
CA2349 Open Error(PAGE 40-293) ENG L03 system
Failure code [CA2353] EGR Valve Solenoid Electrical
CA2353 Short Error(PAGE 40-295) ENG L03 system
Failure code [CA2357] EGR Valve Servo Error Electrical
Failure code [CA2381] KVGT Pos Sens High Electrical
Failure code [CA2382] KVGT Pos Sens Low Electrical
Failure code [CA2383] KVGT Solenoid Open Electrical
Failure code [CA2386] KVGT Solenoid Short Electrical
PC490LC-10 40-111
40 Troubleshooting

Failure code [CA2387] KVGT Servo Error Electrical
Failure code [CA2555] Grid Htr Relay Open Electrical
CA2555 Circuit Error(PAGE 40-307) ENG L01 system
Failure code [CA2556] Grid Htr Relay Short Electrical
CA2556 Circuit Error(PAGE 40-309) ENG L01 system
Failure code [CA2637] KDOC Face Plugging Electrical
Failure code [CA2639] Manual Stationary Electrical
CA2639 Regeneration Request(PAGE 40-313) ENG L01 system
Failure code [CA2741] Dosing Fuel Valve Electrical
CA2741 Swap Error(PAGE 40-320) ENG L03 system
Failure code [CA2765] Inj Trim Data Error Electrical
CA2878 Servo Error(PAGE 40-322) ENG L03 system
Failure code [CA2881] Dosing Fuel Pressure Electrical
CA2881 Low Error 1(PAGE 40-325) ENG L03 system
Failure code [CA3133] KDPF Outlet Pressure Electrical
Failure code [CA3167] Fuel Doser Electrical
CA3167 Degradation(PAGE 40-338) ENG —
system
Failure code [CA3251] KDOC Inlet Electrical
CA3251 Temperature High Error(PAGE 40-341) ENG L03 system
Failure code [CA3253] KDOC Temp Error - Electrical
CA3253 Non Regeneration(PAGE 40-344) ENG L03 system
Failure code [CA3254] KDOC Outlet Temp Electrical
CA3254 High Error 1(PAGE 40-347) ENG L01 system
Failure code [CA3255] KDPF Temp Error - Electrical
CA3255 Non Regeneration(PAGE 40-350) ENG L03 system
Failure code [CA3256] KDPF Outlet Temp Electrical
CA3313 Temperature Sensor Low Error(PAGE 40-363) ENG L03 system
CA3314 Temperature Sensor High Error(PAGE 40-366) ENG L03 system
Failure code [CA3315] KDOC Intlet
Electrical
CA3315 Temperature Sensor In Range Error(PAGE 40- ENG L03 system
370)
Failure code [CA3316] KDOC Outlet Electrical
Failure code [CA3317] KDOC Outlet Electrical
40-112 PC490LC-10
40 Troubleshooting

Failure code [CA3319] KDPF Outlet Electrical
Failure code [CA3321] KDPF Outlet Electrical
CA3419 Power Supply High Error(PAGE 40-399) ENG L03 system
CA3421 Power Supply Low Error(PAGE 40-401) ENG L03 system
Failure code [D110KB] Battery Relay Drive S/ Electrical
D110KB C(PAGE 40-403) ENG L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Abnormality(PAGE 40-405) MON L03 system
Failure code [D811MC] KOMTRAX Error Electrical
D811MC (PAGE 40-408) KOMTRAX —
system
Failure code [D862KA] GPS Antenna Open Electrical
D862KA Circuit(PAGE 40-409) KOMTRAX —
system
Failure code [D8ALKA] Operating Lamp Open Electrical
D8ALKA Circuit (KOMTRAX)(PAGE 40-410) KOMTRAX —
system
Failure code [D8ALKB] Operating Lamp Short Electrical
D8ALKB Circuit (KOMTRAX)(PAGE 40-412) KOMTRAX —
system
Failure code [D8AQKR] CAN2 Discon Electrical
D8AQKR (KOMTRAX)(PAGE 40-413) MON —
system
Failure code [DA20MC] Pump Controller Electrical
DA20MC Malfunction(PAGE 40-414) PUMP —
system
Failure code [DA22KK] Pump Solenoid Power Electrical
DA22KK Low Error(PAGE 40-415) PUMP L03 system
Failure code [DA25KP] 5V Sensor1 Power Electrical
DA25KP Abnormality(PAGE 40-417) PUMP —
system
Failure code [DA29KQ] Model Selection Electrical
DA29KQ Abnormality(PAGE 40-419) PUMP L01 system
Failure code [DA2LKA] Operating Lamp Open Electrical
DA2LKA Circuit (Pump Con)(PAGE 40-422) PUMP —
system
Failure code [DA2LKB] Operating Lamp Short Electrical
DA2LKB Circuit (Pump Con)(PAGE 40-424) PUMP —
system
Failure code [DA2QKR] CAN2 Discon (Pump Electrical
DA2QKR Con)(PAGE 40-425) MON L03 system
Failure code [DA2RKR] CAN1 Discon ( Pump Electrical
DA2RKR Con)(PAGE 40-428) MON L04 system
Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB Abnormality(PAGE 40-429) MON —
system
Failure code [DAF0MC] Monitor Error(PAGE Electrical
DAF0MC 40-430) MON —
system
Failure code [DAF8KB] Camera Power Supply Electrical
DAF8KB Short Circuit(PAGE 40-431) MON L03 system
Failure code [DAF9KQ] Model Selection Electrical
DAF9KQ Abnormality(PAGE 40-433) MON L03 system
Failure code [DAFGMC] GPS Module Error Electrical
DAFGMC (PAGE 40-434) KOMTRAX —
system
Failure code [DAFLKA] Operating Lamp Open Electrical
DAFLKA Circuit (Monitor)(PAGE 40-435) MON —
system
Failure code [DAFLKB] Operating Lamp Short Electrical
DAFLKB Circuit (Monitor)(PAGE 40-437) MON —
system
PC490LC-10 40-113
40 Troubleshooting

Failure code [DAFQKR] CAN2 Discon Electrical
DAFQKR (Monitor)(PAGE 40-438) KOMTRAX —
system
Failure code [DAZ9KQ] AC Model Selection Electrical
DAZ9KQ Abnormality(PAGE 40-439) MON —
system
Failure code [DAZQKR] CAN2 Discon (AC) Electrical
DAZQKR (PAGE 40-440) MON L01 system
Failure code [DB2QKR] CAN2 Discon (Engine Electrical
DB2QKR Con)(PAGE 40-445) MON L03 system
Failure code [DB2RKR] CAN1 Discon (Engine Electrical
DB2RKR Con)(PAGE 40-450) MON L04 system
Failure code [DGH2KA] Hyd Oil Temp Sensor Electrical
DGH2KA Open(PAGE 40-455) PUMP L01 system
Failure code [DGH2KB] Hyd Oil Sensor Short Electrical
DGH2KB Circuit(PAGE 40-457) PUMP L01 system
Failure code [DHA4KA] Air Cleaner Clogging Electrical
DHA4KA Sensor Open Circuit(PAGE 40-459) MON L01 system
Failure code [DHPAMA] Pump Press Sensor Electrical
DHPAMA Abnormality(PAGE 40-461) PUMP L01 system
Failure code [DHPBMA] R Pump Press Electrical
DHPBMA Sensor Abnormality(PAGE 40-464) PUMP L01 system
Failure code [DHS3MA] Arm IN PPC Sen. Electrical
DHS3MA Abnormality(PAGE 40-467) PUMP L01 system
Failure code [DHS4MA] Bucket CURL PPC Electrical
DHS4MA Press Sensor Abnormality(PAGE 40-469) PUMP L01 system
Failure code [DHS8MA] Boom RAISE PPC Electrical
DHS8MA Press Sensor Abnormality(PAGE 40-472) PUMP L01 system
Failure code [DHS9MA] Boom LOWER Press Electrical
DHS9MA Sensor Abnormality(PAGE 40-475) PUMP L01 system
Failure code [DHSAMA] Swing RH PPC Press Electrical
DHSAMA Sensor Abnomality(PAGE 40-478) PUMP L01 system
Failure code [DHSBMA] Swing LH PPC Press Electrical
DHSBMA Sensor Abnomality(PAGE 40-481) PUMP L01 system
Failure code [DHSCMA] Arm OUT PPC Press Electrical
DHSCMA Sensor Abnormality(PAGE 40-484) PUMP L01 system
Failure code [DHSDMA] Bucket Dump PPC Electrical
DHSDMA Press Sensor Abnormality(PAGE 40-487) PUMP L01 system
Failure code [DHSFMA] Travel FW L PPC Electrical
DHSFMA Press Sensor Abnormality(PAGE 40-490) PUMP L01 system
Failure code [DHSGMA] Travel FW R PPC Electrical
DHSGMA Press Sensor Abnormality(PAGE 40-493) PUMP L01 system
Failure code [DHSHMA] Travel BW L PPC Electrical
DHSHMA Press Sensor Abnormality(PAGE 40-496) PUMP L01 system
Failure code [DHSJMA] Travel BW R PPC Electrical
DHSJMA Press Sensor Abnormality(PAGE 40-499) PUMP L01 system
Failure code [DKR0MA] F pump S/P sensor Electrical
DKR0MA Abnormality(PAGE 40-502) PUMP L01 system
Failure code [DKR1MA] R pump S/P sensor Electrical
DKR1MA Abnormality(PAGE 40-504) PUMP L01 system
Failure code [DLM3KA] Fan speed sensor: Electrical
DLM3KA Open circuit(PAGE 40-506) PUMP L01 system
Failure code [DLM3KB] Fan Speed Sensor Electrical
DLM3KB Short Circuit(PAGE 40-507) PUMP L01 system
Failure code [DLM3MB] Fan Control Mismatch Electrical
DLM3MB (PAGE 40-508) PUMP L01 system
Failure code [DR21KX] Camera 2 Picture Rev. Electrical
DR21KX Drive Abnormality(PAGE 40-509) PUMP L01 system
40-114 PC490LC-10
40 Troubleshooting

Failure code [DR31KX] Camera 3 Picture Rev. Electrical
DR31KX Drive Abnormality(PAGE 40-511) PUMP L01 system
Failure code [DV20KB] Travel Alarm Short Electrical
DV20KB Circuit(PAGE 40-513) PUMP L01 system
Failure code [DW43KA] Travel Speed Sol Electrical
DW43KA Open Circuit(PAGE 40-515) PUMP L01 system
Failure code [DW43KB] Travel Speed Sol Electrical
DW43KB Short Circuit(PAGE 40-517) PUMP L01 system
Failure code [DW45KA] Swing Brake Sol Electrical
Failure code [DW45KB] Swing Brake Sol Short Electrical
DW45KB Circuit(PAGE 40-522) PUMP L03 system
Failure code [DW7BKA] Fan Reverse Sol Electrical
DW7BKA Open Circuit(PAGE 40-524) PUMP L01 system
Failure code [DW7BKB] Fan Reverse Sol Electrical
DW7BKB Short Circuit(PAGE 40-526) PUMP L01 system
Failure code [DW91KA] Travel Junction Sol Electrical
Failure code [DW91KB] Travel Junction Sol Electrical
DW91KB Short Circuit(PAGE 40-530) PUMP L01 system
Failure code [DWA2KA] Attachment Sol Open Electrical
DWA2KA Circuit(PAGE 40-532) PUMP L03 system
Failure code [DWA2KB] Attachment Sol Short Electrical
DWA2KB Circuit(PAGE 40-534) PUMP L03 system
Failure code [DWK0KA] 2-stage Relief Sol Electrical
DWK0KA Open Circuit(PAGE 40-536) PUMP L01 system
Failure code [DWK0KB] 2-stage Relief Sol Electrical
DWK0KB Short Circuit(PAGE 40-538) PUMP L01 system
Failure code [DWK2KA] Variable Back Electrical
DWK2KA Pressure Sol Open Circuit(PAGE 40-540) PUMP L01 system
Failure code [DWK2KB] Variable Back Electrical
DWK2KB Pressure Sol Short Circuit(PAGE 40-542) PUMP L01 system
Failure code [DWK8KA] Swing C/O Solenoid Electrical
DWK8KA Open Circuit(PAGE 40-544) PUMP L01 system
Failure code [DWK8KB] Swing C/O Solenoid Electrical
DWK8KB Short Circuit(PAGE 40-546) PUMP L01 system
Failure code [DX16KA] Fan Pump EPC Sol Electrical
DX16KA Open Circuit(PAGE 40-548) PUMP L03 system
Failure code [DX16KB] Fan Pump EPC Sol Electrical
DX16KB Short Circuit(PAGE 40-550) PUMP L03 system
Failure code [DXA8KA] PC-EPC (F) Sol Open Electrical
DXA8KA Circuit(PAGE 40-552) PUMP L03 system
Failure code [DXA8KB] PC-EPC (F) Sol Short Electrical
DXA8KB Circuit(PAGE 40-554) PUMP L03 system
Failure code [DXA9KA] PC-EPC (R) Sol Open Electrical
DXA9KA Circuit(PAGE 40-556) PUMP L03 system
Failure code [DXA9KB] PC-EPC (R) Sol Short Electrical
DXA9KB Circuit(PAGE 40-558) PUMP L03 system
Failure code [DXE0KA] LS-EPC Sol Open Electrical
DXE0KA Circuit(PAGE 40-560) PUMP L01 system
Failure code [DXE0KB] LS-EPC Sol Short Electrical
DXE0KB Circuit(PAGE 40-562) PUMP L01 system
Failure code [DXE4KA] Service Current EPC Electrical
DXE4KA Disc.(PAGE 40-564) PUMP —
system
Failure code [DXE4KB] Service Current EPC Electrical
DXE4KB S/C(PAGE 40-565) PUMP —
system
PC490LC-10 40-115
40 Troubleshooting

Failure code [DXE5KA] Merge-divider Main Electrical
DXE5KA Sol Open Circuit(PAGE 40-566) PUMP L01 system
Failure code [DXE5KB] Merge-divider Main Electrical
DXE5KB Sol Short Circuit(PAGE 40-568) PUMP L01 system
Failure code [DXE6KA] Merge-divider LS Sol Electrical
DXE6KA Open Circuit(PAGE 40-570) PUMP L01 system
Failure code [DXE6KB] Merge-divider LS Sol Electrical
DXE6KB Short Circuit(PAGE 40-572) PUMP L01 system
Failure code [DY20KA] Wiper Working Electrical
DY20KA Abnormality(PAGE 40-574) PUMP —
system
Failure code [DY20MA] Wiper Parking Electrical
DY20MA Abnormality(PAGE 40-576) PUMP —
system
Failure code [DY2CKB] Washer Drive Short Electrical
DY2CKB Circuit(PAGE 40-578) PUMP —
system
Failure code [DY2DKB] Wiper Drive (For) Electrical
DY2DKB Short(PAGE 40-580) PUMP —
system
Failure code [DY2EKB] Wiper Drive (Rev) Electrical
DY2EKB Short(PAGE 40-582) PUMP —
system
a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
a A component in charge means a controller or the machine monitor that is in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action code columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The "Category of record" shows the abnormality record into which the failure is classified, the electrical
system or mechanical system, when it is recorded in the abnormality record of the service menu.
For details, see "Troubleshooting by failure code (Display of code)".
40-116 PC490LC-10
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Troubleshooting by failure code (Display of code) (ALL-3840-001-A-00-A)
Failure code [879AKA] A/C Inner Sensor Open Circuit (PC400-879AKA-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879AKA] Air Conditioner Inner Sensor Open Circuit"
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
PC490LC-10 40-117
40 Troubleshooting
Failure code [879AKB] A/C Inner Sensor Short Circuit (PC400-879AKB-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879AKB] Air Conditioner Inner Sensor Short Circuit" .
a Since the inner air temperature sensor connector cannot be disconnected with the sensor installed on the
machine, the air conditioner controller or air conditioner unit must be replaced.
40-118 PC490LC-10
40 Troubleshooting
Failure code [879BKA] A/C Outer Sensor Open Circuit (PC400-879BKA-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879BKA] Air Conditioner Outer Sensor Open Circuit" .
PC490LC-10 40-119
40 Troubleshooting
Failure code [879BKB] A/C Outer Sensor Short Circuit (PC400-879BKB-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879BKB] Air Conditioner Outer Sensor Short Circuit" .
40-120 PC490LC-10
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Open Circuit (PC400-879CKA-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879CKA] Ventilating Sensor Open Circuit"
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
PC490LC-10 40-121
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit (PC400-879CKB-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879CKB] Ventilating Sensor Short Circuit"
a Since the ventilating sensor (evaporator temperature sensor) cannot be disconnected with the sensor
installed on the machine, the air conditioner controller or air conditioner unit must be replaced.
40-122 PC490LC-10
40 Troubleshooting
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit (PC400-879DKZ-441-

A-Z0-A)
See chapter 80 Appendix "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit".
PC490LC-10 40-123
40 Troubleshooting
Failure code [879EMC] Ventilation Damper Abnormality (PC400-879EMC-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879EMC] Ventilation Damper Abnormality".

a Since the vent select servo motor cannot be disconnected on the machine, the air conditioner controller or
air conditioner unit must be replaced.
40-124 PC490LC-10
40 Troubleshooting
Failure code [879FMC] Air Mix Damper Abnormality (PC400-879FMC-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879FMC] Air Mix Damper Abnormality".
a Since the air mix servo motor connector cannot be disconnected on the machine, the air conditioner
controller or air conditioner unit must be replaced.
PC490LC-10 40-125
40 Troubleshooting
Failure code [879GKX] Refrigerant Abnormality (PC400-879GKX-441-A-Z0-A)
See chapter 80 Appendix "Failure code [879GKX] Refrigerant Abnormality".
40-126 PC490LC-10
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution 1 (PC400-989L00-400-A-Z0-A)
Action level Failure code Engine Controller Lock Caution 1

Failure
– 989L00 (Machine monitor system)
Detail of • Engine controller lock up is detected (Factor 1).
failure
Action of • None in particular
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to one before replacement.
information • Method of reproducing failure code: Turn starting switch to ON position.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
PC490LC-10 40-127
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution 2 (PC400-989M00-400-A-Z0-A)

Failure
– 989M00 (Machine monitor system)
failure
monitor
Problem on • Engine cannot be started.
machine
• If this failure code is generated after machine monitor is replaced, user password must be
Related changed to one before replacement.
Replacement of machine This problem may be caused by replacement of machine monitor.
1
monitor
If this failure code is displayed while machine monitor is not replaced,
2 Defective machine monitor machine monitor may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
40-128 PC490LC-10
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution 3 (PC400-989N00-400-A-Z0-A)

Failure
– 989N00 (Machine monitor system)
failure
Action of • Tries automatic recovery.
monitor
Problem on
machine
Related • Method of reproducing failure code: Failure code cannot be reproduced since machine
information recovers when cause of failure disappears.
If this failure code is generated repeatedly, engine controller may be
1 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
PC490LC-10 40-129
40 Troubleshooting
Failure code [A1U0N3] HC Desorb Request 1 (PC400-A1U0N3-400-A-Z0-A)
Action level Failure code HC Desorb Request 1

Failure
L01 A1U0N3 (Engine controller system)
Detail of • Unburned fuel remains in KDPF because engine has been run at low idle or with low load
failure for a long time.
Action of • Requests manual stationary regeneration (fuel drying) to operator.
controller a Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
Related engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
information and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationery regeneration) is performed due to guidance
of monitor displaying failure code [A1U0N3] or [A1U0N4], fuel dosing is disabled.
Accordingly, each temperature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to
approximately 250 to 400 °C.
• When active regeneration (manual stationary regeneration) except above is in progress,
KDOC inlet temperature is approximately 250 to 400 °C, and KDOC outlet temperature
and KDPF outlet temperature are approximately 450 to 550 °C.
• If KDOC inlet temperature differs noticeably from KDOC outlet temperature when KDPF is
completely cool or engine running at idle (non-regeneration), replace KDOC inlet
temperature sensor or KDOC outlet temperature sensor, whichever is suspected to be
abnormal, judging by KDPF outlet temperature reading.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
• Method of reproducing failure code: Turn starting switch to ON position.
Performing manual stationary 1. Perform manual stationary regeneration by following instructions of
regeneration monitor.
1
If this failure code is cleared after regeneration is performed, repair is
(to dry KDPF)
complete.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
2 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is also displayed,
3 temperature sensor perform troubleshooting for [CA3313], [CA3314], or [CA3315].
40-130 PC490LC-10
40 Troubleshooting

1. Turn starting switch to ON position.
4 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
a Turn starting switch to ON position and check that this failure code is not displayed.
PC490LC-10 40-131
40 Troubleshooting
Failure code [A1U0N4] HC Desorb Request 2 (PC400-A1U0N4-400-A-Z0-A)
Action level Failure code HC Desorb Request 2

Failure
L03 A1U0N4 (Engine controller system)
Detail of • Unburned fuel remains in KCSF because engine has been run at low idle or low load for a
failure long time.
Action of Requests manual stationary regeneration (fuel drying) to operator.
controller Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)
k Since the temperature of the KDPF and KDOC will become higher than 500 °C , take
care not to get burn injury.
function. (Code: 47301(V))
function. (Code: 47300 (°C ))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
engine running at idle (without regenerating) are all approximately 100 to 250 °C and
temperature differences among them are approximately 10 °C (KDOC inlet
Related temperature>KDOC outlet temperature>KDPF outlet temperature).
information • When manual stationary regeneration is performed as an action taken for A1U0N3 or
A1U0N4, dosing fuel is not injected. Therefore, KDOC inlet, KDOC outlet, and KDPF
outlet temperatures will be around 250 to 400 °C .
• In other cases than the above, when active regeneration (manual stationary regeneration)
is in progress, the KDOC inlet temperature will be approximately 250 to 400 °C , and the
KDOC outlet temperature and KDPF outlet temperature will both be approximately 450 to
550 °C .
• It takes approximately 40 minutes to perform active regeneration (manual stationary
regeneration).
• If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
"TEMP3").
1. Perform manual stationary regeneration by following the instructions
Performing manual stationary on the monitor.
1
regeneration (to dry KCSF) If this failure code is cleared after regeneration is performed, repair is
complete.
Defective wiring harness information on troubleshooting", and check it.
2 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
40-132 PC490LC-10
40 Troubleshooting

Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
3 temperature sensor troubleshooting for it.
a Turn the starting switch ON and make sure that this failure code and code [A1U0N3] are not displayed.
PC490LC-10 40-133
40 Troubleshooting
Failure code [AA10NX] Air Cleaner Clogging (PC400-AA10NX-400-A-Z0-A)
Action level Failure code Air cleaner clogging

Failure
L01 AA10NX (Machine monitor system)
Detail of • Air cleaner clogging switch signal voltage was not 1 V or less while engine was running,
failure and machine monitor detected clogging of air cleaner (open of switch contacts).
Action of • Displays air cleaner clogging monitor in yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may be damaged.
machine
• Input state (ON/OFF) from air cleaner clogging switch can be checked by using
Related monitoring function. (Code 04501 "Monitor Input 2")
information • Method of reproducing failure code: Start engine.
Clogged air cleaner
Air cleaner may be clogged. Check it for clogging and then clean or replace if
1 (when system is
clogged.
normal)
1. Turn starting switch to OFF position.
2. Disconnect connector P23 and connect T-adapter to male side.
Defective air cleaner 3. Start engine
2 clogging switch (Internal When air cleaner is
open circuit) Max. 1 z
Between P23 (male) (1) normal *1
Resistance and (2) When air cleaner is
clogged *2 Min. 1 Mz
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors CM02 and P23, and connect T-adapters to each
3 (wire breakage or female side.
defective contact of Between CM02 (female) (4) and P23 (female) (1) Max. 1 z
connector) Resistance
Between P23 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine
Defective machine
4 When air cleaner is
monitor Max. 1 V
Between CM02 (4) and normal
Voltage
CM01 (3) When air cleaner is
clogged Min. 10 V
• Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
40-134 PC490LC-10
40 Troubleshooting
Circuit diagram related to air cleaner clogging
PC490LC-10 40-135
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low (PC400-AB00KE-400-A-Z0-A)
Action level Failure code Charging voltage low

Failure
L03 AB00KE (Machine monitor system)
Detail of • While engine is running, voltage from alternator drops, and machine monitor detects that
failure battery charge voltage is low (below 7.8 V).
Action of • Displays charge level monitor red on machine monitor.
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • If machine is operated as it is, battery may not be charged.
machine
• Signal voltage from alternator can be checked with monitoring function.
Related (Code: 04300 Charge voltage)
Loose alternator terminal or 1.Turn starting switch to OFF position.
1 open circuit at terminal 2.Check terminal.
1.Turn starting switch to OFF position.
Defective generation by 2.Insert T-adapters into connector M17.
2 alternator 3.Start engine
(when system is normal) Between M17 (2) Engine speed: Medium 27.5 to 29.5
Voltage
and ground or higher V
2. Disconnect diode D01 and connect T-adapter to male side.
3 Defective diode a Check by using multimeter in diode range.
Between D01 (male) (2) (+) and (6) (-) No continuity
Continuity
Between D01 (male) (6) (+) and (2) (-) Continuity
Defective wiring harness or 2. Insert T-adapters into connector CM01.
4 3. Start engine
machine monitor
Voltage Between CM01 (16) and ground 20 to 30 V
a If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
5 (wire breakage or defective 2. Disconnect connectors CM01 and M17, and connect T-adapters to
contact of connector) each female side.
Resis- Between C0M1 (female) (16) and M17
(female) (2) Max. 1 z
tance
Ground fault in wiring harness
6 2. Disconnect connectors CM01 and M17, and connect T-adapter to
(contact with ground circuit) either female side.
Resis- Between CM01 (female) (16) or M17 (female)
(2) and ground Min. 1 Mz
tance
If cause is not found by above checks, machine monitor is defective.
7 Defective machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)
40-136 PC490LC-10
40 Troubleshooting
Electrical diagram related to charging cricuit
PC490LC-10 40-137
40 Troubleshooting
Failure code [B@BAZG] Eng Oil Press Low (PC400-BaBAZG-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Low

Failure
L03 B@BAZG (Engine controller system)
Detail of • While engine is running, signal voltage from engine oil pressure sensor drops, so engine
failure controller determines that engine oil pressure is low.
Action of • Displays engine oil pressure monitor red on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Engine oil pressure sensor signal is input to engine controller and then transmitted to
machine monitor through CAN communication system.
Related • Engine oil pressure can be checked by using monitoring function.
information (Code: 37200)
• Method of reproducing failure code: Start engine.
Low engine oil pressure
1 (when system works Engine oil pressure may be low. Check it and remove cause if it is low.
properly)
If no failure is found by checks on cause 1, engine oil pressure sensor circuit
Defective engine oil
2 may be defective. Perform troubleshooting for failure codes [CA135] and
pressure sensor circuit
[CA141].
40-138 PC490LC-10
40 Troubleshooting
Failure code [B@BAZK] Eng Oil Level Low (PC400-BaBAZK-400-A-Z0-A)
Action level Failure code Engine oil level low

Failure
L01 B@BAZK (Machine monitor system)
Detail of • While engine is running, signal voltage from engine oil level switch is not below 1 V, so
failure machine monitor determines that engine oil level is low (oil level switch is open).
Action of • Displays engine oil level monitor yellow on machine monitor.
controller
machine
• Input (ON/OFF) from engine oil level switch can be checked by using monitoring function.
Related (Code 04501: Monitor Input 2)
information • Method of reproducing failure code: Start engine
Low engine oil level
1 Check engine oil level. If it is low, remove cause.
(when system is normal)
Defective engine oil level 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P44 and connect T-adapter to male side.
2
(internal defect) Resis- Between P44 (male) (1) and ground
Max. 1 z
tance
Open circuit in wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapters to
3 (wire breakage or defective each female side.
contact of connector) Resis- Between CM02 (female) (2) and P44 (female)
(1) Max. 1 z
tance
If no failure is found by above checks, machine monitor is defective.
• Reference
2. Disconnect connectors CM01 and CM02 and connect T-adapters to
4 Defective machine monitor each female side.
Between CM02 (female) (2) and CM01 (female)
Voltage Max. 1 V
(3)
Circuit diagram related to engine oil level
PC490LC-10 40-139
40 Troubleshooting
Failure code [B@BCNS] Eng Water Overheat (PC400-BaBCNS-400-A-Z0-A)
Action level Failure code Engine Water Overheat

Failure
L02 B@BCNS (Engine controller system)
Detail of • While engine is running, voltage from engine coolant temperature sensor drops, so engine
failure controller determines that engine coolant is overheated.
Action of • Displays engine coolant temperature monitor red on machine monitor.
controller
machine
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function
information (Code: 04107 Engine coolant temperature)
Overheating of engine
1 coolant Engine coolant may overheat. Check it and remove cause if it overheats.
(when system is normal)
If no failure is found by checks on cause 1, engine coolant temperature
Defective engine coolant
2 sensor system may be defective. Carry out troubleshooting for failure
temperature sensor system
codes [CA144] and [CA145].
40-140 PC490LC-10
40 Troubleshooting
Failure code [B@BCZK] Eng Water Level Low (PC400-BaBCZK-400-A-Z0-A)
Action level Failure code Radiator coolant level low

Failure
L01 B@BCZK (Machine monitor system)
• While starting switch is at ON position (with engine stopped) or engine is running, radiator
Detail of coolant level switch signal voltage does not remain below 1 V, so machine monitor
failure determines that radiator coolant level is low (sensor contact is open).
Action of • Displays radiator coolant level monitor in yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may overheat.
machine
• Input (ON/OFF) from radiator coolant level switch can be checked with monitoring
Related function. (Code: 04500 "Monitor Input 1")
Lowered radiator
coolant level Check radiator sub tank for lowering of coolant level. If coolant level is low,
1
(when system works add coolant.
properly)
Defective coolant level 2. Disconnect connector P24 and connect T-adapters to male side.
2 switch Between FULL and LOW
(internal defect) Between P24 (male) (1) Max. 1 z
Resistance and (2) lines
Below LOW line Min. 1 Mz
Open circuit in wiring 2. Disconnect connectors CM02 and P24, and connect T-adapters to each
harness female side.
3
(open circuit or a Add coolant.
defective contact) Between CM02 (female) (3) and P24 (female) (1) Max. 1 z
Resistance
Between P24 (female) (2) and ground (T09) Max. 1 z
• Reference
Defective machine 2. Insert T-adapters into connector CM02.
monitor
Between FULL and LOW
Between CM02 (3) and Max. 1 V
Voltage lines
CM01 (3)
Below LOW line Min. 10 V
PC490LC-10 40-141
40 Troubleshooting
Circuit diagram related to radiator coolant level switch
40-142 PC490LC-10
40 Troubleshooting
Failure code [B@HANS] Hyd Oil Overheat (PC400-BaHANS-400-A-Z0-A)
Action level Failure code Hydraulic oil overheat

Failure
L02 B@HANS (Pump controller system)
Detail of • While engine is running, overheating of hydraulic oil (above approx. 102 °C ) is detected
failure from signal voltage of hydraulic oil temperature sensor.
Action of • Displays hydraulic oil temperature monitor red on machine monitor.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • If machine is operated as it is, hydraulic components may be damaged.
machine
• Signal of hydraulic oil temperature sensor is input to pump controller and then the data is
transmitted to machine monitor through CAN communication system.
Related • Hydraulic oil temperature can be checked with monitoring function
information (Code: 04401 Hydraulic oil temperature)
• See E-mode troubleshooting E-21 and E-22 in "Hydraulic oil temperature gauge display".
Overheating of hydraulic oil
1 (when system works Hydraulic oil may overheat. Check it and remove cause if it overheats
properly)
If no failure is found by check on cause 1, hydraulic oil temperature
Defective hydraulic oil
2 monitoring system may be defective. Perform troubleshooting for failure
temperature gauge system
code [DGH2KB].
PC490LC-10 40-143
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error (PC400-CA115-400-A-Z0-A)
Action level Failure code Engine Ne and Bkup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Detail of • Abnormality is detected in signal circuits of Ne and Bkup speed sensors at the same time.
failure
Action of • Stops engine.
controller
Problem on • Engine does not start (if engine is stopped).
machine • Engine stops (if engine is running).
Related • Method of reproducing failure code: Start engine.
information
Defective Ne speed sensor
1 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
system
If no failure is found by above checks, engine controller is defective.
3 Defective engine controller
40-144 PC490LC-10
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error (PC400-CA122-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor High Error
Failure
Detail of • High voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Acceleration performance of engine drops.
machine • Engine output reduces.
• Signal voltage from charge (boost) pressure sensor can be checked with monitoring
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
Related
monitoring function. (Code: 36500 (kPa))
information
• If sensor connector is disconnected, failure code [CA123] for "Low Error" is displayed
even in normal condition.
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
2. Disconnect connector PIM.
If failure code changes from [CA122] to [CA123], charge (boost) pressure
sensor is defective.
Defective charge
3 (boost) pressure sensor • Reference
2. Insert T-adapter into connector J1 or PIM.
Between J1 (15) and (59), or between Sensor
Voltage 0.3 to 4.7 V
PIM (3) and (2) output
harness 2. Disconnect connectors J1 and PIM, and connect T-adapters to each
defective contact of a To check open circuit in GND line
connector) Resistance Between J1 (female) (59) and PIM (female) (2) Max. 1 z
1. Turn starting switch to OFF position, then perform troubleshooting.
2. Disconnect connectors J1 and PIM, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between J1 (female) (15) and (60), or between PIM
Resistance (female) (3) and (1) Min. 1 Mz

2. Disconnect connector PIM, and connect T-adapter to female side or insert
Hot short circuit in T-adapters into connector J1.
6 wiring harness 3. Turn starting switch to ON position (with connector PIM disconnected).
Between PIM (female) (3) and (2), or between J1
Voltage Max. 1 V
(15) and (59)
Defective engine If no failure is found by above checks, engine controller is defective.
7
controller (Since this is an internal defect, troubleshooting cannot be performed.)
PC490LC-10 40-145
40 Troubleshooting
Circuit diagram related to charge pressure sensor
40-146 PC490LC-10
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error (PC400-CA123-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor Low Error
Failure
Detail of • Low voltage appears in boost pressure sensor signal circuit.
failure
• Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to
run.
Problem on • Acceleration performance of engine drops.
machine • Engine output lowers.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
using monitoring function (Code: 36501 (V)).
Related • Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor)
information can be checked by using monitoring function (Code: 36500 (kPa)).
• If sensor connector is disconnected, this failure code is displayed.
harness connector
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
2 system of boost 2. Disconnect connectors PIM and connect T-adapter to female side.
pressure sensor 3. Switch: ON
Voltage Between PIM (female) (1) and (2) Power input 4.75 to 5.25
V
harness 2. Disconnect connectors J1 and PIM and connect T-adapters to each
female side.
3 (wire breakage or Between J1 (female) (60) and PIM (female) (1) Max. 1 z
defective contact of
connector) Resistance Between J1 (female) (15) and PIM (female) (3) Max. 1 z
Between J1 (female) (59) and PIM (female) (2) Max. 1 z
2. Disconnect connectors J1 and PIM and connect T-adapters to either
Short circuit in wiring female side.
4
harness 3.
Between J1 (female) (15) and (59) or between PIM
Ground fault in wiring 1. Turn starting switch to OFF position, then perform troubleshooting.
harness 2. Disconnect connectors J1 and PIM and connect T-adapter to either female
5 side.
(contact with ground
Between J1 (female) (15) or PIM (female) (3) and
circuit) Resistance ground Min. 1 Mz
a If no failure is found by checks on causes 1 to 5 and check result on cause

6 is abnormal, sensor is defective.
Defective charge 1. Turn starting switch to OFF position.
6 pressure (boost 2. Insert T-adapter into connector J1 or PIM.
pressure) sensor 3. Turn starting switch to ON position.
Between J1 (15) and (59), or between Sensor 0.3 to 4.7 V
Voltage
PIM (3) and (2) output
PC490LC-10 40-147
40 Troubleshooting

7
Circuit diagram related to boost pressure sensor
40-148 PC490LC-10
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error (PC400-CA131-400-A-Z0-A)
Action level Failure code Throttle sensor high error

Failure
Detail of • High voltage appears in signal circuit of fuel dial sensor.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected
Action of with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after failure
detection.
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
Related (Code: 03000 Fuel control dial voltage)
connector
Defective throttle sensor If failure code [CA2185] is also displayed, perform troubleshooting for it
2 power supply system first.
2. Disconnect connector P20 and connect T-adapters to male side.
Between P20 (male) (1) and (3) 4.0 to 6.0
Defective fuel control dial kz
3 (throttle sensor) Resis- Between P20 (male) (2) and (3) 0.25 to 5.0
tance kz
kz
2. Disconnect connector CE03, and connect T-adapters to female side.
Open or short circuit in wiring 4.0 to 6.0
4 Between CE03 (female) (41) and (42)
harness Resis- kz
tance Between CE03 (female) (51) and (42) 0.25 to 5.0
kz
5 Short circuit in wiring harness 2. Disconnect connectors CE03 and P20, and connect T-adapters to
either female side.
Resis- Between CE03 (female) (51) and (42), or
between P20 (female) (1) and (2) Min. 1 Mz
tance
2. Disconnect connector P20 and connect T-adapters to female side.
Hot short circuit in harness 3. Turn starting switch to ON position.
6
(contact with 24 V circuit)
Voltage Between P20 (female) (2) and ground Max. 1 V
PC490LC-10 40-149
40 Troubleshooting

• Reference
2. Insert T-adapters into connector CE03.
7 Defective engine controller 3. Turn starting switch to ON position.
4. Operate fuel control dial and perform troubleshooting.
Power 4.75 to 5.25
Between CE03 (42) and (41)
supply V
Voltage
Sensor
Between CE03 (51) and (41) 0.5 to 4.5 V
output
Circuit diagram related to throttle sensor
40-150 PC490LC-10
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error (PC400-CA132-400-A-Z0-A)
Action level Failure code Throttle sensor low error

Failure
Detail of • Low voltage appears in fuel control dial circuit.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected with
Action of starting switch at ON position.
detection.
machine
• Signal voltage from fuel control dial can be checked with monitoring function.
Related (Code:03000Fuel Dial Sensor Volt)
connector
Defective throttle sensor If failure code [CA2186] is also displayed, perform troubleshooting for it
Defective fuel control dial Between P20 (male) (1) and (3) 4.0 to 6.0 kz
3 (throttle sensor) 0.25 to 5.0
Resis- Between P20 (male) (2) and (3)
tance kz
kz
Open or short circuit in wiring
4 Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
harness Resis-
tance Between CE03 (female) (41) and (51) 0.25 to 5.0
kz
2. Disconnect connectors CE03 and P20, and connect T-adapters to
Open circuit in wiring each female side.
harness Between CE03 (female) (42) and P20 (female)
5 Max. 1 z
(wire breakage or defective (1)
contact of connector) Resis- Between CE03 (female) (51) and P20 (female)
(2) Max. 1 z
tance
Between CE03 (female) (41) and P20 (female)
(3) Max. 1 z

Short circuit in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapters to
6
harness either female side.
Resis- Between CE03 (female) (51) and (41), or
between P20 (female) (2) and (3) Min. 1 Mz
tance
PC490LC-10 40-151
40 Troubleshooting

Ground fault in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapters to
7 harness either female side.
(contact with ground circuit) Re- Between CE03 (female) (51) or P20 (female) (2)
sis- and ground Min. 1 Mz
tance
• Reference
8 Defective engine controller 2. Insert T-adapters into connector CE03.
4. Operate fuel control dial and perform troubleshooting.
Between CE03 (42) and (41) Power supply 4.75 to 5.25 V
Voltage
Between CE03 (51) and (41) Sensor output 0.4 to 4.5 V
40-152 PC490LC-10
40 Troubleshooting
Failure code [CA135] Eng Oil Press Sensor High Error (PC400-CA135-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Sensor High Error
Failure
Detail of • High voltage occurs in engine oil pressure sensor signal circuit.
failure
Action of • Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2}) and runs engine.
controller
Problem on
machine
• Signal voltage from engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 (V))
Related • Engine oil pressure sensed by engine oil pressure sensor can be checked with monitoring
information function. (Code: 37200 (kPa))
harness connector
Defective power supply
system of engine oil If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
pressure sensor for it first.

2. Disconnect connector POIL.
If failure code changes from [CA135] to [CA141] , engine oil pressure sensor
is defective.
Defective engine oil
3 pressure sensor • Reference
2. Insert T-adapters into connector J1 or POIL.
Between J1 (2) and (59) or between Sensor
POIL (3) and (2) output
harness 2. Disconnect connectors J1 and POIL, and connect T-adapters to each
connector) Resistance Between J1 (female) (59) and POIL (female) (2) Max. 1 z
2. Disconnect connectors J1 and POIL, and connect T-adapter to either
5 female side.
harness
Between J1 (female) (2) and (60), or between POIL

2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL, or insert T-adapter
Hot short circuit in
6 into connector J1.
wiring harness
4. Turn starting switch to ON position (with connector POIL disconnected).
Between J1 (2) and (59) or between POIL (female)
Voltage Max. 1 V
(3) and (2)
7
PC490LC-10 40-153
40 Troubleshooting
Circuit diagram related to engine oil pressure sensor
40-154 PC490LC-10
40 Troubleshooting
Failure code [CA141] Eng Oil Press Sensor Low Error (PC400-CA141-400-A-Z0-A)
Action level Failure code Engine Oil Pressure Sensor Low Error
Failure
Detail of • Low voltage appears in engine oil pressure sensor signal circuit.
failure
Action of • Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2}), and allows engine to run.
controller
Problem on
machine
• Signal voltage from engine oil pressure sensor can be checked by using monitoring
Related • Engine oil pressure sensed by engine oil pressure sensor can be checked by using
information monitoring function. (Code: 37200 (kPa))
connector
If failure code [CA187] or [CA227] is displayed, perform troubleshooting
for it first.
2 system of engine oil pressure 2. Disconnect connector POIL and connect T-adapter to female side.
sensor 3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between POIL (female) (1) and (2)
input V
2. Disconnect connectors J1 and POIL and connect T-adapters to each
female side.
a If power supply input in checks on cause 2
is normal, this check is not required.
Max. 1 z
Open circuit in wiring harness Between J1 (female) (60) and POIL
3 (wire breakage or defective (female) (1)
contact of connector) Resis-
a If power supply input in checks on cause 2
tance
is normal, this check is not required.
Max. 1 z
Between J1 (female) (59) and POIL
(female) (2)
Between J1 (female) (2) and POIL (female) (3)
(Sensor output) Max. 1 z

Ground fault in wiring 2. Disconnect connectors J1 and POIL, and connect T-adapter to either
4 harness female side.
(contact with ground circuit) Resis- Between J1 (female) (2) and ground, or
between POIL (female) (3) and ground Min. 1 Mz
tance
2. Disconnect connectors J1 and POIL, and connect T-adapter to either
5 Short circuit in wiring harness female side.
Resis- Between J1 (female) (2) and (59), or between
POIL (female) (2) and (3) Min. 1 Mz
tance
PC490LC-10 40-155
40 Troubleshooting

a If no failure is found by checks on causes 1 to 5 and check result of
Defective engine oil pressure cause 6 is abnormal, sensor is defective.
sensor 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector J1 or POIL.
(improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Between J1 (2) and (59) or Sensor
between POIL (3) and (2) output
Circuit diagram related to engine oil pressure sensor
40-156 PC490LC-10
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error (PC400-CA144-400-A-Z0-A)
Action level Failure code Coolant Temperature Sensor High Error

Failure
Detail of • High voltage occurs in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed value (90°C) and runs engine.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• This failure code appears if sensor connector is disconnected.
Related
• Since female connector alone is provided for "socket" used for troubleshooting of this
information
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
k Drain approximately 10l l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
equipment" in "Checks before troubleshooting" of "Related
connector
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700
z to 37 kz when coolant temperature is min. 0°C.
Defective coolant
2 temperature sensor 0°C 30 to 37 kz
Between TWTR (male) (A) and (B) 25°C 9.3 to 10.7 kz
Resis-
50°C 3.2 to 3.8 kz
tance a Coolant temperature-
Resistance characteristics 80°C 1.0 to 1.3 kz
95°C 700 to 800 z
2. Disconnect connector J1 and connect T-adapter to female side.
Open or short circuit in Between J1 (female) (14) and (13) (Coolant
3 wiring harness temperature: Min. 0 °C)
Resis- 700 z to 37
tance a Use Coolant temperature-Resistance kz
characteristics table for check on cause 2
as resistance criteria.
PC490LC-10 40-157
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-158 PC490LC-10
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error (PC400-CA145-400-A-Z0-A)
Action level Failure code Coolant Temperature Sensor Low Error

Failure
Detail of • Low voltage occurs in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed value (90°C) and runs engine.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
• Temperature sensed by engine coolant temperature sensor can be checked with
Related
• If temperature sensor connector is disconnected, failure code [CA144] for high error is
information
displayed in place of this failure code.
k Drain approximately 10l l of coolant beforehand, because you may get scalded by
hot water spurting out from mounting location of coolant temperature sensor when
removing radiator cap during checking and replacing coolant temperature sensor.
equipment" in "Checks before troubleshooting" of "Related information
Defective wiring harness on troubleshooting", and check it.
connector
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700 z
to 37 kz when coolant temperature is min. 0°C.
0°C 30 to 37 kz
Between TWTR (male) (A) and (B) 25°C 9.3 to 10.7 kz
Defective coolant
2 a Coolant temperature-Resistance 50°C 3.2 to 3.8 kz
temperature sensor
characteristics 80°C 1.0 to 1.3 kz
Resis- 95°C 700 to 800 z
tance Whole
coolant
Between TWTR (male) (B) and
tempera- Min. 1 Mz
ground
ture
range
Between J1 (female) (14) and (13) (Coolant
3 temperature: Min. 0 °C)
harness Resis-
700 z to 37 kz
tance a Use Coolant temperature-Resistance
characteristics table for check on cause 2
as resistance criteria.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and TWTR, and connect T-adapter to female
4 side of connector J1.
circuit) Resis- Between J1 (female) (14) and ground Min. 1 Mz
tance
PC490LC-10 40-159
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-160 PC490LC-10
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error (PC400-CA153-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor High Error
Failure
Detail of • High voltage appears in boost temperature sensor signal circuit.
failure
Action of • Takes it that boost temperature is at fixed temperature (70 °C ) and allows engine to run.
controller
Problem on • Engine does not start easily at low temperatures.
machine
• Signal voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
• Temperature sensed by boost temperature sensor can be checked with monitoring
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed as a T-adapter).
• This failure code is displayed if temperature sensor connector is disconnected.
connector
2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z to 382 kz, regard
boost temperature sensor as normal.
291 to 382
-40 °C
Defective boost temperature kz
2
sensor -20 °C 85 to 109 kz
Between TIM (male) (A) and (B)
Resis- 0 °C 29 to 36 kz
tance a Boost temperature-Resistance 30 °C 7.3 to 8.8 kz
chariacteristic 60 °C 2.3 to 2.7 kz
90 °C 860 to 970 z
130 °C 280 to 320 z
2. Disconnect connector J1 and connect T-adapters to female side.
Open or short circuit in wiring Between J1 (female) (5) and (59)
3
harness Resis- a Use Temperature-Resistance 280 z to 382
tance characteristics table for troubleshooting on kz
cause 2.
PC490LC-10 40-161
40 Troubleshooting
Circuit diagram related to boost temperature sensor
40-162 PC490LC-10
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error (PC400-CA154-400-A-Z0-A)
Action level Failure code Charge Air Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in boost temperature sensor signal circuit.
failure
• Takes it that boost temperature is at fixed temperature (70 °C ) and allows engine to run.
Problem on • Engine does not start easily at low temperatures.
machine • Engine output lowers.
• Signal voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
• Temperature sensed by boost temperature sensor can be checked with monitoring
Related function. (Code: 18500 (°C))
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA153] for "High Error" is displayed.
connector
2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z to 382 kz, regard
boost temperature sensor as normal.
291 to 382
-40 °C
kz
Defective boost temperature -20 °C 85 to 109 kz
2 Between TIM (male) (A) and (B)
sensor 0 °C 29 to 36 kz
Resis- a Boost temperature-Resistance 30 °C 7.3 to 8.8 kz
tance chariacteristic 60 °C 2.3 to 2.7 kz
90 °C 860 to 970 z
130 °C 280 to 320 z
Between TIM (male) (B) and Whole
ground range Min. 1 Mz

Short circuit in wiring Between J1 (female) (5) and (59)
3
harness Resis- a Use Temperature-Resistance 280 z to 382
tance characteristics table for troubleshooting on kz
cause 2.
Ground fault in wiring 2. Disconnect connectors J1 and TIM, and connect T-adapter to the
4 harness female side of connector J1.
(contact with ground circuit) Resis- Between J1 (female) (5) and ground
Min. 1 Mz
tance
PC490LC-10 40-163
40 Troubleshooting
Circuit diagram related to boost temperature sensor
40-164 PC490LC-10
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Volt Low Error (PC400-CA187-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage Low Error

Failure
Detail of • Low voltage appears in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is at fixed
value (250 kPa {2.5 kg/cm2}), and allows engine to run.
• Ignores signals from ambient pressure sensor, takes it that ambient pressure is at fixed
value (52.44 kPa {0.53 kg/cm2}), and allows engine to run.
Action of • Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value
controller (400 kPa {4.1 kg/cm2}), and allows engine to run.
• Ignores signals from crankcase pressure sensor, takes it that crankcase pressure is at
fixed value (approx. 0 kPa), and allows engine to run.
• Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
Problem on • Engine output lowers.
machine
information
connector
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. After each troubleshooting, turn starting switch to OFF position.
If this failure code is not displayed when a connector is disconnected,
that sensor or engine wiring harness is defective.
a Other failure codes are displayed, too. This is because the connector
Defective sensor or wiring is disconnected. Ignore failure codes other than [CA187].
2
harness
Sensor or harness Connector
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Boost pressure sensor PIM connector
Ambient pressure sensor PAMB connector
Crankcase pressure sensor P57 connector
Engine wiring harness J1
3 Defect in related system If another failure code is displayed, perform troubleshooting for it.
2. Disconnect connector J1 and connect T-adapter to male side.
4 Defective engine controller 3. Turn starting switch to ON position with connector J1 disconnected.
Voltage Between J1 (male) (60) and (59) 4.75 to 5.25
V
PC490LC-10 40-165
40 Troubleshooting
Circuit diagram related to sensor power supply 2 (5 V)
40-166 PC490LC-10
40 Troubleshooting
Failure code [CA221] Ambient Press Sensor High Error (PC400-CA221-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor High Error

Failure
Detail of • High voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
Problem on • Engine output reduces.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
harness connector
Defective ambient
2 pressure sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
supply system for it first.

2. Disconnect connector PAMB.
If failure code changes from [CA221] to [CA222], sensor is defective.
Defective ambient • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1 or PAMB.
PAMB (3) and (2) output
harness 2. Disconnect connectors J1 and PAMB, and connect T-adapters to each
connector) Resistance Between J1 (female) (59) and PAMB (female) (2) Max. 1 z
2. Disconnect connectors J1 and PAMB, and connect T-adapter to either
5 female side.
harness
Between J1 (female) (60) and (16), or between
Resistance PAMB (female) (1) and (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector PAMB, and connect T-adapter to female side.
6 wiring harness 3. Turn starting switch to ON position.
Voltage Between PAMB (female) (3) and (2) Max. 1 V
7
PC490LC-10 40-167
40 Troubleshooting
Circuit diagram related to ambient pressure sensor
40-168 PC490LC-10
40 Troubleshooting
Failure code [CA222] Ambient Press Sensor Low Error (PC400-CA222-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (not designed as T-adapter).
harness connector
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective ambient 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector PAMB, and connect T-adapter to female side.
supply system 3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between PAMB (female) (1) and (2)
supply input V
2. Disconnect connectors PAMB and J1, and connect T-adapter to either
3 female side.
harness
Between J1 (female) (16) and (59), or between
Resistance PAMB (female) (3) and (2) Min. 1 Mz

harness 2. Disconnect connectors PAMB and J1, and connect T-adapter to either
4 female side.
Between ground and J1 (female) (16) or PAMB
circuit) Resistance (female) (3) Min. 1 Mz

2. Disconnect connectors PAMB and J1, and connect T-adapters to each
Open circuit in wiring female side.
5 Between J1 (female) (16) and PAMB (female) (3) Max. 1 z
harness
Resistance Between J1 (female) (59) and PAMB (female) (2) Max. 1 z
Between J1 (female) (60) and PAMB (female) (1) Max. 1 z
PC490LC-10 40-169
40 Troubleshooting

a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective ambient 1. Turn starting switch to OFF position.
6 pressure sensor 2. Insert T-adapters into connector J1 or PAMB.
PAMB (3) and (2) output
7
Circuit diagram related to ambient pressure sensor
40-170 PC490LC-10
40 Troubleshooting
Failure code [CA227] Sensor 2 Supply Volt High Error (PC400-CA227-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage High Error

Failure
Detail of • High voltage appears in sensor power supply 2 (5V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is at
fixed value (250 kPa {2.5 kg/cm2}), and allows engine to run.
• Ignores signals from ambient pressure sensor, takes it that ambient pressure is at fixed
value (52.44 kPa {0.53 kg/cm2}), and allows engine to run.
Action of • Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value
controller (400 kPa {4.1 kg/cm2}), and allows engine to run.
• Ignores signals from crankcase pressure sensor, takes it that crankcase pressure is at
fixed value (0 kPa), and allows engine to run.
Problem on • Engine output decreases.
machine
information
Defective sensor power
supply 2 circuit
PC490LC-10 40-171
40 Troubleshooting
Failure code [CA234] Eng Overspeed (PC400-CA234-400-A-Z0-A)
Action level Failure code Engine Overspeed

Failure
Detail of • Engine speed exceeds its operating range.
failure
Action of • Regulates fuel injection rate so that engine speed lowers within operating range.
controller
Problem on • Engine speed fluctuates.
machine
Related • Engine speed can be checked with monitoring function. (Code: 01002 (rpm))
information • Method of reproducing failure code: Start engine and run at high idle.
No. Cause Procedure, measuring location, criteria, and remarks
1 Improper fuel is used. Fuel used may be improper. Check it.
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
2
them.
Method of using machine may be improper, so instruct operator on how
3 Improper machine usage
to use machine properly.
40-172 PC490LC-10
40 Troubleshooting
Failure code [CA238] Ne Speed Sensor Supply Volt Error (PC400-CA238-400-A-Z0-A)
Action level Failure code Ne speed sensor supply voltage error

Failure
Detail of • Ne speed sensor power supply (5 V) circuit is defective.
failure
Action of • Controls engine by using signals of Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also abnormal).
machine • Stopped engine cannot be started (when Bkup(G) speed sensor is also abnormal).
information
harness connector
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
Defective sensor or If this failure code is not displayed when a sensor is disconnected, sensor or
2 wiring harness engine wiring harness is defective.
a Other failure codes are displayed, too. This is because connector is
disconnected. Ignore failure codes other than [CA238].
Ne speed sensor NE
Connector
Engine wiring harness J1
Defective engine 3. Turn starting switch to ON position with engine wiring harness
3
controller disconnected.
V
Circuit diagram related to Ne speed sensor
PC490LC-10 40-173
40 Troubleshooting
Failure code [CA239] Ne Speed Sens Supply Volt High Error (PC400-CA239-400-A-Z0-
A)
Action level Failure code Ne Speed Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also defective).
machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).
information
2. Disconnect connector NE.
If this failure code is not displayed, disconnected sensor or engine wiring
2 Defective Ne speed sensor
harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than [CA239].
2. Disconnect connector J1.
3 Defective wiring harness If this failure code disappears, wiring harness is defective.
2. Disconnect connector J1 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
V
Circuit diagram related to Ne speed sensor
40-174 PC490LC-10
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error (PC400-CA271-400-A-Z0-A)
Action level Failure code IMV/PCV1 Short Error

Failure
Detail of • Short circuit is detected in supply pump PCV1 circuit.
failure
Action of
controller
machine
• Under normal conditions, pulse voltage of approximately 24 V is applied to PCV1 (1)
Related while engine is running. However, it cannnot be measured by using multimeter since it is
information pulse voltage.
connector
2. Disconnect connectors PCV1 and connect socket to male side.
Defective supply pump PCV1 3. Turn starting switch to ON position.
2 Resis- Between PCV1 (male) (1) and (2) 2.3 to 5.3
(internal short circuit)
tance z
Resis- Between PCV1 (male) (1) and ground
Min. 1 Mz
tance
3 Short circuit in wiring harness
Resis- Between J2 (female) (4) and (5) (PCV1 2.3 to 5.3
tance resistance) z
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV1 and connect T-adapter to
4 female side of connector J2.
(contact with ground circuit)
Resis- Between J2 (female) (5) and ground
Min. 1 Mz
tance
If no abnormality is found by above diagnosis, engine controller is
5 Defective engine controller defective.
Circuit diagram related to PCV1
PC490LC-10 40-175
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error (PC400-CA272-400-A-Z0-A)
Action level Failure code IMV/PCV1 Open Error

Failure
Detail of • Open circuit is detected in supply pump PCV1 circuit.
failure
Action of
controller
machine
• Under normal conditions, pulse voltage of approximately 24 V is applied to PCV1 (1) while
engine is runing. However, it cannot be measured by using multimeter since it is pulse
Related voltage.
information • Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
connector
Defective supply pump PCV1 2. Disconnect connectors PCV1 and connect socket to male side.
2
(internal open circuit) Resis- Between PCV1 (male) (1) and (2)
2.3 to 5.3 z
tance
Open or short circuit in wiring 2. Disconnect connector J2 and connect T-adapters to female side.
3
harness Resis- Between J2 (female) (4) and (5) (PCV1
resistance) 2.3 to 5.3 z
tance
Ground fault in wiring 2. Disconnect connectors J2 and PCV1.
4 harness 3. Connect T-adapter to female side of connector J2.
(contact with ground circuit) Resis- Between J2 (female) (5) and ground
Min. 1 Mz
tance
40-176 PC490LC-10
40 Troubleshooting
Failure code [CA273] PCV2 Short Error (PC400-CA273-400-A-Z0-A)
Action level Failure code PCV2 Short Error

Failure
Detail of • Short circuit is detected in supply pump PCV2 circuit.
failure
Action of
controller
machine
Related • Under normal conditions, pulse voltage of approximately 24 V is applied to PCV2 (1)
information while engine is running. However, it cannot be measured by using multimeter since it is
pulse voltage.
connector
2. Disconnect connector PCV2 and connect socket to male side.
Defective supply pump PCV2 Resis- Between PCV2 (male) (1) and (2) 2.3 to 5.3
2
(internal short circuit) tance z
Resis- Between PCV2 (male) (1) and ground
Min. 1 Mz
tance
Resis- Between J2 (female) (1) and (2) (PCV2 2.3 to 5.3
tance resistance) z
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV2 and connect T-adapter to
Min. 1 Mz
tance
PC490LC-10 40-177
40 Troubleshooting
Failure code [CA274] PCV2 Open Error (PC400-CA274-400-A-Z0-A)
Action level Failure code PCV2 Open Error

Failure
Detail of • Open circuit is detected in supply pump PCV2 circuit.
failure
Action of
controller
machine
• Under normal conditions, pulse voltage of approximately 24 V is applied to PCV2 (1)
while engine is running. However, it cannot be measured by using multimeter since it is
Related pulse voltage.
information • Because troubleshooting "socket" for this sensor features female connector alone, it is
not connectable to female connector of sensor wiring harness, and thus not usable for
connector
Defective supply pump PCV2 2. Disconnect connector PCV2 and connect socket to male side.
2
(internal open circuit) Resis- Between PCV2 (male) (1) and (2) 2.3 to 5.3
tance z
3
harness Resis- Between J2 (female) (1) and (2) (PCV2 2.3 to 5.3
tance resistance) z
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV2.
4 3. Connect T-adapter to female side of connector J2.
Min. 1 Mz
tance
40-178 PC490LC-10
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error (PC400-CA322-400-A-Z0-A)
Action level Failure code Injector #1(L#1) Open/Short Error

Failure
Detail of • Open circuit or short circuit is detected in injector #1 circuit.
failure
Action of
controller
machine • Engine speed does not stabilize.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
connector
2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1 Resis- Between CN1 (male) (1) and (2)
0.4 to 1.1 z
tance
Resis- Between CN1 (male) (1) and ground
Min. 1 Mz
tance
Open circuit or ground fault in Resis- Between J1 (female) (48) and (58)
3 wiring harness 0.4 to 1.1 z
tance
Min. 1 Mz
tance
Open circuit in wiring harness 2. Disconnect connectors J1 and CN1, and connect T-adapters to each
4 (wire breakage or defective female side.
contact of connector) Resis- Between J1 (female) (48) and CN1 (female)
(1) Max. 1 z
tance
Resis- Between J1 (female) (58) and CN1 (female)
(2) Max. 1 z
tance
5 2. Disconnect connectors J1 and CN1, and connect T-adapters to
Resis- Between J1 (female) (48) or CN1 (female) (1)
and ground Min. 1 Mz
tance
PC490LC-10 40-179
40 Troubleshooting

2. Disconnect connectors J1 and CN1, and connect T-adapters to
female side of connector J1.
a Check by using multimeter in continuity mode.
No
6 Short circuit in wiring harness Between J1 (female) (48) and and each other continuity
pin (No sound
is heard)
Continuity
No
continuity
Between J1 (female) (58) and each other pin
(No sound
is heard)
Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them, too.
Circuit diagram related to injector #1
40-180 PC490LC-10
40 Troubleshooting

Failure
failure
Action of
controller
multimeter.
connector
2 Defective injector #5
Resis- Between CN5 (male) (1) and (2) 0.4 to 1.1 z
tance Between CN5 (male) (1) and ground Min. 1 Mz
Open circuit or ground fault in 2. Disconnect connector J1 and connect T-adapters to female side.
3 wiring harness Resis- Between J1 (female) (44) and (54) 0.4 to 1.1 z
tance Between J1 (female) (44) and ground Min. 1 Mz
Open circuit in wiring harness 2. Disconnect connectors J1 and CN5, and connect T-adapter to each
contact of connector) Between J1 (female) (44) and CN5 (female)
Max. 1 z
Resis- (1)
tance Between J1 (female) (54) and CN5 (female)
(2) Max. 1 z

5 2. Disconnect connectors J1 and CN5, and connect T-adapter to either
(contact with ground circuit) female side.
tance
2. Disconnect connectors J1 and CN5, and connect T-adapter to the
No
Short circuit in wiring harness continuity
6 Between J1 (female) (44) and each other pin
(No sound
is heard)
Continuity
No
continuity
(No sound
is heard)
PC490LC-10 40-181
40 Troubleshooting

40-182 PC490LC-10
40 Troubleshooting

Failure
failure
Action of
controller
multimeter.
connector
Max. 1 z
Resis- (1)
(2) Max. 1 z

tance
No
(No sound
is heard)
Continuity
No
continuity
(No sound
is heard)
PC490LC-10 40-183
40 Troubleshooting

40-184 PC490LC-10
40 Troubleshooting

Failure
failure
Action of
controller
multimeter.
connector
Max. 1 z
Resis- (1)
(2) Max. 1 z

tance
No
(No sound
is heard)
Continuity
No
continuity
(No sound
is heard)
PC490LC-10 40-185
40 Troubleshooting


40-186 PC490LC-10
40 Troubleshooting

Failure
failure
Action of
controller
multimeter.
connector
Max. 1 z
Resis- (1)
(2) Max. 1 z

tance
No
(No sound
is heard)
Continuity
No
continuity
(No sound
is heard)
PC490LC-10 40-187
40 Troubleshooting

40-188 PC490LC-10
40 Troubleshooting

Failure
failure
Action of
controller
multimeter.
connector
Max. 1 z
Resis- (1)
(2) Max. 1 z

tance
No
(No sound
is heard)
Continuity
No
continuity
(No sound
is heard)
PC490LC-10 40-189
40 Troubleshooting

40-190 PC490LC-10
40 Troubleshooting
Failure code [CA343] ECM Critical Internal Failure (PC400-CA343-400-A-Z0-A)
Action level Failure code ECM Critical Internal Failure

Failure
Detail of • Engine controller has internal defect.
failure
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine start if it is stopped.
• Power supply voltage of engine controller can be checked with monitoring function.
Related (Code: 03203)
information • Method of reproducing failure code: Turn starting switch to ON position
Defective engine
controller system
PC490LC-10 40-191
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error (PC400-CA351-400-A-Z0-A)
Action level Failure code Injectors Drive Circuit Error

Failure
Detail of • Injector drive circuit is defective.
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
machine
Related • Method of reproducing failure code: Start engine.
information
Check failure code (injector system failure code) that is displayed at the
1 Defect in related system
same time. If another code is displayed, perform troubleshooting for it.
Defective engine controller
system
40-192 PC490LC-10
40 Troubleshooting
Failure code [CA352] Sensor 1 Supply Volt Low Error (PC400-CA352-400-A-Z0-A)
Action level Failure code Sensor 1 Supply Voltage Low Error

Failure
Detail of • Low voltage appears in sensor power supply 1 (5 V) circuit.
failure
• Ignores signals from dosing (post-treatment injector) fuel pressure sensor, and stops
Action of KDPF regeneration control.
controller • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run.
machine
information
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine
harness is defective.
Defective sensor or wiring
2 a Other failure codes (many codes) are also displayed. They are
harness
Dosing fuel pressure sensor PDOSER connector
EGR valve lift sensor SEGR connector
Connector
KVGT position sensor SVGT connector
Engine harness J2
3
them.
2. Disconnect connector J2 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with connector J2 disconnected.
V
PC490LC-10 40-193
40 Troubleshooting
Circuit diagram related to sensor power supply 1 (5 V)
40-194 PC490LC-10
40 Troubleshooting
Failure code [CA356] Mass Air Flow Sensor High Error (PC400-CA356-400-A-Z0-A)
Action level Failure code Mass air flow sensor high error
Failure
Detail of • High frequency input appears in mass air flow sensor signal circuit.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
Action of • Closes EGR valve.
controller • Limits engine output.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
Related • Mass air flow sensor and intake temperature sensor are integrated.
connector
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 2. Disconnect connector P55.
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code changes to [CA357], mass air flow sensor is
defective.
1. Be ready with starting switch to OFF position.
2. Disconnect connector P55, and connect T-adapters to female side.
supply system
Power Approx. 12
Voltage Between P55 (female) (2) and (3)
supply V
Open circuit in wiring harness 2. Disconnect connectors J1 and P55 and connect T-adapters to each
a Open circuit in GND line
Resis- Between J1 (female) (22) and P55 (female) (3)
Max. 1 z
tance
2. Disconnect connectors J1 and P55, and connect T-adapters to
Resis- Between J1 (female) (23) and each of other pin
Min. 1 Mz
tance
Hot short circuit in wiring 2. Disconnect connector P55, and connect T-adapters to female side.
7 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) • Ignore displayed failure codes.
Voltage Between P55 (female) (1) and (3) Max. 1 V
PC490LC-10 40-195
40 Troubleshooting
Circuit diagram related to mass air flow sensor
40-196 PC490LC-10
40 Troubleshooting
Failure code [CA357] Mass Air Flow Sensor Low Error (PC400-CA357-400-A-Z0-A)
Action level Failure code Mass air flow sensor low error
Failure
Detail of • Low frequency input error has occurred in the mass air flow sensor signal circuit.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
• Mass air flow sensor and intake temperature sensor are integrated.
Related • If the sensor connector is disconnected, this failure code is displayed together with failure
information code [CA691].
connector
Defective mass air flow 2. Replace mass air flow sensor
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code does not appear, the old mass air flow sensor was
defective.
2. Disconnect connector P55, and connect T-adapters to female side.
supply system
Power Approx. 12
supply V
2. Disconnect connectors J1 and P55 and connect T-adapters to each
female side.
Open circuit in wiring harness a If no failure is found by check on cause 4,

this check is not required. Max. 1 z
5 (wire breakage or defective Between J1 (female) (21) and P55 (female) (2)
tance a If no failure is found by check on cause 4,
Between J1 (female) (22) and P55 (female) (3)
Between J1 (female) (23) and P55 (female) (1) Max. 1 z
Ground fault in wiring harness 2. Disconnect connectors J1 and P55 and connect T-adapter to either
6 female side.
Resis- Between J1 (female) (23) or P55 (female) (1)
tance
PC490LC-10 40-197
40 Troubleshooting

Resis- Between J1 (female) (23) and each of other pin
Min. 1 Mz
tance
Hot short circuit in wiring 2. Disconnect connector P55, and connect T-adapters to female side.
(circuit) • Ignore displayed failure codes.
40-198 PC490LC-10
40 Troubleshooting
Failure code [CA386] Sensor 1 Supply Volt High Error (PC400-CA386-400-A-Z0-A)
Action level Failure code Sensor 1 Supply Voltage High Error

Failure
Detail of • High voltage appears in sensor power supply 1 (5 V) circuit.
failure
• Ignores signals from dosing (post-treatment injector) fuel pressure sensor, and stops
Action of KDPF regeneration control.
controller • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run.
machine
information
supply 1 circuit
PC490LC-10 40-199
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error (PC400-CA441-400-A-Z0-A)
Action level Failure code Battery voltage low error

Failure
Detail of • Low voltage appears in controller power supply circuit.
failure
Action of • Continue operation setting power supply voltage to the fixed value (24 V).
controller
machine start if it is stopped.
• Power supply voltage of engine controller can be checked with monitoring function.
Related (Code: 03203)
Loose or corroded
1 Battery cable terminal may be loose or corroded. Check it.
battery terminal
Loose terminal or partial 1. Turn starting switch to OFF position.
2 open circuit at terminal Check terminals of alternator, battery relay, ground terminal (T12), etc.
harness connector
1. Turn starting switch to OFF position, then perform troubleshooting.
4 Lowered battery voltage 2. Measure voltage while cranking engine.
Voltage Between battery terminals (+) and (-). 20 to 30 V
2. Insert T-adapters into connector M17.
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Voltage Between M17 (2) and ground 26 to 30.5 V
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Insert T-adapters into connector CE03.
Defective engine 3. Turn the battery disconnect switch to the ON position.
6
controller 4. Measure voltage with starting switch at OFF position and when starting
engine.
Between CE03 (1) and (21) 20 to 30 V
Voltage
40-200 PC490LC-10
40 Troubleshooting
Circuit diagram related to engine controller power supply
PC490LC-10 40-201
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error (PC400-CA442-400-A-Z0-A)
Action level Failure code Battery Voltage High Error

Failure
Detail of • High voltage (approximately 36 V or higher) appears in controller power supply circuit.
failure
Action of • Sets power supply voltage to fixed value (24 V) and allows engine to run.
controller
machine restart if it is stopped.
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03203)
Defective power supply
system of engine controller
40-202 PC490LC-10
40 Troubleshooting
Failure code [CA449] Rail Press Very High Error (PC400-CA449-400-A-Z0-A)
Action level Failure code Rail Pressure Very High Error

Failure
Detail of • High voltage (exceeding the preset limit) occurs in common rail pressure sensor circuit.
failure
Action of • Limits engine output and allows engine to run (limits common rail pressure).
controller
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
Defective common rail
pressure sensor system
PC490LC-10 40-203
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error (PC400-CA451-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of common rail pressure sensor.
failure
controller
machine
• This failure code appears if common rail pressure sensor connector is disconnected.
a If failure code [CA515] or [CA516] is also displayed, perform
troubleshooting for it first.
Defective common rail 2. Disconnect connector PFUEL, and connect T-adapter to female side
2 pressure sensor power supply of connector.
system 3. Turn starting switch to ON position.
Power
Between PFUEL (female) (1) and
Voltage supply 4.75 to 5.25
(3) V
input
2. Disconnect connectors PFUEL and J2, and connect T-adapters to
each female side of connectors.
a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Open circuit in wiring harness Between J2 (female) (31) and PFUEL
3 (wire breakage or defective (female) (1)
Resistance a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Between J2 (female) (21) and PFUEL
(female) (3)
(female) (2) (sensor output) Max. 1 z

2. Disconnect connectors PFUEL and J2.
4 Short circuit in wiring harness 3. Connect T-adapter to either female side.
Between J2 (female) (55) and (31), or Min. 1 Mz
Resistance between PFUEL (2) and (1)
40-204 PC490LC-10
40 Troubleshooting

2. Disconnect connector PFUEL and J2.
3. Connect T-adapter to either female side.
4. Turn starting switch to ON position (with connector PFUEL
Hot short circuit in wiring disconnected).
5
harness
a Pin (55) of connector J2 is connected to 5 V circuit via resistor inside
engine controller.
Between PFUEL (2) and (3), or J2 (55) and
Voltage Approx. 5 V
(21)
a If no failure is found by checks on causes 1 to 5 and if failure is
Defective common rail found by check on cause 6, sensor is defective.
pressure sensor 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connector PFUEL and J2.
(improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Between PFUEL (2) and (3), or J2 Sensor
Voltage
(55) and (21) output 0.2 to 4.6 V
Circuit diagram related to common rail pressure sensor
PC490LC-10 40-205
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error (PC400-CA452-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Low Error

Failure
Detail of • Low voltage occurs in signal circuit of common rail pressure sensor.
failure
controller
machine
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400 (MPa))
• If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code is not displayed, wiring harness connector is
defective.
a If failure code [CA515] or [CA516] is also displayed, perform
Defective common rail 2. Disconnect connector PFUEL, and connect T-adapter to female side
2 pressure sensor power supply of connector.
system 3. Turn starting switch to ON position.
Power
Between PFUEL (female) (1)
Voltage supply 4.75 to 5.25 V
and (3)
input
2. Disconnect connector PFUEL.
If failure code [CA452] changes to [CA451], sensor is defective.
Defective common rail • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PFUEL or J2.
Between PFUEL (2) and (3), or Sensor
between J2 (55) and (21) output
2. Disconnect connectors J2 and PFUEL, and connect T-adapters to
Open circuit in wiring harness each female side of connectors.
4 (wire breakage or defective
contact of connector) a Open circuit of 5 V circuit
Resistance (female) (1) Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
5 either female side.
Between ground and PFUEL (female) (2) or Min. 1 Mz
Resistance J2 (female) (55)
40-206 PC490LC-10
40 Troubleshooting

2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
6 Short circuit in wiring harness either female side.
Between PFUEL (female) (2) and (3) or
Resistance between J2 (female) (55) and (21) Min. 1 Mz
PC490LC-10 40-207
40 Troubleshooting
Failure code [CA515] Rail Press Sens Sup Volt High Error (PC400-CA515-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage High Error
Failure
Detail of • High voltage occurs in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and runs engine.
controller • Limits the common rail pressure.
machine
information
1
defective.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
codes other than this code.
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
Hot short circuit in wiring 2. Disconnect connector PFUEL, and connect T-adapter to female side
4 of connector.
harness
Voltage Between PFUEL (female) (1) and (3) 4.75 to 5.25
V
Voltage Between J2 (male) (31) and (21) 4.7 to 5.25 V
40-208 PC490LC-10
40 Troubleshooting
PC490LC-10 40-209
40 Troubleshooting
Failure code [CA516] Rail Press Sens Sup Volt Low Error (PC400-CA516-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and allows engine to run.
controller • Limits the common rail pressure.
machine
information
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
4 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
(contact with ground circuit) female side of either connector.
Resis- Between ground and J2 (female) (31) or
PFUEL (female) (1) Min. 1 Mz
tance
5 Short circuit in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
female side of either connector.
Resis- Between J2 (female) (21) and (31), or
between PFUEL (female) (1) and (2) Min. 1 Mz
tance
2. Disconnect connector J2, and connect T-adapter to male side.
6 Defective engine controller 3. Turn starting switch to ON position.
V
40-210 PC490LC-10
40 Troubleshooting
PC490LC-10 40-211
40 Troubleshooting
Failure code [CA553] Rail Press High Error (PC400-CA553-400-A-Z0-A)
Action level Failure code Rail Pressure High Error

Failure
Detail of • High voltage (above the limit) appears and continued 15 or more seconds in signal circuit
failure of common rail pressure sensor.
controller
machine
1
them.
2 Improper fuel Fuel used may be improper. Check it (the viscosity is high).
Defective electric system of Electrical system of common rail pressure sensor may be defective.
3 common rail pressure sensor Perform troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system
4 of common rail pressure Common rail pressure sensor may have mechanical failure. Check it.
sensor
The overflow valve may has a damaged spring, worn seat, or ball
5 Defective overflow valve clogging trouble. Check it.
6 Clogging of overflow piping Check overflow piping for clogging.
7 Defective pressure limiter The pressure limiter may have a mechanical failure. Check it.
40-212 PC490LC-10
40 Troubleshooting
Failure code [CA555] Crankcase Press High Error 1 (PC400-CA555-400-A-Z0-A)
Action level Failure code Crankcase Pressure High Error 1

Failure
Detail of • High pressure error of crankcase pressure is detected.
failure
Action of • None in particular.
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
1 Clogged KCCV filter Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
Blocked KCCV gas piping emulsion is found inside KCCV, KCCV blowby gas piping may be
2
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Crankcase pressure sensor Crankcase pressure sensor system may be defective. Perform
3 troubleshooting for failure codes [CA1843] and [CA1844].
defective
PC490LC-10 40-213
40 Troubleshooting
Failure code [CA556] Crankcase Press High Error 2 (PC400-CA556-400-A-Z0-A)
Action level Failure code Crankcase Pressure High Error 2

Failure
Detail of • Crankcase pressure high error (level 2) occurs.
failure
Action of • Limits engine output and runs engine.
controller
machine
(Code: 48401 (V))
information (Code: 48400 (kPa))
• Method of reproducing failure code: Starting switch ON
1 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
2 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
40-214 PC490LC-10
40 Troubleshooting
Failure code [CA559] Rail Press Low Error (PC400-CA559-400-A-Z0-A)
Action level Failure code Rail Pressure Low Error

Failure
Detail of • Supply pump does not feed fuel (level 1).
failure
Action of
controller
machine
• Common rail pressure sensed by common rail pressure sensor can be checked by using
Related monitoring function. (Code: 36400 (MPa))
1 Defect in related system If another failure code is displayed, perform troubleshooting for it first.
2 Use of improper fuel Check fuel used (as it may be improper).
a For details on troubleshooting, see "Note 1".
a For check of pressure in fuel low-pressure circuit, see Testing and
adjusting, "Testing fuel pressure" in Testing and adjusting.
Defect in low-pressure circuit
3 Pressure in low-pressure fuel
parts
circuit
0.15 to 0.3 MPa
(At high idle or under load
{1.5 to 3.0 kg/cm2}
equivalent to rated output
operation)
4 Clogged fuel filter,or strainer a For details of troubleshooting, see Note 2.
Defective electrical system of Electrical system of supply pump PCV may be defective. Perform
5 supply pump PCV troubleshooting for failure code [CA271], [CA272], [CA273], or [CA274].
Defective common rail Common rail pressure sensor may be defective. Check wiring harness
6 pressure sensor for damage.
a For check of leakage from pressure limiter, see "Checking fuel return
rate and leakage" in Testing and adjusting.
7 Defective pressure limiter Leakage from pressure limiter
(Equivalent operation to rated Max. 10 cc/min
output operation (load by stalling))
a For check of limit return rate (spill) from injector, see "Checking fuel
return rate and leakage" in Testing and adjusting.
Engine speed during equivalent
operation to rated output operation Injector return rate (spill) limit
(load by stalling)
8 Defective injector
1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
PC490LC-10 40-215
40 Troubleshooting
<How to use check sheet>

Perform the above troubleshooting and fill in the check results on the attached " Check sheet for pressure low
error" .
Note 1: To determine that low-pressure circuit parts are defective, check following items.
1. Fuel level
2. Clogging of fuel tank breather
3. Seizure and wear of feed pump and clogging of filter
4. Leakage from or clogging of low-pressure fuel piping
5. Malfunction of bypass valve and installation of wrong part (See Fig. 1)
6. Clogged fuel filter
7. Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1) , bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is visible through hole on nut side.
• Fuel inlet joint (3): Gauze filter is visible through both holes
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1. Gauze filter: Disassemble and check. If clogged, clean.
2. Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3. Fuel filter: If the problem is not solved by performing 1) and 2) above, replace the fuel filter.
Check sheet for no-pressure feed

Model Work No.
Machine serial No. # Date of check / /
Engine SAA6D125E–6 Service meter reading h
Engine serial No. # Worker's name
A. Visual check Good NG
1 Fuel leakage to outside
2 Clogging of fuel tank breather
40-216 PC490LC-10
40 Troubleshooting
B. Inspection with machine monitor

Good NG
(02 = abnormality record; 01 = Monitoring; 09 = Cylinder cutout mode operation)
3 Check of failure code / / / /
Check of monitoring information
Standard
value Measured Good NG
Code Display item Testing conditions SI unit (Reference
value
value)
Low speed r/min 825 ± 25
01002 Engine Speed Full speed r/min 1,980 ± 50
At torque converter stall r/min 1,800
Low speed % 0
31701 Throttle Position
Full speed % 100
Last fuel injection
18600 quntity command At torque converter stall mg/st – – –
4
(in weight)
Rail Press At torque converter stall –
36200 MPa
Command
36400 Rail Pressure At torque converter stall MPa –
Low speed CA – – –
Injection Timing Full speed – – –
36300 CA
Command
At torque converter stall CA – – –
36500 Boost pressure At torque converter stall kPa – – –
Coolant
04107 Temperature Low speed °C – – –
Fuel
14200 Temperature Low speed °C – – –
Check result of cylinder cutout mode operation (engine speed)
Standard
Function Cutout cylinder Testing conditions SI unit (Reference
value
value)
5 No. 1 cylinder Low speed r/min – – –
No. 2 cylinder Low speed r/min – – –
Set by No. 3 cylinder Low speed r/min – – –
cylinder No. 4 cylinder Low speed r/min – – –
Standard
C. Check of fuel circuit pressure Testing conditions Unit (Reference value
value)
High idle or under load MPa
Fuel low-pressure circuit 0.15 to 0.3
6 pressure equivalent to rated output {kg/
operation (stalling) {1.5 to 3.0}
cm2}
D. Check of strainers and filters Good NG
7 Visual inspection of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
PC490LC-10 40-217
40 Troubleshooting
Standard
E. Check of leakage and return Testing conditions Unit (Reference value
value)
Under load equivalent to
Leakage from pressure rated output operation (at
11 cc/min Max. 10
limiter stalling)
Torque converter stall at
1,600 rpm cc/min 960
cc/min 1,020
1,700 rpm
Torque converter stall at Speed:
12 Return rate from injector 1,800 rpm cc/min 1,080
Return rate:
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
40-218 PC490LC-10
40 Troubleshooting
Failure code [CA595] Turbo Speed High Error 2 (PC400-CA595-400-A-Z0-A)
Action level Failure code Turbocharger Speed High Error 2

Failure
Detail of • Turbocharger runs at abnormally high speed.
failure
Action of • Takes it that turbocharger is at fixed value of 130,000 (rpm), and allows engine to run.
controller
Problem on
machine
• Turbocharger speed sensed by turbocharger speed sensor can be checked with
Related monitoring function. (Code: 48100 (rpm))
Increased turbocharger
1 Turbocharger speed may increase abnormally high. Check it.
speed
2 Defective turbocharger Turbocharger may be defective. Check it.
If no failure is found by check on cause 1, turbocharger speed sensor
Defective turbocharger speed system may be defective. Perform troubleshooting for failure code
3
sensor [CA687].
PC490LC-10 40-219
40 Troubleshooting
Failure code [CA687] Turbo Speed Low Error (PC400-CA687-400-A-Z0-A)
Action level Failure code Turbocharger Speed Low Error

Failure
Detail of • Turbocharger rotates at abnormally low speed.
failure
Action of • Takes it that turbocharger is at fixed value of 130,000 (rpm), and allows engine to run.
controller
Problem on
machine
k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • Turbocharger speed sensed by turbocharger speed sensor can be checked with
monitoring function. (Code: 48100 (rpm))
• Method of reproducing failure code: Start engine and sets engine speed to 1200 rpm or
higher.
If regeneration is defective or unusual noise is heard from KVGT,
perform following checks.
1 Defective KVGT 1. Move KVGT vanes with hand in axial and radial directions to make
judgement.
If KVGT shaft does not rotate, KVGT is defective.
Defective sensor power If failure code [CA283] is also displayed, perform troubleshooting for it
3 supply system first.
Defective turbocharger speed 2. Disconnect connector VGT REV. and connect T-adapter to female
4 sensor side of connector.
(internal defect) Resis- Between VGT REV. (female) (1) and (2) 600 to 1600
tance z
Open or short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector J2 and connect T-adapter to female side.
5 (short circuit, wire breakage
or defective contact of Resis- Between J2 (female) (32) and (33) 600 to 1600
connector) tance z
2. Disconnect connectors J2 and VGT REV. and connect T-adapter to
Ground fault in wiring harness either female side.
6 Resis- Between ground and J2 (female) (32) or VGT
(contact with ground circuit) REV. (female) (1) Min. 1 Mz
tance
Resis- Between ground and J2 (female) (33) or VGT
REV. (female) (2) Min. 1 Mz
tance
Short circuit in wiring harness 2. Disconnect connectors J2 and VGT REV. and connect T-adapter to
Resis- Between J2 (female) (32) and (33), or
between VGT REV. (female) (1) and (2) Min. 1 Mz
tance
Defective installation of Turbocharger speed sensor may be installed incorrectly (loose fitting) or
8 sensor or defective speed speed sensor parts (internal parts of KVGT) may be defective (due to
sensing part thermal deformation). Check them.
40-220 PC490LC-10
40 Troubleshooting
Replace body of KVGT if boost pressure is low, see "Measuring boost

9 Defective body of KVGT
pressure" in Testing and adjusting.
Circuit diagram related to turbocharger speed sensor
PC490LC-10 40-221
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error (PC400-CA689-400-A-Z0-A)
Action level Failure code Engine Ne Speed Sensor Error

Failure
Detail of • Engine Ne speed sensor signal is abnormal.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Bkup speed sensor is also defective).
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• The speed sensor detects holes drilled through the flywheel and calculates the engine
speed.
Defective Ne speed sensor If failure code [CA238] is also displayed, perform troubleshooting for it
Breakage or improper
Engine Ne speed sensor may be broken or installed improperly
3 installation (loosened) of
(loosened). Check it.
engine Ne speed sensor
2. Disconnect connector NE, and connect T-adapter to female side.
Defective Ne speed sensor 3. Turn starting switch to ON position.
4 power supply input Power
Voltage Between NE (female) (1) and (2) supply 4.75 to 5.25
input V

2. Disconnect connectors J1 and NE, and connect T-adapter to each
female side.
If no failure is found by check on cause 4, this
Open circuit in wiring harness check is not required. Max. 1 z
5 (wire breakage or defective Between J1 (female) (36) and NE (female) (1)
contact of connector) Resis- If no failure is found by check on cause 4, this
tance check is not required. Max. 1 z
Between J1 (female) (37) and NE (female) (2)
Between J1 (female) (26) and NE (female) (3) Max. 1 z
2. Disconnect connectors J1 and NE, and connect T-adapter to either
female side.
6 Short circuit in wiring harness Between J1 (female) (36) and (26), or
Min. 1 Mz
Resis- between NE (female) (1) and (3)
tance Between J1 (female) (37) and (26), or
between NE (female) (2) and (3) Min. 1 Mz

Ground fault in wiring 2. Disconnect connectors J1 and NE, and connect T-adapter to either
(contact with ground circuit) Resis- Between ground and J1 (female) (26) or NE Min. 1 Mz
tance (female) (3)
40-222 PC490LC-10
40 Troubleshooting

Hot short circuit in wiring 2. Disconnect connector NE, and connect T-adapter to female side.
harness
Voltage Between NE (female) (3) and ground Max. 1 V
If no failure is found by above checks, engine Ne speed sensor may be
Defective engine Ne speed defective. (Since this is an internal defect, troubleshooting cannot be
9
sensor performed.)
Circuit diagram related to engine Ne speed sensor
• The Ne speed sensor detects area (A) where holes (H) are not drilled through flywheel (1), and the engine
controller calculates the engine speed and signal phase.
PC490LC-10 40-223
40 Troubleshooting
Failure code [CA691] Intake Temperature Sensor High Error (PC400-CA691-400-A-Z0-

A)
Action level Failure code Intake Air Temp Sens High Error
Failure
Detail of • High voltage appears in intake temperature sensor signal circuit.
failure
Action of • Takes it that intake temperature is at fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake temperature sensor are integrated.
Related • If sensor connector is disconnected, this failure code is displayed together with failure
information code [CA357].
connector
-30 °C 25 to 28 kz
Defective intake temperature Between P55 (male) (3) and (4) 0 °C 5.5 to 6.1 kz
2 sensor 25 °C 1.9 to 2.1 kz
(internal defect) Resis- a Intake temperature - resistance
tance characteristics 40 °C 1.1 to 1.2 kz
100 °C 180 to 185 z
Between P55 (male) (3) and Whole
ground (sensor body) range Min. 1 Mz

harness (short circuit, open Resis- Between J1 (female) (6) and (22) 180 z to 28
3 circuit, defective contact of tance kz
connector)
a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Hot short circuit in wiring 2. Disconnect connector P55.
harness 3. Insert T-adapters to connector J1, or connect T-adapters to female
4
side of connector P55.
Between J1 (6) and (22) or between P55
Voltage Max. 5.25 V
(female) (1) and (3)
Resis- Between J1 (female) (6) and each of other
pins Min. 1 Mz
tance
40-224 PC490LC-10
40 Troubleshooting
Circuit diagram related to intake temperature sensor
PC490LC-10 40-225
40 Troubleshooting
Failure code [CA692] Intake Temperature Sensor Low Error (PC400-CA692-400-A-Z0-A)
Action level Failure code Intake Air Temp Sens Low Error
Failure
Detail of • Low voltage appears in intake temperature sensor signal circuit.
failure
Action of • Takes it that intake temperature is at fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
Related • Mass air flow sensor and intake temperature sensor are integrated.
connector
2. Disconnect connector P55.
If this failure code changes to [CA691], the intake temperature sensor is
defective.
• Reference
Defective intake temperature 1. Turn starting switch to OFF position.
2 sensor 2. Disconnect connector P55 and connect T-adapters to male side.
(internal defect) -30 °C 25 to 28 kz
Between P55 (male) (3) and (4) 0 °C 5.5 to 6.1 kz
25 °C 1.9 to 2.1 kz
Resis- a Intake temperature - resistance
tance characteristics 40 °C 1.1 to 1.2 kz
100 °C 180 to 185 z
Between P55 (male) (3) and Whole
ground (sensor body) range Min. 1 Mz

harness (short circuit, open Resis- Between J1 (female) (6) and (22) 180 zto 28
3 circuit, defective contact of tance kz
connector)
a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
4 female side.
tance
Resis- Between J1 (female) (6) and each of other
pins Min. 1 Mz
tance
40-226 PC490LC-10
40 Troubleshooting
Circuit diagram related to intake temperature sensor
PC490LC-10 40-227
40 Troubleshooting
Failure code [CA697] ECM Internal Temp Sensor High Error (PC400-CA697-400-A-Z0-
A)
Action level Failure code ECM Internal Temperature Sensor High Error
Failure
Detail of • High voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by
Related using monitoring function (Code: 18900(°C)).
1 Improper usage of controller Check if the controller has been used in high temperature environments.
40-228 PC490LC-10
40 Troubleshooting
Failure code [CA698] ECM Int Temp Sensor Low Error (PC400-CA698-400-A-Z0-A)
Action level Failure code ECM Internal Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in engine controller internal temperature sensor signal circuit.
failure
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by

Related using monitoring function (Code: 18900(°C)).

1 Improper usage of controller Check if the controller has been used in low temperature environments.
PC490LC-10 40-229
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error (PC400-CA731-400-A-Z0-A)
Action level Failure code Engine Bkup Speed Sensor Phase Error
Failure
• Engine controller receives signals from engine Bkup sensor, and detects a signal phase
Detail of error.
failure (The signal is out of phase when compared with signals sent from Ne speed sensor.)
Action of • Controls engine by using signals from engine Ne speed sensor.
controller
Problem on • Running engine stops (when Ne speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Ne speed sensor is also defective).
Related
information a The fuel supply pump must also be replaced during replacement of Bkup speed sensor.
(See Disassembly and assembly, "Removal and installation of fuel supply pump".)
Defective engine Ne speed Engine Ne speed sensor may be defective. Perform troubleshooting for
1 failure code [CA689].
sensor circuit
Defective engine Bkup speed Engine Bkup speed sensor may be defective. Perform troubleshooting
2 for failure code [CA778].
sensor circuit
40-230 PC490LC-10
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error (PC400-CA778-400-A-Z0-A)
Action level Failure code Engine Bkup Speed Sensor Error

Failure
Detail of • Abnormality occurred in engine Bkup speed sensor circuit.
failure
Action of • Controls engine by using signals of Ne speed sensor.
controller
Problem on • Running engine stops (when Ne speed sensor is also defective).
machine • Stopped engine cannot be started (when Ne speed sensor is also defective).
a If engine Bkup speed sensor needs to be replaced, fuel supply pump must be
replaced as a unit.
Related (See "Disassembly and assembly", "Removal and installation of fuel supply pump".)
information • Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor
cannot be determined to be normal by measuring its resistance by using multimeter .
• Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be
measured by using multimeter.
connector
Damage or improper
Engine Bkup speed (G) sensor may be damaged or improperly installed
3 installation (loose) of engine
(loose). Check it.
Bkup speed (G) sensor
Defective resistor (G-RES) 2. Disconnect connector G-RES and connect T-adapter to male side.
4
Resis- Between G-RES (male) (1) and (2)
620 z
tance
2. Disconnect connector G and connect T-adapter to female side.
Defective engine Bkup speed
sensor power supply input
Power 4.75 to 5.25
Voltage Between G (female) (1) and (2)
supply V
Open or short circuit in wiring 2. Disconnect connectors J1 and G, and connect T-adapter to the
6 harness (resistor RES line) female side of connector J1.
Resis- Between J1 (female) (9) and (60)
620 z
tance
2. Disconnect connectors J1, G, and G-RES, and connect T-adapters
to each female side.
a If power supply voltage in checks on
Open circuit in wiring harness cause 5 is normal, this check is not Max. 1 z
required.
7 (wire breakage or defective Between J1 (female) (60) and G (female) (1)
tance a If power supply voltage in checks on
cause 5 is normal, this check is not Max. 1 z
required.
Between J1 (female) (59) and G (female) (2)
Between J1 (female) (9) and G (female) (3) Max. 1 z
PC490LC-10 40-231
40 Troubleshooting

2. Disconnect connectors J1, G, and G-RES, and connect T-adapter to
female side of J1 or G.
8 Short circuit in wiring harness Between J1 (female) (60) and (9), or between
Min. 1 Mz
Resis- G (female) (1) and (3)
tance Between J1 (female) (59) and (9), or between
G (female) (2) and (3) Min. 1 Mz

Ground fault in wiring harness 2. Disconnect connectors J1 and G and connect T-adapter to either
9 female side.
Resis- Between J1 (female) (9) or G (female) (3) and
ground Min. 1 Mz
tance
2. Disconnect connectors G and G-RES, and connect T-adapter to
Hot short circuit in wiring female side of G.
10
harness 3. Turn starting switch to ON position.
Voltage Between G (female) (3) and ground Max. 1 V
If no problem is found by above checks, engine Bkup speed sensor may
Defective engine Bkup speed be defective.
11
sensor
Circuit diagram related to engine Bkup speed sensor
40-232 PC490LC-10
40 Troubleshooting
Failure code [CA1117] Persistent Data Lost Error (PC400-CA1117-400-A-Z0-A)
Action level Failure code Persistent Data Lost Error

Failure
Detail of
• Internal defect occurred in controller.
failure
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on start if it is stopped.
machine • Engine controller cannot store internal data correctly.
Related • Since the engine controller internal data (KDPF related, etc.) may be lost, appropriate
information actions must be taken after the system recovers from the error.
Since the power supply circuit may be defective, carry out
1 Defective power supply circuit
troubleshooting for failure code [CA441].
Improper operation of battery Battery disconnect switch may have been operated improperly.
2
disconnect switch
Actions to be
taken after See "How to perform regeneration for service" section.
recovery from
error
PC490LC-10 40-233
40 Troubleshooting
Failure code [CA1664] KDOC Malfunction (PC400-CA1664-400-A-Z0-A)
Action level Failure code KDOC Malfunction

Failure
• During KDPF regeneration, KDOC inlet temperature sensor and KDOC outlet
Detail of temperature sensor indicate similar values (temperature difference is approximately within
failure 10°C).
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measures by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
machine
injury.
Related • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
information engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
difference between these temperatures is approx. 10°C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approx. 250 to 400°C, and KDOC outlet temperature and KDPF outlet
temperature are approx. 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to the
OFF position. So when you restart engine, wait one minute minimum before turning
starting switch to the ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and repair
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after repair.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is also displayed, perform
1 temperature sensor troubleshooting for [CA3313], [CA3314], or [CA3315].
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] is also displayed, perform
40-234 PC490LC-10
40 Troubleshooting

See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "General information on
3
harness connector troubleshooting", and check it and fix trouble as needed.
2. Monitor signal voltages from KDOC inlet temperature sensor and KDOC
outlet temperature sensor, and note signal voltages from respective
temperature sensors in initial condition (see Related information).
4. Disconnect either connector TEMP1 or TEMP2.
Short circuit in wiring 5. Turn starting switch to ON position.
4 6. Monitor signal voltages from KDOC inlet temperature sensor and KDOC
harness
outlet temperature sensor, and note second signal voltages from
respective temperature sensors (see Related information).
If second signal voltages sensed by KDOC inlet temperature sensor and
KDOC outlet temperature sensor do not change notably (almost same as first
signal voltages), check wiring harness for short circuit (troubleshooting for
failure codes [CA3313] and [CA3316]).
5 Defective KDOC 1. Check that KDPF is installed to exhaust system.

2. Check that KDOC is installed to KDPF.
B. Machine operation for clearing failure code
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle (with no load) for approximately 1 minute.
3. Use monitoring function to display KDOC inlet and outlet temperatures.
a To clear this failure code, KDOC inlet temperature must be 250°C or higher.
4. Use work equipment to raise either track off ground.
5. Set swing lock switch to ON position and working mode to P-mode.
6. Run that track idle off ground for continuous 15 minutes with fuel control dial at MAX position and travel
speed at Hi setting.
If failure code disappears after steps 1 to 6 are implemented, repair work is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
6 engine controller is defective.
controller
PC490LC-10 40-235
40 Troubleshooting
Circuit diagram related to KDOC and KDPF temperature sensors
40-236 PC490LC-10
40 Troubleshooting
Failure code [CA1691] Regeneration Ineffective (PC400-CA1691-400-A-Z0-A)
Action level Failure code Regeneration Ineffective

Failure
• KDOC efficiency (catalyst action) is degraded. (Soot trapped in KCSF does not burn
Detail of sufficiently because the KDOC outlet temperature does not rise enough. During
failure regeneration, KDOC inlet temperature is normally approximately 250 to 400°C, and
KDOC outlet temperature is normally approximately 450 to 550°C.)
• Closes EGR valve and open KVGT fully.
controller • Stops KDPF regeneration control.
machine
injury.
function. (Code: 47400 (°C)
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
• When manual stationary regeneration (normal) is in progress, KDOC inlet temperature is
approximately 250 to 400°C, and KDOC outlet temperature and KDPF outlet temperature
are approximately 450 to 550°C.
Related • When manual stationary regeneration without injecting dosing fuel (KDOC drying) is in
information progress, KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature are all approximately 250 to 400°C.
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then perform "Manual Stationary Regeneration (manual stationary
regeneration will be completed in approximately 40 minutes).
a Failure code [CA2637] may be displayed at the same time, however, perform
troubleshooting for this failure code [CA1691].
• Method of reproducing failure code:
When KDOC is changed, there is no need to check completion of repair.
When KDOC is not changed, start engine and turn manual stationary regeneration switch
ON. (See cause 6.)
PC490LC-10 40-237
40 Troubleshooting

• If there is a significant difference between KDOC outlet temperature
Defective KDOC outlet and KDOC inlet temperature and KDPF outlet temperature when
1 temperature sensor KDPF is completely cool or engine running at idle (not regenerating),
replace KDOC outlet temperature sensor.
1. Rapidly accelerate engine from low idle to high idle 2 times, and then
keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
2 Unusual exhaust gas color
clogged in a short time".
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
a Dry KDOC.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor, note temperature values from each
Defective KDOC sensor with KDPF under initial condition and during manual
3 stationary regeneration, and check that KDOC outlet temperature
(KDOC drying)
sensor is normal. (See "Related information".)
3. Perform manual stationary regeneration. (See "Related
information".)
a Since this is for drying KDOC, dosing fuel is not injected during
regeneration.
k Perform after KDPF and KDOC are sufficiently cooled.
1. Remove KDPF.
Defective KDOC 2. Remove KDOC.
4 (dirty or cracked or damaged 3. Blow air from KDOC outlet side to clean ceramic surfaces inside
KDOC surface) KDOC.
4. Check ceramic inside KDOC for cracks.
If cracks are found in KDOC, KDOC is defective (replace KDOC).
a Perform the following regardless whether KDOC is replaced or not.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
a When reset after KDOC change is performed, failure codes
5 Reset after KDOC change [CA1691] and [CA2637] will not be displayed. At that time, remedy of
not injecting dosing fuel when the failure code is displayed is
released.
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
manual stationary regeneration.
40-238 PC490LC-10
40 Troubleshooting

a Perform this troubleshooting when KDOC is not changed.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor, note temperature values from each
sensor with KDPF under initial condition and during manual
stationary regeneration, and check that KDOC outlet temperature
sensor is normal. (See "Related information".)
Defective KDOC 3. Perform manual stationary regeneration. (See "Related
information".)
6 (degraded KDOC catalyst 4. Turn starting switch to OFF position.
action) 5. Start engine and perform manual stationary regeneration again.
(Check whether failure code [CA2637] is displayed or not.)
a Check that failure code is not displayed and finish troubleshooting.
a If failure code [CA2637] is displayed after manual stationary
regeneration is completed, KDOC is defective (catalyst action of
KDOC is degraded. Change KDOC).
a When KDOC is changed, perform troubleshooting for cause 5 again.
PC490LC-10 40-239
40 Troubleshooting
Failure code [CA1695] Sens supply 5 volt high error (PC400-CA1695-400-A-Z0-A)
Action level Failure code Sensor power supply volt 5 high error
Failure
Detail of • Low voltage appears in 5 V power supply circuit for KDPF delta pressure sensor and
failure KDPF outlet pressure sensor.
• Takes it that KDPF outlet pressure is at fixed value (0 kPa{0 kg/cm 2}) and allows engine to
run.
• Takes it that KDPF delta pressure is at recommended value and allows engine to run
Action of (uses delta pressure of 0 kPa in some cases) .
controller • Closes EGR valve and opens KVGT fully.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
connector
Defective KDPF delta 2. Disconnect connector E25.
pressure (outlet pressure) 3. Turn starting switch to ON position.
2 sensor (internal) a Ignore displayed failure codes other than this code.
(internal defect) If this failure code is not displayed, KDPF delta pressure (outlet
pressure) sensor is defective.
2. Disconnect connectors CE03 and E25, and connect T-adapters to
3 female side of connector CE03.
harness
Resis- Between CE03 (female) (52) and each pin
other than (52) Min. 1 Mz
tance
2. Disconnect connector E25.
3. Insert T-adapters to connector CE03, or connect T-adapters to
4 Defective engine controller female side of connector E25.
Between CE03 (female) (52) and (43), or
between E25 (female) (4) and (1)
Circuit diagram related to KDPF delta pressure sensor and KDPF outlet pressure sensor
40-240 PC490LC-10
40 Troubleshooting
Failure code [CA1696] Sens supply 5 volt low error (PC400-CA1696-400-A-Z0-A)
Action level Failure code Sensor power supply 5 volt low error
Failure
Detail of • Low voltage appears in 5 V power supply circuit for KDPF delta pressure sensor and
failure KDPF outlet pressure sensor.
• Takes it that KDPF outlet pressure is at fixed value (0 kPa{0 kg/cm 2}) and allows engine to
run.
• Takes it that KDPF delta pressure is at recommended value and allows engine to run
Action of (uses delta pressure of 0 kPa in some cases) .
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
connector
Defective KDPF delta 3. Turn starting switch to ON position.
2 pressure (outlet pressure)
sensor (internal defect) a Ignore displayed failure codes other than this code.
If this failure code is not displayed, KDPF delta pressure (outlet
pressure) sensor is defective.
Ground fault in wiring 2. Disconnect connectors CE03 and E25, and connect T-adapters to
(contact with ground circuit) Resis- Between ground and CE03 (female) (52) or
E25 (female) (4) Min. 1 Mz
tance
2. Disconnect connectors CE03 and E25, and connect T-adapters to
4 female side of connector CE03.
harness
Resis- Between CE03 (female) (52) and each pin
other than (52) Min. 1 Mz
tance
3. Insert T-adapters to connector CE03, or connect T-adapters to
5 Defective engine controller female side of connector E25.
Between CE03 (female) (52) and (43), or
between E25 (female) (4) and (1)
PC490LC-10 40-241
40 Troubleshooting
Circuit diagram related to KDPF delta pressure sensor and KDPF outlet pressure sensor
40-242 PC490LC-10
40 Troubleshooting
Failure code [CA1843] Crankcase Pressure Sensor High Error (PC400-CA1843-400-

A-Z0-A)
Action level Failure code Crankcase pressure sensor high error

Failure
Detail of • High voltage appears in the crankcase pressure sensor signal circuit.
failure
Action of • Sets crankcase pressure to fixed value (approx. 0 kPa), and allows engine to run.
controller
Problem on
machine
(Code: 48401(V))
Related • Crankcase pressure sensed by crankcase pressure sensor can be checked with
connector
If failure code changes from [CA1843] to [CA1844], crankcase pressure
Crankcase pressure sensor sensor is defective.
3 defective • Reference
(internal defect) 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector P57.
Sensor
Voltage Between P57 (female) (3) and (2) 0.3 to 4.7 V
output
Open circuit in wiring harness female side.
contact of connector) a To check for open circuit in GND line
Resis- Between J1 (female) (59) and P57 (female)
(2) Max. 1 z
tance
2. Disconnect connectors J1 and P57 and connect T-adapters to either
P57 (female) (1) and (3) Min. 1 Mz
tance
Hot short circuit in harness 2. Disconnect connector P57 and connect T-adapter to female side.
7 Defective engine controller • Reference
2. Insert T-adapters into connector J1.
PC490LC-10 40-243
40 Troubleshooting

Sensor
Voltage Between J1 (3) and (59) 0.3 to 4.7 V
output
Circuit diagram related to crankcase pressure sensor
a Connector PPCV is a dummy connector (no sensors are connected).
40-244 PC490LC-10
40 Troubleshooting
Failure code [CA1844] Crankcase Press Sensor Low Error (PC400-CA1844-400-A-Z0-A)
Action level Failure code Crankcase pressure sensor low error

Failure
Detail of • Low voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of • Set crankcase pressure to the fixed value (approx. 0 kPa), and run engine.
controller
Problem on
machine
(Code: 48401(V))
Related • Crankcase pressure sensed by crankcase pressure sensor can be checked with
connector
If failure code [CA187] or [CA227] is also displayed, perform
Defective sensor power 1. Turn starting switch to OFF position.

2 supply system 2. Disconnect connector P57 and connect T-adapters to female side.
Power 4.75 to 5.25
supply V
female side.
a If any failure is found in harness, disconnect connector BREAK OUT
and check further to determine which is defective; engine harness or
chassis harness.
Open circuit in wiring harness a If no failure is found by check on cause 2,

Resis- this check is not required.
3 (wire breakage or defective Max. 1 z
tance Between J1 (female) (60) and P57
(female) (1)
a If no failure is found by check on cause 2,
Resis- this check is not required.
Max. 1 z
tance Between J1 (female) (59) and P57
(female) (2)
Resis- Between J1 (female) (3) and P57 (female) (3) Max. 1 z
tance
PC490LC-10 40-245
40 Troubleshooting

female side.
Ground fault in wiring
4 harness a If any failure is found in harness, disconnect connector BREAK OUT
(contact with ground circuit) and check further to determine which is defective; engine harness or
chassis harness.
tance
tance
Defective crankcase 2. Insert T-adapters into connector P57.
6 pressure sensor (internal 3. Turn starting switch to ON position.
defect) Sensor
Voltage Between P57 (female) (3) and (2) 0.3 to 4.7 V
output
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
Sensor
Voltage Between J1 (3) and (59) 0.3 to 4.7 V
output
Circuit diagram related to crankcase pressure sensor
a Connector PPCV is dummy (no sensor is connected to it).
40-246 PC490LC-10
40 Troubleshooting
Failure code [CA1879] KDPF Delta Pressure Sensor High Error (PC400-CA1879-
400-A-Z0-A)
Action level Failure code KDPF delta pressure sensor high error
Failure
Detail of • High voltage appears in KDPF delta pressure sensor signal circuit.
failure
• Takes it that KDPF delta pressure is at recommended value and allows engine to run.
(If another failure code is also generated, controller may run engine using delta pressure
Action of of 0 kPa.)
machine
k Since the temperature of the KDPF will become higher than 500 °C, take care not to
get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
Related • If failure code [CA1695] is not displayed but failure code [CA3133] is displayed, GND line
information may have open circuit (defective connection of connector).
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47100(V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47101 (MPa))
harness connector
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
it first.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25
V
Defective KDPF delta If failure code changes to [CA1881], KDPF delta pressure sensor is defective.
3 pressure sensor
a If this failure code is still displayed, the wiring harness or engine controller
is defective.
a Ignore other displayed failure codes.
harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to each
a To check for open circuit in GND line
connector)
Max. 1 z
Resistance Between CE03 (female) (43) and E25 (female) (1)
PC490LC-10 40-247
40 Troubleshooting

2. Disconnect connectors CE03 and E25, and connect T-adapters to female
side of connector CE03.
5
harness a Check by using multimeter in continuity mode.
Between CE03 (female) (55) and No continuity
Continuity
each other pin (No sound is heard)
Defective engine If this failure code appears and no failure is found by above checks, engine
6
controller controller is defective. (Since this is an internal defect, troubleshooting cannot
be performed.)
Circuit diagram related to KDPF delta pressure sensor
40-248 PC490LC-10
40 Troubleshooting
Failure code [CA1881] KDPF Delta Pressure Sensor Low Error (PC400-CA1881-
400-A-Z0-A)
Action level Failure code KDPF deltal pressure sensor low error
Failure
Detail of • Low voltage appears in the KDPF delta pressure sensor signal circuit.
failure
• Takes it that KDPF delta pressure is at recommended value and allows engine to run.
(If another failure code is also generated, controller may run engine using delta pressure
Action of of 0 kPa.)
machine
k Since the temperature of the KDPF will become higher than 500 °C, take care not to
get burn injury.
• If failure code [CA1696] is not displayed but failure code [CA3134] is displayed, the
Related sensor connector may be disconnected or an open circuit (poor connection in connector)
information is suspected in the 5 V line.
• This failure code is displayed if the sensor connector is disconnected.
(Code: 47100(V))
• Differential pressure sensed by KDPF delta pressure sensor can be checked with
monitoring function. (Code: 47101 (MPa))
harness connector
it first.
V
2. Disconnect connectors CE03 and E25, and connect T-adapters to each
female side.
Open circuit in wiring a If no failure is found by check on cause 2, this
harness check is not required. Max. 1 z
3 (wire breakage or Between CE03 (female) (43) and E25 (female) (1)
connector) Resistance a If no failure is found by check on cause 2, this
check is not required. Max. 1 z
Between CE03 (female) (52) and E25 (female) (4)
Between CE03 (female) (55) and E25 (female) (2) Max. 1 z
PC490LC-10 40-249
40 Troubleshooting

harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to either
4 female side.
Between CE03 (female) (55) or E25 (female) (2)
circuit) Resistance and ground Min. 1 Mz

5
Continuity
Defective KDPF delta 2. Insert T-adapter into connector E25.
6 pressure 3. Turn starting switch to ON position.
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
7
be performed.)
40-250 PC490LC-10
40 Troubleshooting
Failure code [CA1883] KDPF Delta Pressure Sensor In Range Error (PC400-
CA1883-400-A-Z0-A)
Action level Failure code KDPF Delta Pressure Sensor In Range Error
Failure
Detail of • Signal voltage from KDPF delta pressure sensor is out of range. (Signal voltage from
failure sensor is within operating range.)
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
run engine.)
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
(Code: 47101 (V))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• Temperature sensed by torque converter oil temperature sensor can be checked with
a Use "Short-circuit connector: 799T-601-4611".
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
Machine O
clearing
after repair.
troubleshooting for [CA1695] or [CA1696] first.
1 supply system 2. Disconnect connector E25 and connect T-adapter to female side.
V
2
PC490LC-10 40-251
40 Troubleshooting

If failure code [CA1881] is not displayed, wiring harness or engine controller is
defective.
a Perform check on cause 2 again.
Defective wiring 1. Turn starting switch to OFF position.
3 harness or engine 2. Disconnect connector E25 and connect short-circuit connector to female
controller side.
a To connect 5 V line to signal line (to short pin (4) to pin (2) of connector
E25).
defective.
Defective KDPF delta a If failure codes [CA1881] and [CA1879] are displayed in check on cause 3,
4 pressure sensor KDPF delta pressure sensor is defective.
female side.
Open circuit in wiring
harness a If no failure is found by check on cause 1, this
a If no failure is found by check on cause 1, this
harness 2. Disconnect connectors CE03 and E25, and connect T-adapter to either
6 female side.
Between ground and CE03 (female) (55) or E25

2. Disconnect connectors CE03 and E25, and connect T-adapter to female
Short circuit in wiring side of CE03.
7
Between CE03 (female) (55) and No continuity (no sound
Continuity
each pin other than pin (55) is heard)
1. Remove KDPF delta pressure sensor tube.
2. Clean KDPF delta pressure sensor tube to clear clogging.
3. Check KDPF delta pressure sensor tube for cracks and damage.
4. Install KDPF delta pressure sensor tube with both tube ends connected
securely.
Defective KDPF delta
8 • Reference
pressure sensor tube
How to check KDPF delta pressure sensor tube for clogging
2. Monitor delta pressure sensed by KDPF delta pressure sensor on
monitoring screen of machine monitor.
Code 47,100 (kPa) 0 ± 3 (kPa)
40-252 PC490LC-10
40 Troubleshooting

k Place the machine on a level ground.
1. Turn starting switch to ON position and leave it in that position for 1 minute. (In order to allow engine
controller to determine drift of voltage when starting switch is turned to ON position)
4. After finishing warm-up operation, set swing lock switch to OFF position, working mode to P-mode, and
fuel control dial to MAX position.
5. Perform arm IN relief for 40 seconds.
a Take care not to overheat hydraulic oil.
a If failure code disappears, repair is complete.
6. If failure code still remains displayed, repeat above step 5 three times.
a If failure code disappears, repair is complete.
command.
controller
PC490LC-10 40-253
40 Troubleshooting
Failure code [CA1921] KDPF Soot Load High Error 1 (PC400-CA1921-400-A-Z0-A)
Action level Failure code KDPF Soot Load High Error 1

Failure
• Soot accumulation of KDPF reaches level 6 or 7. As much soot is accumulated in KCSF,
Detail of the user is requested to perform "Manual Stationary Regeneration" immediately.
failure (If soot accumulation reaches level 8, KDPF must be replaced.)
controller • Disables automatic regeneration but allows manual stationary regeneration.
machine
k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.
(Code: 47101 (V))
Related • Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
• When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approximately 250 to 400°C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550°C.
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
40-254 PC490LC-10
40 Troubleshooting
a Time required for the manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: approximately 40 minutes to 1 hour
• If soot accumulation is level 5: approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: approximately 1 to 3 hours
• If soot accumulation is level 8: The manual stationary regeneration can not be performed.
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that leads to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
a If failure code [CA1922] has been displayed originally, it changes to [CA1921] during
troubleshooting process of [CA1922]. In such case, refer to failure code [CA1922].
• Method of reproducing failure code: Turn starting switch to the ON position.
1. Check if the regeneration stop button is pressed down from the
machine monitor.
a If the regeneration stop button is pressed down, release it.
4. Perform manual stationary regeneration from user mode.
a When the manual stationary regeneration is finished correctly, the
Excessive KDPF (KCSF) repair is completed.
1
soot accumulation level
a If the regeneration does not complete within 3 hours, perform the
troubleshooting of [CA2639].
a Check that failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1922] or [CA2639] is displayed after manual
stationary regeneration is completed, proceed to checks on
cause 2.
a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".
2 Unusual exhaust gas color a When checking the exhaust gas color, perform the "Regeneration
Disable" from the machine monitor.
PC490LC-10 40-255
40 Troubleshooting

idle.
a Check that no failure code appears.
a When you finish the check of the exhaust gas color, release
"Regeneration Disable".
40-256 PC490LC-10
40 Troubleshooting
Failure code [CA1922] KDPF Soot Load High Error 2 (PC400-CA1922-400-A-Z0-A)
Action level Failure code KDPF Soot Load High Error 2

Failure
• Soot accumulation in KDPF is very high, and machine must be stopped and performed
Detail of maintenance immediately.
failure • Soot accumulation reaches level 8 (KDPF is completely clogged with soot).
controller • Disables the automatic regeneration and the manual stationary regeneration.
machine
injury.
(Code: 47101 (V))
Related • Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
• When the active regeneration (the manual stationary regeneration) is in progress, KDOC
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
PC490LC-10 40-257
40 Troubleshooting
• If soot accumulation is level 4: approximately 40 minutes to 1 hour
• If soot accumulation is level 5: approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: approximately 1 to 3 hours
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that lead to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
• Procedure of performing the manual stationary regeneration from the "Regeneration for
Service".
performed only from the "Regeneration for Service".
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"Regeneration for Service", and then perform the "Manual Stationary Regeneration".
a Resetting after KDPF cleaning
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Cleaning" (reset after KDPF cleaning).
a Resetting after KDPF change
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Change" (resetting after KDPF change).
a When KCSF in KDPF is changed, always perform resetting procedures for KDPF cleaning
and KDPF change, and then perform the "Manual Stationary Regeneration" from the
"Regeneration for Service" to eliminate moisture from KCSF.
• Method of reproducing failure code: Turn starting switch to the ON position.
40-258 PC490LC-10
40 Troubleshooting

Increase of soot machine monitor.
1 accumulation due to a If the regeneration stop button is pressed down, release it.
"Regeneration Disable"
a After releasing the "Regeneration Disable", proceed to checks on
causes 2 and after.
• Check the abnormality record.
1. Turn starting switch to the ON position.
2. From the machine monitor, displays the abnormality record screen
and check the history of failure codes CA2639, CA1921 and
CA1922.
Interval between failure code CA2639 and CA1921
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
and
Interval between failure code CA1921 and CA1922
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
[When above conditions are satisfied]
a As much soot is accumulated, KDPF regeneration can not be
performed.
1. Replace the KCSF or the KDPF.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
a If the failure code [CA1922] continues, check the resetting
Defective KDPF (KCSF)
2 procedure after KDPF cleaning, and perform the reset after KDPF
(change KCSF) cleaning again.
3. Reset the KDPF after its change (see "Related information").
4. Perform checks on causes 4 to 7 (When KDPF is changed, this is not
needed.)
7. Perform regeneration for service.
repair is completed.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after
manual stationary regeneration is completed, perform checks on
cause 8.
[When above conditions are not satisfied]
(When the actual soot accumulation is less than the displayed value)
Proceed to checks on cause 3 and after.
PC490LC-10 40-259
40 Troubleshooting

a When the actual soot accumulation is less than the displayed value
on the machine monitor
1. Proceed to checks on cause 4 to 7.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
a If the failure code [CA1922] continues, check the resetting
procedure after KDPF cleaning, and perform the reset after KDPF
cleaning again.
Defective KDPF (KCSF) 5. Perform manual stationary regeneration from user mode.
3 (abnormal condition of soot
accumulation) a When the manual stationary regeneration is finished correctly, the
a If failure code [CA1922] is displayed again within 1 hour after
starting the manual stationary regeneration, perform Step 2 and 3
again.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after
manual stationary regeneration is completed, perform checks on
cause 8.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] is displayed, perform
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform
6 temperature sensor troubleshooting for [CA3316], [CA3321] or [CA3322].
2. Monitor differential pressure sensed by KDPF differential pressure
sensor on monitoring screen of machine monitor.
Code 47,100 (kPa) 0 ± 3 (kPa)
a If the differential pressure is outside of the above range, perform the
Defective KDPF differential following.
7 pressure sensor
1. Remove KDPF differential pressure sensor tube.
(including sensor tubes) 2. Clean KDPF differential pressure sensor tube to clear clogging.
a If the KDPF differential pressure sensor tube is not clogged,
perform the following.
3. Perform for "Short circuit in wiring harness" of failure code [CA1881]
or [CA1883]. (If no short circuit occurs, replace the KDPF differential
pressure sensor.)
40-260 PC490LC-10
40 Troubleshooting

a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
a When checking the exhaust gas color, perform the "Regeneration
8 Unusual exhaust gas color keep engine running at high idle for 5 seconds.
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
PC490LC-10 40-261
40 Troubleshooting
Failure code [CA1923] Dosing Fuel Valve 1 High Error (PC400-CA1923-400-A-Z0-A)
Action level Failure code Dosing Fuel Valve 1 High Error

Failure
Detail of Abnormal low voltage (or high circuit resistance) has occurred in dosing fuel solenoid valve 1
failure (shut-off valve).
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.
get burn injury.
Related
information • If failure code [CA2732] is also displayed, the ground (GND) leads may be open.
• See failure code [CA1925].
Defective dosing fuel 2. Disconnect connector SOV1, and connect T-adapter to male side of
2 solenoid valve 1 (shut-off connector.
valve) Resis- Between SOV1 (male) (2) and (1)
4 to 6 z
tance
3
harness Resis- Between J2 (female) (9) and (18)
4 to 6 z
tance a The resistance is the same as above.
2. Disconnect connectors J2 and SOV1, and connect T-adapter to each
Open circuit in wiring harness female side of connectors.
4 (wire breakage or defective a To check open circuit in GND line
Between J2 (female) (9) and SOV1 (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (18) and SOV1 (female)
(2) Max. 1 z

2. Disconnect connectors J2 and SOV1, and connect T-adapter to
5 Short circuit in wiring harness a Check by using multimeter in continuity mode.

No
Between J2 (female) (9) and each pin other continuity
Continuity
than pin (9) (No sound
is heard)
1. Start engine and run it at low idle for 1 minute.
a If another failure code is displayed, perform troubleshooting for it.
If this failure code appears and no failure is found by above checks,
40-262 PC490LC-10
40 Troubleshooting
Circuit diagram related to dosing fuel solenoid valve
PC490LC-10 40-263
40 Troubleshooting
Failure code [CA1924] Dosing Fuel Valve 1 Low Error (PC400-CA1924-400-A-Z0-A)
Action level Failure code Dosing Fuel Valve 1 Low Error

Failure
Detail of Abnormal high voltage (or low circuit resistance) has occurred in dosing fuel solenoid valve 1
failure (shut-off valve).
controller
get burn injury.
Related
information • If sensor connector is disconnected, failure code [CA1923] appears.
Defective harness troubleshooting", and check it.
connector
Defective fuel doser 2. Disconnect connector SOV1, and connect T-adapter to male side of
2 solenoid valve 1 connector.
(shut-off valve) Between SOV1 (male) (2) and (1) 4 to 6 z
Resistance
Between SOV1 (male) (1) and ground (SOV body) Min. 1 Mz
Open or short circuit in
3 wiring harness Between J2 (female) (9) and (18)
Resistance a The resistance is the same as that of shut-off 4 to 6 z
valve.
harness
4 2. Disconnect connectors J2 and SOV1, and connect T-adapter to female
(contact with ground side of either connector.
circuit) Between ground and J2 (female) (9) or SOV1
Resistance (female) (1) Min. 1 Mz

2. Disconnect connectors J2 and SOV1, and connect T-adapter to female
Short circuit in wiring side of connector J2.
5
Between J2 (female) (9) and each pin No continuity
Continuity
other than pin (9) (No sound is heard)
Defective dosing fuel
6 solenoid valve 1 (shut- Replace dosing fuel solenoid valve 1 (shut-off valve).
off valve)
Defective engine a If another failure code is displayed, perform troubleshooting for it.
7 If this failure code appears and no failure is found by above checks, engine
controller
controller is defective. (Since this is an internal defect, troubleshooting cannot
be performed.)
40-264 PC490LC-10
40 Troubleshooting
Circuit diagram related to fuel doser

A: From electric fuel pump
B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
JB: Fuel tube joint bolt
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel solenoid valve 1 (shut-off valve)
connector
SOV2: Dosing fuel solenoid valve 2 (drain valve)
connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor
PC490LC-10 40-265
40 Troubleshooting
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error (PC400-CA1925-400-A-Z0-A)
Action level Failure code Dosing Fuel Valve 1 In Range Error

Failure
Dosing fuel solenoid valve 1 does not operate normally. (The valve at fuel inlet is half open
Detail of although it must be fully closed. Therefore, the dosing fuel pressure does not drop
failure sufficiently.)
controller
get burn injury.
• In this failure code, the dosing fuel valve 1 (shut-off valve) is determined defective from
the fuel pressure change caused by the operation of solenoid valve.
• Therefore, the pressure check by fuel pressure sensor is required.
• When the starting switch is turned to ON position, the fuel pressure is checked by the
engine controller.
Related • Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
information (Code: 47601 (V))
• Pressure detected by dosing fuel pressure sensor can be checked with monitoring
• Method of reproducing failure code: Start the engine (and observe for 3 minutes).
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approximately 3 minutes, repair is completed.
Defective dosing fuel 2. Disconnect fuel supply line (2) from fuel doser (1).
2 pressure sensor 3. Turn starting switch to ON position.
If the dosing fuel pressure is clearly different from ambient pressure, the
dosing fuel pressure sensor is defective (see "Related information").
a The dosing fuel pressure must be equal to the ambient pressure.
2. Disconnect fuel supply line (2) from fuel doser (1).
3. Disconnect connector SOV1.
4. Connect the disconnected SOV1 connector to a new SOV connector
socket.
Defective dosing fuel shut-off a If connector SOV1 is open, failure code [CA1923] is displayed
3
valve and the pressure test (which checks the fuel dosing system) is
not carried out. Also, the electric fuel pump is not driven.
6. Start engine.
If fuel leaks from the fuel connector of fuel supply line (2), dosing fuel
solenoid valve 1 (shut-off valve) (3) is defective.
40-266 PC490LC-10
40 Troubleshooting

1. Start engine and run it for 3 minute.
2. If this failure code appears, perform procedure for <How to clear
Defective engine controller failure code> in "Related information".
4
If this failure code is still displayed and no failure is found by above
checks, engine controller is defective. (Since this is an internal defect,


B: Fuel return
PDOSER Dosing fuel pressure sensor connector
connector
connector
1. Fuel doser
2. Fuel supply line
PC490LC-10 40-267
40 Troubleshooting
Failure code [CA1927] Dosing Fuel Press Sens High Error (PC400-CA1927-400-A-Z0-A)
Action level Failure code Dosing Fuel Pressure Sensor High Error
Failure
Detail of • Signal voltage from doser fuel pressure sensor indicates a value higher than the
failure threshold.
controller
k Since the temperature of the exhaust connector and KDPF will become higher than
500 °C , take care not to get burn injury.
Related • Signal voltage from the doser fuel pressure sensor can be checked by using monitoring
information function. (Code: 47601(V))
• The pressure sensed by the doser fuel pressure sensor can be checked by using
monitoring function. (Code: 47600 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position (observe for 1
minute) (since this is L01, check on the abnormality record screen).
1. Perform checks referring to harness and connecter related
descriptions in "c: Electrical equipment" of "Checks before
Defective wiring harness troubleshooting" in "General information on troubleshooting".
connector
for it first.
Doser fuel pressure sensor
2 power supply error 2. Disconnect connector PDOSER and connect T-adapter to female
side.
Voltage Between PDOSER (female) (1) and (2) 4.75 to 5.25 V
2. Disconnect connector PDOSER.
Defective doser fuel pressure If failure code changes from [CA1927] to [CA1928], doser fuel pressure
3
sensor sensor is defective.
• Carry out troubleshooting for cause 1 again.
• If failure code [CA1927] does not changes to [CA1928], the wiring
harness or engine controller is defective.
2. Disconnect connectors J2 and PDOSER, and connect T-adapters to
Open circuit in wiring each female side.
harness a To check for open circuit in GND line
4
(wire breakage or defective
contact of connector) a If no failure is found by check on cause 2,
Resis- this check is not required. Max. 1 z
tance Between J2 (female) (47) and PDOSER
(female) (2)
40-268 PC490LC-10
40 Troubleshooting

2. Disconnect connectors J2 and PDOSER and connect T-adapter to
5 a Check by using multimeter in continuity mode.
harness
No continuity
Continuity Between J2 (female) (36) and each other pin (No sound is
heard)
1. Start the engine and run at low idle for 1 minute.
Circuit diagram related to doser fuel pressure sensor
PC490LC-10 40-269
40 Troubleshooting
Failure code [CA1928] Dosing Fuel Press Sens Low Error (PC400-CA1928-400-A-Z0-A)
Action level Failure code Dosing Fuel Pressure Sensor Low Error
Failure
Detail of • Signal voltage from dosing fuel pressure sensor is lower than threshold value.
failure
controller
get burn injury.
• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
Related (Code: 47600 (V))
information • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
minute) (since action level of this failure code is L01, check it on abnormality record
screen).
connector
for [CA352] or [CA386] first.
2 system of dosing fuel 2. Disconnect connector PDOSER and connect T-adapter to female
pressure sensor side.
Voltage Between PDOSER (female) (1) and (2) 4.75 to 5.25 V
Defective dosing fuel 2. Insert T-adapter into connector PDOSER.
Voltage Between PDOSER (3) and (2) 0.5 to 4.5 V
2. Disconnect connectors J2 and PDOSER, and connect T-adapters to
each female side.
Open circuit in wiring this check is not required. Max. 1 z
harness Between J2 (female) (30) and PDOSER
4 (female) (1)
(Wire breakage or defective
tance
Between J2 (female) (47) and PDOSER
(female) (2)
Between J2 (female) (36) and PDOSER

Short circuit in wiring 2. Disconnect connectors J2 and PDOSER, and connect T-adapter to
harness
40-270 PC490LC-10
40 Troubleshooting

No continuity
Between J2 (female) (36) and each pin other
Continuity (No sound is
than pin (36)
heard.)
6 Defective engine controller If this failure code is displayed and no failure is found by above checks,
Circuit diagram related to dosing fuel pressure sensor
PC490LC-10 40-271
40 Troubleshooting
Failure code [CA1942] Crankcase Press Sens In Range Error (PC400-CA1942-400-A-

Z0-A)
Action level Failure code Crankcase Pressure Sensor In Range Error

Failure
Detail of • Output value from crankcase pressure sensor is out of normal range.
failure
controller
Problem on
machine
(Code: 48401 (V))
information (Code: 48400 (MPa))
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
sensor
2 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
3 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.
40-272 PC490LC-10
40 Troubleshooting
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error (PC400-CA1963-400-A-Z0-A)
Action level Failure code Dosing Fuel Valve 1 Servo Error

Failure
Detail of • Although dosing fuel solenoid valve 1 (shut-off valve) is ON, the pressure detected by
failure dosing fuel pressure sensor is below the threshold.
controller
get burn injury.
(Code: 47601 (V))
Related • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
• Method of reproducing failure code: Start the engine (and observe for 3 minutes).
Turn starting switch ON from OFF position to start engine. If failure code is cleared after
equipment" in "Checks before troubleshooting" of "Related information on
harness connector
If failure code [CA1923] or [CA1924] or [CA1925] is also displayed, perform
2 solenoid valve 1 (shut-
troubleshooting for [CA1923] or [CA1924] or [CA1925] first.
off valve)
3 solenoid valve 2 (drain
valve)
Defective dosing fuelIf failure code [CA1927] or [CA1928] is also displayed, perform
4 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
Defective fuel supplyIf failure code [CA559] is also displayed, perform troubleshooting for [CA559]
5 pump first.
Defective fuel feed If failure code [CA2265] or [CA2266] is also displayed, perform
6 pump system troubleshooting for [CA2265] or [CA2266] first.
7 Clogging of fuel filter
Check fuel filter for clogging.
If fuse No. 12 in fuse box FS12 is blown, circuit probably has ground fault.
Defective fuse for fuel
8 feed pump Perform troubleshooting for cause 10 first.
• Check of power supply in fuel feed pump.
2. Disconnect connector EPP, and connect T-adapter to female side.
harness (wire breakage Voltage Between EPP (female) (3) and (10) 20 to 30 V
9 or defective contact of
connector) 2. Disconnect connector EPP, and connect T-adapter to female side.
3. Remove fuse No. 12 in fuse box FS12.
Between FS12–12 and EPP (female) (3) Max. 1 z
Resistance
Between EPP (female) (10) and ground Max. 1 z
10 harness (contact with 2. Disconnect connector EPP, and connect T-adapter to female side.
ground circuit) 3. Remove fuse No. 12 in fuse box FS12.
PC490LC-10 40-273
40 Troubleshooting

Resistance Between EPP (female) (3) and ground Min. 1 Mz
2. Loosen the joint bolt (JB) of fuel tube.
3. Tilt the switch for the fuel feed pump to ON position while starting switch is
Defective fuel feed in OFF position.
11 pump (Be careful since fuel may spurt out.)
When completing the check, turn the starting switch to ON position or tilt
the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB) of fuel tube, fuel feed pump is
defective.
4. See Related information, and display dosing fuel pressure and ambient
Defective dosing fuel pressure on the machine monitor at the same time.
12 pressure sensor
If the dosing fuel pressure is clearly different from ambient pressure, the
dosing fuel pressure sensor is defective.
a The dosing fuel pressure must be equal to the ambient pressure because
fuel supply line (2) is disconnected.
13 solenoid valve 1 (shut- Replace dosing fuel solenoid valve 1 (shut-off valve).
off valve)

B: Fuel return
connector
connector
1. Fuel doser
2. Fuel supply line
40-274 PC490LC-10
40 Troubleshooting
Circuit diagram related to fuel feed pump
PC490LC-10 40-275
40 Troubleshooting
Failure code [CA1977] Fuel Doser Open/Short Error (PC400-CA1977-400-A-Z0-A)
Action level Failure code Fuel Doser Open/Short Error

Failure
Detail of • The fuel doser circuit is short-circuited or opened.
failure
controller
get burn injury.
Related (Code: 47600 (V))
information • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
minute).
1
defective.
2. Disconnect connector DOSER, and connect T-adapter to male side
of connector.
2 Defective fuel doser (injector)
Between DOSER (male) (1) and (2) 0.5 to 2 z
Resis-
Between DOSER (male) (1) and ground (fuel
tance Min. 1 Mz
doser body)
3
harness Resis-
a The resistance is the same as fuel doser 0.5 to 2 z
tance
(injector).
Open circuit in wiring harness 2. Disconnect connectors J2 and DOSER, and connect T-adapters to
4 (Wire breakage or defective each female side.
contact of connector) Between J2 (female) (50) and DOSER (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (60) and DOSER (female)
(2) Max. 1 z

Ground fault in wiring 2. Disconnect connectors J2 and DOSER, and connect T-adapter to
(Contact with ground circuit) Resis- Between J2 (female) (50) or DOSER (female)
(1) and ground (frame) Min. 1 Mz
tance
2. Disconnect connectors J2 and DOSER, and connect T-adapter to
6 Short circuit in wiring harness female side of connector J2.
40-276 PC490LC-10
40 Troubleshooting

Between J2 (female) (50) and each No continuity (no sound
Continuity
pin other than pin (50) is heard)
7 Defective engine controller If this failure code is displayed and no failure is found by above checks,
Circuit diagram related to fuel doser (injector)
PC490LC-10 40-277
40 Troubleshooting
Failure code [CA1993] KDPF Delta Pressure Low Error (PC400-CA1993-400-A-Z0-A)
Action level Failure code KDPF Delta Pressure Low Error

Failure
Detail of • Signal voltage from KDPF delta pressure sensor is lower than threshold value.
failure
machine
(Code: 47101 (V))
information • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
Machine O
clearing
after repair.
Defective KDPF delta If failure code [CA1879], [CA1881], or [CA1883] is displayed, perform
1 pressure sensor troubleshooting for [CA1879], [CA1881], or [CA1883] first.
1. Turn starting switch to OFF position once, and then turn it to ON position.
2. Check whether failure codes other than [CA1993] are generated.
3. Start engine and accelerate it suddenly from low idle to full speed two
times, then run it at full speed for 5 seconds. During above operation,
check exhaust gas color at exhaust pipe when engine accelerates
2 KCSF abnormality 1 suddenly and runs at full speed.
4. If black smoke is exhausted from exhaust pipe in above step 3, KCSF is
abnormal. Check whether KCSF is installed. If yes, check KCSF for
damage and foreign material in it, and fix trouble as needed.
a If black smoke is not exhausted, proceed to checks on causes 3 and after.
40-278 PC490LC-10
40 Troubleshooting

Perform following checks.
1. Check whether KDPF delta pressure sensor tube is installed.
Defective KDPF delta 2. Check whether KDPF delta pressure sensor tube is connected correctly.
3 pressure sensor tube 3. Remove KDPF delta pressure sensor tube and check it for clogging,
cracks, and damage.
4. Check both ends of KDPF delta pressure sensor tube for loose
connection.

5. Perform arm IN relief for continuous 1 minute.
a Take care not to overheat hydraulic oil.
a If failure code disappears after implementing steps 1 to 5, repair work is complete.
a If failure code still remains displayed, repeat above step 5 three times.
command.
If this failure code is still displayed after above procedures are implemented,
remove KDPF and KCSF, and check whether filter in KCSF is installed. If yes,
4 KCSF abnormality 2 check filter for damage and foreign material in it, and fix trouble as needed.
After repair, implement above "B. Machine operation for clearing failure code".
controller
PC490LC-10 40-279
40 Troubleshooting
Failure code [CA2185] Throt Sensor Sup Volt High Error (PC400-CA2185-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in throttle sensor power supply (5 V) circuit.
failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "General information
connector
If this failure code disappears, wiring harness connector is defective.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2185].
2. Disconnect connectors CE03 and P20, and connect T-adapter to
3 female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than pin CE03 (female) (42)
Hot short circuit in wiring 1. Turn starting switch to OFF position.
2. Disconnect connector P20, and connect T-adapter to female side.
Voltage Between P20 (female) (1) and ground 4.75 to 5.25 V
• Reference
2. Insert T-adapter into connector CE03.
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
40-280 PC490LC-10
40 Troubleshooting
PC490LC-10 40-281
40 Troubleshooting
Failure code [CA2186] Throt Sensor Sup Volt Low Error (PC400-CA2186-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in throttle sensor power supply (5 V) circuit.
failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
equipment" in "Checks before troubleshooting" of "General information
connector
If this failure code disappears, wiring harness connector is defective.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2186].
Ground fault in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapter to either
(contact with ground circuit) Resis- Between ground and CE03 (female) (42) or P20
Min. 1 Mz
tance (female) (1)
2. Disconnect connectors CE03 and P20, and connect T-adapter to
Short circuit in wiring female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than pin CE03 (female) (42)
• Reference
2. Insert T-adapter into connector CE03.
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
40-282 PC490LC-10
40 Troubleshooting
PC490LC-10 40-283
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error (PC400-CA2249-400-A-Z0-A)
Action level Failure code Rail Pressure Very Low Error

Failure
Detail of • Supply pump does not feed fuel (level 2).
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
Supply pump pressure low Perform troubleshooting for failure code [CA559].
1
error
40-284 PC490LC-10
40 Troubleshooting
Failure code [CA2265] Fuel feed pump open circuit error (PC400-CA2265-400-A-Z0-A)
Action level Failure code Fuel feed pump open circuit error
Failure
Detail of • Open circuit occurs on the fuel feed pump drive signal circuit (when pump timer switch is
failure ON).
controller
Problem on • KDPF regeneration does not work.
machine
Related
information a Since this failure code has action level of L01, check if this failure code is currently active
on abnormality record screen.
connector
Open circuit in wiring harness 2. Disconnect connectors CE03 and S50, and connect T-adapters to
each female side.
2 (wire breakage or defective Between CE03 (female) (14) and S50
contact of connector) Resis- (female) (5) Max. 1 z
tance
Between S50 (female) (10) and ground Max. 1 z
If no failure is found by above troubleshooting, engine controller or fuel
feed pump switch timer is defective.
• Reference
Defective engine controller or 1. Turn starting switch to OFF position.
3 fuel feed pump switch timer 2. Insert T-adapters into connector CE03.
Between CE03 (14) When switch timer
and (21) operates Max. 1 V
Voltage
and (21) stops 20 to 30 V
PC490LC-10 40-285
40 Troubleshooting
40-286 PC490LC-10
40 Troubleshooting
Failure code [CA2266] Fuel feed pump short circuit error (PC400-CA2266-400-A-Z0-A)
Action level Failure code Fuel feed pump short circuit error
Failure
Detail of • Short circuit occurs on the fuel feed pump drive signal circuit (when pump timer switch is
failure ON).
controller
machine • KDPF regeneration does not work.
Related
information a Since this failure code has action level of L01, check if this failure code is currently active
on abnormality record screen.
connector
2. Disconnect connector M37
2 Defective fuel feed pump
If this failure code [CA2266] goes off, fuel feed pump is defective.
• Since connector is disconnected, other failure code than currently
displayed failure code can be ignored.
2. Disconnect connector S50
Defective fuel feed pump If this failure code [CA2266] goes off, fuel feed pump timer switch is
3
timer switch defective.
a Since connector is disconnected, other failure code than currently
displayed failure code can be ignored.
Ground fault in wiring harness 2. Disconnect connectors CE03 and S50, and connect T-adapters to
Resis- Between CE03 (female) (14) or S50 (female)
tance
2. Disconnect connectors CE03, S50 and M37, and connect T-
adapters to each female side of CE03 and M37.
Between CE03 (female) (14) and each of
Resis- (21), (22), (31) and (32) Min. 1 Mz
tance
Between M37 (female) (1) and (2) Min. 1 Mz
If no failure is found by above troubleshooting, engine controller or fuel
feed pump switch timer is defective.
• Reference
Defective engine controller or 1. Turn starting switch to OFF position.
6 fuel feed pump switch timer 2. Insert T-adapters into connector CE03.
and (21) operates Max. 1 V
Voltage
and (21) stops 20 to 30 V
PC490LC-10 40-287
40 Troubleshooting
40-288 PC490LC-10
40 Troubleshooting
Failure code [CA2271] EGR Valve Pos Sens High Error (PC400-CA2271-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor High Error
Failure
Detail of • High voltage appears in EGR valve lift sensor signal circuit.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked by using monitoring function.
(Code: 18100 (mm))
Related • EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using
information monitoring function. (Code: 18101 (V))
connector
Defective EGR valve lift 2. Disconnect connector SEGR.
3 sensor 3. Turn starting switch to ON position (with connector SEGR
(internal defect) disconnected).
2. Disconnect connectors J2 and SEGR, and connect T-adapters to
Open circuit in wiring harness each female side.
contact of connector) a To check for open circuit in GND line
Resis- Between J2 (female) (47) and SEGR (female)
(2) Max. 1 z
tance
2. Disconnect connectors J2 and SEGR, and connect T-adapter to
Short circuit in wiring harness either female side.
5
Between J2 (female) (30) and (59), between
Resis- SEGR (female) (1) and (3), or between SEGR
Min. 1 Mz
tance (female) (1) and (4)
2. Disconnect connector SEGR and connect T-adapter to female side.
6 Hot short circuit in harness 3. Turn starting switch to ON position (with connector SEGR
disconnected).
Voltage Between SEGR (female) (3) or (4) and (2) Max. 1 V
• Reference
Voltage Between J2 (59) and (47) 1.0 to 4.0
V
PC490LC-10 40-289
40 Troubleshooting
Circuit diagram related to EGR valve lift sensor
40-290 PC490LC-10
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error (PC400-CA2272-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor Low Error
Failure
Detail of • Low voltage appears in EGR valve lift sensor signal circuit.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked by using monitoring function.
(Code: 18101 (V))
Related • EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using
information monitoring function. (Code: 18100 (mm))
connector

2 supply system 2. Disconnect connector SEGR and connect T-adapter to female side.
Between SEGR (female) (1) and Power 4.75 to 5.25
Voltage
(2) supply V
2. Disconnect connectors SEGR and J2, and connect T-adapters to
each female side.
a If power supply voltage in check on cause
2 is normal, this check is not required.
Open circuit in wiring Max. 1 z
harness Between J2 (female) (30) and SEGR
3 (female) (1)
tance
Max. 1 z
Between J2 (female) (47) and SEGR
(female) (2)
Between J2 (female) (59) and SEGR (female)
(3), (4) (sensor output) Max. 1 z

Ground fault in wiring 2. Disconnect connectors J2 and SEGR, and connect T-adapter to
between SEGR (female) (3) and ground Min. 1 Mz
tance
2. Disconnect connectors J2 and SEGR, and connect T-adapter to
harness
SEGR (female) (2) and (3) Min. 1 Mz
tance
PC490LC-10 40-291
40 Troubleshooting

cause 6 is abnormal, sensor is defective.
Defective EGR valve lift 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector J2 or SEGR.
sensor
Between J2 (59) and (47), or between SEGR
(3) and (2)
Circuit diagram related to EGR valve lift sensor
40-292 PC490LC-10
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Error (PC400-CA2349-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Open Error

Failure
Detail of • Open circuit is in EGR valve solenoid drive circuit .
failure
machine
• Signal current to the EGR valve solenoid can be checked with monitoring function. (Code:
Related 48600 (mA))
connector
Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male
2 side.
(internal open circuit)
Resis- Between EGR-SOL (male) (1) and (2)
5 to 10 z
tance
Open or short circuit in wiring a If resistance is above 1 Mz, wiring harness has open circuit. If
3
harness resistance is below 1z, wiring harness has short circuit.
5 to 10 z
tance
Open circuit in wiring harness 2. Disconnect connectors J2 and EGR-SOL, and connect T-adapters to
contact of connector) Between J2 (female) (6) and EGR-SOL
Max. 1 z
Resis- (female) (1)
tance Between J2 (female) (16) and EGR-SOL

2. Disconnect connector EGR-SOL and connect T-adapter to female
side.
5 Hot short circuit in harness 3. Turn starting switch to ON position (with connector EGR-SOL
disconnected).
Voltage Between EGR-SOL (female) (1) and (2) Max. 3 V
PC490LC-10 40-293
40 Troubleshooting
Circuit diagram related to EGR valve solenoid
40-294 PC490LC-10
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Error (PC400-CA2353-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Short Error

Failure
Detail of
• Short circuit is in EGR valve solenoid drive circuit.
failure
machine
• Signal current to the EGR valve solenoid can be checked with monitoring function. (Code:
Related 48600 (mA))
connector
Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male
2 side.
Resis- Between EGR-SOL (male) (1) and (2) 5 to 10 z
tance Between EGR-SOL (male) (1) and ground Min. 1 Mz
3
5 to 10 z
tance
2. Disconnect connectors J2 and EGR-SOL, and connect T-adapter to
EGR-SOL (female) (1) and (2) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors J2 and EGR-SOL.
5
(contact with ground circuit) Resis- Between J2 (female) (6) or EGR-SOL (female)
tance
2. Disconnect connector EGR-SOL and connect T-adapter to female
side.
6 Hot short circuit in harness 3. Turn starting switch to ON position (with connector EGR-SOL
disconnected).
Voltage Between EGR-SOL (female) (1) and (2) Max. 3 V
If no abnormality is found in the above, engine controller is defective.
PC490LC-10 40-295
40 Troubleshooting
Circuit diagram related to EGR valve solenoid
40-296 PC490LC-10
40 Troubleshooting
Failure code [CA2357] EGR Valve Servo Error (PC400-CA2357-400-A-Z0-A)
Action level Failure code EGR Valve Servo Error

Failure
Detail of • EGR valve servo error occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
Action of • Does not supply current to EGR valve (closes EGR valve).
controller • Fully open KVGT.
machine
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Related Position (mm))
1
them.
a For testing of EGR valve drive pressure, see .Testing and adjusting,
Insufficient EGR valve drive "Testing EGR valve and KVGT drive oil pressure".
2 pressure
If EGR valve drive pressure is abnormal, perform checks on causes 3
and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
3 system (main circuit) If engine oil pressure is abnormal, perform troubleshooting (S mode) for
mechanical system. (S-12 Oil pressure lowers.)
Defective oil pump for EGR Oil pump or relief valve for EGR valve circuit may be defective. Check
4
valve them.
Defective hydraulic piping for Hydraulic piping of EGR valve circuit may be defective. Check it.
5
EGR valve
Defective return hydraulic
6 Return hydraulic piping for EGR valve circuit may be defective. Check it.
piping for EGR valve
7 Defective EGR valve EGR valve may have mechanical trouble. Check it.
Defective EGR valve lift Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
sensor
If no failure is found by checks on causes 1 to 8, engine controller is
PC490LC-10 40-297
40 Troubleshooting
Failure code [CA2381] KVGT Pos Sens High Error (PC400-CA2381-400-A-Z0-A)
Action level Failure code KVGT Position Sensor High Error

Failure
Detail of • High voltage appears in KVGT position sensor signal circuit.
failure
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position (mm) sensed by KVGT position sensor can be checked with monitoring function.
information (Code: 48700 (mm))
connector
Defective sensor power If failure code [CA1695] or [CA1696] is displayed, perform
Defective KVGT position 2. Disconnect connector SVGT.
3 sensor 3. Turn starting switch to ON position (with connector SVGT
(internal defect) disconnected).
2. Disconnect connectors J2 and SVGT, and connect T-adapters to
contact of connector) a To check open circuit in GND line
Resis- Between J2 (female) (47) and SVGT (female)
(B) Max. 1 z
tance
2. Disconnect connectors J2 and SVGT, and connect T-adapters to
SVGT (female) (A) and (C) Min. 1 Mz
tance
2. Disconnect connector SVGT and connect T-adapters to female side.
6 Hot short circuit in harness 3. Turn starting switch to ON position (with connector SVGT
disconnected).
Voltage Between SVGT (female) (C) and (B) Max. 1 V
• Reference
Voltage Between J2 (38) and (47) 1.0 to 4.0
V
40-298 PC490LC-10
40 Troubleshooting
Circuit diagram related to KVGT position sensor
PC490LC-10 40-299
40 Troubleshooting
Failure code [CA2382] KVGT Pos Sens Low Error (PC400-CA2382-400-A-Z0-A)
Action level Failure code KVGT Position Sensor Low Error

Failure
Detail of • Low voltage appears in KVGT position sensor signal circuit.
failure
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position (mm) sensed by KVGT position sensor can be checked with monitoring function.
information (Code: 48700 (mm))
connector

2 supply system 2. Disconnect connector SVGT and connect T-adapters to female side.
Between SVGT (female) (A) and Power 4.75 to 5.25
Voltage
(B) supply V
2. Disconnect connectors SVGT2 and J, and connect T-adapters to
each female side.
Max. 1 z
Open circuit in wiring harness Between J2 (female) (30) and SVGT
3 (wire breakage or defective (female) (A)
tance
Max. 1 z
Between J2 (female) (47) and SVGT
(female) (B)
Between J2 (female) (38) and SVGT (female)
(C) (Sensor output) Max. 1 z

Ground fault in wiring 2. Disconnect connectors J2 and SVGT, and connect T-adapter to
between SVGT (female) (C) and ground Min. 1 Mz
tance
2. Disconnect connectors J2 and SVGT, and connect T-adapter to
Resis- Between ENG (female) (38) and (47), or
between SVGT (female) (B) and (C) Min. 1 Mz
tance
40-300 PC490LC-10
40 Troubleshooting

cause 6 is abnormal, sensor is defective.
Defective KVGT position 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector J2 or SVGT.
sensor
Between J2 (38) and (47), or between SVGT
(C) and (B)
Circuit diagram related to KVGT solenoid
PC490LC-10 40-301
40 Troubleshooting
Failure code [CA2383] KVGT Solenoid Open Error (PC400-CA2383-400-A-Z0-A)
Action level Failure code KVGT Solenoid Open Error

Failure
Detail of • Open circuit occurs in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48600
Related (mA))
1
defective.
Defective KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapter to male
2 side.
Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
Open or short circuit in wiring a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z
3
harness or below, harness has short circuit.
5 to 10 z
tance
Open circuit in wiring harness 2. Disconnect connectors J2 and VGT-SOL, and connect T-adapters to
contact of connector) Between J2 (female) (10) and VGT-SOL
Max. 1 z
Resis- (female) (1)
tance Between J2 (female) (20) and VGT-SOL

2. Disconnect connector VGT-SOL and connect T-adapter to female
Hot short circuit in wiring side.
5 3. Turn starting switch to ON position (with connector VGT-SOL
harness
disconnected).
Voltage Between VGT-SOL (female) (1) and (2) Max. 3 V
40-302 PC490LC-10
40 Troubleshooting
PC490LC-10 40-303
40 Troubleshooting
Failure code [CA2386] KVGT Solenoid Short Error (PC400-CA2386-400-A-Z0-A)
Action level Failure code KVGT Solenoid Short Error

Failure
Detail of
• Short circuit is detected in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48600
Related (mA))
connector
2. Disconnect connector VGT-SOL and connect T-adapters to male
KVGT solenoid defective
2 side.
Resis- Between VGT-SOL (male) (1) and (2) 5 to 10 z
tance Between VGT-SOL (male) (1) and ground Min. 1 Mz
3
5 to 10 z
tance
2. Disconnect connectors J2 and VGT-SOL, and connect T-adapter to
VGT-SOL (female) (1) and (2) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors J2 and VGT-SOL, and connect T-adapters to
5 each female side.
Resis- Between J2 (female) (10) or VGT-SOL (female)
tance
2. Disconnect connector VGT-SOL and connect T-adapter to female
side.
6 Hot short circuit in harness 3. Turn starting switch to ON position (with connector VGT-SOL
disconnected).
Voltage Between VGT-SOL (female) (1) and (2) Max. 1 V
If no abnormality is found in the above, engine controller is defective.
40-304 PC490LC-10
40 Troubleshooting
PC490LC-10 40-305
40 Troubleshooting
Failure code [CA2387] KVGT Servo Error (PC400-CA2387-400-A-Z0-A)
Action level Failure code KVGT servo error

Failure
Detail of • KVGT servo error has occurred.
failure (Response from KVGT position sensor differs from KVGT opening command.)
machine
information
1 Defect in related system If another failure code is indicated, carry out troubleshooting for it.
For testing of KVGT drive pressure, see Testing and adjusting, "Testing
KVGT drive oil pressure EGR valve and KVGT oil pressure".
2
abnormal
a If the KVGT drive pressure is abnormal, check causes 3 and 4.
For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
3 system
(main circuit) a If engine oil pressure is not normal, perform troubleshooting (S
mode) for mechanical system. (S-12 Oil pressure lowers.)
4 Defective oil pump for KVGT Oil pump or relief valve for KVGT circuit may be defective. Check them.
Defective oil supply pipe for Oil supply pipe for the KVGT circuit may be defective. Check it.
5
KVGT
Defective oil return pipe for Oil return pipe for KVGT circuit may be defective. Check it.
6
KVGT
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged
7 Defective KVGT after performing regeneration for service, KVGT is defective.
(Since the time required for manual stationary regeneration depends on
the accumulated soot level, see failure code CA2639. )
Defective KVGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
8
sensor
9 Defective engine controller If no failure is found by above checks, engine controller is defective.
40-306 PC490LC-10
40 Troubleshooting
Failure code [CA2555] Grid Htr Relay Open Circuit Error (PC400-CA2555-400-A-Z0-A)
Action level Failure code Intake air heater relay open circuit
Failure
Detail of • Open circuit is detected in drive circuit (primary circuit) of preheat relay.
failure
controller
Problem on • Intake air heater does not work in auto preheating (degraded starting performance at low
machine temperature and emission of white smokes)
• Temperature sensed by engine coolant temperature sensor can be checked by using
• Method of reproducing failure code: Turn starting switch to ON position (Coolant
temperature: Max. -5 °C )
Related • Troubleshooting for this failure code covers circuit starting from engine controller to
information primary (coil) side of preheater relay R18.
• For troubleshooting related to heater relay and secondary side of preheater relay R18,
see E-2 in E-mode.
a Relay R18 is called preheat relay in this manual.
connector
2. Disconnect relay R18, and connect T-adapters to male side.
Resis- Between R18 (male) (1) and (2)
200 to 400 z
tance
2 Defective preheater relay R18
2. Replace relay R18 with another one.
If this failure code disappears, original preheater relay R18 is defective.
Open or short circuit in wiring 2. Disconnect connector CE03, and connect T-adapters to female side.
3
harness Resis- Between CE03 (female) (4) and (13)
200 to 400 z
tance a Preheater relay R18 coil resistance
2. Disconnect connector CE03 and relay R18, and connect T-adapters
4 Open circuit in wiring harness to each female side.
Between CE03 (female) (4) and R18 (female)
Max. 1 z
Resis- (1)
tance Between CE03 (female) (13) and R18
PC490LC-10 40-307
40 Troubleshooting
Circuit diagram related to intake air heater relay
40-308 PC490LC-10
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Short Circuit Error (PC400-CA2556-400-A-Z0-A)
Action level Failure code Intake air heater relay short circuit
Failure
Detail of • Short circuit is detected in drive circuit (primary circuit) of preheater relay.
failure
controller
Problem on • Intake air heater does not work in auto preheating (degraded starting performance at low
machine temperature and emission of white smokes)
• Temperature sensed by engine coolant temperature sensor can be checked by using
• Method of reproducing failure code: Turn starting switch to ON position (Coolant
temperature: Max. -5 °C )
Related • Troubleshooting for this failure code covers circuit starting from engine controller to
information primary (coil) side of preheater relay R18.
• For troubleshooting related to heater relay and secondary side of preheater relay R18,
see E-2 in E-mode.
a Relay R18 is called preheater relay in this manual to distinguish it from heater relay HT.
connector
Resis- Between R18 (male) (1) and (2) 200 to 400
tance z
2 Defective preheater relay R18
2. Replace relay R18 with another one.
If this failure code disappears, original preheater relay R18 is defective.
2. Disconnect connector CE03 and relay R18, and connect T-adapter
3 Ground fault in wiring harness to either female side.
Resis- Between CE03 (female) (4) or R18 (female)
tance
2. Disconnect connector CE03 and relay R18, and connect T-adapter
to female side of CE03.

No
continuity
Continuity Between CE03 (female) (4) and each other pin
(No sound
is heard)
PC490LC-10 40-309
40 Troubleshooting
Circuit diagram related to intake air heater relay
40-310 PC490LC-10
40 Troubleshooting
Failure code [CA2637] KDOC Face Plugging (PC400-CA2637-400-A-Z0-A)
Action level Failure code KDOC Face Plugging

Failure
• KDOC face is plugged.
1. The KDOC surface is contaminated due to the operating conditions, and the catalytic
Detail of efficiency has dropped (clean the DOC).
failure 2. Deteriorated KDOC due to high temperature, dropped efficiency due to deposit, or
dropped efficiency due to damage (Replace KDOC with a new or used one.)
Action of • Stops fuel dosing.
controller
Problem on • None in particular
machine
k Since temperature of the turbocharger exhaust connector, KDOC and KDPF

exceeds 500 °C, take care not to get burn injury.
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
performed only from "Regeneration for Service".
Related 1. Start the engine.
information 2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"02 Regeneration for service", and then perform the "Manual Stationary
Regeneration".
• If the KDOC efficiency is still low, this failure code [CA2637] may be displayed repeatedly
and failure code [CA1691] indicating the poor regeneration may be displayed.
• Start the engine and perform the warm-up operation, then operate the machine under
normal conditions for approximately 3 hours.
(If the exhaust gas temperature is high, this operation time can be reduced.)
1 Defective KVGT If failure code [CA238*] is displayed, troubleshoot for it first.
If failure code [CA227*], [CA23**] or others is displayed, troubleshoot for
2 Defective EGR valve
it first.
1. Remove turbocharger exhaust connector.
Defective turbocharger 2. Check for oil or fuel inside turbocharger exhaust connector.
3
exhaust connector • If contaminated, troubleshoot for failure codes [CA227*], [CA23**],
etc., relating to the EGR valve and KVGT.
Defective exhaust connector Check exhaust system between turbocharger and KDPF for damage of
4 and ducts connected to the connector and ducts, and for loose connection.
KDPF
• If excessive black smoke is exhausted when running the engine at
high idle, troubleshoot for "S-9 KDPF gets clogged in a short time".
5 Unusual exhaust gas color
idle.
PC490LC-10 40-311
40 Troubleshooting

1. Remove KDPF.
2. Remove KDOC.
• Check KDOC for cracks (replace KDOC if cracks are found).
• Check whether more than 50% of KDOC inlet surface is plugged with
6 Defective KDOC soot or not.
(KDOC cleaning)
a When KDOC is replaced, perform check on cause 7. And when
cleaning of KDOC is done, perform checks on causes 7 and 8.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
7 Reset after KDOC change
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
manual stationary regeneration.
1. Perform manual stationary regeneration from Regeneration for
Service.
3. Repeat the "Regeneration for service" (to check the repair
Performing manual stationery completion).
8 regeneration
a If failure code [CA2637] is displayed after you have completed the
"Regeneration for Service", the KDOC efficiency has dropped.
Replace the KDOC and perform reset after KDOC change (see
Cause 7).
a Operate the machine approximately 3 hours and check that this failure code is not displayed.
40-312 PC490LC-10
40 Troubleshooting
Failure code [CA2639] Manual Stationary Regeneration Request (PC400-CA2639-

400-A-Z0-A)
Action level Failure code Manual Stationary Regeneration Request

Failure
The "Manual Stationary Regeneration Request" prompts operator to forcibly perform the
Detail of "Manual Stationary Regeneration", which is more effective to remove soot, because soot
failure accumulation in the KCSF of KDPF has exceeded level for the automatic regeneration.
• Soot accumulation reaches level 4 or 5.
Action of
• Normal control
controller

machine
injury.
a If the manual stationary regeneration is started when KDOC inlet temperature is below
approximately 250°C, fuel dosing will be disabled, so actually regeneration will not start.
• KVGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
Related temperature > KDOC outlet temperature > KDPF outlet temperature)
information • When the active regeneration (the manual stationary regeneration) is in progress, KDOC
• How to perform the manual stationary regeneration
3. From the service menu of the machine monitor, display the "Diagnostic Tests" screen,
open "02 Regeneration for Service", and perform the "Manual Stationary Regeneration".
a Switch operation during regeneration for service: By pressing "1", "2", "3" in order while
numeral input switch [4] is pressed, the screen changes to "Monitoring / Custom". For
details, see "Testing (Regeneration for Service)" in Testing and adjusting.
• If soot accumulation is level 4: Approximately 40 minutes to 1 hour
• If soot accumulation is level 5: Approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: Approximately 1 to 3 hours
PC490LC-10 40-313
40 Troubleshooting
a If this failure code is still displayed after several hours have passed after the manual
stationary regeneration, perform the following troubleshooting procedures.
a If another failure code is displayed (including when the manual stationary regeneration is
in progress), perform troubleshooting for it first.
40-314 PC490LC-10
40 Troubleshooting

machine monitor.
If the regeneration stop button is pressed down, release it.
Increase of soot 3. Make sure that machine is in safe condition.
1 accumulation due to 4. Start the engine, and perform the manual stationary regeneration
"Regeneration Disable" from user mode.
a If the regeneration does not complete within 3 hours, proceed to
checks on cause 2 and after.
• If there is a significant difference between KDOC inlet temperature
Defective KDOC inlet and KDOC outlet temperature when KDPF is completely cool or
2 temperature sensor engine running at idle (not regenerating), replace KDOC inlet
temperature sensor.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged after
3 Defective KVGT performing regeneration for service, KVGT is defective.
(The time required for the manual stationary regeneration depends on
the accumulated soot level. See "Related information".)
Defective KDPF (KDOC, 1. Perform the troubleshooting "S-22 Active regeneration takes time" of
4 KCSF) S mode.
a If failure code [CA2639] is displayed after the manual stationary
regeneration is completed, perform the following.
a When checking the exhaust gas color, perform the "Regeneration
5 Unusual exhaust gas color • If excessive black smoke is exhausted when accelerating engine or
running it at high idle, troubleshoot for "S-9 KDPF gets clogged in a
short time".
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
PC490LC-10 40-315
40 Troubleshooting
Failure code [CA2732] Dosing Fuel Valve 2 High Error (PC400-CA2732-400-A-Z0-A)
Action level Failure code Dosing Fuel Valve 2 High Error

Failure
Detail of Abnormal high voltage (or high circuit resistance) has occurred in dosing fuel solenoid valve 2
failure (drain valve).
controller
get burn injury.
Related
information • If failure code [CA1923] is also displayed, the ground (GND) leads may be open.
Defective dosing fuel 2. Disconnect connector SOV2, and connect T-adapter to male side of
2 solenoid valve 2 (drain valve) connector.
Resis- Between SOV2 (male) (2) and (1)
4 to 6 z
tance
3
harness Resis-
a The resistance is the same as that of 4 to 6 z
tance
dosing fuel solenoid valve 2.
2. Disconnect connectors J2 and SOV2, and connect T-adapter to each
Open circuit in wiring harness female side of connectors.
4 (wire breakage or defective a To check open circuit in GND line
Between J2 (female) (8) and SOV2 (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (18) and SOV2 (female)
(2) Max. 1 z

No
continuity
Between J2 (female) (8) and each pin other
Continuity (No sound
than pin (8)
is heard)
40-316 PC490LC-10
40 Troubleshooting

PC490LC-10 40-317
40 Troubleshooting
Failure code [CA2733] Dosing Fuel Valve 2 Low Error (PC400-CA2733-400-A-Z0-A)
Action level Failure code Dosing Fuel Valve 2 Low Error

Failure
Detail of Abnormal low voltage (or low circuit resistance) has occurred in dosing fuel solenoid valve 2
failure (drain valve).
controller
get burn injury.
Related
information • If sensor connector is disconnected, failure code [CA2732] is displayed.
2. Disconnect connector SOV2, and connect T-adapter to male side of
Defective dosing fuel connector.
2 solenoid valve 2 (drain valve) Between SOV2 (male) (2) and (1) 4 to 6 z
Resis-
Between SOV2 (male) (1) and ground (dosing
tance Min. 1 Mz
fuel valve 2 body)
3
harness Resis-
a The resistance is the same as that of 4 to 6 z
tance
dosing fuel solenoid valve 2.
Ground fault in wiring 2. Disconnect connectors J2 and SOV2, and connect T-adapter to
4 harness female side of either connector.
(contact with ground circuit) Resis- Between ground (frame) and J2 (female) (8) or
SOV2 (female) (1) Min. 1 Mz
tance

No
Between J2 (female) (8) and each pin other continuity
Continuity
than pin (8) (No sound
is heard)
40-318 PC490LC-10
40 Troubleshooting
PC490LC-10 40-319
40 Troubleshooting
Failure code [CA2741] Dosing Fuel Valve Swap Error (PC400-CA2741-400-A-Z0-A)
Action level Failure code Dosing Fuel Valve Swap Error

Failure
Detail of • Dosing fuel solenoid valve 1 (shut-off valve) and dosing fuel solenoid valve 2 (drain valve)
failure are connected reversely.
controller
get burn injury.
Related
Reverse connection of wiring
1 1. Check connectors SOV1 and SOV2.
harness

connector
connector
1. Fuel doser
2. Fuel supply line

B: Fuel return
40-320 PC490LC-10
40 Troubleshooting
Failure code [CA2765] Inj Trim Data Error (PC400-CA2765-400-A-Z0-A)
Action level Failure code Injector Trim Data Error

Failure
Detail of • Injector trim data input to to the engine controller is not correct.
failure
Action of
controller
Problem on • Since the engine controller can not know the production variance of each injector, the
machine exhaust gas purification will be degraded.
information
1 Injector trim data mismatch a When replacing injectors, see chapter 30 Testing and adjusting,
"Injector trim".
PC490LC-10 40-321
40 Troubleshooting
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error (PC400-CA2878-400-A-Z0-A)
Action level Failure code Dosing Fuel Valve 2 Servo Error

Failure
• When fuel pressure is checked immediately after engine startup, the ON/OFF command
of dosing fuel solenoid valve 2 (SOV2 drain valve) does not match with the expected
value of fuel pressure detected by dosing fuel pressure sensor.
Detail of
1. When Open SOV1 Valve and Close SOV2 Valve commands are given, the dosing fuel
failure
pressure detected by dosing fuel pressure sensor does not increase sufficiently.
2. When Close SOV1 Valve and Open SOV2 Valve commands are given, the dosing fuel
pressure detected by dosing fuel pressure sensor does not decrease sufficiently.
controller
get burn injury.
(Code: 47601 (V))
• Method of reproducing failure code: Start the engine (observe for 3 minutes).
2 Defective fuel system For above check, see Testing and adjusting, "Measuring fuel pressure".
If failure code [CA1923], [CA1924] or [CA1925] is also displayed,
3 solenoid valve 1 (shut-off
perform troubleshooting for [CA1923], [CA1924] or [CA1925] first.
valve)
Defective dosing fuel If failure code [CA2732] or [CA2733] is also displayed, perform
4 solenoid valve 2 (drain valve) troubleshooting for [CA2732] or [CA2733] first.
2. Disconnect connector SOV2, and connect T-adapter to female side
Hot short circuit in wiring of connector.
6
Voltage Between SOV2 (female) (1) and (2) Max. 4.7 V
40-322 PC490LC-10
40 Troubleshooting

2. Disconnect connectors SOV1 and SOV2.
3. Replace dosing fuel solenoid valve 1 with dosing fuel solenoid valve
2.
Defective dosing fuel solenoid
7 a Do not replace the SOV1 and SOV2 connectors.
valve 2 (drain valve)
If this failure code changes to [CA1963], the previous dosing fuel
solenoid valve 2 (drain valve) is defective.
8 Clogging of fuel return tube Disconnect the fuel return tube and check it for clogging.
Defective fuel shut-off valve Disconnect the fuel system tube and check the fuel connector of fuel
9 shut-off valve manifold for clogging.
manifold
Defective dosing fuel pressure 4. See "Related information",and display dosing fuel pressure and
10 ambient pressure at the same time.
sensor
If the dosing fuel pressure is clearly different from ambient pressure,
the dosing fuel pressure sensor is defective.
PC490LC-10 40-323
40 Troubleshooting

B: Fuel return
connector
connector
1. Fuel doser
2. Fuel supply line
40-324 PC490LC-10
40 Troubleshooting
Failure code [CA2881] Dosing Fuel Pressure Low Error 1 (PC400-CA2881-400-A-Z0-A)
Action level Failure code Dosing Fuel Pressure Low Error 1

Failure
Detail of Pressure detected by dosing fuel pressure sensor during dosing is below the threshold value
failure (the fuel pressure is low).
Action of • You can cancel above measure by "turning starting switch to OFF position once, then
controller turning starting switch to ON position" after failure code is generated.
get burn injury.
(Code: 47600 (V))
position. So when you restart engine, wait 1 minute and more before turning starting
• When this failure code appears, perform troubleshooting according to the following work
flow.
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code does not disappear by simply turning starting switch to ON position from
after repair.
1
defective.
If failure code [CA1923] or [CA1924] or [CA1925] is also displayed,
perform troubleshooting for [CA1923] or [CA1924] or [CA1925] first.
valve)
Defective dosing fuel If failure code [CA2732] is also displayed, perform troubleshooting for
3 solenoid valve 2 (drain valve) [CA2732] first.
If failure code [CA559] is also displayed, perform troubleshooting for
5 Defective fuel supply pump
[CA559] first.
6 Defective fuel feed pump 2. Loosen the joint bolt (JB) of fuel tube.
3. Tilt the switch for the fuel feed pump to ON position while starting
switch is in OFF position.
(Be careful since fuel may spurt out.)
PC490LC-10 40-325
40 Troubleshooting

When completing the check, turn the starting switch to ON position or
tilt the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB) of fuel tube, fuel feed pump is
defective.
2. Disconnect connector SOV2, and connect T-adapter to female side
Hot short circuit in wiring of connector.
7
Voltage Between SOV2 (female) (1) and (2) Max. 4.7 V
8 Clogging of fuel filter Check fuel filter for clogging.
9 Defective fuel system For above check, see Testing and adjusting, "Testing fuel pressure".
Clogging of fuel supply tube
10 or leakage from connector Check the fuel supply tube and its joint bolt (JB).
Defective fuel shut-off valve Disconnect the fuel system tube and check the fuel connector of fuel
11 shut-off valve manifold for clogging.
manifold
Defective dosing fuel 3. Turn starting switch to ON position.
12 pressure sensor If the dosing fuel pressure is clearly different from ambient pressure, the
dosing fuel pressure sensor is defective (see "Related information").
13 solenoid valve 2 (drain valve) Replace dosing fuel solenoid valve 2 (drain valve).

2. Start engine and increase the engine speed from low idle (with no load) to high idle (with no load). After
engine speed reaches to high idle speed (approximately 2,200 rpm with no load), decrease it to low idle
speed.
a Automatic regeneration is started after performing the preceding procedure, then engine speed is
maintained at low idle speed (approximately 1,000 rpm).
a If automatic regeneration is started and fuel pressure of fuel doser increases properly, the failure code
is cleared.
a If automatic regeneration is not started (*), perform following steps.
4. Disconnect either connector MAF from mass air flow sensor or TEMP1, TEMP2, or TEMP3 from
temperature sensor consolidating box. (You may disconnect all of them.)
5. Turn starting switch to ON position and wait until soot accumulation level becomes "3" on machine
monitor (approximately 7 minutes).
40-326 PC490LC-10
40 Troubleshooting
a At this time, the next failure codes appear, however, ignore them because they are open circuit errors
caused by disconnecting the connectors.
• When disconnecting connector MAF from mass air flow sensor: [CA357], [CA691]
• When disconnecting connector TEMP1 from temperature sensor: [CA3314]
• When disconnecting all the connectors: [CA3314], [CA3317], [CA3319]
7. Connect the disconnected sensor connectors.
8. If automatic regeneration is started and fuel pressure of fuel doser increases properly by performing the
preceding operations 1 and 2, the failure code is cleared.
*: When automatic regeneration is not started
In the following cases, automatic regeneration may not be started after performing the preceding operations
1 and 2. At that time, perform the operations 3 to 8.
• When "Regeneration Disable" is set from machine monitor.
• When failure code [CA2881] appears during regeneration for service.
• When failure code [CA2881] appears during automatic regeneration or manual stationary regeneration of
user mode, and also machine is operated for long period at heavy load (under high exhaust temperature)
after the regeneration.
PC490LC-10 40-327
40 Troubleshooting

B: Fuel return
connector
connector
1. Fuel doser
2. Fuel supply line
40-328 PC490LC-10
40 Troubleshooting
PC490LC-10 40-329
40 Troubleshooting
Failure code [CA3133] KDPF Outlet Pressure Sensor High Error (PC400-CA3133-
400-A-Z0-A)
Action level Failure code KDPF outlet pressure sensor high error
Failure
Detail of • High voltage error has occurred in the KDPF outlet pressure sensor signal circuit.
failure
• Sets KDPF delta pressure to a recommended value (gauge pressure) and continues
Action of operation.
controller (If another failure code is also displayed, the machine may be operated at 0 kPa (gauge
pressure)).
Problem on
• None
machine
k Since the temperature of the KDPF will become higher than 500°C, take care not to
get burn injury.
Related • If failure code [CA1695] is not displayed but failure code [CA1879] is displayed, an open
information circuit (poor connection in connector) is suspected in the GND line.
• Signal voltage from the KDPF outlet pressure sensor can be checked by using monitoring
• Differential pressure sensed by the KDPF outlet pressure sensor can be checked by
using monitoring function. (Code: 47000 (kPa))
harness connector
it first.
V
Defective KDPF outlet If failure code changes to [CA3134], KDPF outlet pressure sensor is
3 pressure sensor defective.
is defective.
harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to each
4 (wire breakag or female side.
a To check for open circuit in GND line
connector)
Max. 1 z
Resistance Between CE03 (female) (43) and E25 (female) (1)
40-330 PC490LC-10
40 Troubleshooting

5
Continuity
6
be performed.)
Circuit diagram related to KDPF outlet pressure sensor
PC490LC-10 40-331
40 Troubleshooting
Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error (PC400-CA3134-
400-A-Z0-A)
Action level Failure code KDPF outlet pressure sensor low error
Failure
Detail of • Low voltage error has occurred in the KDPF outlet pressure sensor signal circuit.
failure
• Sets KDPF outlet pressure to a recommended value (gauge pressure) and continues
Action of operation.
controller (If another failure code is also displayed, the machine may be operated at 0 kPa (gauge
pressure)).
Problem on
• None
machine
k Since the temperature of the KDPF will become higher than 500 °C , take care not to
get burn injury.
• If failure code [CA1696] is not displayed but failure code [CA1881] is displayed, the
Related sensor connector may be disconnected or an open circuit (poor connection in connector)
information is suspected in the 5 V line.
• This failure code is displayed if the sensor connector is disconnected.
• Signal voltage from the KDPF outlet pressure sensor can be checked by using monitoring
• Differential pressure sensed by the KDPF outlet pressure sensor can be checked by
using monitoring function. (Code: 47000 (kPa))
harness connector
it first.
V
female side.
Open circuit in wiring a If no failure is found by check on cause 2, this
harness check is not required. Max. 1 z
connector) Resistance a If no failure is found by check on cause 2, this
40-332 PC490LC-10
40 Troubleshooting

harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to either
4 female side.
Between CE03 (female) (58) or E25 (female) (3)
circuit) Resistance and ground Min. 1 Mz

5
Continuity
Defective KDPF outlet 2. Insert T-adapter into connector E25.
Voltage Between E25 (3) and (1) 0.5 to 4.5 V
7
be performed.)
PC490LC-10 40-333
40 Troubleshooting
Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error (PC400-
CA3135-400-A-Z0-A)
Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
Detail of • Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
failure (Signal voltage from sensor is within operating range.)
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on
• None
machine
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
a Use "Short-circuit connector: 799T-601-4670" (its wiring is not identical with that of "Short-
circuit connector: 799T-601-4611).
Machine O
clearing
after repair.
1 supply system 2. Disconnect connector E25 and connect T-adapter to female side.
V
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
2
40-334 PC490LC-10
40 Troubleshooting

Defective wiring
3 harness or engine If failure code [CA3134] is not displayed, wiring harness or engine controller is
controller defective.
2. Disconnect connector E25 and connect short-circuit connector to female
side.
a To connect 5 V line to signal line (to short pin (4) to pin (3) of connector
Defective wiring E25).
3 harness or engine 3. Turn starting switch to ON position.
controller If failure code [CA3133] is not displayed, wiring harness or engine controller is
defective.
Defective KDPF outlet a If failure codes [CA3134] and [CA3133] are displayed in check on cause 3,
4 pressure sensor KDPF outlet pressure sensor is defective.
2. Disconnect connectors CE03 and E25, and connect T-adapter to each
female side.
harness a If no failure is found by check on cause 1, this
harness 2. Disconnect connectors EC3 and E25, and connect T-adapter to either
6 female side.
Between ground and CE03 (female) (58) or E25

7
Continuity
1. Remove KDPF delta pressure sensor tube.
2. Clean KDPF delta pressure sensor tube to clear clogging.
3. Check KDPF delta pressure sensor tube for cracks and damage.
4. Install KDPF delta pressure sensor tube with both tube ends connected
securely.
Defective KDPF delta
8 • Reference
pressure sensor tube
How to check KDPF delta pressure sensor tube for clogging
2. Monitor outlet pressure sensed by KDPF outlet pressure sensor on
monitoring screen of machine monitor.
Code 47,000 (kPa) 0 ± 3 (kPa)
PC490LC-10 40-335
40 Troubleshooting


3. Referring to Related information, display KDOC inlet and outlet temperatures and KDPF outlet
temperature.
5. Perform arm IN relief for continuous 40 seconds.
a If failure code disappears after implementing steps 1 to 7, repair work is complete.
command.
controller
40-336 PC490LC-10
40 Troubleshooting
PC490LC-10 40-337
40 Troubleshooting
Failure code [CA3167] Fuel Doser Degradation (D155-CA3167-400-A-Z0-A)
Action level Failure code Fuel Doser Degradation

Failure
― CA3167 (Engine controller system)
Detail of • Fuel doser is deteriorated.
failure • The injection port of fuel doser is clogged.
Action of None in particular
controller
Problem on • It takes time to perform automatic regeneration. (KDOC outlet temperature does not rise
machine easily and it takes much time to burn the soot.)
k Since exhaust connector and KDPF are heated to 500 °C or above, take care not to
get burn injury.
(Code: 47600 (V))
• Pressure sensed by dosing fuel pressure sensor can be checked with monitoring function.
Related (Code: 47601 (kPa))
information • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
• For the cleaning method of the fuel doser, see Chapter 30 Testing and adjusting
"Procedures for cleaning fuel doser".
• Since this failure code has no action level, it is not displayed in the user screen of the
machine monitor. It is displayed in the service screen of the machine monitor and
KOMTRAX.
When this failure code appears, perform troubleshooting according to following work flow.
A: Identification of cause
O
B: Fuel doser memory reset
a When this failure code is displayed, the fuel doser injection amount is corrected. After
repair trouble, it is necessary to reset the corrected information of fuel doser injection
amount. Be sure to perform the fuel doser memory reset after repair.
a If it is not performed, there is a danger that KCSF may be damaged.
You can cancel above measure by "turning starting switch to the OFF position" once, then
Machine "turning starting switch to the ON position" after failure code is generated.
operation for
clearing a In the following cases, this failure code does not disappear by simply "turning starting
failure code switch to ON position from OFF position". It disappears after performing the next
automatic regeneration.
1. After this failure code is displayed, any other failure code related to fuel doser is displayed
before "turning starting switch to the OFF position" is performed.
2. After this failure code is displayed, "B. Fuel doser memory reset" is performed before
"turning starting switch to the OFF position" is performed.
3. After this failure code is displayed, the automatic regeneration is performed before
"turning starting switch to the OFF position" is performed.
a When service tool "INSITE" is available, you can clear every failure code by executing
"Reset All Faults" command.
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it and fix trouble as
needed.
If failure code [CA1923], [CA1924] or [CA1925] is also displayed,
perform troubleshooting for [CA1923], [CA1924] or [CA1925] first.
valve)
40-338 PC490LC-10
40 Troubleshooting

4 solenoid valve 2 (drain valve) troubleshooting for [CA2732] or [CA2733] first.
If failure code [CA1977] is displayed, perform troubleshooting for
5 Defective fuel doser system
[CA1977] first.
Defective fuel doser solenoid If failure code [CA1963], [CA2878] or [CA2881] is also displayed,
6 perform troubleshooting for [CA1963], [CA2878] or [CA2881] first.
valve
Clogged fuel doser injection 2. Remove fuel doser (1) from exhaust connector.
7 port 3. Clean fuel doser.
a For the cleaning method of the fuel doser, see "Related information".
1. Turn starting switch to the OFF position.
2. Remove fuel doser (1) from exhaust connector.
3. Install replacement fuel doser to exhaust connector.
a This is for prevention of exhaust gas leakage from fuel doser
8 Defective fuel doser mounting hole.
5. Perform the "Regeneration Disable".
6. Start engine.
7. Run engine at low idle and wait 2 minutes.
If fuel leaks from the tip end of fuel doser (1), fuel doser is defective.
If this failure code appears again after above procedures are performed,
doser fuel block is clogged with some foreign materials, etc. In this case,
9 Defective fuel doser system replace the doser fuel block itself.
After replacing, perform "B: Fuel doser memory reset (as follows)".
If this failure code appears again after above procedures are performed,
10 Defective engine controller engine controller is defective.
B: Fuel doser memory reset
How to perform "Fuel doser memory reset"
1. Turn starting switch to the ON position. (Do not start the engine.)
2. From the service menu of the machine monitor, display the "KDPF Memory Reset" and perform "04 Fuel
Doser Cleaning".
PC490LC-10 40-339
40 Troubleshooting
A: From fuel feed pump

B: Fuel return
PDOSER: Dosing fuel pressure sensor connector
connector
connector
1. Fuel doser
2. Fuel supply line
40-340 PC490LC-10
40 Troubleshooting
Failure code [CA3251] KDOC Inlet Temperature High Error (PC400-CA3251-400-A-Z0-A)
Action level Failure code KDOC Inlet Temperature High Error

Failure
Detail of • KDOC inlet temperature remains at high level.
failure
controller • You can cancel above measures by "turning starting switch to OFF position once, then
machine
injury.
Related • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
of KDPF".
Machine O
clearing
after repair.
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is also displayed,
1 temperature sensor perform troubleshooting for [CA3313], [CA3314] or [CA3315] first.
Defective fuel doser solenoid If failure code [CA1925] or [CA1963] is also displayed, perform
2 troubleshooting for [CA1925] or [CA1963] first.
valve 1
Defective wiring harness equipment" in "Checks before troubleshooting" of "General
3
connector information on troubleshooting", and check it and fix trouble as
needed.
PC490LC-10 40-341
40 Troubleshooting

2. Disconnect connectors CE03 and TEMP1 (KDOC inlet temperature
sensor), and connect T-adapter to female side of CE03.
Continuity
2. Use monitoring function to display signal voltages and temperatures
from KDOC inlet temperature sensor, KDOC outlet temperature
sensor, and KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
5. Monitor temperature from each sensor.
Defective KDOC inlet
5 temperature sensor If temperature of any temperature sensor fluctuates 24°C or greater,
regard that temperature sensor as defective.
a If none of temperature sensor values changes more than 24°C,
problem is not in sensor system. Perform checks on causes 5 and
after.
a If another failure code appears with engine running at idle, perform
Check intake system hoses, clamps, and tubes for damage and
6 Malfunction of intake system
loosening. Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
Testing and adjusting, "Handling of cylinder cutout mode operation).
2. Check for oil or fuel inside turbocharger exhaust connector.
Oil leak into turbocharger • If oil or fuel is found, visually check for oil leaks from EGR valve and
8
exhaust connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel
leaking in.
Oil leak into exhaust
9 connector and ducts leading • Wipe off oil or fuel if found.
to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and
clean or replace it as necessary.
If failure code disappears, repair is complete.
command.
If this failure code appears again after above procedures are
10 Defective engine controller implemented, engine controller is defective.
40-342 PC490LC-10
40 Troubleshooting
PC490LC-10 40-343
40 Troubleshooting
Failure code [CA3253] KDOC Temp Error - Non Regeneration (PC400-CA3253-400-A-

Z0-A)
Action level Failure code KDOC Temperature Error - Non Regeneration

Failure
Detail of • KDOC outlet temperature remains at high level when active regeneration is not
failure performed.
controller
machine
injury.
Related function. (Code: 47201 (V))
2. Since cylinders other than disabled cylinder increase their fuel injection to compensate
for torque drop, exhaust temperature may rise and KDOC inlet temperature high error
may be generated.
of KDPF".
O
Machine B. Machine operation for clearing failure code
operation for
clearing a This failure code does not disappear by simply turning starting switch to ON position from
failure code OFF position after repair. You must perform machine operation for clearing failure code
after repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
Defective KDOC inlet Perform checks on causes 1 and 3 to 5 of troubleshooting for failure code
1 temperature sensor [CA3251] (causes related to sensor and wiring harness).
Defective KDOC outlet Perform checks on causes 1 and 3 to 5 of troubleshooting for failure code
2 temperature sensor [CA3254] (causes related to sensor and wiring harness).
40-344 PC490LC-10
40 Troubleshooting

1. Remove KDPF.
2. Remove KDOC.
a When KDOC in KDPF is replaced, perform reset procedure for KDOC
change and then finish troubleshooting without performing manual
3 Defective KDOC
stationary regeneration.
(See check on cause 7 of failure code [CA2637])
• Check whether more than 50% of KDOC inlet surface is plugged with soot
or not.
(KDOC cleaning)
2. Start engine and run it at low idle for approximately 15 minutes.
• If failure code disappears, repair is complete.
If failure code is not cleared, perform following steps.
a If failure code remains uncleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 4 and 6 are required to satisfy temperature
requirements.
• KDOC inlet temperature X 200°C
• KDOC outlet temperature X 200°C
3. Use monitoring function to display KDOC inlet and outlet temperatures.
6. Run that track idle off ground for 3 minutes with fuel control dial at MAX position and travel speed at Hi
setting.
• After above steps are implemented, if failure code is not cleared because of low ambient temperature
(at -20°C level), perform following steps.
8. Disconnect connector E26 (in KDPF temperature sensor consolidating box) and install dummy
temperature sensor to wiring harness side.
10.Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
11.Start engine and run it at low idle (with no load) for approximately 15 minute.
If failure code disappears after implementing steps 7 to 11, repair work is complete.
13.Remove dummy temperature sensor to restore connector connection.
command.
controller
PC490LC-10 40-345
40 Troubleshooting
40-346 PC490LC-10
40 Troubleshooting
Failure code [CA3254] KDOC Outlet Temp High Error 1 (PC400-CA3254-400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature High Error 1

Failure
Detail of • KDOC outlet temperature remains at high level.
failure
controller
machine
injury.
of KDPF".
Machine O
clearing
after repair.
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
Defective fuel doser If failure code [CA1925] or [CA1963] is also displayed, perform
solenoid valve 1
3
PC490LC-10 40-347
40 Troubleshooting

2. Disconnect connectors CE03 and TEMP2 (KDOC outlet temperature
Short circuit in wiring sensor), and connect T-adapter to female side of CE03.
4
Continuity
2. Use monitoring function to display signal voltages and temperatures from
KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor on screen.
Defective KDOC outlet 5. Monitor temperature from each sensor.
5 temperature sensor If temperature of any temperature sensor fluctuates 24°C or greater, regard
that temperature sensor as defective.
a If none of temperature sensor values changes more than 24°C, problem is
not in sensor system. Perform checks on causes 5 and after.
Malfunction of intake Check intake system hoses, clamps, and tubes for damage and loosening.
6 system Repair as necessary. (Repair intake air leaks.)
Oil leak into 2. Check for oil or fuel inside turbocharger exhaust connector.
8 turbocharger exhaust • If oil or fuel is found, visually check for oil leaks from EGR valve and
connector turbocharger. Repair if any failure is found.
Check exhaust system between turbocharger and KDPF for oil or fuel leaking
Oil leak into exhaust in.
9 connector and ducts • Wipe off oil or fuel if found.
leading to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and clean or
replace it as necessary.
1. Remove KDPF.
2. Remove KDOC.
a When KDOC of KDPF is replaced, perform reset procedure for KDOC
10 Defective KDOC change and then finish troubleshooting without performing manual
stationary regeneration (see check on cause 7 of failure code [CA2637]).
• Check whether more than 50% of KDOC inlet surface is plugged with soot
or not.
(KDOC cleaning)
40-348 PC490LC-10
40 Troubleshooting

4. End regeneration for service.
(You may end regeneration for service when 15 minutes minimum have elapsed from its start.)
If failure code disappears when regeneration for service is ended, repair is complete.
command.
controller
PC490LC-10 40-349
40 Troubleshooting
Failure code [CA3255] KDPF Temp Error - Non Regeneration (PC400-CA3255-400-A-

Z0-A)
Action level Failure code KDPF Temperature Error - Non Regeneration

Failure
Detail of • KDPF outlet temperature remains at high level when active regeneration is not performed.
failure
controller
machine
injury.
of KDPF".
O
Machine B. Machine operation for clearing failure code
operation for
clearing a This failure code does not disappear by simply turning starting switch to ON position from
failure code OFF position after repair. You must perform machine operation for clearing failure code
after repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is also displayed, perform
Defective wiring
2 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and fix trouble as needed.
2. Disconnect connectors CE03 and TEMP3 (KDPF outlet temperature
harness
Continuity is heard)
each pin other than pin (54)
40-350 PC490LC-10
40 Troubleshooting

Defective KDPF outlet
4 5. Monitor temperature from each sensor.
temperature sensor
If temperature of any temperature sensor fluctuates 24°C or greater, regard
• If none of temperature sensor values changes more than 24°C, problem is
• If another failure code appears with engine running at idle, perform
2. Check inside of turbocharger exhaust connector for adhesion of oil and
Oil leak into fuel.
1. Turn starting switch from OFF position to ON position and leave it there for 1 minute.
PC490LC-10 40-351
40 Troubleshooting

a If failure code remains uncleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 3 and 4 are required to satisfy temperature
requirements.
• KDOC outlet temperature X 200°C
• KDPF outlet temperature X 200°C
3. Use monitoring function to display KDOC outlet and KDPF outlet temperatures.
6. Run that track idle off ground for continuous 3 minutes with fuel control dial at MAX position and travel
speed at Hi setting.
• After above steps are implemented, if failure code is not cleared because of low ambient temperature
(at -20°C level), perform following steps.
8. Disconnect connector E26 (in KDPF temperature sensor consolidating box) and install dummy
temperature sensor to wiring harness side.
10.Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
11.Start engine and run it at low idle (with no load) for approximately 15 minute.
If failure code disappears after implementing steps 7 to 11, repair work is complete.
13.Remove dummy temperature sensor to restore connector connection.
command.
controller
40-352 PC490LC-10
40 Troubleshooting
PC490LC-10 40-353
40 Troubleshooting
Failure code [CA3256] KDPF Outlet Temp High Error 1 (PC400-CA3256-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature High Error 1

Failure
Detail of • KDPF outlet temperature remains at high level.
failure
controller
machine
injury.
of KDPF".
Machine O
clearing
after repair.
2
40-354 PC490LC-10
40 Troubleshooting

3
Between CE03 (female) (54) and each pin other No continuity (no sound
than pin (54) is heard)
Defective KDPF outlet 5. Monitor temperature from each sensor.
4 temperature sensor
Oil leak into fuel.
4. End regeneration for service.
(You may end regeneration for service when 15 minutes minimum have elapsed from its start.)
If failure code disappears when regeneration for service is ended, repair is complete.
command.
controller
PC490LC-10 40-355
40 Troubleshooting
40-356 PC490LC-10
40 Troubleshooting
Failure code [CA3311] KDOC Outlet Temp High Error 2 (PC400-CA3311-400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature High Error 2

Failure
Detail of • KDOC outlet temperature remains extremely high relative to KDOC inlet temperature.
failure
controller
machine
injury.
Related • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
of KDPF".
OFF position. So when you restart engine, wait 1 minute minimum before turning starting
switch to the ON position again.
Machine O
operation for C. Machine operation for confirming completion of repair
clearing
failure code a This failure code disappears when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
Defective wiring
2 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and fix trouble as needed.
2. Disconnect connectors CE03 and TEMP2 (KDOC outlet temperature
harness
Continuity is heard)
PC490LC-10 40-357
40 Troubleshooting

Defective KDOC outlet 5. Monitor temperature from each sensor.
Oil leak into fuel.
C. Machine operation for confirming completion of repair
a Failure code disappears once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
• [CA3316] KDOC Outlet Temp Sens Low Error
• [CA3317] KDOC Outlet Temp Sens High Error
controller
40-358 PC490LC-10
40 Troubleshooting
PC490LC-10 40-359
40 Troubleshooting
Failure code [CA3312] KDPF Outlet Temp High Error 2 (PC400-CA3312-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature High Error 2

Failure
Detail of • KDPF outlet temperature remains at very high level.
failure
controller
machine
injury.
of KDPF".
Machine O
operation for C. Machine operation for confirming completion of repair
clearing
failure code a This failure code disappears when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
Defective fuel doser If failure code [CA1925] or [CA1963] is also displayed, perform
solenoid valve 1
3
40-360 PC490LC-10
40 Troubleshooting

4
Continuity
Defective KDPF outlet 5. Monitor temperature from each sensor.
5 temperature sensor If temperature of any temperature sensor fluctuates 24°C or greater, regard
a If none of temperature sensor values changes more than 24°C, problem is
Oil leak into 2. Check for oil or fuel inside turbocharger exhaust connector.
C. Machine operation for confirming completion of repair
a Failure code disappears once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
• [CA3319] KDPF Outlet Temp Sens Low Error
• CA3321] KDPF Outlet Temp Sens High Error
controller
PC490LC-10 40-361
40 Troubleshooting
40-362 PC490LC-10
40 Troubleshooting
Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error (PC400-
CA3313-400-A-Z0-A)
Action level Failure code KDOC inlet temperature sensor low error
Failure
Detail of • Low voltage appears in KDOC inlet temperature sensor circuit.
failure
• KDOC outlet temperature is substituted for KDOC inlet temperature to continue operation.
(If KDOC outlet temperature sensor is also abnormal, takes it that KDOC inlet
Action of temperature is default value (250 °C) and allows engine to run.)
machine
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3314] for "High Error" appears.
• KDOC inlet temperature sensor connector label "TEMP1" is indicated on KDPF
"TEMP3").
<Clearing failure code>
Since error may occur during operation, start engine and run it at low idle for approximately
one minute. If this failure code disappears, repair is complete.
a After this failure code is cleared, soot accumulation level becomes level "3" and automatic
regeneration starts. This regeneration is intentionally performed to reduce soot
accumulation and does not matter.
harness connector
2. Disconnect TEMP1 (KDOC inlet temperature sensor).
Defective KDOC inlet If this failure code changes to [CA3314], KDOC inlet temperature sensor is
2 temperature sensor defective.
• Reference
PC490LC-10 40-363
40 Troubleshooting

2. Disconnect connector TEMP1 and connect T-adapters to male side.
-10 °C 33 to 65 kz
0 °C 25 to 47 kz
7.8 to 12.2
Between TEMP1 (male) (1) and (2) 50 °C
kz
Defective KDOC inlet 3.2 to 4.5
2 temperature sensor Resistance a Temperature-Resistance 100 °C
characteristics kz
200 to 240
400 °C
z
700 °C 64 to 69 z
Between TEMP1 (male) (1) and ground Min. 1 Mz
harness 2. Disconnect connectors CE03 and TEMP1, and connect T-adapters to
(contact with ground either female side.
3 circuit)
(including inside of
Between ground and CE03 (female) (45) or TEMP1
KDPF temperature Resistance (female) (1) Min. 1 Mz
sensor consolidating
box)
Short circuit in wiring 1. Turn starting switch to OFF position.
female side of connector CE03.
4 (including inside of
KDPF temperature a Check by using multimeter in continuity mode.
sensor consolidating Between CE03 (female) (45) and No continuity
box) Continuity
a If no failure is found by checks on causes 3 and 4, this check is not
required.
2. Disconnect connector E26 and connect T-adapters to male side.
Defective KDPF 3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
5 temperature sensor a If no failure is found by check on cause 3, this
consolidating box check is not required. Min. 1 Mz
Between E26 (male) (3) and ground
Resistance
check is not required. Min. 1 Mz
Between E26 (male) (3) and each other pin
harness
6 2. Disconnect connectors CE03 and E26, and connect T-adapters to either
(contact with ground female side.
circuit) Between ground and CE03 (female) (45) or E26

Short circuit in wiring side of connector CE03.
7
harness
Continuity
each pin other than pin (45) (No sound is heard)
Defective engine 1. Turn starting switch to ON position.

8 2. If this failure code appears, perform procedure for <Clearing failure code>
controller
in "Related information".
40-364 PC490LC-10
40 Troubleshooting

If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
PC490LC-10 40-365
40 Troubleshooting
Failure code [CA3314] KDOC Inlet Temperature Sensor High Error (PC400-
CA3314-400-A-Z0-A)
Action level Failure code KDOC inlet temperature sensor high error
Failure
Detail of • High voltage has appeared in the KDOC inlet temperature sensor circuit.
failure
• KDOC outlet temperature is substituted for KDOC inlet temperature to continue operation.
(If the KDOC outlet temperature sensor is also abnormal, the default value (250 ° C) is
Action of taken as KDOC inlet temperature to continue operation.)
machine
• Signal voltage from the KDOC inlet temperature sensor can be checked by using
monitoring function. (Code: 47301(V))
information • This failure code is displayed if the sensor connector is disconnected.
• If failure codes [CA3317] and [CA3319] are also displayed, the KDPF temperature
sensors integrated box connector is disconnected, or an open circuit (poor connection in
connector) is suspected in the GND line.
"TEMP3").
Since error may occur during operation, start engine and run it at low idle for approximately
one minute. If this failure code disappears, repair is complete.
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
40-366 PC490LC-10
40 Troubleshooting

2. Disconnect TEMP1 (KDOC inlet temperature sensor) and connect T-
adapter to male side.
3. Connect T-box to T-adapter and connect T-box pins (1) and (2) using a
jumper wire.
a Connect signal wire to ground.
If this failure code changes to [CA3313], KDOC inlet temperature sensor is
defective.
Defective KDOC inlet is defective.
2 temperature sensor • Reference
2. Disconnect connector TEMP1 and connect T-adapter to female side.
-10 °C 33 to 65 kz
0 °C 25 to 47 kz
7.8 to 12.2
Between TEMP1 (female) (1) and (2) 50 °C
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100 °C
characteristics kz
200 to 240
400 °C
z
700 °C 64 to 69 z
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector CE03, and connect T-adapters to female side.
(including inside of Between CE03 (female) (45) and (19)
3
KDPF temperature 64 z to 65
sensor consolidating Resistance a Resistance accords with value in the above
kz
box) Temperature-Resistance characteristics table.
harness
(wire breakage or
2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to
female side of CE03 and male side of TEMP1.
4 connector)
Between CE03 (female) (45) and TEMP1 (male) (1) Max. 1 z
Between CE03 (female) (19) and TEMP1 (male) (2)
KDPF temperature Resistance
sensor consolidating Max. 1 z
box)
Short circuit in wiring 2. Disconnect connectors CE03 and TEMP1, and connect T-adapters to
harness female side of connector CE03.
sensor consolidating No continuity
Between CE03 (female) (45) and
box) Continuity (No sound is heard)
PC490LC-10 40-367
40 Troubleshooting

a If no abnormality is found in checks on causes 3 to 5, this check is not
required.
3. Disconnect connectors TEMP1, TEMP2, TEMP3, and connect T-adapter
to male side of TEMP1.
Defective KDPF a If no abnormality is found in checks on causes 3
6 temperature sensor or 4, this check is not required. Max. 1 z
consolidating box Between E26 (male) (2) and TEMP1 (male) (2)
a If no abnormality is found in checks on causes 3
Resistance or 4, this check is not required. Max. 1 z
Between E26 (male) (3) and TEMP1 (male) (1)
a If cause 5 is not the cause for the trouble, this
a If no abnormality is found in checks on causes 3 or 4, this check is not
Open circuit in wiring required.
harness 1. Turn starting switch to OFF position.
7 (wire breakage or 2. Disconnect connectors CE03 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between CE03 (female) (45) and E26 (female) (3) Max. 1 z
Resistance
a If cause 5 is not the cause for the trouble, this check is not required.
8
harness
Continuity
each pin other than pin (45) (No sound is heard)
2. If this failure code appears, perform procedure for <Clearing failure code>
Defective engine in "Related information".
9
controller If this failure code is still displayed and no failure is found by above checks,
40-368 PC490LC-10
40 Troubleshooting
PC490LC-10 40-369
40 Troubleshooting
Failure code [CA3315] KDOC Intlet Temperature Sensor In Range

Error (PC400-CA3315-400-A-Z0-A)
Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
• Difference between temperature sensed by KDOC inlet temperature sensor and that by
Detail of KDOC outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor, too, controller takes it that
Action of KDOC inlet temperature is at default value (250°C) and allows engine to run.)
machine
injury.
Related • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
of KDPF".
Machine O
clearing
after repair.
Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for
1 temperature sensor it first.
2
40-370 PC490LC-10
40 Troubleshooting

2. Disconnect TEMP1 (KDOC inlet temperature sensor).
defective.
3 harness or engine 2. Disconnect connector TEMP1 and connect T-adapter to male side.
controller 3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box with
jumper cable.
a To connect ground line to signal line
defective.
(wire breakage or female side of CE03 and male side of TEMP1.
defective contact of Between CE03 (female) (45) and TEMP1 (male) (1) Max. 1 z
4 connector)
(including wiring
harness in KDPF Resistance
temperature sensor
consolidating box)
harness 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to
(contact with ground female side of CE03 or male side of TEMP1.
5 circuit)
(including wiring
Between ground and CE03 (female) (45) or TEMP1
harness in KDPF Resistance (male) (1) Min. 1 Mz
temperature sensor
consolidating box)
harness
female side of CE03.
(including wiring
harness in KDPF
temperature sensor Between CE03 (female) (45) and No continuity (no sound
consolidating box) Continuity is heard)
PC490LC-10 40-371
40 Troubleshooting

2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP1.
Defective KDPF a If no failure is found by check on cause 4, this
7 temperature sensor check is not required. Max. 1 z
Resistance
Between E26 (male) (3) and each pin other than
pin (3)
Open circuit in wiring a If no failure is found by check on cause 4, this check is not required.
8 (wire breakage or 2. Disconnect connectors CE03 and E26, and connect T-adapter to each
Resistance
harness
9 2. Disconnect connectors CE03 and E26, and connect T-adapter to either

10
harness
Continuity
wiring harness 2. Disconnect connector CE03, and connect T-adapter to female side.
(including wiring Between CE03 (female) (45) and (19)
11 64 z to 65
harness in KDPF
temperature sensor Resistance a Use Temperature-Resistance characteristics kz
consolidating box) shown below as resistance criteria.
40-372 PC490LC-10
40 Troubleshooting

a When failure codes [CA3314] and [CA3313] are displayed in check on
cause 3 and no failure is found by checks on causes 2 and 4 to 10, and if
failure is found by check on cause 11, KDOC inlet temperature sensor is
defective.
• Reference
Defective KDOC inlet -10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP1 (female) (1) and (2) 50°C
kz
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
setting.
a Soot accumulation is expressed as level "3" while this failure code is displayed. This may cause
automatic regeneration to start after this failure code is cleared. Controller takes this measure
intentionally to reduce soot accumulation and it is not failure.
command.
controller
PC490LC-10 40-373
40 Troubleshooting
40-374 PC490LC-10
40 Troubleshooting
Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error (PC400-
CA3316-400-A-Z0-A)
Action level Failure code KDOC outlet temperature sensor low error
Failure
Detail of • Low voltage has appeared in the KDOC outlet temperature sensor circuit.
failure
• KDOC inlet temperature is substituted for KDOC outlet temperature to continue operation.
(If the KDOC inlet temperature sensor is also abnormal, the default value (250 ° C) is
Action of taken as KDOC outlet temperature to continue operation.)
machine
k Since the temperature of the KDPF and KDOC will become higher than 500 °C, take
• If the sensor connector is disconnected or an open circuit occurs, this failure code is not
generated but failure code [CA3317] for "High Error" is generated.
"TEMP3").
<Clearing failure codes>
Since there is a possibility of error occurring during operation, start the engine and let it idle
for one minute. If this failure code is cleared, repair is complete.
1
harness connector
PC490LC-10 40-375
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).
If failure code changes to [CA3317], KDOC outlet temperature sensor is
defective.
is defective.
• Reference
Defective KDOC outlet 2. Disconnect connector TEMP2 and connect T-adapter to female side.
2 temperature sensor -10 °C 33 to 65 kz
0 °C 25 to 47 kz
7.8 to 12.2
kz
a Temperature-Resistance 3.2 to 4.5
Resistance 100 °C
characteristics kz
200 to 240
400 °C
z
700 °C 64 to 69 z
Between TEMP2 (female) (1) and ground Min. 1 Mz
circuit)
3
(including inside of Between CE03 (female) (48) or TEMP2 (male) (1)
KDPF temperature Resistance and ground Min. 1 Mz
box)
4
box) Continuity
required.
Resistance
harness
circuit) Between CE03 (female) (48) or E26 (female) (1) Min. 1 Mz
Resistance and ground
40-376 PC490LC-10
40 Troubleshooting

7
harness
Continuity
If this failure code is displayed, perform <Clearing failure codes> in
Defective engine "Related information".
8
PC490LC-10 40-377
40 Troubleshooting
Failure code [CA3317] KDOC Outlet Temperature Sensor High Error (PC400-
CA3317-400-A-Z0-A)
Action level Failure code KDOC outlet temperature sensor high error
Failure
Detail of • High voltage has appeared in the KDOC outlet temperature sensor circuit.
failure
• KDOC inlet temperature is substituted for KDOC outlet temperature to continue operation.
(If the KDOC inlet temperature sensor is also abnormal, the default value (250°C) is taken
Action of as KDOC outlet temperature to continue operation.)
machine
"TEMP3").
Since error may occur during operation, start engine and run it at low idle for one minute. If
this failure code disappears, repair is complete.
1
harness connector
40-378 PC490LC-10
40 Troubleshooting

2. Disconnect KDOC outlet temperature sensor (connector TEMP2) and
connect T-adapter to female side.
jumper wire.
If failure code changes to [CA3316], KDOC outlet temperature sensor is
defective.
Defective KDOC outlet is defective.
-10 °C 33 to 65 kz
0 °C 25 to 47 kz
7.8 to 12.2
kz
100 °C
characteristics kz
200 to 240
400 °C
z
700 °C 64 to 69 z
3
kz
harness
(wire breakage or
4 connector)
sensor consolidating Between CE03 (female) (19) and TEMP2 (male) (2) Max. 1 z
box)
Short circuit in wiring 2. Disconnect connectors CE03 and TEMP2, and connect T-adapter to
each other pin
PC490LC-10 40-379
40 Troubleshooting

required.
Resistance
8
harness
Continuity
9
40-380 PC490LC-10
40 Troubleshooting
PC490LC-10 40-381
40 Troubleshooting
Failure code [CA3318] KDOC Outlet Temp Sensor In Range Error (PC400-
CA3318-400-A-Z0-A)
Action level Failure code KDOC outlet temperature sensor in range error
Failure
• Difference between temperature sensed by KDOC outlet temperature sensor and that by
Detail of KDOC inlet temperature sensor differs from expected value.
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor, too, controller takes it that KDOC
outlet temperature is at default value (250°C) and allows engine to run.)
machine
injury.
of KDPF".
Machine O
clearing
after repair.
Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform troubleshooting for
2
40-382 PC490LC-10
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).
defective.
3 harness or engine 2. Disconnect connector TEMP2 and connect T-adapter to male side.
jumper cable.
defective.
4 connector)
(including wiring
Resistance
harness in KDPF Between CE03 (female) (19) and TEMP2 (male) (2) Max. 1 z
temperature sensor
consolidating box)
circuit)
5
(including wiring Between ground and CE03 (female) (48) or TEMP2
temperature sensor
consolidating box)
harness
6 (including wiring
harness in KDPF a Check by using multimeter in continuity mode.
PC490LC-10 40-383
40 Troubleshooting

Resistance
pin (1)
Resistance
harness

10
harness
Continuity
11 64 z to 65
harness in KDPF
40-384 PC490LC-10
40 Troubleshooting

cause 3 and no failure is found by checks on causes 2 and 4 to 10, and if
failure is found by check on cause 11, KDOC outlet temperature sensor is
defective.
• Reference
Defective KDOC outlet -10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
kz
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
setting.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may cause automatic
regeneration to be started after this failure code is cleared. Controller takes this measure intentionally to
reduce soot accumulation and it is not failure.
command.
controller
PC490LC-10 40-385
40 Troubleshooting
40-386 PC490LC-10
40 Troubleshooting
Failure code [CA3319] KDPF Outlet Temperature Sensor High Error (PC400-
CA3319-400-A-Z0-A)
Action level Failure code KDPF outlet temperature sensor high error
Failure
Detail of • High voltage has appeared in the KDPF outlet temperature sensor circuit.
failure
• KDOC outlet temperature is substituted for KDPF outlet temperature to continue
operation.
(If the KDOC outlet temperature sensor is also abnormal, the default value (250 ° C) is
Action of taken as KDPF outlet temperature to continue operation.)
machine
"TEMP3").
1
harness connector
PC490LC-10 40-387
40 Troubleshooting

2. Disconnect KDPF outlet temperature sensor (connector TEMP3) and
connect T-adapter to female side.
jumper wire.
If failure code changes to [CA3321], KDPF outlet temperature sensor is
defective.
Defective KDPF outlet is defective.
-10 °C 33 to 65 kz
0 °C 25 to 47 kz
7.8 to 12.2
50 °C
Between TEMP3 (female) (1) and (2) kz
100 °C
kz
characteristics
200 to 240
400 °C
z
700 °C 64 to 69 z
3
kz
harness
(wire breakage or
4 connector)
sensor consolidating Between CE03 (female) (19) and TEMP3 (male) (2) Max. 1 z
box)
Short circuit in wiring 2. Disconnect connectors CE03 and TEMP3, and connect T-adapter to
each other pin
40-388 PC490LC-10
40 Troubleshooting

required.
Resistance
8
harness
Continuity
9
PC490LC-10 40-389
40 Troubleshooting
40-390 PC490LC-10
40 Troubleshooting
Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error (PC400-
CA3321-400-A-Z0-A)
Action level Failure code KDPF outlet temperature sensor low error
Failure
Detail of • Low voltage has appeared in the KDPF outlet temperature sensor circuit.
failure
• KDOC outlet temperature is substituted for KDPF outlet temperature to continue
operation.
(If the KDOC outlet temperature sensor is also abnormal, the default value (250° C) is
Action of taken as KDPF outlet temperature to continue operation.)
machine
• If the sensor connector is disconnected or an open circuit occurs, this failure code is not
generated but failure code [CA3319] for "High Error" is generated.
"TEMP3").
harness connector
2. Disconnect TEMP3 (KDPF outlet temperature sensor).
Defective KDPF outlet
2 temperature sensor If failure code changes to [CA3319], KDPF outlet temperature sensor is
defective.
is defective.
PC490LC-10 40-391
40 Troubleshooting

• Reference
-10 °C 33 to 65 kz
0 °C 25 to 47 kz
Defective KDPF outlet 7.8 to 12.2
2 Between TEMP3 (female) (1) and (2) 50 °C
temperature sensor kz
a Temperature-Resistance 3.2 to 4.5
Resistance 100 °C
characteristics kz
200 to 240
400 °C
z
700 °C 64 to 69 z
Between TEMP3 (female) (1) and ground Min. 1 Mz
(contact with ground female side of CE03 and male side of TEMP3.
circuit)
3
(including inside of Between CE03 (female) (54) or TEMP3 (male) (1)
KDPF temperature Resistance and ground Min. 1 Mz
box)
4
box) Continuity
required.
Resistance
harness
circuit) Between CE03 (female) (54) or E26 (female) (4)
Resistance and ground Min. 1 Mz

7
No continuity
Continuity (No sound is heard)
each other pin
40-392 PC490LC-10
40 Troubleshooting

2. If this failure code is displayed, perform <Clearing failure codes> in
Defective engine "Related information".
8
PC490LC-10 40-393
40 Troubleshooting
Failure code [CA3322] KDPF Outlet Temp Sensor In Range Error (PC400-
CA3322-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor In Range Error
Failure
Detail of • Temperature sensed by KDPF outlet temperature sensor differs from expected value.
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor, controller takes it that KDPF
outlet temperature is at default value (250°C) and allows engine to run.)
machine
injury.
of KDPF".
Machine O
clearing
after repair.
Defective KDPF outlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for
2
harness connector troubleshooting", and check it.
40-394 PC490LC-10
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).
defective.
3 harness or engine 2. Disconnect TEMP3 and connect T-adapter to female side.
jumper cable.
defective.
4 connector)
(including wiring
Resistance
harness in KDPF Between CE03 (female) (19) and TEMP3 (male) (2) Max. 1 z
temperature sensor
consolidating box)
circuit)
5
(including wiring Between ground and CE03 (female) (54) or TEMP3
temperature sensor
consolidating box)
harness
6 (including wiring
harness in KDPF a Check by using multimeter in continuity mode.
PC490LC-10 40-395
40 Troubleshooting

Resistance
pin (4)
Resistance
harness

10
harness
Continuity
11 64 z to 65
harness in KDPF
40-396 PC490LC-10
40 Troubleshooting

cause 3 and no failure is found by checks on causes 2 and 4 to 10, if
failure is found by check on cause 11, KDOC inlet temperature sensor is
defective.
• Reference
Defective KDPF outlet -10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
kz
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
setting.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may cause automatic
regeneration to be started after this failure code is cleared. Controller takes this measure intentionally to
reduce soot accumulation and it is not failure.
command.
controller
PC490LC-10 40-397
40 Troubleshooting
40-398 PC490LC-10
40 Troubleshooting
Failure code [CA3419] Mass Air Flow Sensor Power Supply High
Error (PC400-CA3419-400-A-Z0-A)
Action
Failure code Mass Air Flow Sensor Power Supply High Error
level Failure
(Engine controller system)
L03 CA3419
Detail of • High voltage appears in mass air flow sensor power supply (12 V) circuit.
failure
a If mass air flow sensor signal voltage becomes abnormal, the following actions similar to
those for codes [CA356] and [CA357] should be taken.
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
controller • Closes EGR valve.
machine
information
connector
Defective sensor
2 If this failure code does not appear, the mass air flow sensor is
(internal defect) defective.
a Other failure codes are displayed at the same time. This is because
connector is disconnected. Ignore failure codes other than this one.
3 Defective harness If this failure code does not appear, the wiring harness is defective.
4 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
PC490LC-10 40-399
40 Troubleshooting
40-400 PC490LC-10
40 Troubleshooting
Failure code [CA3421] Mass Air Flow Sensor Power Supply Low
Error (PC400-CA3421-400-A-Z0-A)
Action
Failure code Mass Air Flow Sensor Power Supply Low Error
level Failure
(Engine controller system)
L03 CA3421
Detail of • High voltage appears in mass air flow sensor power supply (12V) circuit.
failure
a If mass air flow sensor signal voltage becomes abnormal, the following actions similar to
those for codes [CA356] and [CA357] should be taken.
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
controller • Closes EGR valve.
machine
information
connector
Defective mass air flow 3. Turn starting switch to ON position.
2 sensor If this failure code does not appear, the mass air flow sensor is
(internal defect) defective.
Defective harness or 3. Turn starting switch to ON position.
3 If this failure code does not appear, the wiring harness is defective.
connector
4 female side.
tance
2. Disconnect connectors J1 and P55 and connect T-adapter to either
tance
6 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
PC490LC-10 40-401
40 Troubleshooting
40-402 PC490LC-10
40 Troubleshooting
Failure code [D110KB] Battery Relay Drive S/C (PC400-D110KB-400-A-Z0-A)
PC490LC-10
Action level Failure code Battery Relay Drive Short Circuit
Failure
L01 D110KB (Pump controller system)
Detail of • Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
failure
• Stops 24 V output to battery relay primary circuit (coil side).
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Each controller may fail in writing of data into its ROM (non-volatile memory).
machine
• As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
be measured at pump controller connector.
Related • Output state (ON/OFF) to battery relay can be checked with monitoring function.
information (Code: 03700 Controller output 1)
• Method of reproducing failure code: Turn starting switch to ON position, then turn it to
OFF position.
Defective battery relay 1. Turn starting switch to OFF position.
1
(Internal short circuit) Continuity Between terminals R01 and R02 Continuity
2. Turn the battery disconnect switch to OFF position (to prevent short
circuit during work).
3. Disconnect wires from terminals R01 and R02, and disconnect
2 connectors D01, H15 and CP02.
Between terminal R02 (BR) and ground Min. 1 Mz
Resis- Between ground and terminal CP02 (female)
tance (108), R02 (harness side), D01 (female) (1) or Min. 1 Mz
(2)
If no failure is found by above checks, pump controller is defective.
• Reference
2. Insert T-adapters into connector D01.
3 Defective pump controller
4. Measure voltage within 0.5 second after turning staring switch to
OFF position from ON position.
Voltage Between D01 (1) and ground 20 to 30 V
PC490LC-10 40-403
40 Troubleshooting
Circuit diagram related to battery relay
40-404 PC490LC-10
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality (PC400-D19JKZ-400-A-Z0-A)
Action level Failure code Personal Code Relay Abnormality

Failure
L03 D19JKZ (Machine monitor system)
Detail of • Disconnection or short circuit was detected in primary coil side of personal code relay
failure circuit.
• None in particular (when open circuit is detected).
• Shuts of power supply to personal code relay (when short circuit is detected).
Action of • If cause of failure disappears, machine becomes normal by itself (when open circuit is
machine detected).
monitor • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when short circuit is detected).
Problem on
machine
• This failure code is displayed only when engine lock function is enabled.
• Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble
Related cannot be reproduced on machine (Short circuit).
information • Troubleshooting for this failure code covers circuit starting from No. 3 fuse of fuse box
F01, through primary (coil) circuit of personal code relay R07, to machine monitor.
Defective No. 3 of fuse F01
1 If fuse is blown, circuit probably has ground fault.
(3rd from right top)
Resis- Between R07 (male) (1) and (2)
200 to 600 z
tance
Defective personal code relay
2 1. Turn starting switch to OFF position.
R07
2. Replace relay R07 with preheater relay R18.
If this failure code disappears, original personal code relay R07 is
defective.
2. Remove fuse No. 3 of fuse box F01 (3rd fuse from the right top).
3. Disconnect connectors CM01 and S14, and connect T-adapter to
Open circuit or short circuit or
3 female side of CM01.
ground fault in wiring harness
Between F01-3 and CM01 (female) (6) 200 to 600 z
Resis-
Between F01-3 or CM01 (female) (6) and
tance Min. 1 Mz
ground
4 Open circuit in wiring harness 3. Disconnect connector CM01 and relay R07, and connect T-adapters
Between F01-3 and R07 (female) (1) Max. 1 z
Resis-
Between R07 (female) (2) and CM01
tance Max. 1 z
(female) (6)
3. Disconnect connector CM01 and relay R07, and connect T-adapters
5 Ground fault in wiring harness to either female side.
Between F01-3 or R07 (female) (1) and
Min. 1 Mz
Resis- ground
tance Between R07 (female) (2) and ground, or
between CM01 (female) (6) and ground Min. 1 Mz
PC490LC-10 40-405
40 Troubleshooting

3. Disconnect connectors CM01 and relay R07, and connect T-adapter
to female side of connector CM01.
No continuity
Between CM01 (female) (6) and each pin
Continuity (No sound is
other than pin (6)
heard)
If no failure is found by above checks, machine monitor (KOMTRAX
Defective machine monitor
7 portion) is defective. (Since this is an internal defect, troubleshooting
(KOMTRAX section)
40-406 PC490LC-10
40 Troubleshooting
Circuit diagram related to personal code relay
PC490LC-10 40-407
40 Troubleshooting
Failure code [D811MC] KOMTRAX Error (PC400-D811MC-400-A-Z0-A)
Action level Failure code KOMTRAX Error

Failure
– D811MC (KOMTRAX system)
Detail of
• KOMTRAX malfunctions.
failure
Action of
controller
Problem on • KOMTRAX system does not operate properly.
machine
information
KOMTRAX is defective.
1 Malfunction of KOMTRAX
40-408 PC490LC-10
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit (PC400-D862KA-400-A-Z0-A)
Action level Failure code GPS Antenna Open Circuit

Failure
- D862KA (KOMTRAX system)
Detail of • Open circuit occurs in GPS antenna circuit.
failure
monitor
Problem on • GPS positioning system does not work.
machine
information
Defective GPS antenna or GPS antenna may be defective, or antenna cable may have open or
1 short circuit, or poor contact at terminal area (GPS).
antenna cable
Figure of structure
PC490LC-10 40-409
40 Troubleshooting
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) (PC400-

D8ALKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (KOMTRAX)

Failure
— D8ALKA (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which KOMTRAX outputs no current to
system operating lamp.
Action of • It does not output for system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
• Although KOMTRAX is not able to light up system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
Defective fuse No. 16 in a If room lamp lights up, this check is not required.
1
fuse box F01. If fuse is blown, circuit probably has ground fault.

harness 2. Remove fuse No. 16 in fuse box F01.
3. Disconnect connectors CK01 and L19, and connect T-adapters to each
2 (Wire breakage or female side.
defective contact of Between CK01 (female) (15) and L19 (female) (2) Max. 1 z
Between F01-16 and L19 (female) (1) Max. 1 z
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective. (Since
3 this is an internal defect, troubleshooting cannot be performed.)
terminal
40-410 PC490LC-10
40 Troubleshooting
Circuit diagram related to system operating lamp
PC490LC-10 40-411
40 Troubleshooting
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) (PC400-

D8ALKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (KOMTRAX)

Failure
- D8ALKB (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit shorts because voltage of output
Detail of circuit does not become low level while KOMTRAX outputs current to system operating
failure lamp.
Action of • Stops driving system operating lamp.
controller
Problem on position. Turning battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX memory.
Related • Although KOMTRAX is not able to light up system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
2. Remove fuse No. 16 in fuse box F01.
Short circuit in wiring 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19, and connect
1
harness T-adapter to female side of connector L19.
Resistance Between L19 (female) (1) and (2) Min. 1 Mz
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective. (Since
terminal
40-412 PC490LC-10
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) (PC400-D8AQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (KOMTRAX)

Failure
– D8AQKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor cannot recognize pump controller through CAN communication 2 line
failure (KOMNET/c).
Action of
machine • None
monitor
Problem on
• None
machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• If any of failure codes [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller
may be defective.
• Machine monitor indicates a CAN communication error in CAN2 with failure code
[DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR]. If all four of these failure code are
displayed, harness (CAN communication line) may have ground fault, short circuit, or hot
short circuit. Since air conditioner is also controlled via CAN communication, check
whether air conditioner can be operated (ON/OFF and air flow adjustment) on air
Related conditioner screen.
information a If ID controller is not installed, failure code [F7FQKR] is not generated. Therefore, the
number of failure codes that may be generated are four; [DA2QKR], [DB2QKR],
[D8AQKR], and [DAZQKR].
a Air conditioner can be operated even when a failure code is displayed on machine
monitor screen. If air conditioner is operated, there is no possibility of ground fault, short
circuit, or hot short circuit in harness (CAN communication line).
• Since each controller and machine monitor are directly connected to continuous power
supply, they receive continuous power even while starting switch is at OFF position.
• Since active CAN communication line signal is pulse voltage, it cannot be measured by
using multimeter.
2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05 Resis- Between F05 (female) (1) and (2)
Max. 1 z
tance
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in fuse
2 2. Remove fuse No. 17 of fuse box F01.
box F01
When fuse is blown, circuit may have ground fault.
Power supply to KOMTRAX Perform troubleshooting for E mode, "E-57".
3
terminal defective
Defective CAN [Perform troubleshooting for failure code [DB2QKR], cause 4 to 9.
4
communication 2 line
If no failure is found by above checks, KOMTRAX terminal is defective.
5 Defective KOMTRAX terminal
PC490LC-10 40-413
40 Troubleshooting
Failure code [DA20MC] Pump Controller Malfunction (PC400-DA20MC-400-A-Z0-A)
Action level Failure code Pump controller malfunction

Failure
– DA20MC (Pump controller system)
Detail of • Pump controller malfunctions.
failure
Action of
controller
Problem on • Pump controller does not function normally
machine
information
Malfunction of pump Pump controller is defective.
1
40-414 PC490LC-10
40 Troubleshooting
Failure code [DA22KK] Pump Solenoid Power Low Error (PC400-DA22KK-400-A-Z0-A)
Action level Failure code Pump solenoid power supply low error
Failure
L03 DA22KK (Pump controller system)
Detail of • Power supply voltage of controller for driving solenoids is below 20 V.
failure
• Stops detection of failures (open circuit and short circuit) in all solenoid systems while this
Action of failure code is active.
• No solenoid valve is energized properly, so machine does not work properly.
Problem on (Work equipment, swing, and travel systems do not work.)
machine • Hydraulic fan does not rotate in reverse direction.
• If failure code [D110KB] is displayed, perform troubleshooting for it first.
Related • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
information be measured at pump controller connector.
1 Defective fusible link F04 If fusible link is blown, circuit probably has ground fault (see Cause 5).
Defective fuse No. 2 in fuse If fuse is blown, circuit probably has ground fault (see Cause 7).
2
box F01
3 Lowered battery voltage 2. After measuring voltage, measure it again when starting engine.
Voltage Between battery (+) and ground 20 to 30 V
1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
2. Disconnect connector CP02 and connect T-adapters to female side.
4 Defective wiring harness 3. Turn battery disconnect switch to ON position, and turn starting
switch to ON position.
Between ground and each of CP02 (female)
Voltage 20 to 30 V
(116), (118) and (121)
a fusible link or fuse is blown, replace it in advance.
Resis- Between R03 and each of CP02 (female) (116),
(118) and (121) Max. 1 z
5 Open circuit in wiring harness tance
a If no abnormality is found by above checks, this check is not
required.
1. Disconnect fusible link F04 and connect T-adapters to male side
furthermore.
Between F04 (male) (2) and each of CP02
Resis- (female) (116), (118) and (121) Max. 1 z
tance
Between F04 (male) (1) and terminal R03 (M) Max. 1 z
2. Remove wire from terminal R03.
Ground fault in wiring harness 3. Disconnect fusible link F04 and connector CP02, and connect T-
6 (contact with ground circuit) adapters to female side of CP02 and male side of F04.
Between ground and CP02 (female)(116), (118)
Min. 1 Mz
Resis- or (121), or F04 (male) (2)
tance Between ground and F04 (male) (1) or terminal
R03 (M) Min. 1 Mz
PC490LC-10 40-415
40 Troubleshooting

Circuit diagram related to solenoid power supply
40-416 PC490LC-10
40 Troubleshooting
Failure code [DA25KP] 5V Sensor1 Power Abnormality (PC400-DA25KP-400-A-Z0-A)
Action level Failure code 5 V sensor1 power abnormality

Failure
— DA25KP (Pump controller system)
Detail of • Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
failure
• Stops output from 5V sensor power supply output 1.
• Signals of pressure sensors and jet sensor are not input normally.
• Error codes for failures in pressure sensors are also displayed.
Problem on • Travel and work equipment speeds are slow.
machine • Automatic travel speed selector function does not work (pump pressure sensor system).
• Auto-decelerator function remains activated or fine control performance of work
equipment is poor.
information
2. Disconnect following sensors one by one, and turn starting switch to ON
position for each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear. Ignore all
displayed failure codes other than this.
Bucket CURL pressure sensor P01
Boom LOWER pressure sensor P02
Swing (L) pressure sensor P03
Arm IN pressure sensor P04
Defective pressure
sensor Bucket DUMP pressure sensor P05
1
(internal short circuit) Boom RAISE pressure sensor P06
Swing (R) pressure sensor P07
Arm OUT pressure sensor P08
Connector L.H. travel FORWARD pressure sensor P09
L.H. travel REVERSE pressure sensor P10
R.H. travel FORWARD pressure sensor P11
RH. travel REVERSE pressure sensor P12
F pump pressure sensor P25
R pump pressure sensor P26
F pump swash plate sensor P27
R pump swash plate sensor P28
Service pressure sensor (dummy) P49
a To measure voltage before controller stops output of power.
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors P01 to P12, P25 to P28, and P49.
2
(contact with 24 V 3. Connect T-adapters to female side of connector P01.
circuit) 4. Turn starting switch to ON position (with connector disconnected).
Voltage Between P01 (female) (3) and ground 4.5 to 5.5 V
2. Disconnect connectors CP01, P01 to P12, and P49.
3 harness (contact with
3. Connect T-adapter to female side of connector CP01.
ground circuit)
Resistance Between CP01 (female) (6) and ground Min. 1 Mz
Defective pump If no failure is found by above checks, pump controller is defective. (Since this
4 is an internal defect, troubleshooting cannot be performed.)
controller
PC490LC-10 40-417
40 Troubleshooting
Circuit diagram related to 5 V sensor power supply 1 circuit
40-418 PC490LC-10
40 Troubleshooting
Failure code [DA29KQ] Model Selection Abnormality (PC400-DA29KQ-400-A-Z0-A)
Action level Failure code Model selection abnormality

Failure
L01 DA29KQ (Pump controller system)
Detail of • Model code signal for model which is not registered in controller is input.
failure
• Controls machine taking it that machine is default model (PC400 standard specification
Action of machine).
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • No problem appears if machine is PC400 standard specification machine.
machine • Overheat may occur on Colorado specification machine.
• Pat number of pump controller assembly can be checked with monitoring function.
(Code: 20229 Assembly part number (pump controller))
• Signal status (ON/OFF) of model selection signal can be checked by using monitoring
function.
(Code: 02201 Switch Input 2)
a Correct signal for STD specification a Correct signal for Colorado specification
Related machine machine
information Model selection signal 1: ON Model selection signal 1: OFF
Model selection signal 2: ON Model selection signal 2: OFF
Model selection signal 3: ON Model selection signal 3: ON
Model selection signal 4: OFF Model selection signal 4: OFF
Model selection signal 5: ON Model selection signal 1: OFF
• Standard specification
Pump controller with wrong 1. Use monitoring function to display assembly part number and check
1 part number whether it is identical to that listed in Parts book.
2. Disconnect connector S30 and connect T-adapters to female side.
Defective model selection Between S30 (female) (1) and (8) Max. 1 z
2 connector (internal open Between S30 (female) (1) and (2) Max. 1 z
circuit or short circuit) Resis- Between S30 (female) (2) and (3)
Max. 1 z
tance
Between S30 (female) (3) and (4) Min. 1 Mz
Between S30 (female) (7) and (8) Max. 1 z
Turn starting switch to OFF position.
Disconnect connector CP01 and connect T-adapters to female side.
Between CP01 (female) (21) and ground Max. 1z
Resis- Between CP01 (female) (40) and ground Max. 1z
tance Between CP01 (female) (58) and ground Max. 1z
Between CP01 (female) (59) and ground Max. 1z
2. Disconnect connectors CP01 and S30, and insert T-adapters into
4 Short circuit in wiring harness connector S30.
Resis- Between S30 (3) and (4)
Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connector CP01 and connect T-adapters to female side.
5 (contact with ground circuit) Resis- Between CP01 (female) (77) and ground
Min. 1 Mz
tance
PC490LC-10 40-419
40 Troubleshooting
Circuit diagram related to model selection connector (for standard specification machine)
• Colorado specification
Pump controller with wrong 1. Use monitoring function to display assembly part number and check
1 part number whether it is identical to that listed in Parts book.
Defective model selection Between S30 (female) (1) and (8) Min. 1 Mz
2 connector (internal open Between S30 (female) (2) and (8) Min. 1 Mz
circuit or short circuit) Resis- Between S30 (female) (3) and (8)
Max. 1 z
tance
2. Disconnect connector CP01 and connect T-adapter to female side.
contact of connector) Resis- Between CP01 (female) (21) and ground
Max. 1 z
tance
40-420 PC490LC-10
40 Troubleshooting

2. Disconnect connectors CP01 and S30, and insert T-adapter into
connector S30.
4 Short circuit in wiring harness Between S30 (3) and (1) Min. 1 Mz
Resis- Between S30 (3) and (2) Min. 1 Mz
tance Between S30 (3) and (4) Min. 1 Mz
Between S30 (3) and (7) Min. 1 Mz
Ground fault in wiring harness Between CP01 (female) (40) and ground Min. 1 Mz
5 (contact with ground circuit) Resis- Between CP01 (female) (58) and ground Min. 1 Mz
tance Between CP01 (female) (59) and ground Min. 1 Mz
Between CP01 (female) (77) and ground Min. 1 Mz
Circuit diagram related to model selection (Colorado specification)
PC490LC-10 40-421
40 Troubleshooting
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) (PC400-
DA2LKA-400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Pump Controller)
Failure
- DA2LKA (Pump controller system)
• Pump controller determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at approximately 5 V or below for approximately 3 seconds after
failure starting switch is turned to ON position, during which pump controller outputs no current to
system operating lamp.
controller
Problem on position. If the battery disconnect switch is turned OFF, the data stored in the pump
machine controller memory may be destroyed.
• Although work equipment controller is not able to light up system operating lamp, no
Related trouble will result unless battery disconnect switch is turned to OFF position.
1

3. Disconnect connectors CP02 and L19, and connect T-adapters to each
defective contact of Between CP02 (female) (100) and L19 (female) (2) Max. 1 z
Pump controller is If no failure is found by above checks, monitor controller is defective. (Since
3 this is an internal defect, troubleshooting cannot be performed).
defective.
40-422 PC490LC-10
40 Troubleshooting
PC490LC-10 40-423
40 Troubleshooting
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) (PC400-
DA2LKB-400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Pump Controller)
Failure
- DA2LKB (Pump controller system)
• Pump controller determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become Low level while pump controller outputs current to system
failure operating lamp.
controller
Problem on position. If the battery disconnect switch is turned OFF, the data stored in the pump
machine controller memory may be destroyed.
Related • Although work equipment controller is not able to light up system operating lamp, no
information trouble will result unless battery disconnect switch is turned to OFF position.
1
Pump controller is If no failure is found by above checks, monitor controller is defective. (Since
2 this is an internal defect, troubleshooting cannot be performed).
defective.
40-424 PC490LC-10
40 Troubleshooting
Failure code [DA2QKR] CAN2 Discon (Pump Con) (PC400-DA2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Pump Controller)

Failure
L03 DA2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication 2 line
failure (KOMNET/c).
Action of
• Holds information at the time of occurrence of failure.
controller
• Information to be obtained from pump controller is not displayed or special function that
Problem on uses information from pump controller does not work. Or received data (failure codes,
machine monitoring codes, etc. transmitted from pump controller) is no longer updated.
switch is received.
• If any of failure codes [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller
may be defective.
• Machine monitor uses four failure codes, [DA2QKR], [DB2QKR], [D8AQKR], and
[DAZQKR], to indicated failure in CAN communication through CAN 2 line. When all of
these failure code are displayed simultaneously on screen, ground fault, short circuit, or
hot short circuit may occur in wiring harness (CAN communication line). Since air
conditioner is also controlled through CAN communication, check whether air conditioner
Related is operated (ON/OFF and air flow adjustment) on air conditioner screen.
information a If ID controller is not installed, failure code [F7FQKR] is not generated. Therefore, failures
in CAN communication through communication 2 line are indicated with failure codes
[DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR].
a Air conditioner can be operated even when failure code is displayed on machine monitor
screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or
hot short circuit in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected to continuous power supply,
they receive continuous power even while starting switch is at OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05 Resis- Between F05 (female) (1) and (2)
Max. 1 z
tance
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in fuse
2 2. Remove fuse No. 17 in fuse box F01.
box F01
When fuse is blown, circuit may have ground fault.
a Check ground terminal T04 for looseness and rust.
Improper power supply to 2. Disconnect connector CP01 and connect T-adapters to female side.
3 pump controller 3. Turn starting switch to ON position.
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
Between CP01 (female) (4) and (5) 20 to 30 V
PC490LC-10 40-425
40 Troubleshooting

Open circuit in wiring harness 2. Remove fuse No. 17 in fuse box F01.
3. Disconnect fusible link F05 and connector CP01, and connect T-
4 (wire breakage or defective adapters to each female side.
Between terminal R04 and F05 (female) (1) Max. 1 z
Resis- Between F05 (female) (2) and F01-16D Max. 1 z
tance Between F01-17 and CP01 (female) (1) Max. 1 z
Between F01-17 and CP01 (female) (4) Max. 1 z
Defective CAN Perform checks on cause 4 to 9 in troubleshooting for failure code
5 [DB2QKR].
communication 2 line
40-426 PC490LC-10
40 Troubleshooting
Circuit diagram related to pump controller power supply
PC490LC-10 40-427
40 Troubleshooting
Failure code [DA2RKR] CAN1 Discon ( Pump Con) (PC400-DA2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection ( Pump Controller)

Failure
L03 DA2RKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication line 1
failure (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains current setting (Hi/Lo) of travel speed.
• Information to be obtained from pump controller is not displayed or special function that
uses information from pump controller does not work. Or received data is no longer
updated.
Problem on • Pump control is disabled.
machine • Hydraulic oil temperature gauge needle goes off on machine monitor screen.
• Wiper operation is disabled.
• Washer operation is disabled.
• Flow control of attachment hydraulic line is disabled.
switch is received.
• If any of failure codes [DY20KA], [DY20MA] or [DW43KA] is also displayed, pump
controller may be defective.
• Machine monitor indicates CAN communication failure with failure codes [DA2RKR] or
[DB2RKR]. If failure code [DB2RKR] is also displayed, wiring harness (CAN
Related communication line) may have ground circuit, short circuit, or hot short circuit.
information • Terminating resistor of CAN1 on cab side is inside machine monitor, and that on engine
side is connector "B_RES". (Connector "B_RES" is not on CAN communication 1 line but
connected to it via connector "J2").
using multimeter.
Defective pump controller Perform checks on causes 1 to 4 in troubleshooting for failure code
1 power supply system [DA2QKR].
Defective CAN Perform checks on causes 2 to 8 in troubleshooting for failure code
2 communication 1 system [DB2RKR].
40-428 PC490LC-10
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality (PC400-DAF0MB-400-A-Z0-A)
Action level Failure code Monitor ROM Abnormality

Failure
– DAF0MB (Machine monitor system)
Detail of • Program of machine monitor is rewritten (program error).
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
PC490LC-10 40-429
40 Troubleshooting
Failure code [DAF0MC] Monitor Error (PC400-DAF0MC-400-A-Z0-A)
Action level Failure code Monitor Error

Failure
– DAF0MC (Machine monitor system)
Detail of
• Machine monitor malfunctions.
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Machine monitor is defective.
40-430 PC490LC-10
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit (PC400-DAF8KB-400-A-Z0-

A)
Action level Failure code Camera Power Supply Short Circuit

Failure
L03 DAF8KB (Machine monitor system)
Detail of • Output power supply voltage (rating: 8 V) from machine monitor to camera is below 6.0 V
failure or above 10 V.
Action of • Stops output power supply voltage (rating: 8 V) to camera.
machine • Even if cause of failure disappears, machine does not become normal until starting switch
monitor is turned to OFF position.
Problem on • Camera image is not displayed on monitor screen.
machine
information
Cause Procedure, measuring location, criteria and remarks

2. Disconnect camera connector A45, and turn starting switch to ON
Defective camera position.
1
After above operation (disconnecting camera connector and performing
failure code reproducing procedure), if failure code disappears, camera
has internal defect.
2. Disconnect connector CM04.
2 Defective machine monitor 3. Connect T-adapters to male side of connector CM04.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
Ground fault in wiring harness 2. Disconnect connector CM04 and camera connector A45.
3 3. Connect T-adapters to female side of connector CM04.
Resis- Between CM04 (female) (1) and ground
Min. 1 Mz
tance
2. Disconnect camera connector A45.
Hot short circuit in wiring 3. Insert T-adapters into connector CM04.
(contact with 24 V circuit) (Disconnect camera and check that camera is not defective in
advance.)
Voltage Between CM04 (1) and (5) Max. 10 V
PC490LC-10 40-431
40 Troubleshooting
Circuit diagram related to camera power supply
40-432 PC490LC-10
40 Troubleshooting
Failure code [DAF9KQ] Model Selection Abnormality (PC400-DAF9KQ-400-A-Z0-A)
Action level Failure code Model selection abnormality

Failure
L03 DAF9KQ (Machine monitor system)
Detail of • Model registered in the machine monitor and pump controller differs.
failure (Machine monitor or pump controller has been replaced with a wrong part.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Assembly part No. of pump controller program can be checked by using monitoring
function (Code: 20229)
Related • Assembly part No. of machine monitor program can be checked by using monitoring
information function (Code: 20227)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
1 Defective machine monitor Defective machine monitor
(a different model is registered)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
Defective pump controller
PC490LC-10 40-433
40 Troubleshooting
Failure code [DAFGMC] GPS Module Error (PC400-DAFGMC-400-A-Z0-A)
Action level Failure code GPS Module Error

Failure
- DAFGMC (KOMTRAX system)
Detail of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX
failure communication modem in 50 seconds after KOMTRAX started.
monitor
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (at least 50
information seconds after starting switch is turned to ON position).
GPS module in machine monitor may be defective.
40-434 PC490LC-10
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) (PC400-DAFLKA-

400-A-Z0-A)
Action level Failure code Operating Lamp Open Circuit (Monitor)

Failure
- DAFLKA (Machine monitor system)
• Machine monitor determines that system operating lamp circuit is open because voltage
Detail of of output circuit remains at approximately 5 V or less for approximately 3 seconds after
failure starting switch is turned to ON position, during which machine monitor outputs no current
to system operating lamp.
controller
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine machine monitor terminal memory.
• Although machine monitor is not able to light system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
1

3. Disconnect connectors CM01 and L19, and connect T-adapters to each
defective contact of Between CP02 (female) (100) and L19 (female) (2) Max. 1 z
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
PC490LC-10 40-435
40 Troubleshooting
40-436 PC490LC-10
40 Troubleshooting
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) (PC400-DAFLKB-

400-A-Z0-A)
Action level Failure code Operating Lamp Short Circuit (Monitor)

Failure
- DAFLKB (Machine monitor system)
• Machine monitor determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become low level while machine monitor outputs current to system
failure operating lamp.
controller
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine machine monitor terminal memory.
Related • Although machine monitor is not able to light system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
1
Defective machine If no failure is found by above checks, machine monitor is defective. (Since
monitor
PC490LC-10 40-437
40 Troubleshooting
Failure code [DAFQKR] CAN2 Discon (Monitor) (PC400-DAFQKR-400-A-Z0-A)
Action code Failure code CAN2 Disconnection (Monitor)

Failure
- DAFQKR (KOMTRAX system)
Detail of • KOMTRAX terminal does not recognize machine monitor through CAN communication 2
failure line.
Action of
controller
Problem on • System may not function normally.
machine
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
Related not displayed on machine monitor and it can be observed only through KOMTRAX
information system.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
using multimeter.
Defective power supply Perform troubleshooting for "E-5" in E mode troubleshooting.
1
to machine monitor
Defective CAN Perform checks on causes 4 and after in troubleshooting for failure code
2 [DB2QKR]
communication
40-438 PC490LC-10
40 Troubleshooting
Failure code [DAZ9KQ] AC Model Selection Abnormality (PC400-DAZ9KQ-400-A-Z0-A)
Action level Failure code Air Conditioner Model Selection Abnormality

Failure
– DAZ9KQ (Machine monitor system)
Detail of • Model registered in the machine monitor and air conditioner controller differs.
failure (Machine monitor or air conditioner controller has been replaced with a wrong part.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Model code registered in air conditioner controller can not be checked by using
monitoring function.
• Model codes registered in machine monitor can be checked by using monitoring function.
(Code: 00500)
Related • Air conditioner control data (series and model) in the machine monitor can be checked by
information using monitoring function. (Code: 55200)
• Air conditioner control data (series and model) in the air conditioner controller can be
checked by using monitoring function. (Code: 55201) (It is normal if control data is 01H
(which means PC).)
Defective air conditioner Defective air conditioner controller
2
controller (a different model is registered)
PC490LC-10 40-439
40 Troubleshooting
Failure code [DAZQKR] CAN2 Discon (AC) (PC400-DAZQKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Air Conditioner)

Failure
L01 DAZQKR (Detected by machine monitor) (Machine monitor system)
Detail of • In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air
failure conditioner controller.
Action of
controller
• Function to collect information from engine controller does not work.
Problem on codes sent from engine controller)
machine • Air conditioner will be inoperable.
• Air conditioner control screen will not be displayed correctly on the machine monitor.
switch is received.
• When the machine monitor detects a CAN communication error in CAN2, failure code
[DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR] becomes active. If all four of these
failure code are displayed, there is a possibility of short circuit to ground, another circuit,
or positive side of battery in the harness (CAN communication line).
Related
number of failure codes that may be generated is four; [DA2QKR], [DB2QKR], [D8AQKR],
and [DAZQKR].
using multimeter.
Defective power supply to air a Perform troubleshooting in Chapter 80 "Troubleshooting for power
1
conditioner controller supply system".
Defective CAN terminating 1. Turn starting switch to OFF position.

resis- 2. Disconnect connectors CM02 and K02, and connect T-adapters to
2 each male side.
tor (internal open or short
circuit) Resis- Between K02 (male) (A) and (B) 120 ± 12 z
tance Between CM02 (male) (7) and (9) 120 ± 12 z
40-440 PC490LC-10
40 Troubleshooting

• CAN communication line
a Machine monitor also has 120 z CAN terminating resistor in it. Since
120 z resistors are connected in parallel, if resistance measured at
connector of controller other than machine monitor is 60 z which is
combined resistance, there is no open circuit in wiring harness.
2. Disconnect related connectors and connect T-adapters to connector
at which measurement is performed.
a If short circuit occurs (if resistance between terminals is 1 z or less),
disconnect CAN communication connectors of all controllers. Then,
check whether short circuit is in wiring harnesses or within controller.
3 Approx.
harness Between CM02 (female) (8) and (9)
120 z
Between CE03 (female) (17) and (18) Approx. 60
z
Between CP01 (female) (45) and (64) Approx. 60
z
Resis- Between AC01 (female) (1) and (2) Approx. 60
tance z
Between CK01 (female) (10) and (11) Approx. 60
z
*Between CC01 (female) (10) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx.
120 z
PC490LC-10 40-441
40 Troubleshooting

• ACC signal from starting switch (CAN communication start is not
sensed)
2. Disconnect connector at which measurement is performed and
insert T-adapters into it.
3. Turn battery disconnect switch to ON position, and turn starting
Between CM01 (10) and (3) 20 to 30 V
Between CP01 (24), (43), (80) and (2) 20 to 30 V
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
*Between CC01 (2) and (7) 20 to 30 V
2. Disconnect related connectors and connect T-adapters to female
side of connector at which measurement is performed.
Between CM02 (female) (8) and CP01 (female)
Open circuit in wiring harness (45) Max. 1 z
4 (wire breakage or defective Between CM02 (female) (9) and CP01 (female)
contact of connector) (64) Max. 1 z
Between CM02 (female) (8) and CE03 (female)
(17) Max. 1 z
(18) Max. 1 z
Between CM02 (female) (8) and AC01 (female)
(1) Max. 1 z
Max. 1 z
Resis- (2)
tance Between CM02 (female) (8) and CK01 (female)
(10) Max. 1 z
Between CM02 (female) (9) and CK01 (female)
(11) Max. 1 z
Between CM02 (female) (8) and CC01 (female)
(3) Max. 1 z
(9) Max. 1 z
Between CE03 (female) (17) and K02 (female)
(A) Max. 1 z
(B) Max. 1 z
40-442 PC490LC-10
40 Troubleshooting

a If no failure is found by checks on cause 3 (no open circuit), measure
voltage at one connector.
Ground fault in wiring harness 2. Disconnect related connectors and connect T-adapters to female
5
(contact with ground circuit) side of connector at which measurement is performed.
Between CP01 (female) (45), CM02 (female)
Min. 1 Mz
Resis- (7), (8), or CE03 (female) (17) and ground
tance Between CP01 (female) (64), CM02 (female)
(9), or CE03 (female) (18) and ground Min. 1 Mz

insert T-adapters into connector.
3. Turn the battery disconnect switch to the ON position.
Short circuit or hot short 4. Turn starting switch to ON position.
circuit in wiring harness a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including
6 (contact with 24 V during communication, harnesses are considered normal as long as
circuit) their voltages are between 1 and 4 V.
Between ground and any one of CM02 (female)
(8), CP01 (female) (45), CK01 (female) (10),
AC01 (female) (2), CC01 (female) (3), or CE03 1 to 4 V
(female) (17)
Voltage
(female) (18)
• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and
[DAZQKR] are displayed
a Repeat following steps 1. to 3. to disconnect controllers one by one
from CAN communication and to identify defective controller.
Defective engine controller, switch to OFF position.
pump controller, air 2. Disconnect CAN communication connector of engine controller
7 conditioner unit, *ID (connector CE03), pump controller (connector CP01), air conditioner
controller, or KOMTRAX unit (connector AC01), *ID controller (connector CC01), and
terminal KOMTRAX terminal (connector CK01) one by one.
3. Turn battery disconnect switch to ON position, turn starting switch to
ON position, then perform troubleshooting.
4. Return to step 1. and troubleshoot next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
If no abnormality is found by above diagnosis, air conditioner controller
Defective air conditioner is defective.
8
controller
*The ID controller is an optional device.
PC490LC-10 40-443
40 Troubleshooting
Circuit diagram related to CAN communication 2
40-444 PC490LC-10
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con) (PC400-DB2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Engine Controller)

Failure
L03 DB2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor cannot recognize engine controller through CAN communication 2 line
failure (KOMNET/c).
Action of
controller
• Information to be obtained from engine controller is not displayed and special functions
Problem on that use them do not work. Or, received data is no longer updated. (such as failure codes
machine and monitoring
codes sent from engine controller)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
• ID controller is optional device (connector CC01)
• Machine monitor indicates a CAN communication error in CAN2 with failure code
[DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR]. If all four of these failure code are
displayed, harness (CAN communication line) may have ground fault, short circuit, or hot
short circuit. Since air conditioner is also controlled via CAN communication, check
whether air conditioner is operated (ON/OFF and air flow adjustment) on air conditioner
Related screen.
number of failure codes that may be generated is four; [DA2QKR], [DB2QKR], [D8AQKR],
and [DAZQKR].
a Air conditioner can be operated even when failure code is displayed on machine monitor
screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or
hot short circuit in harness (CAN communication line).
using multimeter.
Defective fuses Nos. 15 and
1 2. Remove fuses No. 15 and No. 18 from fuse box F01.
18 in fuse box F01
• When fuse is blown, engine controller may have short circuit in it.
a If fuse is not blown, this check is not required.
2 Defective engine controller 2. Disconnect connector CE03 and connect T-adapters to male side.
Resis- Between CE03 (male) (1) and (21) Min. 10 z
tance Between CE03 (male) (11) and (31) Min. 10 z
a Check ground terminal T12 for looseness and rust.
Improper power supply to 3. Turn starting switch to ON position.
3 engine controller
a If result is abnormal, perform troubleshooting for [CA441].
Between CE03 (female) (1) and (21) 20 to 30 V
Voltage
Between CE03 (female) (11) and (31) 20 to 30 V
resis- 2. Disconnect connectors CM02 and K02, and connect T-adapters to
4 each male side.
circuit) Resis- Between K02 (male) (A) and (B) 120 ± 12 z
PC490LC-10 40-445
40 Troubleshooting

2. Disconnect related connectors and connect T-adapters to connector
at which measurement is performed.
a If short circuit occurs (if resistance between terminals is 1 z or less),
disconnect CAN communication connectors of all controllers. Then,
check whether short circuit is in wiring harnesses or within controller.
5 Approx.
harness Between CM02 (female) (8) and (9)
120 z
Between CE03 (female) (17) and (18) Approx. 60
z
z
Resis- Between AC01 (female) (1) and (2) Approx. 60
tance z
Between CK01 (female) (10) and (11) Approx. 60
z
*Between CC01 (female) (10) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx.
120 z
sensed)
insert T-adapters into it.
Open circuit in wiring harness Between CE03 (3) and (21) 20 to 30 V
6 (wire breakage or defective Between CP01 (24), (43), (80) and (2) 20 to 30 V
contact of connector) Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
*Between CC01 (2) and (7) 20 to 30 V
side of connector at which measurement is performed.
40-446 PC490LC-10
40 Troubleshooting

(45) Max. 1 z
(64) Max. 1 z
(17) Max. 1 z
(18) Max. 1 z
(1) Max. 1 z
Open circuit in wiring harness Max. 1 z
Resis- (2)
6 (wire breakage or defective tance Between CM02 (female) (8) and CK01 (female)
contact of connector) Max. 1 z
(10)
Between CM02 (female) (9) and CK01 (female)
(11) Max. 1 z
(3) Max. 1 z
(9) Max. 1 z
(A) Max. 1 z
(B) Max. 1 z

Ground fault in wiring harness side of connector at which measurement is performed.
7
(contact with ground circuit) Between ground and any point in CP01
(female) (45), CM02 (female) (7), (8) or CE03 Min. 1 Mz
Resis- (female) (17)
tance Between ground and any point in CP01
(female) (64), CM02 (female) (9) or CE03 Min. 1 Mz
(female) (18)
PC490LC-10 40-447
40 Troubleshooting

a If no failure is found by check on cause 5 (no open circuit), measure
in only one place each.
insert T-adapters into connector.
circuit in wiring harness a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including
8 (contact with 24 V during communication, harnesses are considered normal as long as
circuit) their voltages are between 1 and 4 V.
(female) (17)
Voltage
(female) (18)
• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and
[DAZQKR] are displayed
a Repeat following steps 1. to 3. to disconnect controllers one by one
from CAN communication and to identify defective controller.
Defective engine controller, switch to OFF position.
pump controller, air 2. Disconnect CAN communication connector of engine controller
9 conditioner unit, *ID (connector CE03), pump controller (connector CP01), air conditioner
controller, or KOMTRAX unit (connector AC01), *ID controller (connector CC01), and
terminal KOMTRAX terminal (connector CK01) one by one.
3. Turn battery disconnect switch to ON position, turn starting switch to
ON position, then perform troubleshooting.
4. Return to step 1. and troubleshoot next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
*The ID controller is an optional device.
40-448 PC490LC-10
40 Troubleshooting
PC490LC-10 40-449
40 Troubleshooting
Failure code [DB2RKR] CAN1 Discon (Engine Con) (PC400-DB2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection (Engine Controller)

Failure
L03 DB2RKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize engine controller through CAN communication 1 line
failure (KOMNET/r).
• Retains current working mode.
Action of
• Retains current selection of auto-deceleration.
controller
• Information to be obtained from engine controller is not displayed and special functions
that use them do not work. Or, received data is no longer updated.
Problem on • Engine cannot be controlled.
machine • Engine speed and coolant temperature cannot be detected.
• Engine coolant and hydraulic oil temperature gauge needles go off on machine monitor
screen.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller may be defective (cause 1).
• Machine monitor uses failure codes [DB2RKR] or [DA2RKR] to indicate failure in CAN
communication through CAN communication 1 line. If failure code [DA2RKR] is also
displayed, wiring harness (CAN communication line) may have ground fault, short circuit
Related or hot short circuit.
information • Terminating resistor of CAN1 on cab side is inside machine monitor, and that on engine
side is connector "B_RES". (Connector "B_RES" is not on CAN communication 1 line but
connected to it via connector "J2").
using multimeter.
Defective engine controller [Perform checks on causes 1 to 3 in troubleshooting for failure code
1 system [DB2QKR].
resis- 2. Disconnect connectors CM02 and B_RES, and connect T-adapters
2 to each male side.
circuit) Resis- Between B_RES (male) (A) and (B) 120 ± 12 z
40-450 PC490LC-10
40 Troubleshooting

2. Disconnect connectors CM02, CP01, J1, J2, and B_RES one by
one, and connect T-adapters to female side of connector
disconnected.
Open or short circuit in wiring a If short circuit occurs (if resistance between terminals is 1 z or less),
3 disconnect all CAN communication connectors of each controller.
harness
Then, check whether short circuit is in wiring harness or within
controller.
Between CM02 (female) (11) and (12) Approx.
120 z
z
Resis- Between B_RES (female) (A) and (B) Approx.
tance 120 z
Between J1 (female) (8) and (18) Approx.
120 z
Between J2 (female) (24) and (25) Approx.
120 z
recognized)
2. Disconnect CM01, CP01, CE03 and insert T-adapters.
Voltage
Between CP01 (2) and each of (24), (43), and
(80) 20 to 30 V

Open circuit in wiring harness 1. Turn starting switch to OFF position, and set battery disconnect
4 (wire breakage or defective switch to OFF position.
contact of connector) 2. Disconnect connectors CM02, CP01, J1, J2, and B_RES, and
connect T-adapters to each female side.
Between CM02 (female) (11) and CP01
Between CM02 (female) (12) and CP01
Between CM02 (female) (11) and J1 (female)
Max. 1 z
Resis- (8)
tance Between CM02 (female) (12) and J1 (female)
(18) Max. 1 z
Between J2 (female) (24) and B_RES (female)
(A) Max. 1 z
Between J2 (female) (25) and B_RES (female)
(B) Max. 1 z
PC490LC-10 40-451
40 Troubleshooting

2. Disconnect connectors CM02, CP01, J1, J2, and B_RES, and
connect T-adapters to any female side.
Between ground and any one of CP01 (female)
Ground fault in wiring harness (7), CM02 (female) (10), (11), or J1 (female) (8) Min. 1 Mz
5
(contact with ground circuit) Between ground and J2 (female) (24) or
Min. 1 Mz
Resis- B_RES (female) (A)
tance Between ground and any one ofCP01 (female)
(26), CM02 (female) (12), or J1 (female) (18) Min. 1 Mz
Between ground and J2 (female) (25) or
B_RES (female) (B) Min. 1 Mz
a If no failure (no open circuit) is found by check on cause 3, measure

2. Disconnect any one of connectors CM02, CP01, B_RES, and
connect T-adapter to female side of connector disconnected.
circuit in wiring harness a Do not take measurements at J1 or J2.
6 (contact with 24 V
circuit) a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including
during communication, regard wiring harness as normal if voltage is
between 1 and 4 V.

(7), CM02 (female) (10), (11), or B_RES 1 to 4 V
(female) (A)
Voltage
(26), CM02 (female) (12), or B_RES (female) 1 to 4 V
(B)
40-452 PC490LC-10
40 Troubleshooting

• If failure code [DA2RKR] is also displayed
a Disconnect pump controller and engine controller one by one from
CAN communication line to determine which controller is defective.
7 Defective pump controller switch to OFF position.
2. Disconnect pump controller (connector CP01).
Does either or both of failure codes [DA2RKR] If YES, pump controller
and [DB2RKR] disappear? is defective.
• If failure code [DA2RKR] is also displayed
a Disconnect pump controller and engine controller one by one from
CAN communication line to determine which controller is defective.
8 Defective engine controller switch to OFF position.
2. Disconnect engine controller (connector J1).
Does either or both of failure codes [DA2RKR] If YES, engine
and [DB2RKR] disappear? controller is defective.
PC490LC-10 40-453
40 Troubleshooting
40-454 PC490LC-10
40 Troubleshooting
Failure code [DGH2KA] Hyd Oil Temp Sensor Open (PC400-DGH2KA-400-A-Z0-A)
Action level Failure code Hydraulic Oil Temperature Sensor Open Circuit
Failure
L01 DGH2KA (Pump controller system)
Detail of • Signal voltage of hydraulic oil temperature sensor circuit is below 5 V, so pump controller
failure determines that circuit is open.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • While hydraulic oil temperature rises to normal rage, indicator of hydraulic oil temperature
machine gauge does not move from top of white range (bottom of green range).
• Signal voltage from hydraulic oil temperature sensor can be checked with monitoring
Related function.
information (Code: 04402: Hydr. Temp. Sensor Volt)
Approx. 90
10 °C
Defective hydraulic oil kz
Between P22 (male) (1) and (2) Approx. 35
temperature sensor 30 °C
1 kz
tor (internal open or short Resis- a Temperature-Resistance Approx.
circuit) tance characteristics of oil 80 °C
temperature sensor 6.5 kz
Approx.
100 °C
3.5 kz
Between P22 (male) (2) and ground Min. 1 Mz
2. Disconnect connector P22 and connect T-adapters to female side.
Open circuit, short circuit, a If voltage is 0 V, wiring harness has open circuit or ground fault or
ground fault or hot short short circuit, and if voltage is 24 V, wiring harness has hot short
2
circuit in wiring harness circuit.
a Voltage of approximately 5 V is applied to temperature sensor signal
circuit through resistor in pump controller.
Voltage Between P22 (female) (1) and (2) Approx. 5
V
a Use Temperature-Resistance characteristics table for
Open or short circuit in wiring troubleshooting on cause 1 as resistance criteria.
3
harness
a If resistance is above 1 Mz , wiring harness has open circuit. If
resistance is below 1 z , wiring harness has short circuit.
Resis- Between CP01 (female) (28) and (46) 3.5 to 90
tance kz
Open circuit in wiring harness 2. Disconnect connectors CP01 and P22, and connect T-adapters to
contact of connector) Between CP01 (female) (46) and P22 (female)
Max. 1 z
Resis- (1)
tance Between CP01 (female) (28) and P22 (female)
(2) Max. 1 z
PC490LC-10 40-455
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-456 PC490LC-10
40 Troubleshooting
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit (PC400-DGH2KB-400-A-Z0-A)
Action level Failure code Hydraulic Oil Temperature Sensor Short Circuit
Failure
L01 DGH2KB (Pump controller system)
Detail of • Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so pump controller
failure determines that circuit has ground fault.
controller
Problem on • Hydraulic oil temperature gauge indicates 50°C.
machine
• Signal voltage from hydraulic oil temperature sensor can be checked with monitoring
Related function.
information (Code: 04402 Hydr. Temp. Sensor Volt)
Approx. 90
10°C
kz
Defective hydraulic oil Between P22 (male) (1) and (2) Approx. 35
1 temperature sensor 30°C
kz
(Internal open or short circuit) Resis- a Temperature-resistance Approx. 6.5
tance characteristics of oil 80°C
temperature sensor kz
Approx. 3.5
100°C
kz
2. Disconnect connector P22 and connect T-adapter to female side.
Open circuit, short circuit, a If voltage is 0 V, wiring harness has open circuit, ground fault, or
2 ground fault, or hot short short circuit, and if voltage is 24 V, wiring harness has hot short
circuit in wiring harness circuit.
a Voltage of approximately 5 V is applied to temperature sensor signal
circuits through resistance in pump controller.
Voltage Between P22 (female) (1) and (2) Approx. 5 V
a Use Temperature-Resistance characteristics table for
Short circuit or ground fault in troubleshooting on cause 1 as resistance criteria.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resis- Between CP01 (female) (28) and (46) 3.5 to 90 kz
tance Between CP01 (female) (28) and ground Min. 1 Mz
4 2. Disconnect connectors CP01 and P22, and connect T-adapter to
(Contact with ground circuit) either female side.
Resis- Between ground and CP01 (female) (28) or
P22 (female) (2) Min. 1 Mz
tance
If cause is not found by above checks, pump controller is defective.
PC490LC-10 40-457
40 Troubleshooting
40-458 PC490LC-10
40 Troubleshooting
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit (PC400-
DHA4KA-400-A-Z0-A)
Action level Failure code Air Cleaner Clogging Sensor Open Circuit
Failure
L01 DHA4KA (Machine monitor system)
Detail of • Air cleaner clogging switch signal voltage is not below 1 V while engine is running, so
failure machine monitor determines that air cleaner is clogged (switch contact is open).
Action of • Displays air cleaner clogging monitor in red on machine monitor.
controller
Problem on • If machine is used as it is, engine may be broken.
machine
• Input signal status (ON/OFF) from air cleaner clogging switch can be checked by using
Related monitoring function (Code: 04501 Monitor input: 2).
Clogged air cleaner
Air cleaner may be clogged. Check it for clogging and then clean or replace if
1 (when system is
clogged.
normal)
Defective air cleaner
2 clogging switch (Internal When air cleaner is
Max. 1 z
open circuit) Between P23 (male) (1) normal *1
Resistance and (2) When air cleaner is
clogged *2 Min. 1 Mz
harness 2. Disconnect connectors CM02 and P23, and connect T-adapters to each
defective contact of Between CM02 (female) (4) and P23 (female) (1) Max. 1 z
Between P23 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
Defective machine
4 When air cleaner is
monitor Max. 1 V
Between CM02 (4) and normal
Voltage
CM01 (3) When air cleaner is
clogged Min. 10 V
• Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
PC490LC-10 40-459
40 Troubleshooting
Circuit diagram related to air cleaner clogging
40-460 PC490LC-10
40 Troubleshooting
Failure code [DHPAMA] Pump Press Sensor Abnormality (PC400-DHPAMA-400-A-Z0-A)
Action level Failure code Front Pump Pressure Sensor Abnormality

Failure
L01 DHPAMA (Pump controller system)
Detail of • Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that front pump pressure is 0 MPa {0 kg/cm 2 }.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely,
pressure sensor will be broken. Accordingly, take extreme care when checking.
• Front pump pressure can be checked with monitoring function.
(Code: 01100 F pump pressure).
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
If failure code [DA25KP] is also displayed, perform troubleshooting for it
first.
Defective 5V sensor power 2. Disconnect connector P25, and connect T-adapters to female side.
1 supply 1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to check on cause 3.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
Voltage Between P25 (2) and (1)
output V
a If power supply voltage is normal and sensor output voltage is
abnormal, it is difficult to judge whether cause of failure is defective
Defective front pump sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor (internal below.
defect)
2. Replace connector P25 with connector P26 of R pump PPC
pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed for this failure code, front pump pressure
sensor is defective.
a After finishing test, restore connectors.
PC490LC-10 40-461
40 Troubleshooting

2. Disconnect connectors CP01 and P25, and connect T-adapters to
each female side.
a If power supply voltage measured in check
on cause 1 is normal, this check is not
required. Max. 1 z
Open circuit in wiring harness Between CP01 (female) (18) and P25 (female)
3 (wire breakage or defective (1)
contact of connector) Resis- Between CP01 (female) (11) and P25 (female)
(2) Max. 1 z
tance
required. Max. 1 z
Between CP01 (female) (6) and P25 (female)
(3)
Ground fault in wiring harness 2. Disconnect connectors C01 and P25, and connect T-adapters to
Resis- Between ground and CP01 (female) (11) or P25
(female) (2) Min. 1 Mz
tance
5 harness 3. Connect T-adapters to female side of connector P25.
(contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
40-462 PC490LC-10
40 Troubleshooting
Circuit diagram related to front pump pressure sensor
PC490LC-10 40-463
40 Troubleshooting
Failure code [DHPBMA] R Pump Press Sensor Abnormality (PC400-DHPBMA-400-A-

Z0-A)
Action level Failure code Rear Pump Press Sensor Abnormality

Failure
L01 DHPBMA (Pump controller system)
Detail of • Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that rear pump pressure is 0 MPa {0 kg/cm2 }.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
• Rear pump pressure can be checked with monitoring function.
(Code: 01101 R pump pressure)
first.
Power 4.5 to 5.5
supply V
2. Connect T-adapters to connector P26.
Sensor 0.5 to 4.5
output V
Defective rear pump pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor (internal defect) below.
2. Replace connector P26 with connector P25 of front pump PPC
pressure sensor.
4. If E mark is not displayed for this failure code column, rear pump
pressure sensor is defective.
40-464 PC490LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Ground fault in wiring harness 2. Disconnect connectors CP01 and P26, and connect T-adapters to
tance
PC490LC-10 40-465
40 Troubleshooting
Circuit diagram related to rear pump pressure sensor
40-466 PC490LC-10
40 Troubleshooting
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality (PC400-DHS3MA-400-A-Z0-A)
Action level Failure code Arm IN PPC Sensor Abnormality

Failure
L01 DHS3MA (Pump controller system)
Detail of • Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that arm IN PPC pressure is 0 MPa {0 kg/cm 2 }.
Problem on • Automatic deceleration does not cancel.
machine • Controllability of arm IN deteriorates.
• Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
first.
Defective 5V sensor power 2. Disconnect connector P04 and connect T-adapters to female side.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective arm IN PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
2. Replace connector P04 with connector of other PPC pressure
sensor.
4. If E mark is not displayed again for this failure code, arm IN PPC
pressure sensor is defective.
PC490LC-10 40-467
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Ground fault in wiring harness 2. Disconnect connectors CP01 and P04, and connect T-adapter to
tance
Circuit diagram related to arm IN PPC pressure sensor
40-468 PC490LC-10
40 Troubleshooting
Failure code [DHS4MA] Bucket CURL PPC Press Sensor

Abnormality (PC400-DHS4MA-400-A-Z0-A)
Action level Failure code Bucket CURL PPC Pressure Sensor Abnormality
Failure
Detail of • Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that bucket CURL PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of bucket CURL deteriorates.
• Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective bucket CURL PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, bucket CURL
PPC pressure sensor is defective.
PC490LC-10 40-469
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
40-470 PC490LC-10
40 Troubleshooting
Circuit diagram related to bucket CURL PPC pressure sensor
PC490LC-10 40-471
40 Troubleshooting
Failure code [DHS8MA] Boom RAISE PPC Press Sensor

Abnormality (PC400-DHS8MA-400-A-Z0-A)
Action level Failure code Boom RAISE PPC Pressure Sensor Abnormality
Failure
Detail of • Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that boom RAISE PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of boom RAISE deteriorates.
• Boom RAISE PPC pressure can be checked with monitoring function.
(code: 07400 Boom RAISE PPC pressure)
first.
Power 4.5 to 5.5
supply V
2. Insert T-adapters in connector P06.
Sensor 0.5 to 4.5
output V
Defective boom RAISE PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, boom RAISE
40-472 PC490LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC490LC-10 40-473
40 Troubleshooting
Circuit diagram related to boom RAISE PPC pressure sensor
40-474 PC490LC-10
40 Troubleshooting
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality (PC400-

DHS9MA-400-A-Z0-A)
Action level Failure code Boom LOWER pressure sensor abnormality

Failure
Detail of • Signal voltage of boom LOWER pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
controller
machine • Controllability of boom LOWER deteriorates.
• Boom lower PPC pressure can be checked with monitoring function.
(Code: 07500 Boom LOWER PPC pressure)
first.
Defective 5 V sensor power 2. Disconnect connector P02 and connect T-adapters to female side.
1 supply 2 line 3. Turn starting switch to ON position.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective boom LOWER PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, boom LOWER
PC490LC-10 40-475
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Resis- Between ground and CP01 (female) (13) and
ground, or between P02 (female) (2) Min. 1 Mz
tance
40-476 PC490LC-10
40 Troubleshooting
Circuit diagram related to boom LOWER PPC pressure sensor
PC490LC-10 40-477
40 Troubleshooting
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality (PC400-

DHSAMA-400-A-Z0-A)
Action level Failure code Swing RH PPC Pressure Sensor Abnormality

Failure
L01 DHSAMA (Pump controller system)
Detail of • Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that swing RIGHT PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of swing RIGHT deteriorates.
• Swing RIGHT PPC pressure can be checked with monitoring function.
(Code: 09002 Swing RIGHT PPC Pressure)
first.
Power 4.5 to 5.5
supply V
2. Connect T-adapters to connector P07.
Sensor 0.5 to 4.5
output V
Defective swing right PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor below.
sensor.
4. If E mark is not displayed again in this failure code column, swing
RIGHT PPC pressure sensor is defective.
40-478 PC490LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC490LC-10 40-479
40 Troubleshooting
Circuit diagram related to swing RIGHT PPC pressure sensor
40-480 PC490LC-10
40 Troubleshooting
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality (PC400-

DHSBMA-400-A-Z0-A)
Action level Failure code Swing LH PPC Pressure Sensor Abnormality

Failure
L01 DHSBMA (Pump controller system)
Detail of • Signal voltage of swing LEFT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that swing LEFT PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of swing LEFT deteriorates.
• Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective swing left PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor below.
sensor.
4. If E mark is not displayed again in this failure code column, swing
LEFT PPC pressure sensor is defective.
PC490LC-10 40-481
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
40-482 PC490LC-10
40 Troubleshooting
Circuit diagram related to swing LEFT PPC pressure sensor
PC490LC-10 40-483
40 Troubleshooting
Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality (PC400-
DHSCMA-400-A-Z0-A)
Action level Failure code Arm OUT PPC Pressure Sensor Abnormality
Failure
L01 DHSCMA (Pump controller system)
Detail of • Signal voltage of arm OUT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Problem on • Machine monitor does not display working radius, actual load and lifting height.
machine
• Arm OUT PPC pressure can be checked with monitoring function.
(Code: 07600 Arm OUT PPC pressure)

first.
Defective 5 V sensor power 2. Disconnect connector P08, and connect T-adapters to female side.
1 supply 2 line 3. Turn starting switch to ON position.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective arm OUT PPC sensor, ground fault or hot short circuit in wiring harness. Check as
failure)
sensor.
4. If E mark is not displayed again in this failure code column, arm OUT
40-484 PC490LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC490LC-10 40-485
40 Troubleshooting
Circuit diagram related to arm OUT PPC pressure sensor
40-486 PC490LC-10
40 Troubleshooting
Failure code [DHSDMA] Bucket Dump PPC Press Sensor

Abnormality (PC400-DHSDMA-400-A-Z0-A)
Action level Failure code Bucket Dump PPC Pressure Sensor Abnormality
Failure
L01 DHSDMA (Pump controller system)
Detail of • Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that bucket DUMP PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of bucket DUMP deteriorates.
• Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)

first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective bucket DUMP PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again in this failure code column, bucket
DUMP PPC pressure sensor is defective.
PC490LC-10 40-487
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
(contact with 24 V circuit) 4. Turn starting switch to ON position.
40-488 PC490LC-10
40 Troubleshooting
Circuit diagram related to bucket DUMP PPC pressure sensor
PC490LC-10 40-489
40 Troubleshooting
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality (PC400-

DHSFMA-400-A-Z0-A)
PC490LC-10
Action level Failure code Left Travel FORWARD PPC Pressure Sensor Abnormality
Failure
L01 DHSFMA (Pump controller system)
Detail of • Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of travel deteriorates.
• Left travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07102 Travel Fwd LH PPC pressure)
first.
Power 4.5 to 5.5
supply V
2. Insert T-adapter into connector P09.
Sensor 0.5 to 4.5
output V
Defective left travel sensor, ground fault or hot short circuit in wiring harness. Check as
2 FORWARD PPC pressure below.
sensor (internal defect)
sensor.
4. If E mark is not displayed in this failure code column, travel
FORWARD LH PPC pressure sensor is defective.
40-490 PC490LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC490LC-10 40-491
40 Troubleshooting
Circuit diagram related to travel PPC pressure sensor
40-492 PC490LC-10
40 Troubleshooting
Failure code [DHSGMA] Travel FW R PPC Press Sensor

Abnormality (PC400-DHSGMA-400-A-Z0-A)
Action level Failure code Right Travel FORWARD PPC Pressure Sensor Abnormality
Failure
L01 DHSGMA (Pump controller system)
Detail of • Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above
failure 4.5 V.
• Controls machine taking it that right travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2
Action of }.
• Right travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07103 Travel Fwd RH PPC pressure)
first.
Power 4.5 to 5.5
supply V
2. Insert T-adapter into connector P11.
Sensor 0.5 to 4.5
output V
Defective right travel abnormal, it is difficult to judge whether cause of failure is defective
FORWARD PPC pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor below.
sensor.
FORWARD RH PPC pressure sensor is defective.
PC490LC-10 40-493
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Resis- Between ground and CP01 (female) (72) or P11
tance
(Contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
40-494 PC490LC-10
40 Troubleshooting
PC490LC-10 40-495
40 Troubleshooting
Failure code [DHSHMA] Travel BW L PPC Press Sensor

Abnormality (PC400-DHSHMA-400-A-Z0-A)
Action level Failure code Left Travel REVERSE PPC Pressure Sensor Abnormality
Failure
L01 DHSHMA (Pump controller system)
Detail of • Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2 }.
• Left travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07104 Travel Rev LH PPC Pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective left travel abnormal, it is difficult to judge whether cause of failure is defective
REVERSE PPC pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor below.
sensor.
REVERSE LH PPC pressure sensor is defective.
40-496 PC490LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC490LC-10 40-497
40 Troubleshooting
40-498 PC490LC-10
40 Troubleshooting
Failure code [DHSJMA] Travel BW R PPC Press Sensor

Abnormality (PC400-DHSJMA-400-A-Z0-A)
Action level Failure code Right Travel REVERSE PPC Pressure Sensor Abnormality
Failure
L01 DHSJMA (Pump controller system)
Detail of • Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that right travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of right travel REVERSE deteriorates.
• Right travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07105 Travel Rev RH PPC pressure)
first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective right travel abnormal, it is difficult to judge whether cause of failure is defective
REVERSE PPC pressure sensor, ground fault or hot short circuit in wiring harness. Check as
2 sensor below.
sensor.
REVERSE RH PPC pressure sensor is defective.
PC490LC-10 40-499
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
40-500 PC490LC-10
40 Troubleshooting
PC490LC-10 40-501
40 Troubleshooting
Failure code [DKR0MA] F pump S/P sensor Abnormality (PC400-DKR0MA-400-A-Z0-A)
Action level Failure code Front pump Swash Plate Sensor Abnormality
Failure
L01 DKR0MA (Pump controller system)
Detail of • Signal voltage of front pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
failure
controller
• Automatic deceleration does not cancel.
Problem on • One-touch power maximizing function does not work.
machine • When engine is running with light load, engine control that runs engine at lowered engine-
pump matching speed does not function.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will be broken. Accordingly, take extreme care when checking.
• Voltage from front pump swash plate sensor can be checked with monitoring function.
(Code: 01138 F pump swash plate sensor voltage)
first.
Power 4.5 to 5.5
Voltage Between P27 (female) (A) and (B)
supply V
Between P27 (male) (A) and (B) Approx. 6
kz
Approx. 6
Resis- Between P27 (female) (B) and (C) kz
tance Approx.
Between P27 (female) (A) and (C)
170 z
Between P27 (male) (C) and ground Min. 1 Mz
Defective F pump swash 3. Turn starting switch to ON position.
2 plate sensor Sensor Approx. 3
Voltage Between P27 (C) and (B)
(internal defect) output V
sensor, ground fault or hot short circuit in wiring harness. Check as
below.
2. Replace connector P27 with connector P28.
4. If E mark is not displayed again in this failure code column, F pump
swash plate sensor is defective.
a After finishing test, restore connectors .
3 (wire breakage or defective 2. Disconnect connectors CP01 and P27, and connect T-adapters to
40-502 PC490LC-10
40 Troubleshooting

required. Max. 1 z
(A)
Resis-
tance
required. Max. 1 z
(B)
(C) Max. 1 z

P27 (female) (C) Min. 1 Mz
tance
Voltage Between P27 (female) (C) and ground Max. 1 V
Circuit diagram related to F and R pump swash plate sensors
PC490LC-10 40-503
40 Troubleshooting
Failure code [DKR1MA] R pump S/P sensor Abnormality (PC400-DKR1MA-400-A-Z0-A)
Action level Failure code Rear Pump Swash Plate Sensor Abnormality
Failure
L01 DKR1MA (Pump controller system)
Detail of • Signal voltage of rear pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
failure
controller
• Automatic deceleration does not cancel.
Problem on • One-touch power maximizing function does not work.
machine • When engine is running with light load, engine control that runs engine at lowered engine-
pump matching speed does not function.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will be broken. Accordingly, take extreme care when checking.
• Voltage from rear pump swash plate sensor can be checked with monitoring function.
(Code: 01140 R Pump Sw Plate Sensor Volt)
first.
Power 4.5 to 5.5
Voltage Between P28 (female) (A) and (B)
supply V
Between P28 (male) (A) and (B) Approx. 6
kz
Approx. 6
Resis- Between P28 (female) (B) and (C) kz
tance Approx.
Between P28 (female) (A) and (C)
170 z
Between P28 (male) (C) and ground Min. 1 Mz
2. Insert T-adapters into connector P28
Defective R pump swash 3. Turn starting switch to ON position.
2 plate sensor Sensor Approx. 3
Voltage Between P28 (C) and (B)
(internal defect) output V
sensor, ground fault or hot short circuit in wiring harness. Check as
below.
2. Replace connector P28 with connector P27.
4. If E mark is not displayed again in this failure code column, R pump
swash plate sensor is defective.
3 (wire breakage or defective 2. Disconnect connectors CP01 and P28, and connect T-adapters to
40-504 PC490LC-10
40 Troubleshooting

required. Max. 1 z
(A)
Resis-
tance
required. Max. 1 z
(B)
(C) Max. 1 z

P28 (female) (C) Min. 1 Mz
tance
(contact with 24 v circuit) 4. Turn starting switch to ON position.
Voltage Between P28 (female) (C) and ground Max. 1 V
Circuit diagram related to F and R pump swash plate sensors
PC490LC-10 40-505
40 Troubleshooting
Failure code [DLM3KA] Fan speed sensor: Open circuit (PC400-DLM3KA-400-A-Z0-A)
Action level Failure code Fan speed sensor: Open circuit

Failure
L01 DLM3KA (Pump controller system)
• No pulse voltage is input from fan speed sensor due to open circuit in fan speed sensor
system.
Detail of • This failure code appears under the following conditions.
failure 1. Input voltage is 3 to 4 V.
2. There is no record of pulse input.
3. Engine is running.
controller
Problem on • Accuracy of fan speed control decreases.
machine
Related • Input speed the fan speed sensor can be checked by using the monitoring function
information (Code: 10007 Fan speed)
Defective fan speed sensor 1. Turn starting switch to OFF position.

1 tor (internal open or short
circuit) Resis- Between P50 (male) (1) and (2) 2 to 3 kz
tance Between P50 (male) (1) and ground Min. 1 Mz
Open or short circuit in wiring a If resistance is above 1 Mz , wiring harness has open circuit. If
2
harness resistance is below 1 z , wiring harness has short circuit.
Resis- Between CP01 (female) (25) and (44)
2 to 3 kz
tance
3 (open circuit or defective each female side.
contact) Between CP01 (female) (25) and P50 (female)
Max. 1 z
Resis- (1)
(2) Max. 1 z
Circuit diagram related to fan speed sensor
40-506 PC490LC-10
40 Troubleshooting
Failure code [DLM3KB] Fan Speed Sensor Short Circuit (PC400-DLM3KB-400-A-Z0-A)
Action level Failure code Fan speed sensor: Short circuit

Failure
L01 DLM3KB (Pump controller system)
• No pulse voltage is input from fan speed sensor due to ground fault in fan speed sensor
system.
Detail of • This failure code appears under the following conditions.
failure 1. Failure code [DLM3KA] is not indicated.
2. Engine speed is 800 rpm or above.
3. Fan is not in reverse control.
controller
Problem on • The fan speed fails to accurately meet the specified speed.
machine
Related • Input speed the fan speed sensor can be checked by using the monitoring function
information (Code: 10007 Fan speed)
Defective fan speed sensor 1. Turn starting switch to OFF position.

circuit) Resis- Between P50 (male) (1) and (2) 2 to 3 kz
tance Between P50 (male) (1) and ground Min. 1 Mz
2
Resis- Between CP01 (female) (25) and (44)
2 to 3 kz
tance
Resis- Between CP01 (female) (25) or P50 (female)
tance
harness 2. Disconnect connector P50 and connect T-adapter to female side.
Voltage Between P50 (female) (1) and (2) 3 to 4 V
Circuit diagram related to fan speed sensor
PC490LC-10 40-507
40 Troubleshooting
Failure code [DLM3MB] Fan Control Mismatch (PC400-DLM3MB-400-A-Z0-A)
Action level Failure code Fan control mismatch

Failure
L01 DLM3MB (Pump controller system)
Detail of • Fan speed sensed by fan speed sensor differs from that commanded by pump controller.
failure
Action of
controller
Problem on • Fan speed control does not function normally.
machine
• Fan speed command from pump controller can be checked with monitoring function.
(Code: 10010)
Related • Fan speed sensed by fan speed sensor can be checked with monitoring function (Code:
information 10007).
Defective hydraulic circuit of Perform procedure in Testing and adjusting, "Testing fan pump circuit oil
1 hydraulic fan pressure".
Defective hydraulic fan EPC
2 [Perform troubleshooting for failure codes [DX16KA] and [DX16KB].
solenoid system
Defective fan speed sensor
3 [Perform troubleshooting for failure codes [DLM3KA] and [DLM3KB].
system
40-508 PC490LC-10
40 Troubleshooting
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality (PC400-

DR21KX-400-A-Z0-A)
Action level Failure code Camera 2 Picture Reverse Drive Abnormality

Failure
L01 DR21KX (Machine monitor system)
Detail of • Voltage that is different from output voltage of machine monitor appears in camera 2
failure picture reverse drive circuit (pin 6 of connector CM04).
Action of • Does not display camera 2 image.
controller
Problem on • Camera 2 image is not displayed.
machine
• Normal image is displayed when voltage of camera 2 picture reverse drive circuit (pin 6 of
connector CM04) is 0V, and mirror image is displayed when voltage is 8 V (mirror image
Related command of 8 V is used because camera power supply voltage is 8 V).
information • Since there may be several connectors A46, check connector A41 to identify the camera
2.
2. Disconnect connectors CM04 and A46, and connect T-adapters to
1 (Wire breakage or defective Between CM04 (female) (6) and A46 (female)
Max. 1 z
contact of connector) Resis- (3)
tance Between CM04 (female) (8) and A46 (female)
(4) Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapter to
(Contact with ground circuit)
Resis- Between ground and CM04 (female) (6) or A46
tance
Hot short circuit in wiring 2. Disconnect connector A46 and connect T-adapter to female side.
(Contact with 24 V circuit) a Check that normal image setting is selected for camera 2.
Voltage Between A46 (female) (3) and (4) or ground Max. 1 V
2. Disconnect connector CM04 and connect T-adapter to female side.
Resis- Between CM04 (female) (6) and every pin
other than pin (6) Min. 1 Mz
tance
If no failure is found by above checks, camera 2 is defective. (Since this
5 Defective camera 2 is an internal defect, troubleshooting cannot be performed.)
If no failure is found in above checks, machine monitor is defective.
6 Defective machine monitor (Since this is an internal defect, troubleshooting cannot be performed.)
PC490LC-10 40-509
40 Troubleshooting
Circuit diagram related to camera
40-510 PC490LC-10
40 Troubleshooting
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality (PC400-

DR31KX-400-A-Z0-A)
Action level Failure code Camera 3 Picture Reverse Drive Abnormality

Failure
L01 DR31KX (Machine monitor system)
Detail of • Voltage that is different from output voltage of machine monitor is detected in camera 3
failure picture reverse drive circuit (pin 7 of connector CM04).
Action of • Does not display camera 3 image.
controller
Problem on • Camera 3 image is not displayed.
machine
• Normal image is displayed when voltage of camera 3 picture reverse drive circuit (pin 7 of
connector CM04) is 0 V, and mirror image is displayed when voltage is 8 V (mirror image
Related command of 8 V is used because camera power supply voltage is 8 V).
information • Since there may be several connectors A46, check connector A42 to identify the camera
3.
2. Disconnect connectors CM04 and A46, and connect T-adapters to
1 (Wire breakage or defective Between CM04 (female) (7) and A46 (female)
Max. 1 z
contact of connector) Resis- (3)
tance Between CM04 (female) (8) and A46 (female)
(4) Max. 1 z

Ground fault in wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapter to
Resis- Between ground and CM04 (female) (7) or A46
tance
Hot short circuit in wiring 2. Disconnect connector A46 and connect T-adapter to female side.
(Contact with 24 V circuit) a Check that normal image setting is selected for camera 3.
Voltage Between A46 (female) (3) and (4) or ground Max. 1 V
2. Disconnect connector CM04 and connect T-adapter to female side.
Resis- Between CM04 (female) (7) and every pin
other than pin (7) Min. 1 Mz
tance
If no failure is found by above checks, camera 3 is defective. (Since this
5 Defective camera 3 is an internal defect, troubleshooting cannot be performed.)
If no failure is found in above checks, machine monitor is defective.
PC490LC-10 40-511
40 Troubleshooting
Circuit diagram related to camera
40-512 PC490LC-10
40 Troubleshooting
Failure code [DV20KB] Travel Alarm Short Circuit (PC400-DV20KB-400-A-Z0-A)
Action level Failure code Travel Alarm Short Circuit

Failure
L01 DV20KB (Pump controller system)
Detail of • Abnormal current flows when pump controller drives travel alarm circuit.
failure
• Stops driving travel alarm circuit.
controller is set to OFF position.
Problem on
• Travel alarm does not sound.
machine
2. Disconnect connector M14, and connect T-adapter to female side.
4. Perform troubleshooting by operating the travel lever.
k Never enter under the machine when operating travel lever.
Defective travel alarm
1 a When travel lever is set to the travel position, voltage is applied usually to
(Internal defect)
the travel alarm connector before machine starts moving.
a If the following voltage is normal but travel alarm does not sound, travel
alarm is defective.
Travel lever: Neutral Max. 1 V
Between M14 (female)
Voltage Travel lever: When
(1) and (2) 20 to 30 V
operated
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
2 female side.
(Contact with ground
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz

2. Insert T-adapter into connector M14.
4. Perform troubleshooting by operating the travel lever.
Pump controller is
3
defective. k Never enter under the machine when operating travel lever.
Travel lever: Neutral Max. 1 V
Voltage Between M14 (1) and (2) Travel lever: When
operated 20 to 30 V
PC490LC-10 40-513
40 Troubleshooting
Circuit diagram related to travel alarm
40-514 PC490LC-10
40 Troubleshooting
Failure code [DW43KA] Travel Speed Sol Open Circuit (PC400-DW43KA-400-A-Z0-A)
Action level Failure code Travel Speed Solenoid Open Circuit

Failure
L01 DW43KA (Pump controller system)
Detail of • No current flows when pump controller drives travel speed selector solenoid, so pump
failure controller determines that open circuit exists in travel speed selector solenoid circuit.
Action of • None in particular (Since no current flows, solenoid is not energized.)
Problem on • "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to short
Related
circuit.)
information
(Code: 02300 Solenoid 1)
• Method of reproducing failure code: Start engine, set travel speed to High and operate
travel lever.
Defective travel speed 2. Disconnect connector V04, and connect T-adapters to male side.
1
selector solenoid
Resistance Between V04 (male) (1) and (2) 20 to 60 z
Between CP02 (female) (93) and each of
Resistance (115), (117), and (120) 20 to 60 z
a If no failure is found by above checks , this check is not required.
harness
2 1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V04, and connect T-adapters to
each female side.
Between CP02 (female) (93) and V04
Resistance
Between each of CP02 (female) (115),
(117), and (120), and V04 (female) (2) Max. 1 z
PC490LC-10 40-515
40 Troubleshooting
Circuit diagram related to travel speed selector solenoid
40-516 PC490LC-10
40 Troubleshooting
Failure code [DW43KB] Travel Speed Sol Short Circuit (PC400-DW43KB-400-A-Z0-A)
Action level Failure code Travel Speed Solenoid Short Circuit

Failure
L01 DW43KB (Pump controller system)
• Abnormal current flows when pump controller drives travel speed selector solenoid, so
Detail of
pump controller determines that short circuit exists in travel speed selector solenoid
failure
circuit.
• Stops driving travel speed selector solenoid.
Problem on • "Hi" travel speed is slow. (Although "Hi" is diaplayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
Related
circuit.)
information
• Method of reproducing failure code: Start engine, set travel speed to High and operate
travel lever.
Defective travel speed 1. Turn starting switch to OFF position.
selector solenoid 2. Disconnect connector V04, and connect T-adapters to male side.
1
(internal short circuit or Between V04 (male) (1) and (2) 20 to 60 z
ground fault) Resistance
Between V04 (male) (1) and ground Min. 1 Mz
Short circuit or ground fault in
2 wiring harness Between CP02 (female) (93) and (115),
20 to 60 z
Resistance (117), (120)
a If no abnormality is found in check on cause 2, this check is not
required.
3 harness
2. Disconnect connectors C02 and V04, and connect T-adapter to either
Between ground and CP02 (female) (93) or
Resistance between V04 (female) (1) Min. 1 Mz
PC490LC-10 40-517
40 Troubleshooting
Circuit diagram related to travel speed selector solenoid
40-518 PC490LC-10
40 Troubleshooting
Failure code [DW45KA] Swing Brake Sol Open Circuit (PC400-DW45KA-400-A-Z0-A)
Action
Failure code swing parking brake Solenoid Open Circuit
level Failure
(Pump controller system)
L03 DW45KA
• Controller output voltage to solenoid is above standard value when pump controller does
Detail of not drive swing parking brake solenoid, so pump controller determines that open circuit
failure exists in swing parking brake solenoid circuit.
• None in particular. (Since no current flows, solenoid is not energized, so swing parking
Action of brake is kept applied.)
Problem on • Upper structure does not swing (swing parking brake is not released).
machine
• If solenoid and wiring harness are normal, swing operation is possible by setting swing
parking brake cancel switch to RELEASE position. (However, swing brake is not released
when starting switch is in OFF position. swing parking brake remains applied.)
• Keep swing parking brake cancel switch in RELEASE position during troubleshooting.
When starting switch is turned to ON position in this condition, normally current flows
through swing parking brake solenoid circuit to release swing parking brake.
Related • Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
circuit.)
• Power for swing parking brake solenoid is supplied from pin (101) of pump controller
connector CP02 or fuse No.1 in fuse box F01.
Blown fuse No. 1 (right top
1 If fuse is blown, see failure code [DW45KB].
fuse) in fuse box F01
Defective swing parking 2. Disconnect connector V05, and connect T-adapters to male side.
2
brake solenoid
2. Remove diode arrays D01 and D03, and connect T-adapters to each
male side.
Defective diode array D01 or a Check by using multimeter in diode range.
3
D03 Between D01 (male) (3) (+) and (7) (-) No continuity
Continuity
2. Remove diode D01.
3. Disconnect connector CP02, and connect T-adapter to each female
Open circuit in wiring side.
harness
4 a Swing lock switch OFF position.
contact of connector) Between CP02 (female) (101) and D01
Resistance
Between D01 (female) (3) and CP02
(female) (115) 20 to 60 z
PC490LC-10 40-519
40 Troubleshooting

a If no failure is found by above checks, this check is not required.
Open circuit in wiring 2. Disconnect connectors D01, CP02, and V05, and connect T-adapters
harness to each female side.
4
(wire breakage or defective Between D01 (female) (3) and V05 (female)
contact of connector) (1) Max. 1 z
Resistance
(117), (120), and V05 (female) (2) Max. 1 z
40-520 PC490LC-10
40 Troubleshooting
Circuit diagram related to swing parking brake solenoid
PC490LC-10 40-521
40 Troubleshooting
Failure code [DW45KB] Swing Brake Sol Short Circuit (PC400-DW45KB-400-A-Z0-A)
Action
Failure code Swing Brake Solenoid Short Circuit
level Failure
L03 DW45KB
Detail of • Abnormal current flows when pump controller drives swing parking brake solenoid, so
failure pump controller determines that short circuit exists in swing parking brake solenoid circuit.
• Stops driving swing parking brake solenoid.
Problem on • Upper structure does not swing (swing parking brake is not released).
machine
• If solenoid and wiring harness are normal, swing operation is possible by setting swing
parking brake cancel switch to RELEASE position. (However, swing brake is not released
when starting switch is in OFF position. swing parking brake remains applied.)
• Keep swing lock switch in OFF position and swing parking brake cancel switch in
RELEASE position during troubleshooting. When starting switch is turned to ON position
in this condition, normally current flows through swing parking brake solenoid circuit to
release swing parking brake.
Related
• Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
information
circuit.)
• Power for swing parking brake solenoid circuit is supplied from pin (101) of pump
controller connector CP02 or fuse No.1 in fuse box F01.
Blown fuse No. 1 (right top Even if fuse is blown, perform troubleshooting according to following
1 fuse) in fuse box F01 steps to identify cause.
Defective swing parking 2. Disconnect connector V05, and connect T-adapters to male side.
2
brake solenoid Resis- Between V05 (male) (1) and (2) 20 to 60 z
tance Between V05 (male) (1) and ground Min. 1 Mz
2. Remove diode arrays D01 and D03, and connect T-adapters to each
male side.
a Check by using multimeter in diode range.
Defective diode array D01 or No
3 Between D01 (male) (3) (+) and (7) (-)
D03 continuity
Continuity
No
Between D03 (male) (1) (+) and (5) (-)
continuity
2. Remove fuse No.1 (right top, 10 A) in fuse box F01 and diode D01.
Ground fault in wiring harness 3. Disconnect connectors CP02, D01, and V05.
4 4. Connect T-adapters to female side of connectors CP02 and D01.
Resis- Between CP02 (female) (101) and ground Min. 1 Mz
tance Between D01 (female) (3) and ground Min. 1 Mz
2. Remove fuse No.1 (right top, 10 A) in fuse box F01 and diode D01.
3. Disconnect connector CP02.
4. Connect T-adapters to female side of connectors D01 and CP02.
Resis- Between D01 (female) (3) and CP02 (female)
(115), (117), or (120) 20 to 60 z
tance
40-522 PC490LC-10
40 Troubleshooting
PC490LC-10 40-523
40 Troubleshooting
Failure code [DW7BKA] Fan Reverse Sol Open Circuit (PC400-DW7BKA-400-A-Z0-A)
Action
Failure code Fan Reverse Solenoid Open Circuit
level Failure
L01 DW7BKA
Detail of • No current flows when pump controller drives hydraulic fan reverse solenoid.
failure
Problem on • Hydraulic fan does not rotate in reverse.
machine
• Controller's command (ON/OFF) to fan reverse solenoid can be checked with monitoring
function. (As long as controller's command to solenoid is "ON", sensor status displayed
on monitoring screen is "ON" even if solenoid is not energized due to open circuit.)
Related (Code: 02300 Solenoid 1)
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
• Method of reproducing failure code: Turn starting switch to ON position and set fan
reverse switch to ON position.
Defective hydraulic fan 1. Turn starting switch to OFF position.

reverse solenoid (Internal 2. Disconnect connector V17, and connect T-adapters to male side.
1
open circit) Resis- Between V17 (male) (1) and (2)
20 to 60 Ω
tance
2
Resis- Between CP02 (female) (98) and each of (115),
(117), and (120) 20 to 60 Ω
tance
Open circuit in wiring harness 2. Disconnect connectors CP02 and V17, and connect T-adapters to
contact of connector) Between CP02 (female) (98) and V17 (female)
Max. 1 z
Resis- (1)
tance Between each of CP02 (female) (115), (117)
and (120), and V17 (female) (2) Max. 1 z
40-524 PC490LC-10
40 Troubleshooting
Circuit diagram related to hydraulic fan
PC490LC-10 40-525
40 Troubleshooting
Failure code [DW7BKB] Fan Reverse Sol Short Circuit (PC400-DW7BKB-400-A-Z0-A)
Action
Failure code Fan Reverse Solenoid Short Circuit
level Failure
(Power train controller system)
L01 DW7BKB
Detail of • Abnormal current flows when pump controller drives hydraulic fan reverse solenoid.
failure
• Stops driving hydraulic fan reverse solenoid.
Problem on • Hydraulic fan does not rotate in reverse.
machine
• Controller's command (ON/OFF) to fan reverse solenoid can be checked with monitoring
function. (As long as controller's command to solenoid is "ON", sensor status displayed
on monitoring screen is "ON" even if solenoid is not energized due to short circuit.)
• Method of reproducing failure code: Turn starting switch to ON position and set fan
reverse switch to ON position.
Defective hydraulic fan 2. Disconnect connector V17, and connect T-adapters to male side.
1 reverse solenoid (Internal
disconnection) Resis- Between V17 (male) (1) and (2) 20 to 60 z
tance Between V17 (female) (1) and ground Min. 1 Mz
Ground fault in wiring harness 2. Disconnect connectors V17 and CP02, and connect T-adapters to
2 female side of V17.
Resis- Between V17 (female) (1) and ground
Min. 1 Mz
tance
3 Short circuit in wiring harness female side of V17.
Resis- Between V17 (female) (1) and (2)
Min. 1 Mz
tance
40-526 PC490LC-10
40 Troubleshooting
PC490LC-10 40-527
40 Troubleshooting
Failure code [DW91KA] Travel Junction Sol Open Circuit (PC400-DW91KA-400-A-Z0-A)
Action
Failure code Travel junction solenoid open circuit
level Failure
L01 DW91KA
Detail of not drive travel junction solenoid, so pump controller determines that open circuit exists in
failure travel junction solenoid circuit.
Problem on • Machine does not turn easily during travel.
machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with
Related
circuit.)
information
• Method of reproducing failure code: Start engine and turn machine with right and left
travel levers.
Defective travel junction
2. Disconnect connector V03, and connect T-adapters to male side.
1 solenoid
Resis- Between V03 (male) (1) and (2)
20 to 60 z
tance
Open or short circuit in wiring 2. Disconnect connector CP02 and connect T-adapters to female side.
2
harness Resis- Between CP02 (female) (85) and each of (115),
(117), and (120) 20 to 60 z
tance
Max. 1 z
Resis- (1)
tance Between each of CP02 (female) (115), (117),
(120) and V03 (female) (2) Max. 1 z
40-528 PC490LC-10
40 Troubleshooting
Circuit diagram related to travel junction solenoid
PC490LC-10 40-529
40 Troubleshooting
Failure code [DW91KB] Travel Junction Sol Short Circuit (PC400-DW91KB-400-A-Z0-A)
Action
Failure code Travel Junction Solenoid Short Circuit
level Failure
L01 DW91KB
Detail of • Abnormal current flows when pump controller drives travel junction solenoid, so pump
failure controller determines that short circuit exists in travel junction solenoid circuit.
• Stops driving travel junction solenoid.
Problem on • Machine does not turn during travel.
machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with
Related
circuit.)
information
• Method of reproducing failure code: Start engine and turn machine with right and left
travel levers.
Defective travel junction 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V03, and connect T-adapters to male side.
1
(internal short circuit or Resis- Between V03 (male) (1) and (2) 20 to 60 z
ground fault) tance Between V03 (male) (1) and ground Min. 1 Mz
2 wiring harness Between CP02 (female) (85) and each of (115),
Resis- (117), (120) 20 to 60 z
tance
3 2. Disconnect connectors CP02 and V03, and connect T-adapters to
V03 (female) (1) Min. 1 Mz
tance
40-530 PC490LC-10
40 Troubleshooting
Circuit diagram related to travel junction solenoid
PC490LC-10 40-531
40 Troubleshooting
Failure code [DWA2KA] Attachment Sol Open Circuit (PC400-DWA2KA-400-A-Z0-A)
Action level Failure code Attachment solenoid open circuit

Failure
L03 DWA2KA (Pump controller system)
• Output terminal voltage of controller is above criteria when pump controller does not drive
Detail of attachment return (1-way/2-way) selector solenoid, so pump controller determines that
failure open circuit exists in attachment return (1-way/2-way) selector solenoid circuit.
Problem on • Attachment return circuit does not change to 1-way circuit.
machine
• Controller's command (ON/OFF) to attachment return (1-way/2-way) selector solenoid
can be checked with monitoring function. (As long as controller's command to solenoid is
"ON", sensor status displayed on monitoring screen is "ON" even if solenoid is not
Related energized due to open circuit.)
information (Code: 02301 Solenoid 2)
• Method of reproducing failure code: Turn starting switch to ON position and set machine
in working mode other than breaker mode (B).
Defective attachment 1. Turn starting switch to OFF position.
1 return selector solenoid 2. Disconnect connector V07, and connect T-adapters to male side.
(internal open circuit) Resistance Between V07 (male) (1) and (2) 20 to 60 z
Open circuit or ground 2. Disconnect connector CP02 and connect T-adapters to female side.
2 fault in wiring harness Between CP02 (female) (86) and each of CP02
Resistance (female) (115), (117), (120) 20 to 60 z

harness 2. Disconnect connectors CP02 and V07, and connect T-adapters to each
defective contact of Between CP02 (female) (86) and V07 (female) (1) Max. 1 z
connector) Resistance Between each of CP02 (female) (115), (117), (120)
and V07 (female) (2) Max. 1 z
Defective pump If no failure is found by above checks, pump controller is defective. (Since this
4 is an internal defect, troubleshooting cannot be performed.)
controller
40-532 PC490LC-10
40 Troubleshooting
Circuit diagram related to attachment return (1-way/2-way) selector solenoid
PC490LC-10 40-533
40 Troubleshooting
Failure code [DWA2KB] Attachment Sol Short Circuit (PC400-DWA2KB-400-A-Z0-A)
Action
Failure code Attachment Solenoid Short Circuit
level Failure
L03 DWA2KB
• Abnormal current flows when pump controller drives attachment return (1-way/2-way)
Detail of selector solenoid, so pump controller determines that short circuit exists in attachment
failure return (1-way/2-way) selector solenoid circuit.
• Stops driving attachment return (1-way/2-way) selector solenoid.
Problem on • Attachment return circuit does not change to 1-way circuit.
machine
• Controller's command (ON/OFF) to attachment return (1-way/2-way) selector solenoid
can be checked with monitoring function. (As long as controller's command to solenoid is
"ON", sensor status displayed on monitoring screen is "ON" even if solenoid is not
Related energized due to short circuit.)
information (Code: 02301 Solenoid 2)
• Method of reproducing failure code: Turn starting switch to ON position and set machine in
breaker mode (B).
Defective attachment return 2. Disconnect connector V07, and connect T-adapters to male side.
1 selector solenoid (internal
short circuit or ground fault) Between V07 (male) (1) and (2) 20 to 60 z
Resistance
Open circuit or ground fault 2. Disconnect connector CP02 and connect T-adapters to female side.
2 in wiring harness Between CP02 (female) (86) and each of
Resistance (115), (117), (120) 20 to 60 z

3 harness 2. Disconnect connectors CP02 and V07, and connect T-adapters to
Resistance V07 (female) (1) Min. 1 Mz
40-534 PC490LC-10
40 Troubleshooting
Circuit diagram related to attachment return (1-way/2-way) selector solenoid
PC490LC-10 40-535
40 Troubleshooting
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit (PC400-DWK0KA-400-A-Z0-A)
Action
Failure code 2-stage Relief Solenoid Open Circuit
level Failure
L01 DWK0KA
Detail of not drive 2-stage relief solenoid, so pump controller determines that open circuit exists in
failure 2-stage relief solenoid circuit.
Problem on • Travel power is low (main relief valve is not set to high-pressure setting).
machine • One-touch power maximizing function does not work.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
circuit.)
• Controller detects open circuit only when it does not drive solenoid.
Defective 2-stage relief 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector V08, and connect T-adapters to male side.
2
Resistance (115), (117) and (120) 20 to 60 z

Open circuit in wiring 2. Disconnect connectors CP02 and V08, and connect T-adapters to
harness each female side.
3
(wire breakage or defective Between CP02 (female) (109) and V08
contact of connector) (female) (1) Max. 1 z
Resistance
(117), (120) and V03 (female) (2) Max. 1 z
40-536 PC490LC-10
40 Troubleshooting
Circuit diagram related to 2-stage relief solenoid
PC490LC-10 40-537
40 Troubleshooting
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit (PC400-DWK0KB-400-A-Z0-A)
Action
Failure code 2-stage Relief Solenoid Short Circuit
level Failure
L01 DWK0KB
Detail of • Abnormal current flows when pump controller drives 2-stage relief solenoid, so pump
failure controller determines that short circuit exists in 2-stage relief solenoid circuit.
• Stops driving 2-stage relief solenoid.
controller is set to OFF position.
Problem on • Travel power is low (main relief valve is not set to high-pressure setting).
machine • One-touch power maximizing function does not work.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
circuit.)
• Controller detects open circuit only when Open circuit in 2-stage relief solenoid.
1
ground fault) tance Between V08 (female) (1) and ground Min. 1 Mz
Ground fault in wiring harness 2. Disconnect connectors CP02 and V08, and connect T-adapters to
2 female side of V08.
tance
3 Short circuit in wiring harness female side of V08.
Resis- Between V08 (female) (1) and (2)
Min. 1 Mz
tance
40-538 PC490LC-10
40 Troubleshooting
PC490LC-10 40-539
40 Troubleshooting
Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit (PC400-
DWK2KA-400-A-Z0-A)
Action
Failure code Variable Back Pressure Solenoid Open Circuit
level Failure
L01 DWK2KA
Detail of • No current flows when pump controller drives variable back pressure solenoid, so pump
failure controller determines that open circuit exists in variable back pressure solenoid circuit.
Problem on • Set pressure of back pressure valve cannot be changed.
machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
Related displayed on monitoring screen is "ON" even if solenoid is not energized due to open
information circuit.)
Defective variable back 1. Turn starting switch to OFF position.
1 pressure solenoid valve 2. Disconnect connector V25, and connect T-adapter to male side.
Resistance CP02 (female) (115), (117), (120) 20 to 60 z

3
(wire breakage or defective Between CP02 (female) (113) and V25
contact of connector) (female) (1) Max. 1 z
Resistance
(117), (120) and V25 (female) (2) Max. 1 z
40-540 PC490LC-10
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
PC490LC-10 40-541
40 Troubleshooting
Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit (PC400-
DWK2KB-400-A-Z0-A)
Action
Failure code Variable Back Pressure Solenoid Short Circuit
level Failure
L01 DWK2KB
• Abnormal current flows when pump controller drives variable back pressure solenoid, so
Detail of
pump controller determines that short circuit exists in variable back pressure solenoid
failure
circuit.
• Stops driving variable back pressure solenoid.
Problem on • Set pressure of back pressure valve cannot be changed.
machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
Related displayed on monitoring screen is "ON" even if solenoid is not energized due to short
information circuit.)
Defective variable back 1. Turn starting switch to OFF position.
pressure solenoid valve 2. Disconnect connector V25, and connect T-adapters to male side.
1
(internal short circuit or Between V25 (male) (1) and (2) 20 to 60 z
ground fault) Resistance
Resistance (115), (117), (120) 20 to 60 z

3 harness 2. Disconnect connectors CP02 and V25, and connect T-adapter to
Resistance V25 (female) (1) Min. 1 Mz
40-542 PC490LC-10
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
PC490LC-10 40-543
40 Troubleshooting
Failure code [DWK8KA] Swing C/O Solenoid Open Circuit (PC400-DWK8KA-400-A-Z0-A)
Action level Failure code Swing Cut—off (2–stage relief) Solenoid Open Circuit
Failure
L01 DWK8KA (Pump controller system)
Detail of • No current flows when pump controller drives swing cut-off solenoid, so pump controller
failure determines that open circuit exists in swing cut-off (2–stage relief) solenoid circuit.
Problem on • Swing motor relief pressure setting remains Lo.
machine
• Controller's command (ON/OFF) to swing cut-off (2–stage relief) solenoid can be checked
by using monitoring function. (As long as controller's command to solenoid is "ON",
Related sensor status displayed on monitoring screen is "ON" even if solenoid is not energized
information due to open circuit.)
Defective swing cut-off (2– 1. Turn starting switch to OFF position.
stage relief) solenoid 2. Disconnect connector V02, and connect T-adapters to male side.
1
(internal open circuit) Resis- Between V02 (male) (1) and (2)
20 to 60 z
tance
Open circuit or ground fault in 2. Disconnect connector CP02 and connect T-adapters to female side.
2 wiring harness Resis- Between CP02 (female) (94) and each of CP02
(female) (115), (117), (120) 20 to 60 z
tance
3
(wire breakage or defective Between CP02 (female) (94) and V02 (female)
contact of connector) Max. 1 z
Resis- (1)
(120) and V02 (female) (2) Max. 1 z
40-544 PC490LC-10
40 Troubleshooting
Circuit diagram related to swing cut-off (2–stage relief) solenoid
PC490LC-10 40-545
40 Troubleshooting
Failure code [DWK8KB] Swing C/O Solenoid Short Circuit (PC400-DWK8KB-400-A-Z0-A)
Action level Failure code Swing Cut—off (2–stage relief) Solenoid Short Circuit
Failure
L01 DWK8KB (Pump controller system)
• Abnormal current flows when pump controller drives swing cut-off solenoid, so pump
Detail of
controller determines that short circuit exists in swing cut-off (2–stage relief) solenoid
failure
circuit.
• Swing cut-off solenoid.
Problem on • Swing motor relief pressure setting remains Lo.
machine
• Controller's command (ON/OFF) to swing cut-off (2–stage relief) solenoid can be checked
by using monitoring function. (As long as controller's command to solenoid is "ON",
Related sensor status displayed on monitoring screen is "ON" even if solenoid is not energized
information due to short circuit.)
Defective swing cut-off (2– 1. Turn starting switch to OFF position.
stage relief) solenoid 2. Disconnect connector V02, and connect T-adapters to male side.
1
Open circuit or ground fault in 2. Disconnect connector CP02 and connect T-adapters to female side.
2 wiring harness Resis- Between CP02 (female) (94) and each of (115),
(117), (120) 20 to 60 z
tance
Resis- Between ground and CP02 (female) (94) or V02
tance
40-546 PC490LC-10
40 Troubleshooting
Circuit diagram related to swing cut-off (2–stage relief) solenoid
PC490LC-10 40-547
40 Troubleshooting
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit (PC400-DX16KA-400-A-Z0-A)
Action
Failure code Fan Pump EPC Solenoid Open Circuit
level Failure
L03 DX16KA
Detail of • No current flows through hydraulic fan pump EPC solenoid circuit.
failure
• Induces protection mode, in which engine speed is lowered, to prevent fan over speed
Action of since solenoid is de-energized and swash plate of fan pump is set to maximum angle if
controller open circuit occurs.
• Fan motor speed cannot be controlled.
Problem on
• When open or short circuit occurs in fan pump EPC solenoid circuit, fan does not rotate in
machine
reverse.
• Output (current) to hydraulic fan pump EPC solenoid can be checked with monitoring
function.
Related (Code: 31623 Fan Pump EPC Sol. Curr.)
Defective hydraulic fan pump 1. Turn starting switch to OFF position.

EPC solenoid (Internal open 2. Disconnect connector V13, and connect T-adapters to male side.
1
circuit) Resis- Between V13 (male) (1) and (2)
3 to 14 z
tance
2
Resis- Between CP02 (female) (103) and each of
(115), (117) and (120) 3 to 14 z
tance
contact of connector) Between CP02 (female) (103) and V13
Max. 1 z
Resis- (female) (1)
tance Between each of CP02 (female) (115), (117)
and (120), and V13 (female) (2) Max. 1 z
40-548 PC490LC-10
40 Troubleshooting
PC490LC-10 40-549
40 Troubleshooting
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit (PC400-DX16KB-400-A-Z0-A)
Action
Failure code Fan Pump EPC Solenoid Short Circuit
level Failure
L03 DX16KB
Detail of • Abnormal current flows through hydraulic fan pump EPC solenoid circuit.
failure
• Induces protection mode, in which engine speed is lowered, to prevent fan over speed
Action of
since solenoid is de-energized and swash plate of fan pump is set to maximum angle if
controller
short circuit occurs.
• The fan motor speed cannot be controlled.
Problem on
• When the fan EPC solenoid is disconnected or short-circuited, fan reverse rotation
machine
cannnot be made.
• Output (current) to hydraulic fan pump EPC solenoid can be checked with monitoring
function.
Related (Code: 31623 Fan Pump EPC Sol. Curr.)
Defective hydraulic fan pump 2. Disconnect connector V13, and connect T-adapters to male side.
1 EPC solenoid (Internal short
circuit or ground fault) Resis- Between V13 (male) (1) and (2) 3 to 14 z
tance Between V13 (female) (1) and ground Min. 1 Mz
Ground fault in wiring harness 2. Disconnect connectors CP02 and V13, and connect T-adapters to
tance
Short circuit in wiring harness either female side.
3
Resis- (115), (117), (120), or between V13 (female) (1)
Min. 1 Mz
tance and (2)
40-550 PC490LC-10
40 Troubleshooting
PC490LC-10 40-551
40 Troubleshooting
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit (PC400-DXA8KA-400-A-Z0-A)
Action level Failure code PC-EPC (Front) Solenoid Open Circuit

Failure
L03 DXA8KA (Pump controller system)
Detail of • No current flows when pump controller drives front PC-EPC solenoid, so pump controller
failure determines that open circuit exists in front PC-EPC solenoid circuit.
Problem on • If pump load increases, engine speed decreases largely and engine may stall.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stalling by
setting emergency pump drive switch to ON position.
Related • Drive current to front PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC solenoid current (F))
Incorrect operation of
1 Set emergency pump drive switch at its normal position (lower side).
emergency pump drive switch
Defective front PC-EPC
2. Disconnect connector V11, and connect T-adapters to male side.
2 solenoid
3 to 14 z
tance
2. Disconnect connector S25 and connect T-adapters to male side.
Switch position:
Max. 1 z
Between S25 (male) Normal
Defective emergency pump
(3) and (2) Switch position:
3 drive switch Min. 1 Mz
Resis- Emergency
tance Switch position:
Max. 1 z
Emergency Min. 1 Mz

Open or short circuit in wiring a Check that emergency pump drive switch is at normal position (lower
4
harness side).
Resis- Between CP02 (female) (96) and each of (115),
(117), (120) 3 to 14 z
tance
2. Disconnect connectors CP02, S25 and V11, and connect T-adapters
Open circuit in wiring harness to each female side.
Between CP02 (female) (96) and S25 (female)
(3)
Resis- Between S25 (female) (2) and V11 (female) (1) Max. 1 z
(120) and S25 (female) (6) Max. 1 z
Between S25 (female) (5) and V11 (female) (2) Max. 1 z
40-552 PC490LC-10
40 Troubleshooting
Circuit diagram related to PC-EPC solenoid
PC490LC-10 40-553
40 Troubleshooting
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit (PC400-DXA8KB-400-A-Z0-A)
Action
Failure code PC-EPC (Front) Solenoid Short Circuit
level Failure
L03 DXA8KB
Detail of • Abnormal current flows when pump controller drives front PC-EPC solenoid, so pump
failure controller determines that short circuit exists in front PC-EPC solenoid circuit.
• Stops driving front PC-EPC solenoid.
machine
Related • Drive current to front PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC solenoid current (F))
Defective front PC-EPC 1. Turn starting switch to OFF position.
1
drive switch (internal short Between S25 (male) and each of
2 Switch Min. 1 Mz
circuit or ground fault) Resis- S25 (male) (2) and (3)
position:
tance Between ground and each of S25
Normal Min. 1 Mz
(male) (2) and (3)
Short circuit or ground fault in a Check that emergency pump drive switch is at normal position (lower
3 wiring harness side).
Between CP02 (female) (96) and each of (115),
Resis- (117), (120) 3 to 14 z
tance
Ground fault in wiring harness to any female side.
4
(contact with ground circuit) Between ground and CP02 (female) (96) or
Min. 1 Mz
Resis- S25 (female) (3)
tance Between ground and S25 (female) (5) or V11
40-554 PC490LC-10
40 Troubleshooting
PC490LC-10 40-555
40 Troubleshooting
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit (PC400-DXA9KA-400-A-Z0-A)
Action
Failure code PC-EPC (Rear) Solenoid Open Circuit
level Failure
L03 DXA9KA
Detail of • No current flows when pump controller drives rear PC-EPC solenoid, so pump controller
failure determines that open circuit exists in rear PC-EPC solenoid circuit.
machine
Related • Drive current to rear PC-EPC solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC solenoid current (R))
Incorrect operation of
1 Set emergency pump drive switch at its normal position (lower side).
emergency pump drive switch
Defective rear PC-EPC 1. Turn starting switch to OFF position.
2
(internal open circuit) Resis- Between V12 (male) (1) and (2)
3 to 14 z
tance
Switch position:
Max. 1 z
Defective emergency pump Between S25 (male) Normal
drive (3) and (2) Switch position:
3 Min. 1 Mz
Resis- Emergency
switch (internal open circuit)
tance Switch position:
Max. 1 z
Emergency Min. 1 Mz

Open or short circuit in wiring a Check that emergency pump drive switch is at normal position (lower
4
harness side).
Resis- Between CP02 (female) (104) and each of
(115), (117), (120) 3 to 14 z
tance
Open circuit in wiring harness Between CP02 (female) (104) and S25
5 (wire breakage or defective (female) (9) Max. 1 z
contact of connector) Between S25 (female) (8) and V12 (female) (1) Max. 1 z
Resis-
Between S25 (female) (12) and each of CP02
tance Max. 1 z
(female) (115), (117), (120)
Between S25 (female) (11) and V12 (female)
(2) Max. 1 z
40-556 PC490LC-10
40 Troubleshooting
PC490LC-10 40-557
40 Troubleshooting
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit (PC400-DXA9KB-400-A-Z0-A)
Action
Failure code PC-EPC (Rear) Solenoid Short Circuit
level Failure
L03 DXA9KB
Detail of • Abnormal current flows when pump controller drives rear PC-EPC solenoid, so pump
failure controller determines that short circuit exists in rear PC-EPC solenoid circuit.
• Stops driving rear PC-EPC solenoid.
machine
Related • Drive current to rear PC-EPC solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC solenoid current (R))
Defective rear PC-EPC 1. Turn starting switch to OFF position.
1
drive switch (internal short Between S25 (male) (5) and each
2 Switch Min. 1 Mz
circuit or ground fault) Resis- of (2) and (3)
position:
tance Between ground and each of S25
Normal Min. 1 Mz
(male) (2) and (3)
Short circuit or ground fault in a Check that emergency pump drive switch is at normal position (lower
3 wiring harness side).
Resis- (115), (117), (120) 3 to 14 z
tance
Ground fault in wiring harness to either female side.
4
(contact with ground circuit) Between ground and CP02 (female) (104) or
Min. 1 Mz
Resis- S25 (female) (3)
tance Between ground and S25 (female) (5) or V12
40-558 PC490LC-10
40 Troubleshooting
PC490LC-10 40-559
40 Troubleshooting
Failure code [DXE0KA] LS-EPC Sol Open Circuit (PC400-DXE0KA-400-A-Z0-A)
Action
Failure code LS-EPC Solenoid Open Circuit
level Failure
L01 DXE0KA
Detail of • No current flows when pump controller drives LS-EPC solenoid, so pump controller
failure determines that open circuit exists in LS-EPC solenoid circuit.
Problem on • Travel speed is high with speed setting at Lo and Mi.
machine • Work equipment speed and swing speed are high in fine control mode (L).
• Drive current to LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500 LS-EPC solenoid current)
Defective LS-EPC solenoid 2. Disconnect connector V19, and connect T-adapters to male side.
1
3 to 14 z
tance
2
(117), (120) 3 to 14 z
tance
contact of connector) Resis- Between CP02 (female) (88) and V19 (female)
(1) Max. 1 z
tance
Resis- Between V19 (female) (2) and each of CP02
(female) (115), (117), (120) Max. 1 z
tance
40-560 PC490LC-10
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
PC490LC-10 40-561
40 Troubleshooting
Failure code [DXE0KB] LS-EPC Sol Short Circuit (PC400-DXE0KB-400-A-Z0-A)
Action
Failure code LS-EPC Solenoid Short Circuit
level Failure
L01 DXE0KB
Detail of • Abnormal current flows when pump controller drives LS-EPC solenoid, so pump controller
failure determines that short circuit exists in LS-EPC solenoid circuit.
• Stops driving LS-EPC solenoid.
Problem on • Travel speed is high with speed setting at Lo and Mi.
machine • Work equipment speed and swing speed are high in fine control mode (L).
• Drive current to LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500 LS-EPC solenoid current)
Defective LS-EPC solenoid 1. Turn starting switch to OFF position.

2. Disconnect connector V19 and connect T-adapters to male side.
1 (internal short circuit or
ground fault) Resis- Between V19 (male) (1) and (2) 3 – 14 z
Resis- (117), (120) 3 – 14 z
tance
Resis- Between ground and CP02 (female) (88) or V19
tance
40-562 PC490LC-10
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
PC490LC-10 40-563
40 Troubleshooting
Failure code [DXE4KA] Service Current EPC Disc. (PC400-DXE4KA-400-A-Z0-A)
Action
Failure code Service Current EPC Disconnection
level Failure
— DXE4KA
• No current flows when pump controller drives attachment flow rate adjustment(service
Detail of current) EPC solenoid, so pump controller determines that open circuit exists in
failure attachment flow rate adjustment (service current) EPC solenoid circuit.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
checked with monitoring function.
Related (Code: 01700 Service solenoid current)
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B)
Defective attachment flow 1. Turn starting switch to OFF position.
rate adjustment (service 2. Disconnect connector V30, and connect T-adapters to male side.
1 current) EPC solenoid Resis- Between V30 (male) (1) and (2)
(Internal open circuit) 3 to 14 z
tance
2
(117), (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
tance Between V30 (female) (2) and each of CP02
(female) (115), (117), (120) Max. 1 z
Circuit diagram related to attachment flow rate adjustment (service current) EPC solenoid
40-564 PC490LC-10
40 Troubleshooting
Failure code [DXE4KB] Service Current EPC S/C (PC400-DXE4KB-400-A-Z0-A)
Action
Failure code Service Current EPC Short Circuit
level Failure
– DXE4KB
• Abnormal current flows when pump controller drives attachment flow rate (service
Detail of current) EPC solenoid, so pump controller determines that short circuit exists in
failure attachment flow rate adjustment (service current) EPC solenoid circuit.
• Stops driving attachment flow rate adjustment EPC solenoid.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
Related (Code: 01700 Service solenoid current)
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B).
Defective attachment flow 1. Turn starting switch to OFF position.
rate adjustment (service 2. Disconnect connector V30, and connect T-adapters to male side.
1 current) EPC solenoid
Resis- (117), (120) 3 to 14 z
tance
tance
Circuit diagram related to attachment flow rate (service current) adjustment EPC solenoid
PC490LC-10 40-565
40 Troubleshooting
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit (PC400-DXE5KA-400-A-

Z0-A)
Action
Failure code Merge-divider Main Solenoid Open Circuit
level Failure
L01 DXE5KA
• No current flows when pump controller drives merge-divider (main) EPC solenoid, so
Detail of
pump controller determines that open circuit exists in merge-divider (main) EPC solenoid
failure
circuit.
• Stops output command to merge-divider main solenoid and merge-divider LS solenoid,
Action of and keeps pump always in merged state.
Problem on • Single operation speed of work equipment and swing is high in fine control mode (L).
machine • Machine does not turn easily during travel.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
information (Code: 08000 Merge-divider (main) solenoid current)
Defective merge-divider main 1. Turn starting switch to OFF position.

1 EPC solenoid (internal open 2. Disconnect connector V23, and connect T-adapters to male side.
3 to 14 z
tance
2
harness Resis- Between CP02 (female) (112) and each of
(115), (117), (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
(female) (115), (117), (120) Max. 1 z
40-566 PC490LC-10
40 Troubleshooting
Circuit diagram related to pump merge-divider main EPC solenoid
PC490LC-10 40-567
40 Troubleshooting
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit (PC400-DXE5KB-400-A-

Z0-A)
Action
Failure code Merge-divider Main Solenoid Short Circuit
level Failure
L01 DXE5KB
• Abnormal current flows when pump controller drives merge-divider (main) EPC solenoid,
Detail of
so pump controller determines that short circuit exists in merge-divider (main) EPC
failure
solenoid circuit.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
information (Code: 08000 Merge-divider (main) solenoid current)
Defective merge-divider main 2. Disconnect connector V23, and connect T-adapters to male side.
1 EPC solenoid (internal short
2 wiring harness Between CP02 (female) (112) and each of
Resis- (115), (117), (120) 3 to 14 z
tance
tance
40-568 PC490LC-10
40 Troubleshooting
Circuit diagram related to pump merge-divider main EPC solenoid
PC490LC-10 40-569
40 Troubleshooting
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit (PC400-DXE6KA-400-A-Z0-A)
Action
Failure code Merge-divider LS Solenoid Open Circuit
level Failure
L01 DXE6KA
Detail of • No current flows when pump controller drives merge-divider (LS) EPC solenoid, so pump
failure controller determines that open circuit exists in merge-divider (LS) EPC solenoid circuit.
• Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related (Code: 08001 Merge-divider (LS) solenoid current)
Defective merge-divider LS 1. Turn starting switch to OFF position.

EPC solenoid (internal open 2. Disconnect connector V24, and connect T-adapters to male side.
1
3 to 14 z
tance
2
(117), (120) 3 to 14 z
tance
Max. 1 z
Resis- (1)
(female) (115), (117), (120) Max. 1 z
40-570 PC490LC-10
40 Troubleshooting
Circuit diagram related to merge-divider LS EPC solenoid
PC490LC-10 40-571
40 Troubleshooting
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit (PC400-DXE6KB-400-A-Z0-A)
Action
Failure code Merge-divider LS Solenoid Short Circuit
level Failure
L01 DXE6KB
• Abnormal current flows when pump controller drives merge-divider (LS) EPC solenoid, so
Detail of
pump controller determines that short circuit exists in merge-divider (LS) EPC solenoid
failure
circuit.
• Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related (Code: 08000 Merge-divider (LS) solenoid current)
Defective merge-divider LS 2. Disconnect connector V24, and connect T-adapters to male side.
1 EPC solenoid (internal short
Resis- (117), (120) 3 to 14 z
tance
tance
40-572 PC490LC-10
40 Troubleshooting
Circuit diagram related to merge-divider LS EPC solenoid
PC490LC-10 40-573
40 Troubleshooting
Failure code [DY20KA] Wiper Working Abnormality (PC400-DY20KA-400-A-Z0-A)
Action
Failure code Wiper working Abnormality
level Failure
— DY20KA
Detail of • When windshield wiper works, W signal that indicates wiper motor working area upper
failure end is not input.
Action of • Shuts off power supply to wiper motor.
Problem on • Wiper motor does not work.
machine
• Signal input (ON/OFF) of W contact that indicates wiper working area end can be
Related (Code: 02204 Switch input 5)
• Method of reproducing failure code: Starting switch ON + wiper switch INT or ON position
2. Disconnect connector M05 and connect T-adapters to female side.
Wiper position:
working area upper Max. 1 z
Defective wiper motor Between M05 (female) end
1
(6) and (5) Wiper position: other
Resistance than working area Min. 1 Mz
upper end
Between M05 (female) Wiper position: whole
(1) and (3) range Max. 20 z

2. Disconnect connectors CP01 and CP02, and connect T-adapters to
each female side.
Wiper position:
working area upper Max. 1 z
Between CP01
Open or short circuit in wiring end
2 (female) (56) and
harness Wiper position: other
ground
Resistance than working area Min. 1 Mz
upper end
Between CP02
Wiper position: whole
(female) (114) and Max. 20 z
range
(119)
2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connectors CP01 and CP02
Open circuit in wiring harness and to male side of M05.
Between CP01 (female) (56) and M05 (male)
(6)
Between M05 (male) (5) and ground (T01) Max. 1 z
Resistance Between CP02 (female) (114) and M05 (male)
(1) Max. 1 z
(3) Max. 1 z
40-574 PC490LC-10
40 Troubleshooting
Circuit diagram related to wiper
PC490LC-10 40-575
40 Troubleshooting
Failure code [DY20MA] Wiper Parking Abnormality (PC400-DY20MA-400-A-Z0-A)
Action
Failure code Wiper Parking Abnormality
level Failure
— DY20MA
Detail of • When windshield wiper rests, P signal that indicates rest area of wiper motor is not input.
failure
Action of • Stops output for resting to wiper motor.
Problem on • Wiper motor does not rest.
machine
• Condition of P contact signal of wiper resting area can be checked with monitoring
function.
Related (Code: 02204 Switch input 5)
• Method of reproducing failure code: Starting switch ON + wiper switch INT/ONoOFF
Wiper position: rest
Max. 1 z
Defective wiper motor Between M05 (female) area
1
(4) and (5) Wiper position:
Resistance working area Min. 1 Mz
Between M05 (female) Wiper position: whole
(1) and (3) range Max. 20 z

2. Disconnect diode arrays CP01 and CP02 and connect T-adapters to
each female side.
Wiper position: rest
Between CP01 Max. 1 z
Open or short circuit in wiring area
2 (female) (75) and
harness Wiper position:
ground Min. 1 Mz
Resistance working area
Between CP02
Wiper position: whole
(female) (114) and Max. 20 z
range
(119)
2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connectors CP01 and CP02
Open circuit in wiring harness and to male side of M05.
(4)
Between M05 (male) (5) and ground (T01) Max. 1 z
Resistance Between CP02 (female) (114) and M05 (male)
(1) Max. 1 z
(3) Max. 1 z
40-576 PC490LC-10
40 Troubleshooting
PC490LC-10 40-577
40 Troubleshooting
Failure code [DY2CKB] Washer Drive Short Circuit (PC400-DY2CKB-400-A-Z0-A)
Action level Failure code Washer Drive Short Circuit

Failure
- DY2CKB (Pump controller system)
Detail of • When driving window washer motor (grounded), abnormal current flows and short circuit
failure is detected.
• Stops driving washer motor.
Problem on • Window washer does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position and turn washer
information switch to ON position.
Defective fuse No. 4 in fuse If the fuse is blown, the circuit may have a ground fault, etc. (See failure
1 code [DY2CKA].)
box F01
Defective washer motor 2. Disconnect connector M06, and connect T-adapter to male side.
2 (Internal open circuit or ground Between M06 (male) (1) and (2) Approx. 10
fault) Resis- z
tance Between M06 (male) (1) and ground, or
between M06 (male) (2) and ground Min. 1 Mz

2. Disconnect connector D02 and connect T-adapter to male side.
Defective assembled-type
3 diode D02 a Measure it with diode range of multimeter.
(Internal short circuit) Between D02 (male) (6) (+) and (2) (-) Continuity
Continuity No
Between D02 (male) (2) (+) and (6) (-)
continuity
Open or short circuit in wiring 3. Turn starting switch to ON position.
4
harness
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground 20 to 30 V
a If no failure is found in checks on cause 4, this check is not required.
2. Disconnect fuse No. 4 of fuse box F01.
Ground fault in wiring harness 3. Disconnect connectors M06, CP01, and D02, and connect T-
5 adapter to any one of female sides.
Between ground and any one of F01 (4), M06
Min. 1 Mz
Resis- (female) (2), or D02 (female) (2)
tance Between ground and any one of CP01 (female)
(3), M06 (female) (1), or D02 (female) (6) Min. 1 Mz

2. Disconnect connectors CP01 and M06, and connect T-adapter to
Hot short circuit in wiring female side of CP01.
6 harness 3. Remove fuse No. 4.
(Contact with 24 V circuit) 4. Turn starting switch to ON position.
a Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground Max. 1 V
If cause is not found by above checks, pump controller is defective.
7 Pump controller is defective.
40-578 PC490LC-10
40 Troubleshooting
Circuit diagram related to window washer motor
PC490LC-10 40-579
40 Troubleshooting
Failure code [DY2DKB] Wiper Drive (For) Short (PC400-DY2DKB-400-A-Z0-A)
Action
Failure code Wiper motor drive normal rotation short circult
level Failure
— DY2DKB
Detail of • When normal rotation command to power wiper motor drive is ON, abnormal current flows
failure through circuit and short circuit is detected.
• Shuts off power supply to normal rotation system of wiper motor drive.
Problem on • Windshield wiper does not operate.
machine
Related be measured at pump controller connector.
information • Method of reproducing failure code: Starting switch ON + wiper switch INT or ON position
Defective wiper motor 1. Turn starting switch to OFF position.

ground fault) Resis- Between M05 (female) (3) and (1) Max. 20 z
tance Between M05 (female) (3) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to
2 Short circuit in wiring harness either harness side.
Resis- Between CP02 (female) (119) and (114), or
between M05 (male) (1) and (3) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to
3 either harness side.
Resis- Between CP02 (female) (119) and ground, or
tance
• Reference
4 Defective pump controller 3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF for troubleshooting.
Wiper
Between M05 (3) and switch: Max. 3 V
Voltage OFF
(5)
Wiper Pulse below 3 V io
switch: ON above 20 V
40-580 PC490LC-10
40 Troubleshooting
PC490LC-10 40-581
40 Troubleshooting
Failure code [DY2EKB] Wiper Drive (Rev) Short (PC400-DY2EKB-400-A-Z0-A)
Action
Failure code Wiper motor drive reverse rotation short circuit
level Failure
— DY2EKB
Detail of • When reverse rotation command to wiper motor drive is ON, abnormal current flows
failure through circuit and short circuit is detected.
• Shuts off power supply to reverse rotation system of wiper motor drive.
Problem on • Windshield wiper does not operate.
machine
Related be measured at pump controller connector.
information • Method of reproducing failure code: Starting switch ON + wiper switch INT or ON position
Defective wiper motor 1. Turn starting switch to OFF position.

ground fault) Resis- Between M05 (female) (1) and (3) Max. 20 z
tance Between M05 (female) (1) and ground Min. 1 Mz
2. Disconnect connectors CP02 and M05 and connect T-adapter to
2 Short circuit in wiring harness either harness side.
Resis- Between CP02 (female) (119) and (114), or
between M05 (male) (1) and (3) Min. 1 Mz
tance
Ground fault in wiring harness 2. Disconnect connectors CP02 and M05 and connect T-adapter to
3 either harness side.
Resis- Between CP02 (female) (114) and ground, or
tance
• Reference
4 Defective pump controller 3. Turn starting switch to ON position.
4. Turn wiper switch ON and OFF for troubleshooting.
Wiper
Between M05 (1) and switch: Max. 3 V
Voltage OFF
(5)
Wiper Pulse below 3 V io
switch: ON above 20 V
40-582 PC490LC-10
40 Troubleshooting
PC490LC-10 40-583
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode) (ALL-3840-001-A-01-A)
E-1 Engine does not start (Engine does not crank) (PC400-A21-400-A-Z0-A)
Failure • Engine does not start (engine does not crank)

• Engine starting circuit has following two start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by lock lever position
Related information • If failure symptom "Battery relay operation sound is not heard" appears when
starting switch is turned to ON position, perform troubleshooting for E-1 also.
• If machine monitor does not light up when turning starting switch ON, main electric
power supply system is supposed to be defective. Perform the troubleshooting for E-
5 (lines of fusible link F05 and fuse No. 17).
Loose terminal connection or 1. Turn starting switch to OFF position.

1 open circuit at terminal Check terminals of starting motor, alternator, battery relay, grounds T04
and T08, etc.
Between battery relay terminal R01 and
Defective contact (grounding) ground
2 between battery relay and Resis-
frame a Use machine frame as GND for Max. 1 z
tance
measurement.
a Loosened or rusted terminal T08
a Be ready with starting switch at OFF, then perform troubleshooting
Insufficient battery capacity without turning starting switch to ON position.
3
Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated
Defective engine controller
4 with failure codes [DB2QKR] and [DB2RKR]. If these codes appear,
system
perform troubleshooting for causes 1 to 3 of [DB2QKR] first.
Defective fuse No. 3 in fuse If fuse is blown, circuit probably has ground fault. (See cause 22.)
5
box F01
1. Turn starting switch to ON position (to connect ACC).
6 Defective battery relay system
a If battery relay operation sound is not heard, go to troubleshooting
on cause 19.
1. Turn starting switch to OFF position, and remove fuse No. 3 in fuse
box F01.
Defective fusible link F04 or 2. Turn starting switch to ON position (to connect ACC).
7 wiring harness Between input terminal (1A) of fuse box F01-3
Voltage 20 to 30 V
and ground
a If voltage is unusual, go to troubleshooting on cause 10.
2. Remove fuse No. 18 (30 A) of fuse box F01. (to prevent engine start
Defective starting switch, lock during troubleshooting).
lever switch, starting motor 3. Insert T-adapters into connector M17.
8 cut-off relay R06, personal 4. Turn starting switch to START position and hold (two persons
code relay R07, battery relay, required for this check).
or wiring harness Voltage Between M17 (1) and ground 20 to 30 V
a If voltage is unusual, go to cause 13.
40-584 PC490LC-10
40 Troubleshooting

If fusible link is blown, circuit may have ground fault. In this case,
perform troubleshooting for cause 6 first.
9 Defective fusible link F04 • Fuses No. 1 to 13 are connected to fusible link F04.
a This fusible link protects wide area of circuit. If no failure is found by
check on cause 6, reproduce failure and locate ground fault point by
sound and burnt smell.
1. Turn starting switch to OFF position, and turn battery disconnect
Open circuit in wiring harness switch to OFF position.
1 (To prevent short circuit during troubleshooting)
10 2. Disconnect fusible link F04 and No. 3 of fuse box F01.
contact of connector) 3. Connect T-adapters to male side of connector F04.
Between battery relay (R03) and F04 (male)
Resis- (1) Max. 1 z
tance
Between F04 (male) (2) and F01-1A Max. 1 z
Ground fault in wiring harness 2. Disconnect fusible link F04, fuse No. 3 of fuse box F01, and battery
11 1 relay R03 (M terminal).
(contact with ground circuit) 3. Connect T-adapters to male side of connector F04.
Between ground and battery relay R03
Resis- (harness side) or F04 (male) (1) Min. 1 Mz
tance
Between ground and F04 (male) (2) or F01-1A Min. 1 Mz
2. Disconnect connector H15.
3. After troubleshooting, perform troubleshooting again with starting
switch at ON and START positions.
Defective starting switch Between starting Starting switch: OFF Min. 1 Mz
12 switch terminals B and
(internal open circuit) Starting switch: ON Max. 1 z
BR
Between starting Starting switch: OFF Min. 1 Mz
Resis- switch terminals B and
tance Starting switch: ON Max. 1 z
ACC
Between starting Starting switch: OFF Min. 1 Mz
switch terminals B and Starting switch:
C Max. 1 z
START
Defective lock lever switch 1. Turn starting switch to OFF position.
13 2. Disconnect connector S14 and connect T-adapters to female side.
Resis- Between S14 (female) Lock lever: FREE Min. 1 Mz
tance (1) and (3) Lock lever: LOCK Max. 1 z
PC490LC-10 40-585
40 Troubleshooting

2. Remove starting motor cut-off relay R06 and personal code relay
R07.
Defective starting motor cut-off 200 to 600
relay R06 or personal code Between R06 (male) (1) and (2)
z
14 relay R07
Between R06 (male) (3) and (4) Max. 1 z
(internal open or short circuit) Resis- Between R06 (male) (3) and (5) Min. 1 Mz
tance Between R07 (male) (1) and (2) 200 to 600
z
Between R07 (male) (3) and (4) Max. 1 z
Between R07 (male) (3) and (5) Min. 1 Mz
Defective alternator 2. Turn starting switch to ON position.
15 Input from
(internal short circuit) Between alternator M18 terminal
Voltage alternator Max. 1 V
and ground
generation
2. Turn starting switch to START position and perform troubleshooting.
Between starting motor terminal B Power
(SB) and ground supply 20 to 30 V
Defective starting motor
16 Voltage Starting
(internal defect) Between starting motor terminal C input to
(SC) and ground 20 to 30 V
starting
motor
If power supply and starting input to starting motor are normal but
starting motor does not rotate, starting motor is defective.
2. Disconnect connector D01 and connect T-adapters to diode.
Defective diode D01 a Check by using multimeter in diode range.

17 Between D01 (male) (1) (+) and (5) (-) No continuity
(internal open or short circuit)
• Battery relay
Resis- Between terminal R02 and starting switch
Max. 1 z
tance terminal BR
• Battery relay
18 (wire breakage or defective 2. Turn starting switch to ON position.
contact of connector) a To check to where 24 V is supplied to locate open section
Between terminals R04 and R01 20 to 30 V
Voltage
Between terminal R01 and ground Max. 1 V
40-586 PC490LC-10
40 Troubleshooting

• Alternator and starting motor
2. Turn the battery disconnect switch to the OFF position.
3. Insert T-adapters into connectors S14, R07, and M17.
5. Turn starting switch to START position and perform troubleshooting.
a To check to where 24 V is supplied to locate open section
Between starting switch terminal C and ground 20 to 30 V
Between S14 (1) and ground 20 to 30 V
Between S14 (3) and ground 20 to 30 V
Voltage Between R07 (4) and ground 20 to 30 V
Between M17 (1) and ground 20 to 30 V
Between alternator terminal B and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
• If fuse or fusible link is blown, replace it with a new one.
2. Disconnect connectors S14, R06, R07, and CM01.
3. Connect T-adapters to female sides of R06, R07, CM01 and to male
Open circuit in wiring harness side of S14.
18 (wire breakage or defective 4. Remove fuse F01-3.
contact of connector) Between starting switch terminal C and R06
Between R06 (female) (5) and R07 (female) (3) Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Max. 1 z
Between R07 (female) (2) and CM01 (female)
(6) Max. 1 z
Between R07 (female) (4) and starting motor
Max. 1 z
terminal S
Between alternator terminal B and starting
Resis- motor terminal B Max. 1 z
tance Between starting motor terminal B and battery
relay R03 Max. 1 z
Between alternator terminal R (terminal M18)
and starting motor terminal R Max. 1 z
Between alternator terminal R and D01
Between F01-3 and S14 (male) (1) Max. 1 z
Between S14 (male) (3) and R06 (male) (1) Max. 1 z
Between R06 (female) (2) and ground (T05) Max. 1 z
Defective battery relay If only terminal R03 voltage is unusual among results of battery relay
19 checks on cause 18, battery relay is defective.
(Does not work)
2. Disconnect connectors S14, R06, R07, and M17.
3. Connect T-adapters to female sides of R06 and R07, and to male
side of S14.
4. Remove fuse No. 3 of fuse box F01.
Between ground and starting switch terminal C
or R06 (female) (3) Min. 1 Mz
20 Between ground and R06 (female) (5) or R07
(contact with ground circuit) Min. 1 Mz
(female) (3)
Resis- Between ground and R07 (female) (4) or M17
tance (female) (1) Min. 1 Mz
Between ground and F01-3 or S14 (male) (1) Min. 1 Mz
Between ground and S14 (male) (3) or R06
PC490LC-10 40-587
40 Troubleshooting

Voltage Between ground and M17 (2) or CM01 (16) Max. 1 V
40-588 PC490LC-10
40 Troubleshooting
Circuit diagram related to engine starting circuit
PC490LC-10 40-589
40 Troubleshooting
E-2 Manual preheater does not operate (PC400-FEM-400-A-Z0-A)
Failure Manual preheater does not operate

a This troubleshooting describes procedures to be followed when manual preheating
does not function to heat electrical intake air heater (ribbon heater) mounting
section.
• "Automatic preheater" and "Manual preheater" are provided. When either function is
operated, preheating monitor lights up. (When only preheating monitor does not light
up, troubleshoot "While preheater is operating, preheating monitor does not light
Related information up").
• If "machine monitor does not light up" or "battery relay does not make operating
sound" when turning starting switch ON, main electric power supply system is
supposed to be defective. So, troubleshoot E-5 and E-1.
• If fuse No. 17 in fuse box F01 is blown, perform troubleshooting for "Machine
monitor displays nothing".
• Before performing troubleshooting, check that no related failure code is displayed.
Loose terminal or open circuit
1 Check terminals of heater relay, battery relay, electrical intake air
at terminal
heater (ribbon heater), etc.
If the fuse is blown, the circuit probably has a ground fault or any other
2 Defective fuse FL (80 A)
fault. (See cause 8)
2. Disconnect connector CM01.
Resis- Between starting switch terminal R1 and Approx. 20
tance ground (heater relay coil resistance) z
• Secondary side
Between R17 (heater relay input at contact
Voltage 20 to 30 V
side) and ground
Open circuit or short circuit in • Primary side
3 wiring harness 1. Turn starting switch to OFF position.
2. Disconnect heater relay terminal R16.
a To prevent current from flowing through heater when starting
switch is turned to HEAT position
3. Turn starting switch to HEAT position (Connect R1).
Voltage Between heater relay terminal R15 and ground 20 to 30 V
Between R16 (wiring harness side)
Continuity Continuity
and ground
a If no failure is found by check on cause 3 at primary side, this check
is not required.
Defective diode D02 2. Disconnect connector D02 and connect T-adapters to diode.
4 tor (internal open or short a Check by using multimeter in diode range.
circuit)
Between D02 (male) (1) (+) and (5)
Continuity No continuity
(-)
Between D02 (male) (5) (+) and (1)
Continuity Continuity
(-)
40-590 PC490LC-10
40 Troubleshooting

a If no failure is found by check on cause 3 at primary side, this check
is not required.
2. Turn the battery disconnect switch to the OFF position.
5 Defective starting switch 4. Turn starting switch to OFF/HEAT position and perform
troubleshooting .
OFF Min. 1 Mz
Resis- Between starting switch terminals
tance B and R1 HEAT Max. 1 z
Defective electrical intake air 1. Turn starting switch to OFF position.

6 heater (ribbon heater) 2. Disconnect terminal E01.
Continuity Between E01 terminal and ground Continuity
Defective heater relay
If no failure is found by check on cause 3 and heater relay operation
7 (Does not work) (Terminal sound is not heard, heater relay is defective.
R16)
2. Disconnect connectors H15A, CM01, D02, terminals R15, E01, and
starting motor B terminal.
Ground fault in wiring harness Between heater relay terminal R15 (wiring
8 Min. 1 Mz
(contact with ground circuit) harness side) and ground
Resis- Between heater relay R17 (input terminal on
contact side) and ground Min. 1 Mz
tance
Between heater relay terminal E01 (wiring
harness side) and ground Min. 1 Mz
PC490LC-10 40-591
40 Troubleshooting
Circuit diagram related to preheating of engine
40-592 PC490LC-10
40 Troubleshooting
E-3 Automatic preheater does not operate (PC400-FE1-400-A-Z0-A)
Failure Automatic preheater does not operate

• Automatic preheater operates when engine coolant temperature is below -5 °C .
(Monitoring code Engine coolant temperature: 04107)
• If automatic preheating does not function, check if manual preheating functions.
Related information • Engine controller checks primary (coil) side of preheater relay (connector R18) and
generates failure codes [CA2555] and [CA2556] if it is defective.
• Engine controller troubleshoots engine coolant temperature sensor by failure codes
[CA144] and [CA145].
Defective fuse No. 6 in fuse If fuse No. 6 in fuse box 01 is broken, circuit probably has ground fault.
1 In this case, perform troubleshooting forcause 5 first.
box 01
2. Replace preheater relay (connector R18) with horn relay (connector
Defective preheater relay R18 R08), for example.
2 (internal open or short circuit) 3. Turn starting switch to ON position.
If automatic preheater operates when engine coolant temperature is
below -5 °C , original preheater relay is defective.
2. Disconnect connectors CM01, R18, and D02, and connect T-
adapters to female side of R18.
Open circuit or ground fault in a If resistance is above 1 Mz , wiring harness has open circuit. If
3 wiring harness resistance is below 1 z , wiring harness has short circuit.
a Heater relay coil resistance
Resis- Between R18 (female) (5) and ground Approx. 20
tance z
2. Disconnect connectors R18 and CM01, and connect T-adapters to
Open circuit in wiring harness female side of R18.
4 (open circuit or defective 3. Remove fuse No. 6 in fuse box F01.
contact) Between R18 (female) (3) and F01-6 Max. 1 z
Resis-
tance Between R18 (female) (5) and heater relay
Max. 1 z
terminal R15
If fuse is not blown, this check is not required.
Ground fault in wiring harness 2. Disconnect connector R18 and connect T-adapters to female side.
5
(contact with ground circuit) 3. Remove fuse No. 6 in fuse box F01.
Resis- Between R18 (female) (3) and ground
Min. 1 Mz
tance
PC490LC-10 40-593
40 Troubleshooting
40-594 PC490LC-10
40 Troubleshooting
E-4 While preheater is operating, engine preheating monitor does not

light up (PC400-FE2-400-A-Z0-A)
Failure While preheater is operating, engine preheating monitor does not light up.
• "Automatic preheating" and "Manual preheating" functions are available. When
Related information either function is operated, preheating monitor lights up.
• Check if manual preheating functions first.
2. Disconnect connectors CM01, and R18, and connect T-adapters to
1 (open circuit or defective Between starting switch terminal R1 and CM01
Max. 1 z
contact) Resis- (female) (12)
tance Between R18 (female) (5) and CM01 (female)
(12) Max. 1 z
• Reference
2. Insert T-adapters into connector CM01.
a To prevent current from flowing through heater when starting switch
is turned to HEAT position
4. Turn the starting switch to HEAT position.
Resis- Between CM01 (12) and (3)
20 to 30 V
tance
PC490LC-10 40-595
40 Troubleshooting
40-596 PC490LC-10
40 Troubleshooting
E-5 While starting switch is turned ON, machine monitor displays

nothing (PC400-FEG-400-A-Z0-A)
Failure • When starting switch is turned to ON position, machine monitor displays nothing
• When starting switch is turned to ON position, machine monitor displays KOMATSU
logo screen, password input screen (if set), breaker mode confirmation screen (if
selected), check before starting screen, working mode and travel speed
Related information confirmation screen, and standard screen in order.
• When engine is started, battery voltage may lower suddenly, depending on ambient
temperature and condition of battery.
Battery disconnect switch Turn starting switch to OFF and then make sure battery disconnect
1 inadvertently left off switch is ON.
a Be ready with starting switch at OFF, then perform troubleshooting
Insufficient battery capacity without turning starting switch to ON position.
2
Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
If the fusible link is burnt out, the circuit probably has a grounding fault.
3 Defective fusible link F05 (See Cause 9.)
If the Fuse is blown out, the circuit probably has a grounding fault. (See
4 Defective fuse F01-15 Cause 9.)
If the Fuse is blown out, the circuit probably has a grounding fault. (See
5 Defective fuse F01-17 Cause 9.)
Loose terminal or open circuit 1. Turn starting switch to OFF position.
6
at terminal Check terminals of battery relay, etc.
2. Insert T-adapters into connector CM01.
Defective wiring harness, 3. Turn the battery disconnect switch to ON position, and turn the
7 starting switch, or machine starting switch to ON position (connect ACC).
monitor Between CM01 (1) and (3) 20 to 30 V
Voltage Between CM01 (2) and (4) 20 to 30 V
3. Turn starting switch to ON position and perform troubleshooting
again.
Defective starting switch Between starting
8 Turn starting switch to
switch terminals B and OFF position. Min. 1 Mz
Resis- ACC
tance Between starting Turn starting switch to
switch terminals B and ON position. Max. 1 z
ACC
PC490LC-10 40-597
40 Troubleshooting

If no failure is found by check on cause 7, this check is not required.
2. Disconnect fusible link F05, No. 15 and 17 fuses of F01, and
connector CM01.
3. Connect T-adapters to male side of connector F05 and female side
of CM01.
Between battery (-) and ground Max. 1 z
Open circuit in wiring harness Between battery (+) and F05 (male) (1) Max. 1 z
9 Between F05 (male) (2) and F01-16F Max. 1 z
Between F01-17 and each of CM01 (female)
(1) and (2) Max. 1 z
Resis-
tance Between ground (T04) and CM01 (female) (3),
(4) Max. 1 z
Between F01-17 and starting switch terminal B Max. 1 z
Between starting switch terminal ACC and F01-
Max. 1 z
15E
Between F0-15 and CM01 (female) (10) Max. 1 z
If no failure is found by checks on causes 3 to 5 and 7, this check is not
required.
2. Disconnect fusible link F05, No. 17 of fuse F01, terminal 14D, and
connectors CM01, and CP01.
3. Connect T-adapters to male side of connector F05 and female side
Ground fault in wiring harness of CM01.
10
(contact with ground circuit) Between battery (+) or F05 (male) (1) and
ground Min. 1 Mz
Between ground and F05 (male) (2) or F01-16F Min. 1 Mz
Resis-
Between ground and F01-17 or CM01 (female)
tance Min. 1 Mz
(1), (2) or starting switch terminal B
Between ground and starting switch terminal
ACC or CM01 (female) (10) Min. 1 Mz
If no failure is found by above diagnoses, machine monitor is defective.
40-598 PC490LC-10
40 Troubleshooting
Circuit diagram related to machine monitor power supply
PC490LC-10 40-599
40 Troubleshooting
E-6 While starting switch is turned to ON position (with engine stopped),

engine oil level monitor lights up in yellow (PC400-FEJ-400-A-Z0-A)
While starting switch is turned to ON position (with engine stopped), engine oil level
Failure monitor lights up in yellow.
Related information
Defective engine oil level
1 switch system (machine Perform troubleshooting for failure code [B@BAZK].
monitor system)
If no failure is found by check on cause 1, machine monitor may be
2 Defective machine monitor defective.
40-600 PC490LC-10
40 Troubleshooting
E-7 While starting switch is turned to ON position (with engine stopped),

radiator coolant level monitor lights up in yellow (PC400-FEH-400-A-Z0-A)
While starting switch is turned to ON position (with engine stopped), radiator coolant
Failure level monitor lights up in yellow.
Related information
Low radiator coolant level Coolant level may be low. Check coolant level and add coolant if
1
(when system works properly) necessary.
Radiator sub tank coolant
2 Perform troubleshooting for failure code [B@BCZK].
level switch system
PC490LC-10 40-601
40 Troubleshooting
E-8 Engine coolant temperature monitor lights up in white while engine

is running (PC400-FES-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in white while engine is running
• Signal of engine coolant temperature sensor is input to engine controller and then
data is transmitted to machine monitor through CAN communication system.
Related information • Engine coolant temperature can be checked with monitoring function
(Code: 04107)
If monitor lights up in white, engine coolant temperature may be low
Insufficient warm-up of
(below approximately 30 °C ). Warm up engine.
1 machine
• Lighting up in white: Engine coolant temperature is low.
(when system works properly)
• Lighting up in blue: Engine coolant temperature is proper.
If no failure is found by above diagnoses, engine coolant temperature
gauge system may be defective. Carry out troubleshooting for the
following failures.
2 temperature gauge system • 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 (reading not at minimum or maximum)
40-602 PC490LC-10
40 Troubleshooting
E-9 Hydraulic oil temperature monitor lights up in white while engine is

running (PC400-FEU-400-A-Z0-A)
Failure Hydraulic oil temperature monitor lights up in white while engine is running
• Signal of hydraulic oil temperature sensor is input to pump controller and then data
is transmitted to machine monitor through CAN communication system.
Related information • Hydraulic oil temperature can be checked with monitoring function
(Code: 04401)
If monitor lights up in white, hydraulic oil temperature may be low
Insufficient warm-up of
(below approximately 20 °C ). Warm up engine.
1 machine
• Lighting up in white: Hydraulic oil temperature is low.
• Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by above diagnoses, hydraulic oil temperature
following failures.
2 temperature gauge system • 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 (reading not at minimum or maximum)
PC490LC-10 40-603
40 Troubleshooting
E-10 Charge level monitor lights up in red while engine is running (PC400-FEP-
400-A-Z0-A)
Failure Charge level monitor lights up in red while engine is running

• Power generation voltage of alternator can be checked with monitoring function.
Related information (Code: 04300)

1 Defective alternator system Perform troubleshooting for failure code [AB00KE].
40-604 PC490LC-10
40 Troubleshooting
E-11 Fuel level monitor lights up in red while engine is running (PC400-FEQ-400-A-
Z0-A)
Failure Fuel level monitor lights up in red while engine is running

• Signal voltage of fuel level sensor can be checked with monitoring function.
Low fuel level
1 Fuel level may be low. Check it and add fuel if necessary.
If no failure is found by above diagnoses, fuel gauge system may be
defective. Carry out troubleshooting for the following failures.
Defective fuel level gauge
2 system • E-16 Fuel gauge display does not move from minimum or maximum
• E-17 Display of fuel gauge differs from actual fuel level (reading not
at minimum or maximum)
PC490LC-10 40-605
40 Troubleshooting
E-12 Air cleaner clogging monitor lights up in yellow while engine is

running (PC400-FER-400-A-Z0-A)
Failure Air cleaner clogging monitor lights up in yellow while engine is running
• Air cleaner clogging switch signal can be checked with monitoring function.
Related information (Code 04501)
Clogging of air cleaner Air cleaner may be clogged. Check it, then clean or replace if
1
(when system works properly) necessary.
Defective air cleaner clogging
2 Perform troubleshooting for failure code [AA10NX].
switch system
40-606 PC490LC-10
40 Troubleshooting
E-13 Engine coolant temperature monitor lights up in red while engine is

running (PC400-FET-400-A-Z0-A)
Failure Engine coolant temperature monitor lights up in red while engine is running
• Signal voltage of engine coolant temperature sensor is input to engine controller and
then data is transmitted to machine monitor through CAN communication system.
(Code: 04107)
If monitor lights up in red, engine coolant temperature may be high
(above approximately 102 °C ). Cool down engine coolant (run engine
at low idle).
Overheating of engine coolant • Lighting up in red: Engine coolant temperature is high
1 (overheating).
• Lighting up in blue: Engine coolant temperature is proper.
Perform troubleshooting for "S-17 Coolant temperature becomes too
high (overheating)".
If no failure is found by above diagnoses, engine coolant temperature
following failures.
2 temperature gauge system • E-18 Engine coolant temperature gauge display does not move
PC490LC-10 40-607
40 Troubleshooting
E-14 Hydraulic oil temperature monitor lights up in red while engine is

running (PC400-FEV-400-A-Z0-A)
Failure • Hydraulic oil temperature monitor lights up in red while engine is running
• Signal of hydraulic oil temperature sensor is input to pump controller and then the
data is transmitted to machine monitor through CAN communication system.
(Code: 04401)
If monitor lights up in red, hydraulic oil temperature may be high (above
approximately 102 °C ). Cool down hydraulic oil (run engine at low idle
Overheating of hydraulic oil
1 or stop engine).
• Lighting up in red: Hydraulic oil temperature is high (overheating).
• Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by above diagnoses, hydraulic oil temperature
following failures.
2 temperature gauge system • 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 (reading not at minimum or maximum)
40-608 PC490LC-10
40 Troubleshooting
E-15 Engine oil pressure monitor lights up in red while engine is

running (PC400-FEW-400-A-Z0-A)
Failure Engine oil pressure monitor lights up in red while engine is running
• Signal of engine oil pressure sensor is input to engine controller and then the data is
transmitted to machine monitor through CAN communication system.
Related information • Engine oil pressure can be checked with monitoring function.
• (Code: 37200)
Low of engine oil pressure Check engine oil pressure as low engine oil pressure is detected.
1
(when system works properly) • Perform troubleshooting "S-14 (Oil pressure decreases)".
If no failure is found by checks on cause 1, engine oil pressure sensor
Defective engine oil pressure
2 system may be defective. Perform troubleshooting for failure codes
system
[CA135] and [CA141].
If causes 1 - 2 are not cause for trouble, machine monitor may be
PC490LC-10 40-609
40 Troubleshooting
E-16 Fuel gauge display does not move from minimum or maximum (PC400-
FGE-400-A-Z0-A)
1) While fuel is added, fuel level gauge indicator does not rise above red range (E).
Failure 2) While fuel level is low, fuel level gauge indicator does not lower below green range
top (F).
Defective fuel level sensor 2. Disconnect connector P21 and connect T-adapters to male side.
1 tor (internal open or short Approx. 12
Fuel level: FULL
circuit) Resis- Between P21 (male) z
tance (1) and ground 85 to 110
Fuel level: EMPTY
z
2. Disconnect connector CM01 and connect T-adapters to female
Open circuit or short circuit in side.
2 wiring harness Approx. 12
Between CM01 Fuel level: FULL
Resis- (female) (15) and z
tance ground 85 to 110
Fuel level: EMPTY
z
3 (wire breakage or defective 2. Disconnect connectors CM01 and P21, and connect T-adapters to
Resis- Between CM01 (female) (15) and P21 (female)
(1) Max. 1 z
tance
Ground fault in wiring harness 2. Disconnect connectors CM01 and P21, and connect T-adapters to
Resis- Between ground and CM01 (female) (15) or
tance
Hot short circuit in wiring 3. Insert T-adapters into connector CM01 or connect T-adapters to
5 harness female side of connector P21.
circuit) 4. Turn starting switch to ON position.
Between ground and CM01 (15) or P21 Approx.
Voltage
(female) (1) 3.3 V
Circuit diagram related to fuel level sensor
40-610 PC490LC-10
40 Troubleshooting
E-17 Display of fuel gauge differs from actual fuel level (PC400-FGF-400-A-Z0-A)
1) Indication of fuel level gauge is different from actual fuel level.

Failure
2) Indication of fuel level gauge is different from display of fuel level monitor.
1 Defective fuel level sensor See previous page.
a Turn starting switch to ON position or start engine and perform
troubleshooting.
Fuel level 511 l Fuel gauge level 6
Color of Fuel level 295 l Fuel gauge level 4 Blue
monitor (a) Fuel level 148 l Fuel gauge level 3
Fuel level 76 l Fuel gauge level 1 Red
Fuel level gauge and fuel level monitor
PC490LC-10 40-611
40 Troubleshooting
E-18 Engine coolant temperature gauge display does not move from
minimum or maximum (PC400-FGG-400-A-Z0-A)
1) While engine coolant temperature is rising properly, temperature gauge indicator
does not rise above white range (C).
Failure
2) While engine coolant temperature remains in normal range, temperature gauge
indicator rises to red range (H).
(Code: 04107)
Defective engine coolant Engine coolant temperature sensor system may be defective. Perform
1 temperature sensor system troubleshooting for failure codes [CA144] and [CA145].
40-612 PC490LC-10
40 Troubleshooting
E-19 Display of engine coolant temperature gauge differs from actual

coolant temperature (PC400-FGH-400-A-Z0-A)
1) Indication of the engine coolant temperature gauge is different from actual coolant
temperature.
Failure
2) Display of engine coolant temperature gauge is different from display of engine
coolant temperature monitor.
(Code: 04107)
Defective engine coolant Engine coolant temperature sensor system may be defective. Perform
1 temperature sensor system troubleshooting for failure codes [CA144] and [CA145].
troubleshooting.
Engine coolant
Coolant temperature
temperature gauge
105 °C
level 6
Red
Engine coolant
Coolant temperature
temperature gauge
102 °C
level 5
Engine coolant
Coolant temperature
2 Defective machine monitor temperature gauge
Color of 100 °C
level 4
monitor (a) Engine coolant
Coolant temperature
temperature gauge Blue
85 °C
level 3
Engine coolant
Coolant temperature
temperature gauge
60 °C
level 2
Engine coolant
Coolant temperature
temperature gauge White
30 °C
level 1
Engine coolant temperature gauge and coolant temperature monitor
PC490LC-10 40-613
40 Troubleshooting
E-20 Hydraulic oil temperature gauge display does not move from
minimum or maximum (PC400-FGJ-400-A-Z0-A)
1) While hydraulic oil temperature is rising properly, temperature gauge does not rise
from white range (C).
Failure
2) While hydraulic oil temperature is stabilized properly, temperature gauge rises to red
range (H).
(Code: 04401)
Approx. 90
10 °C
kz
Defective hydraulic oil Approx. 35
Between P22 (male) (1) and (2) 30 °C
1 temperature sensor kz
(internal open or short circuit) Resis- a Temperature characteristics of Approx.
tance oil temperature sensor 80 °C
6.5 kz
Approx.
100 °C
3.5 kz
Between CP01 (female) (28) and (46)
Open circuit or short circuit in
2 3.5 to 90
wiring harness Resis- a Resistance accords with value on kz
tance temperature characteristics table in cause
1.
contact of connector) Between CP01 (female) (28) and P22 (female)
Max. 1 z
Resis- (2)
(1) Max. 1 z

4 2. Disconnect connectors CP01 and P22, and connect T-adapters to
tance
Hot short circuit in wiring 3. Insert T-adapter between male and female sides of connector CP01
5 harness or connect T-adapter to female side of connector P22.
Between ground and CP01 (28) or P22 Approx. 5
Voltage
(female) (2) V
If no failure is found by above diagnoses, pump controller is defective.
40-614 PC490LC-10
40 Troubleshooting
PC490LC-10 40-615
40 Troubleshooting
E-21 Display of hydraulic oil temperature gauge differs from actual oil
temperature (PC400-FGK-400-A-Z0-A)
1) Indication of hydraulic oil temperature gauge is different from actual hydraulic oil
temperature.
Failure
2) Indication of hydraulic oil temperature gauge is different from display of hydraulic oil
temperature monitor.
(Code: 04401)
1 See previous page.
temperature sensor
troubleshooting.
Hydraulic oil Hydraulic oil
temperature 105 °C temperature gauge
level 6
Red
level 5
2 Defective machine monitor temperature 100 °C temperature gauge
Color of level 4
monitor (a) Hydraulic oil
Hydraulic oil
temperature 85 °C temperature gauge Blue
level 3
level 2
temperature 20 °C temperature gauge White
level 1
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
40-616 PC490LC-10
40 Troubleshooting
E-22 Machine monitor does not display partially (PC400-FFC-400-A-Z0-A)
Failure • Machine monitor does not display some items

• LCD panel may have black pixels (that do not light up) or bright pixels (that stay on).
Related information If number of bright and black pixels do not exceed ten, it does not indicate failure or
defect of LCD panel.
a Turn starting switch to ON position and perform troubleshooting.
Defective machine monitor When following switches are operated, if whole LCD panel is lighted up
1
(LCD panel) (whole surface becomes white), LCD panel has no failure.
• Operation of switches: [4] and [F2] (Press simultaneously)
2 defective.
(body)
PC490LC-10 40-617
40 Troubleshooting
E-23 Function switch does not operate (PC400-HBC-400-A-Z0-A)
Failure • Function switch does not work

• Signal of function switch can be checked with monitoring function.
Related information (Code: 04503 Monitor Function Switches)
Machine monitor may be defective. (Since this is an internal defect,
1 Defective machine monitor troubleshooting cannot be performed.)
40-618 PC490LC-10
40 Troubleshooting
E-24 Automatic warm-up system does not work (in cold weather) (PC400-FEN-
400-A-Z0-A)
Failure • Automatic warm-up system does not operate (in cold weather).
• Automatic warm-up function increases engine speed to 1,250 rpm when engine
coolant temperature is below 30 °C .
• With starting switch at ON position or after engine is started, if fuel control dial is kept
at 70% throttle position or higher for 3 seconds, automatic warm-up operation is
Related information
canceled.
• If engine coolant temperature is below 10 °C , turbocharger protection function
works to keep engine speed below 1,000 rpm for up to 20 seconds after engine is
started.
troubleshooting.
a If engine coolant temperature does not match with coolant
temperature gauge level, perform the following troubleshooting
procedures.
• E-18 Engine coolant temperature gauge display does not move
Defective engine coolant Coolant temperature
1 temperature signal system 6 (a: Red)
105 °C
Coolant temperature 5 (a: Red)
Monitoring 102 °C
Coolant code Coolant temperature 4 (a: Blue)
tempera- 04107 100 °C
ture gange Coolant Coolant temperature 3 (a: Blue)
level Tempera- 85 °C
ture Coolant temperature 2 (a: Blue)
60 °C
Coolant temperature 1 (a: White)
30 °C
If no failure is found by checks on cause 1, engine controller is
Engine coolant temperature gauge and engine coolant temperature monitor
PC490LC-10 40-619
40 Troubleshooting
E-25 When auto-decelerator switch is operated, auto-decelerator monitor

does not light up or does not go off (PC400-FFD-400-A-Z0-A)
When auto-deceleration switch is operated, auto-deceleration monitor does not light up
Failure or does not go off.
• Signal of auto-decelerator switch can be checked with monitoring function.
Related information (Code: 04504 Monitor 1st, 2nd row switches)
40-620 PC490LC-10
40 Troubleshooting
E-26 Auto-decelerator is not operated or canceled with lever (PC400-FPM-400-A-Z0-A)
Auto-decelerator is not operated or canceled interlocking with L.H. and R.H. control
Failure
lever.
• Since auto-deceleration set speed is 1,000 rpm, auto-deceleration is not operated or
canceled if engine speed higher than this speed is set by fuel control dial.
Related information • If one-touch power maximizing function does not operate normally, carry out
troubleshooting for "E-38 One-touch power maximizing function does not operate
normally or not displayed on monitor".
a Start engine and perform troubleshooting (with monitoring function).
a If monitoring data show any abnormality, perform troubleshooting
for "E-47 to 55 Monitoring function does not display *** normally".
When lever is
operated: ON
Swing
When lever is in
neutral: OFF
When lever is
operated: ON
Travel
When lever is in
neutral: OFF
When lever is
operated: ON
Monitoring Boom LOWER
code When lever is in
neutral: OFF
01900
When lever is
Pressure operated: ON
Switch 1 Boom RAISE
When lever is in
Defective PPC pressure signal neutral: OFF
1
When lever is
Display of operated: ON
monitoring Arm IN
condition When lever is in
neutral: OFF
When lever is
operated: ON
Arm OUT
When lever is in
neutral: OFF
When lever is
operated: ON
Bucket CURL
When lever is in
Monitoring neutral: OFF
code When lever is
operated: ON
01901 Bucket DUMP
When lever is in
Pressure neutral: OFF
Switch 2 When lever is
operated: ON
Service
When lever is in
neutral: OFF
If no failure is found by above diagnoses, machine monitor may be
If no failure is found by above diagnoses, pump controller may be
3 Defective pump controller defective.
If no failure is found by above diagnoses, engine controller may be
PC490LC-10 40-621
40 Troubleshooting
E-27 When working mode switch is operated, working mode selection

screen is not displayed (PC400-FFE-400-A-Z0-A)
When working mode switch is operated, working mode selection screen is not
Failure displayed.
• Signal of working mode switch can be checked with monitoring function.
40-622 PC490LC-10
40 Troubleshooting
E-28 When working mode is changed, setting of engine and hydraulic

pump is not changed (PC400-FP9-400-A-Z0-A)
Failure When working mode is changed, setting of engine and hydraulic pump is not changed.
Related information

Pump controller may be defective. (Since this is an internal defect,

PC490LC-10 40-623
40 Troubleshooting
E-29 When travel speed switch is operated, travel speed monitor does
not change (PC400-FFF-400-A-Z0-A)
Failure When travel speed switch is operated, travel speed monitor does not change.
• Signal of travel speed selector switch can be checked with monitoring function.
40-624 PC490LC-10
40 Troubleshooting
E-30 When travel speed selection is changed, actual travel speed does
not change (PC400-BQ3-400-A-Z0-A)
Failure When selection of travel speed is changed, actual travel speed does not change.
• When failure due to cause 1 occurs, actual travel speed does not decrease when
travel speed setting is changed to "Lo".
Related information • As T-adapter for pump controller connector is "socket-type box", operating voltage
cannot be measured at pump controller connector.
harness 2. Disconnect connector V04 and connect T-adapters to female side.
circuit)
Voltage Between V04 (female) (2) and ground Max. 4.5 V
If no failure is found by checks for causes 1 and 2, pump controller may
3 Defective pump controller be defective.
Circuit diagram related to travel speed solenoid
PC490LC-10 40-625
40 Troubleshooting
E-31 Alarm buzzer cannot be canceled (PC400-KB3-400-A-Z0-A)
Failure • Alarm buzzer cannot be canceled

• Signal of alarm buzzer cancel switch can be checked with monitoring function.
40-626 PC490LC-10
40 Troubleshooting
E-32 When starting switch is turned OFF, service meter is not

displayed (PC400-FFL-400-A-Z0-A)
Failure • When starting switch is at OFF position, service meter is not displayed.
• While starting switch is at OFF position, if following switches are operated, service
Related information meter is displayed at top center of screen.
Operation of switches: [4] and [1] (Press simultaneously)
If machine monitor displays nothing when the starting switch is turned
ON, the backup power supply system may be defective. Carry out
Defective backup power troubleshooting for the following failures.
1 supply system
• E-5 While starting switch is turned ON, machine monitor displays
nothing
PC490LC-10 40-627
40 Troubleshooting
E-33 Machine monitor cannot be set in service mode (PC400-HB1-400-A-Z0-A)
Failure • Machine monitor cannot be set in service mode

• Following switch operation sets machine monitor in service mode.
Related information Switch operation: [4] and [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in
order)
40-628 PC490LC-10
40 Troubleshooting
E-34 All of work equipments, swing, and travel mechanism do not

move (PC400-FT5-400-A-Z0-A)
Failure Any of work equipment, swing, and travel does not work.
Related information
1 Defective fuse No. 3 of F01 If fuse is blown, circuit may have ground fault. (See cause 7.)
Defective PPC lock switch 3. Operate lock lever and perform troubleshooting.
2
Resis- Between S14 (male) (1) and (2) FREE Max. 1 z
tance LOCK Min. 1 Mz
Defective PPC lock solenoid 1. Turn starting switch to OFF position.
2. Disconnect connector V01 and connect T-adapters to male side.
3 (open or short circuit in
internal wiring, or ground fault) Resis- Between V01 (male) (1) and (2) 20 to 60 z
2. Disconnect connector D01 and connect T-adapter to male side.
Defective diode array D01 a Check by using multimeter in diode range.
4
(internal ground fault) Continuity Between D01 (male) (8) (+) and (4) (-) Continuity
No
Continuity Between D01 (male) (4) (+) and (8) (-)
continuity
2. Remove fuse No. 3.
Open or short circuit in wiring 3. Set PPC lock switch to FREE position.
5
harness
Resis- Between fuse F01-3 and ground
20 to 60 z
tance a Resistance of PPC lock solenoid
a If cause 5 is not cause for trouble, this check is not required.
6 Open circuit in wiring harness 3. Disconnect connectors S14 and V01 and connect T-adapters to
each female side.
Between V01 (female) (2) and ground Max. 1 z
Resis- Between V01 (female) (1) and S14 (male) (2)
Max. 1 z
tance
Between fuse F01-3 and S14 (male) (1) Max. 1 z
a If no failure is found by check for cause 1, this check is not required.
Ground fault in wiring harness 3. Disconnect connectors S14, D01, and V01 and then connect T-
7
(contact with ground circuit) adapter to male side of S14 or female side of V01.
Between ground and V01 (female) (1) or S14
Resis- (male) (2) Min. 1 Mz
tance
Between S14 (male) (1) and ground Min. 1 Mz
PC490LC-10 40-629
40 Troubleshooting
Circuit diagram related to PPC lock solenoid
40-630 PC490LC-10
40 Troubleshooting
E-35 All of work equipment, swing, and travel mechanism do not

lock (PC400-FT7-400-A-Z0-A)
Failure All of work equipment, swing, and travel mechanism do not lock
Related information
Defective lock lever switch 2. Disconnect connector S14 and connect T-adapters to female side.
1
(internal short circuit) Resis- Between S14 (male) Lock lever: LOCK Min. 1 Mz
tance (1) and (2) Lock lever: FREE Max. 1 z
Hot short circuit in wiring 2. Disconnect connector V01 and connect T-adapter to female side.
circuit) 4. Turn lock lever to LOCK position.
Voltage Between V01 (female) (2) and (1) Max. 1 V
Circuit diagram related to PPC lock solenoid
PC490LC-10 40-631
40 Troubleshooting
E-36 When swing brake cancel switch is set to CANCEL position,

machine cannot swing (PC400-FGM-400-A-Z0-A)
Failure When swing brake cancel switch is set to CANCEL position, machine cannot swing.
• Signal of swing lock switch can be checked with monitoring function.
Related information (Pump controller system code: 02200 Switch input 1)
Defective No. 1 in fuse box If fuse is blown out, circuit probably has ground fault. In this case,
1 perform troubleshooting for cause 5 first.
F01

Defective swing brake cancel swing brake cancel
2 switch (internal short circuit) Min. 1 Mz
Resis- Between S25 (male) switch: Normal
tance (13) and (14) swing brake cancel
Max. 1 z
switch: FREE
2. Remove diode array and connect T-adapter to male side.
3
(internal short circuit) Continuity Between D01 (male) (7) (+) and (3) (-) Continuity
No
continuity
2. Remove diode array and connect T-adapter to male side.
4
No
continuity
2. Disconnect connector V05 and connect T-adapter to female side.
5 Defective harness a Swing lock switch OFF position.
swing brake cancel
Between V05 (female) switch: FREE 20 to 30 V
Voltage
(1) and (2) swing brake cancel
Max. 1 V
switch: Normal
Open circuit in wiring harness 2. Disconnect connectors V05 and S25, and connect T-adapters to
each female side.
contact of connector) a Swing lock switch OFF position.
Between V05 (female) (1) and S25 (female)
Resis- (14) Max. 1 z
tance
Ground fault in wiring harness 1. Turn starting switch to OFF position.
7 2. Disconnect connectors S25 and V05, and connect T-adapter to
(contact with ground circuit) female side of V05.
Resis- Between V05 (female) (1) and ground
Min. 1 Mz
tance
40-632 PC490LC-10
40 Troubleshooting
Circuit diagram related to swing holding brake
PC490LC-10 40-633
40 Troubleshooting
E-37 Swing brake does not operate while swing parking brake cancel
switch is set to NORMAL position (PC400-FGN-400-A-Z0-A)
When swing brake cancel switch is set to Normal position, swing parking brake does
Failure not operate.
Related information
Defective swing brake cancel swing brake cancel
1 switch (internal short circuit) Min. 1 Mz
Resis- Between S25 (male) switch: Normal
tance (13) and (14) swing brake cancel
Max. 1 z
switch: FREE
2. Disconnect connector V05 and connect T-adapter to female side.
Hot short circuit in wiring 3. Turn starting switch to ON position.
2 harness 4. Set swing lock switch to ON position.
circuit)
a Measure voltage again under swing lock switch OFF position.
Voltage Between V05 (female) (1) and ground Max. 1 V
40-634 PC490LC-10
40 Troubleshooting
PC490LC-10 40-635
40 Troubleshooting
E-38 One-touch power maximizing function does not operate properly, or

indicator not displayed on monitor (PC400-FGL-400-A-Z0-A)
1) When L.H. knob switch is pressed, one-touch power max. monitor is not displayed.
Failure
2) When L.H. knob switch is pressed, work equipment power is not increased.
• One-touch power max. function does not operate when selected working mode is
not power mode (P) or economy mode (E).
Related information • Signal of L.H. knob switch can be checked with monitoring function.
(Code: 02200 Switch input 1)
When L.H. knob switch is pressed, if work equipment power is
increased but one-touch power max. monitor is not displayed on
1 Defective machine monitor machine monitor, machine monitor may be defective. (Since this is an
internal defect, troubleshooting cannot be performed.)
2 Defective fuse No. 8 If fuse is blown, circuit probably has grounding fault. (See Cause 6.)
2. Disconnect connector S11, and connect T-adapters to male side.
Defective left knob switch L.H. knob switch:
3 Min. 1 Mz
Resis- Between S11 (male) Released
tance (1) and (2) L.H. knob switch:
Max. 1 z
Pressed
solenoid 2. Disconnect connector V08, and connect T-adapter to male side.
4
(internal short circuit or ground Resis- Between V08 (male) (1) and (2) 20 to 60 z
fault) tance Between V08 (female) (1) and ground Min. 1 Mz
Open circuit or ground fault in a Ignore displayed failure code.
5 wiring harness
Between CP01 L.H. knob switch:
Max. 1 V
Voltage (female) (42) and Released
ground L.H. knob switch:
20 to 30 V
Pressed
Open circuit in wiring harness 2. Remove fuse F01-8.
6 (wire breakage or defective 3. Disconnect connectors CP01 and S11, and connect T-adapters to
Between F01-8 and S11 (female) (1) Max. 1 z
Resis-
Between S11 (female) (2) and CP01 (female)
tance Max. 1 z
(41)
2. Remove fuse F01-8.
Ground fault in wiring harness 3. Disconnect connectors CP01 and S11, and connect T-adapter to
7
(contact with ground circuit) female side of S11.
Between ground and F01-8 or S11 (female) (1) Min. 1 Mz
Resis-
Between ground and S11 (female) (2) or CP01
tance Min. 1 Mz
(female) (42)
40-636 PC490LC-10
40 Troubleshooting
Circuit diagram related to one-touch power max. switch
PC490LC-10 40-637
40 Troubleshooting
E-39 One-touch power maximizing function is not cancelled (PC400-FPB-400-A-Z0-A)
Failure When L.H. knob switch is released, work equipment power is not returned to normal.
• Signal of L.H. knob switch can be checked with monitoring function.
Related information (Code: 02200 Switch input 1)
harness 2. Disconnect connector V08 and connect T-adapter to female side.
circuit)
Voltage Between V08 (female) (1) and (2) Max. 4.5 V
If no failure is found by checks on cause 1, pump controller is defective.
40-638 PC490LC-10
40 Troubleshooting
E-40 Alarm does not sound during travel (PC400-KA4-400-A-Z0-A)
Failure Alarm does not sound during travel.

Related • (2 persons are required for this check.)
information
a Be ready with starting switch OFF, then run engine to perform
troubleshooting.
a If monitoring data is not displayed normally, perform troubleshooting for "E-
54 Travel is not displayed correctly with monitoring function".
Monitoring code Item Correct display
Defective travel signal When one lever is
1
01901 operated: ON
Travel steering
Pressure sensor 2 When lever is in neutral:
OFF
When both levers
01900 operated: ON
Travel
Pressure sensor 1 When lever is in neutral:
OFF
2. Disconnect connector M14, and connect T-adapter to female side.
3. Start engine and operate travel lever.
k Never enter under the machine when operating travel lever.
Defective travel alarm
2
(Internal defect) a When travel lever is set to the travel position, voltage is applied usually to
the travel alarm connector before machine starts moving.
a If voltage is normal but travel alarm does not sound, travel alarm is
defective.
Voltage Between M14 (female) (1) and (2) 20 to 30 V
harness 2. Disconnect connectors M14 and CP02, and connect T-adapters to each
defective contact of Between CP02 (female) (107) and M14 (female) (1) Max. 1 z
Between M14 (female) (2) and ground Max. 1 z
harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either
4 female side.
Between CP02 (female) (107) and ground, or M14
circuit) Resistance (female) (1) and ground Min. 1 Mz
PC490LC-10 40-639
40 Troubleshooting
40-640 PC490LC-10
40 Troubleshooting
E-41 Alarm does not stop sounding while machine is stopped (PC400-KB5-400-A-
Z0-A)
Failure Alarm does not stop sounding while machine is stopped.

Related information
harness 2. Disconnect connector M14 and connect T-adapters to female side.
circuit)
Voltage Between M14 (female) (1) and ground Max. 1 V
PC490LC-10 40-641
40 Troubleshooting
E-42 Horn does not sound (PC400-KA2-400-A-Z0-A)
Failure The horn does not sound.

Related information
If fuse F01(5) is broken, circuit probably has ground fault. In this case,
1 Defective fuse F01-5 perform troubleshooting for cause 7 first.
Defective horn relay 2. Replace horn relay (connector: R08) with another relay.
2 tor (internal open or short 3. Turn starting switch to ON position.
circuit) 4. Press right knob switch.
If horn sounds, original horn relay is defective.
Defective horn switch 1. Turn starting switch to OFF position.

circuit) Resis- Between S10 (male) Switch: OFF Min. 1 Mz
tance (1) and (2) Switch: ON Max. 1 z
Defective high-tone horn
2. Disconnect connectors M07 and M08, and connect T-adapters to
(M07) or low-tone horn (M08)
4 each male side.
(open or short circuit in
internal wiring) Continuity Between M07 (male) (1) and (2) Continuity
Continuity Between M08 (male) (1) and (2) Continuity
2.Disconnect connector R08 and connect T-adapters to female side.
3.Turn starting switch to ON position.
5 Defective harness 4.Press right knob switch.
Between R08 (female) (1) and (2) 20 to 30 V
Voltage
Between R08 (female) (3) and (2) 20 to 30 V
2. Disconnect connector R08 and connect T-adapters to female side.
Continuity Between R08 (female) (1) and ground Continuity
Continuity Between R08 (female) (5) and ground Continuity
a If no failure is found by above checks, this check is not required.
6 (open circuit or defective 2. Remove fuse F01-5.
contact) 3. Disconnect connectors R08 and S10, and connect T-adapters to
each female side.
Between F01-5 and S10 (female) (1) Max. 1 z
Resis- Between S10 (female) (2) and R08 (female) (1) Max. 1 z
tance Between R08 (female) (2) and ground Max. 1 z
Between R08 (female) (3) and F01(5) Max. 1 z
2. Remove fuse F01-5.
Ground fault in wiring harness 3. Disconnect connectors R08, M07, and M08, and connect T-
7
(contact with ground circuit) adapters to female side of R08.
Between R08 (female) (1) and ground Min. 1 Mz
Resis- Between R08 (female) (3) and ground
Min. 1 Mz
tance
Between R08 (female) (5) and ground Min. 1 Mz
Defective horn
8 If no failure is found by above checks, horn may be defective.
(internal defect)
40-642 PC490LC-10
40 Troubleshooting
Circuit diagram related to horn
PC490LC-10 40-643
40 Troubleshooting
E-43 Horn does not stop sounding (PC400-KB2-400-A-Z0-A)
Failure Horn does not stop sounding

Related information
Defective horn relay (R08) 1. Turn starting switch to OFF position.
2. Remove horn relay (connector R08).
1 tor (internal open or short 3. Turn starting switch to ON position.
circuit)
If horn stops sounding, original horn relay is defective.
Hot short circuit in wiring 2. Disconnect connectors M07 and M08, and connect T-adapters to
circuit)
Between M07 (female) (2) and (1) Max. 1 V
Voltage
Between M08 (female) (2) and (1) Max. 1 V
Circuit diagram related to horn
40-644 PC490LC-10
40 Troubleshooting
E-44 When wiper switch is operated, wiper monitor does not light up or
go off (PC400-FG4-400-A-Z0-A)
Failure When wiper switch is operated, wiper monitor does not light up or go off.
• Signal of wiper switch can be checked with monitoring function.
PC490LC-10 40-645
40 Troubleshooting
E-45 When wiper switch is operated, windshield wiper does not

operate (PC400-FG0-400-A-Z0-A)
Failure When wiper switch is operated, windshield wiper does not operate.
• Signal of window rear limit switch can be checked with monitoring function.
(Code: 02204 Switch input 5)
Related information • Wiper motor is checked and its failure is expressed in failure code [DY20KA],
[DY20MA], [DY2DKB], or [DY2EKB].
2. Disconnect connector W03.
Defective window rear limit Front window: when
1 switch (Internal short circuit) Min. 1 Mz
Resis- Between W03 (male) set in position
tance (1) and (2) Front window: when
pulled up Max. 1 z

Defective wiper motor 2. Disconnect connector M05 and connect T-adapters to female side.
2
Continuity Between M05 (female) (1) and (3) Continuity
a Wiper motor system

See troubleshooting for failure codes [DY20KA], [DY20MA],
[DY2DKB], and [DY2EKB].
a Rear limit switch system
contact of connector) 1. Turn starting switch to OFF position.
3. Pull up front window.
Resis- Between CP01 (female) (76) and ground
Max. 1 z
tance
Ground fault in wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
4 3. Set front window in position.
Resis- Between CP01 (female) (76) and ground
Min. 1 Mz
tance
40-646 PC490LC-10
40 Troubleshooting
Circuit diagram related to wiper motor
PC490LC-10 40-647
40 Troubleshooting
E-46 When window washer switch is operated, window washer does not
operate (PC400-FH0-400-A-Z0-A)
Failure When window washer switch is operated, window washer does not operate.
• Signal of window washer switch can be checked with monitoring function.
(Code: 04504 Monitor 1st, 2nd row switches)
Related information • Window washer is checked and its failure is expressed in failure codes [DY2CKA] or
[DY2CKB].
40-648 PC490LC-10
40 Troubleshooting
E-47 Boom LOWER indicator is not displayed properly with monitoring

function (PC400-FFR-400-A-Z0-A)
Failure "Boom LOWER" operation signal is not displayed properly on monitoring screen.
Related information • Monitoring code: 01900 Pressure Sensor 1
Defective boom LOWER PPC
oil pressure sensor system
1 Perform troubleshooting for failure code [DHS9MA].
(internal open circuit or short
circuit)
PC490LC-10 40-649
40 Troubleshooting
E-48 Arm OUT indicator is not displayed properly with monitoring

function (PC400-FFS-400-A-Z0-A)
Failure "Arm OUT" operation signal is not displayed properly on monitoring screen.
Defective arm OUT PPC oil
1 Perform troubleshooting for failure code [DHSCMA].
(internal open circuit or short
circuit)
40-650 PC490LC-10
40 Troubleshooting
E-49 Arm IN indicator is not displayed properly with monitoring

function (PC400-FFN-400-A-Z0-A)
Failure "Arm IN" operation signal is not displayed properly on monitoring sceen.
Defective arm IN PPC
1 pressure sensor system Perform troubleshooting for failure code [DHS3MA].
PC490LC-10 40-651
40 Troubleshooting
E-50 Boom RAISE indicator is not displayed properly with monitoring

function (PC400-FFM-400-A-Z0-A)
Failure "Boom RAISE" operation signal is not displayed properly on monitoring screen.
Defective boom RAISE PPC
1 pressure sensor system Perform troubleshooting for failure code [DHS8MA].
40-652 PC490LC-10
40 Troubleshooting
E-51 Bucket CURL indicator is not displayed properly with monitoring

function (PC400-FFP-400-A-Z0-A)
Failure "Bucket CURL" operation signal is not displayed properly on monitoring screen.
Defective bucket CURL PPC
1 Perform troubleshooting for failure code [DHS4MA].
PC490LC-10 40-653
40 Troubleshooting
E-52 Bucket DUMP indicator is not displayed properly with monitoring

function (PC400-FFQ-400-A-Z0-A)
Failure "Bucket DUMP" operation signal is not displayed properly on monitoring screen.
Defective bucket DUMP PPC
1 Perform troubleshooting for failure code [DHSDMA].
40-654 PC490LC-10
40 Troubleshooting
E-53 Swing indicator is not displayed properly with monitoring

function (PC400-FFT-400-A-Z0-A)
Failure "Swing" operation signal is not displayed properly on monitoring screen.
Defective swing PPC pressure
sensor system
1 Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA].
circuit)
PC490LC-10 40-655
40 Troubleshooting
E-54 Travel indicator is not displayed properly with monitoring

function (PC400-FFU-400-A-Z0-A)
Failure "Travel" operation signal is not displayed properly on monitoring screen.
Defective travel PPC oil
pressure sensor system Perform troubleshooting for failure codes [DHSFMA], [DHSGMA],
1 [DHSHMA] and [DHSJMA].
circuit)
40-656 PC490LC-10
40 Troubleshooting
E-55 Service indicator is not displayed properly with monitoring

function (PC400-FFW-400-A-Z0-A)
Failure "Attachment" operation signal is not displayed properly on monitoring screen.
• Monitoring code: 01901 Pressure switch 2
• For safety, use "short connector" 799-601-7230 for 2-pin X connector in
Related information troubleshooting for cause 1 and 2.
k Do not check pressure switch connector while engine is running.
A. If "Service" operation signal displayed on monitoring screen is not
"ON" when engine is started and attachment control pedal is
depressed at front end
2. Disconnect connector P14 and connect "short connector" to female
side.
a After finishing troubleshooting, return connectors as they were.
Defective PPC pressure • If "Service" operation signal displayed on monitoring screen
1 switch (P14) for front end of changes to "ON", front service PPC pressure switch (P14) is
attachment control pedal defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON"
when starting switch is turned to ON position
• If "Service" operation signal displayed on monitoring screen
changes to "OFF", front service PPC pressure switch (P14) is
defective (Note 2).
A. If "Service" operation signal displayed on monitoring screen is not
"ON" when engine is started and attachment control pedal is
depressed at rear end
2. Disconnect connector P15 and connect "short connector" to female
side.
a After finishing troubleshooting, return connectors as they were.
Defective PPC pressure • If "Service" operation signal displayed on monitoring screen
2 switch (P15) for rear end of changes to "ON", rear service PPC pressure switch (P15) is
attachment control pedal defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON"
when starting switch is turned to ON position
• If "Service" operation signal displayed on monitoring screen
changes to "OFF", rear service PPC pressure switch (P15) is
defective (Note 2).
2.Insert T-adapters into P13.
3.Start engine
4.Operate attachment control pedal, and perform troubleshooting.
Defective wiring harness or
3 pump controller Between P13 (1) and attachment control Approx. 7
(2) pedal: Neutral V
Voltage attachment control
Between P13 (1) and
pedal: front end or rear Max. 1 V
(2)
end depressed
PC490LC-10 40-657
40 Troubleshooting

2. Disconnect connectors CP01, P14, and P15, and connect T-
adapters to each female side.
(1) Max. 1 z
contact of connector) Resis- Between CP01 (female) (35) and P15 (female) Max. 1 z
tance (1)
Ground fault in wiring harness 2. Disconnect connectors CP01, P14, and P15, and connect T-
5 adapter to either female side.
Resis- Between ground and CP01 (female) (35), P14
(female) (1), or P15 (female ) (1) Min. 1 Mz
tance
2. Disconnect connectors P14 and P15, and connect T-adapters to
either female side.
Between P14 (female) (1) and ground, or Approx. 7
Voltage
between P15 (female) (1) and ground V
Note 1: If voltage between CP01 (35) and ground is below 1 V but "Service" on monitoring screen is "OFF",
pump controller is defective.
Note 2: If voltage between CP01 (35) and ground is approx. 7 V but "Service" on monitoring screen is "ON",
pump controller is defective.
Circuit diagram related to service pressure switch
40-658 PC490LC-10
40 Troubleshooting
E-56 Attachment hydraulic circuit cannot be changed (PC400-HBD-400-A-Z0-A)
• Attachment circuit can not be changed

1) When working mode P or E is selected, crusher circuit (two-way circuit) is not
Failure selected.
2) When working mode B is selected, breaker circuit (one-way circuit) is not selected.
• Failures (open circuit/short circuit) in attachment oil return selector solenoid are
Related information indicated by failure codes [DWA2KA] and [DWA2KB].
Defective attachment oil return 2. Disconnect connector SSTC and connect T-adapters to male side.
1 selector solenoid (internal
short circuit) Resis- Between V07 (male) (1) and (2) 20 to 60 z
harness 2. Disconnect connector V06 and connect T-adapters to female side.
circuit)
Voltage Between V07 (female) (1) and ground Max. 4.5 V
Circuit diagram related to attachment oil return selector solenoid
PC490LC-10 40-659
40 Troubleshooting
E-57 KOMTRAX system does not operate properly (PC400-F50-400-A-Z0-A)
Failure • KOMTRAX system does not operate properly.

• Perform following troubleshooting if administrator of KOMTRAX system requests to
check whether failure is occurring in system on machine.
Related information • Even when KOMTRAX system is defective, no problem appears on machine.
• Check all of results of troubleshooting on service menu display of machine monitor.
2. Display “Terminal status” screen.
1 Defective communication 1
Monitoring Check item:
To be completed
display Station set-up check
2. Display “GPS & Communication Status” screen.
N ###.##.## (Latitude)
Monitoring Check item:
2 Defective positioning by GPS E ###.##.## (Longitude)
display Positioning
In positioning
If latitude and longitude are not displayed within 5 minutes with
machine stayed outdoor where opens clearly for sky, contact
KOMTRAX service hot line.
Monitoring Check item: Satellite in View or No Satellite in
Defective communication display Communication View
3
environment If Communication Status does never display “Satellite in View” within
15 minutes with machine stayed outdoor where opens clearly for sky,
check if connector of TC330 or antenna on top of cab are properly
connected.
4 Defective communication 2 Check item:
Monitoring
Number of message 0 to 60 (normally 0)
display
not yet sent
a Select “Terminal Status” from “12 Display of KOMTRAX setting” in service menu of machine monitor.
40-660 PC490LC-10
40 Troubleshooting
a Select “GPS & Communication Status” from “12 Display of KOMTRAX setting” in service menu of machine
monitor.
PC490LC-10 40-661
40 Troubleshooting
E-58 Machine push-up function cannot be canceled (PC400-FTH-400-A-Z0-A)
Machine push-up function cannot be canceled.

Failure
• 2-stage safety solenoid is not energized.
• If normal, 2-stage safety solenoid is energized when machine push-up switch is set
Related information to low pressure.
1 Blown fuse No.2 If fuse is blown, circuit may have ground fault. (See cause 7.)
2. Disconnect S05 and connect T-adapter to female side.
Defective machine push-up 3. Turn switch to OFF and ON position and perform troubleshooting.
2 switch (open circuit in internal High pressure (Switch
wiring) Min. 1 Mz
Resis- Between S05 (female) OFF)
tance (5) and (6) Low pressure (Switch
ON) Max. 1 z
Defective 2-stage 1. Turn starting switch to OFF position.

safetysolenoid 2. Remove fuse No. 2.
3 3. Disconnect connector V06, and connect T-adapters to male side.
(open or short circuit in
internal wiring, or ground fault) Resis- Between V06 (male) (2) and (1) 20 to 60 z
2. Remove diode array D03 and connect T-adapter.
4
No
Continuity Between D03 (male) (2) (-) and (6) (+)
continuity
3. Turn machine push-up switch to lower pressure (ON) position and
Open or short circuit in wiring perform troubleshooting.
5
harness
a Resistance of 2-stage safety solenoid coil
Resis- Between F01-2 and ground
20 to 60 z
tance
Open circuit in wiring harness 2. Disconnect connectors S05, V06, and D03, and connect T-adapters
to female side of V06 and to male side of S05.
6 (wire breakage or defective Between F01-2 and S05 (male) (5) Max. 1 z
contact of connector) Resis- Between S05 (male) (6) and V06 (female) (1)
Max. 1 z
tance
Ground fault in wiring harness 3. Disconnect connectors S05, V06, and D03, and connect T-adapter
7 to male side of S05 or female side of V06 or D03.
Between F01-2 and ground, or between S05
Min. 1 Mz
Resis- (female) (5) and ground
tance Between ground and S05 (male) (6), V06
(female) (1), or D03 (female) (2) Min. 1 Mz
40-662 PC490LC-10
40 Troubleshooting
Circuit diagram related to machine push-up switch
PC490LC-10 40-663
40 Troubleshooting
E-59 Machine push-up function does not operate (PC400-FTG-400-A-Z0-A)
Machine push-up function does not work.

Failure
• 2-stage safety solenoid is kept energized.
• If normal, 2-stage safety solenoid is de-energized when machine push-up switch is
Related information set to high pressure.

2. Disconnect S05 and connect T-adapter to male side.
3. Turn machine push-up switch to OFF and ON positions and perform
Defective machine push-up troubleshooting.
1 switch (short circuit in internal
wiring) High pressure (Switch
OFF) Min. 1 Mz
Resis- Between S05 (male)
tance (5) and (6) Low pressure (Switch
ON) Max. 1 z

2. Disconnect connectors D03 and V06, and connect T-adapter to
Hot short circuit in wiring either female side.
2 harness (contact with 24 V 3. Turn starting switch to ON position.
circuit) a Machine push-up switch OFF (High pressure)
Between ground and V06 (female) (2) or D03
Voltage Max. 1 V
(female) (1)
Circuit diagram related to machine push-up switch
40-664 PC490LC-10
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting of hydraulic and mechanical system (H-mode) (ALL-

3840-001-A-02-A)
Information described in troubleshooting table (H-mode) (ALL-5170-010-A-00-A)
(Rev. 2011/03)
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5
PC490LC-10 40-665
40 Troubleshooting
mode)
System diagram of hydraulic equipment system (PC400-C000-054-K-00-A)
a This is a system chart that is drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
40-666 PC490LC-10
40 Troubleshooting
mode)
PC490LC-10 40-667
40 Troubleshooting
mode)
Failure mode and cause table (PC400-5340-40D-A-00-A)

Failed parts Hydraulic pump
Tank Control valve
Piston pump (work equipment, swing, travel)
Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Fan pump (including EPC valve)
Pump merge-divider main valve

Pressure compensation valve
Pump merge-divider LS valve

Self-pressure reducing valve
Boom regeneration valve
Diagnosis codes
Boom lock valve
Main relief valve
Engine system
PC-EPC valve
LS line throttle
LS-EPC valve
Unload valve
Servo piston
Hydraulic oil
PC valve
LS valve
Damper
strainer
Spool
Cap
Failure mode
All work equipment, swing and travel operate slowly or lack
Q Q Q Q Q Q Q Q Q Q Q Q H-1
power
Engine speed lowers extremely or engine stalls Q Q Q Q Q Q Q Q H-2
All work equipment,
swing and travel
All work equipment, travel, and swing systems do not work. Q Q Q Q H-3
Unusual sound is heard from around hydraulic pump Q Q Q Q H-4
Fine control performance or response is poor Q Q Q Q H-5
Speed or power of boom is low Q Q Q Q Q Q Q Q H-6
Speed or power of arm is low Q Q Q Q Q Q H-7
Speed or power of bucket is low Q Q H-8
Work equipment does not move in single operation Q H-9
Boom Q Q
Work equipment
Hydraulic drift of work

Arm Q Q H-10
equipment is large
Bucket Q Q
Time lag of work equipment is large Q Q Q H-11
Other wok equipment moves when one of work equipment
Q H-12
is relieved
One-touch power maximizing function does not work. Q H-13
The machine push-up function does not work. H-14

Work equipment loaded more is slower during combined
Q H-15
operation
Swing and
In combined operations of swing and boom RAISE, boom

boom
H-16
rising speed is low
Swing and
Travel speed drops largely in combined operation of swing

travel
H-17
and travel
40-668 PC490LC-10
40 Troubleshooting
mode)
Failed parts Hydraulic pump

Tank Control valve
Piston pump (work equipment, swing, travel)
Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Fan pump (including EPC valve)
Pump merge-divider main valve

Pressure compensation valve
Pump merge-divider LS valve

Self-pressure reducing valve
Boom regeneration valve
Diagnosis codes
Boom lock valve
Main relief valve
Engine system
PC-EPC valve
LS line throttle
LS-EPC valve
Unload valve
Servo piston
Hydraulic oil
PC valve
LS valve
Damper
Strainer
Spool
Cap
Failure mode
Machine deviates during travel Q Q Q Q Q H-18
Travel speed is low Q Q Q Q H-19

Travel
Machine is not steered well or steering power is low Q Q Q Q Q Q H-20

Travel speed does not change or travel speed is too low or
Q H-21
high
Travel system does not work (only one side) H-22
Upper structure swings
Q
Upper structure does not neither to the right nor left
H-23
swing Upper structure does not
Q
swing in only one direction
Poor or low for both of the
Swing acceleration is poor or right and left Q
H-24
swing speed is low Poor or low for only in one
Q Q
direction
Largely for both of the right
Swing
Upper structure overruns

and left
considerably when it stops H-25
Largely for only in one
swinging Q
direction
Large shock is made when upper structure stops swinging H-26
Large unsual noise is heard when upper structure stops
H-27
swinging
When swing brake works
Hydraulic drift of swing is
When swing brake does not H-28
large Q Q
work
Attachment circuit can not be changed H-29
Attachment
Oil flow in attachment circuit cannot be changed H-30
Fan speed is abnormal (high, low, or 0 rpm) Q H-31

system
Fan
Abnormal sound is heard around the fan. H-32
PC490LC-10 40-669
40 Troubleshooting
mode)
Failed parts Control valve Solenoid valve
Oil flow adjuster EPC valve for attachment

Swing PPC slow return valve
Travel speed selector solenoid

Work equipment lock solenoid
swing parking brake solenoid
Swing 2-stage relief solenoid

PPC valve (travel lever)
ATT return selector solenoid

Arm lock valve (if equipped)
PPC valve (right lever)

Service valve (safety valve)
Machine push-up solenoid

PPC valve (left lever)
Swing LS separator valve
PPC valve (service)
Travel junction solenoid

Arm regeneration valve
Arm quick return valve
2-stage relief solenoid

Travel junction valve
Back pressure valve
Diagnosis codes
LS shuttle valve
Suction valve
Safety valve
Failure mode
All work equipment, swing and travel operate slowly or
H-1
lack power
Engine speed lowers extremely or engine stalls H-2
All work equipment,
swing and travel
All work equipment, travel, and swing systems do not

Q H-3
work.
Unusual sound is heard from around hydraulic pump H-4
Fine control performance or response is poor H-5
Speed or power of boom is low Q Q Q Q Q H-6
Speed or power of arm is low Q Q Q Q Q Q Q H-7
Speed or power of bucket is low Q Q Q Q H-8
Work equipment does not move in single operation Q Q H-9
Boom Q
Hydraulic drift of work
Work equipment
Arm Q Q H-10
equipment is large
Bucket Q
Time lag of work equipment is large Q Q H-11
Other wok equipment moves when one of work
H-12
equipment is relieved
One-touch power maximizing function does not work. Q H-13
The machine push-up function does not work. Q Q H-14

Work equipment loaded more is slower during combined
H-15
operation
Swing and
In combined operations of swing and boom RAISE,

boom
Q H-16
boom rising speed is low
Swing and
Travel speed drops largely in combined operation of

travel
Q H-17
swing and travel
40-670 PC490LC-10
40 Troubleshooting
mode)
Failed parts Control valve Solenoid valve
Oil flow adjuster EPC valve for attachment

Swing PPC slow return valve
Travel speed selector solenoid

Work equipment lock solenoid
Swing holding brake solenoid
Swing 2-stage relief solenoid

PPC valve (travel lever)
ATT return selector solenoid

Arm lock valve (if equipped)
PPC valve (right lever)

Service valve (safety valve)
Machine push-up solenoid

PPC valve (left lever)
Swing LS separator valve
PPC valve (service)
Travel junction solenoid

Arm regeneration valve
2-stage relief solenoid

Travel junction valve
Back pressure valve
Diagnosis codes
LS shuttle valve
Suction valve
Safety valve
Failure mode
Machine deviates during travel Q Q Q H-18
Travel speed is low Q Q Q H-19

Travel
Machine is not steered well or steering power is low Q Q Q Q Q H-20

Travel speed does not change or travel speed is too low
Q H-21
or high
Travel system does not work (only one side) Q H-22
Upper structure swings
Q
Upper structure does not neither to the right nor left
H-23
swing Upper structure does not
Q
swing in only one direction
Poor or low for both of the
Q Q
Swing acceleration is poor right and left
H-24
or swing speed is low Poor or low for only in one
Q
direction
Largely for both of the right
Upper structure overruns
Swing
and left
considerably when it stops H-25
Largely for only in one
swinging Q Q
direction
Large shock is made when upper structure stops
Q Q Q H-26
swinging
Large unsual noise is heard when upper structure stops
Q H-27
swinging
When swing brake works Q
Hydraulic drift of swing is
When swing brake does H-28
large
not work
Attachment circuit can not be changed Q Q H-29
Attachment
Oil flow in attachment circuit cannot be changed Q Q H-30
Fan speed is abnormal (high, low, or 0 rpm) H-31

system
Fan
Abnormal sound is heard around the fan. H-32
PC490LC-10 40-671
40 Troubleshooting
mode)
Failed parts Swing motor Travel motor
Swing motor reverse prevention valve
Fan motor (including relief valve)
Exterior parts around fan

Center swivel joint
Hydraulic cylinder
Swing machinery
Counterbalance valve
Diagnosis codes
Holding brake
Parking brake
Suction valve
Piston motor
Piston motor
Check valve
Safety valve
Check valve
Safety valve
Final drive
Failure mode
All work equipment, swing and travel operate slowly or lack power H-1
Engine speed lowers extremely or engine stalls H-2
All work equipment, travel, and swing systems do not work.

All work equipment,
H-3
swing and travel
Unusual sound is heard from around hydraulic pump H-4
Fine control performance or response is poor H-5
Speed or power of boom is low Q H-6
Speed or power of arm is low Q H-7
Speed or power of bucket is low Q H-8
Work equipment does not move in single operation H-9
Q
Work equipment
Boom
Hydraulic drift of work equipment
Arm Q H-10
is large
Bucket Q
Time lag of work equipment is large H-11
Other wok equipment moves when one of work equipment is relieved H-12
One-touch power maximizing function does not work. H-13
The machine push-up function does not work. H-14
Work equipment loaded more is slower during combined operation H-15

Swing and
In combined operations of swing and boom RAISE, boom rising

boom
H-16
speed is low
Swing and
travel
Travel speed drops largely in combined operation of swing and travel H-17
40-672 PC490LC-10
40 Troubleshooting
mode)
Failed parts Swing motor Travel motor
Fan motor (including relief valve)
Exterior parts around fan

Center swivel joint
Hydraulic cylinder
Swing machinery
Counterbalance valve
Diagnosis codes
Shockless valve
Holding brake
Parking brake
Suction valve
Piston motor
Piston motor
Check valve
Check valve
Safety valve
Safety valve
Final drive
Failure mode
Machine deviates during travel Q Q Q Q Q H-18
Travel speed is low Q Q H-19

Travel
Machine is not steered well or steering power is low Q Q Q Q H-20
Travel speed does not change or travel speed is too low or high Q H-21
Travel system does not work (only one side) Q Q Q Q Q H-22

Upper structure swings neither to
Q Q Q Q
the right nor left
Upper structure does not swing H-23
Upper structure does not swing
Q Q
in only one direction
Poor or low for both of the right
Q Q Q Q
Swing acceleration is poor or and left
H-24
swing speed is low Poor or low for only in one
Q Q
direction
Swing
Upper structure overruns Largely for both of the right and

Q Q
considerably when it stops left H-25
swinging Largely for only in one direction Q Q
Large shock is made when upper structure stops swinging Q H-26
Large unsual noise is heard when upper structure stops swinging Q Q Q H-27
When swing brake works Q

Hydraulic drift of swing is large When swing brake does not H-28
Q Q Q Q
work
Attachment circuit can not be changed H-29
Attachment
Oil flow in attachment circuit cannot be changed H-30
Fan speed is abnormal (high, low, or 0 rpm) Q H-31

system
Fan
Abnormal sound is heard around the fan. Q H-32
PC490LC-10 40-673
40 Troubleshooting
mode)
H-1 Speed or power of all work equipment, swing, and travel is low. (PC400-
A8A-400-A-Z0-A)
Failure • All work equipment, swing and travel operate slowly or lack power
• Perform all troubleshooting with working mode in power mode (P).
• If a failure code appears, perform troubleshooting for the corresponding failure
codes (DKR0MA, DKR1MA, DXA8KA, DXA8KB, DXA9KA, DXA9KB, DXE0KA,
DXE0KB).
• For items other than swing, check whether speed becomes normal when swing lock
Related information switch is turned to ON position.
If speed becomes normal, check swash plate sensor of pump in Cause 1 for
malfunction.
If speed does not become normal, perform troubleshooting in Cause 2 and after.
• F pump pressure and R pump pressure can also be checked by using the monitor
(monitoring code: 01100 for F pump pressure, 01101 for R pump pressure).
a Be ready with engine stopped, then troubleshoot with engine at full
speed.
Measurement Sensor output voltage
Control lever
conditions
Malfunction of swash plate When all control levers
1 sensor of pump are in NEUTRAL 1.52 ± 0.63 V
• Hydraulic oil position
temperature: Within
Run one track idle off
operation range
ground 3.54 ± 0.63 V
Swing lock switch: ON
speed.
Measurement Relief pressure
2 Malfunction of unload valve Control lever
conditions
• Hydraulic oil When all control levers 4.12 ± 1.0 MPa
temperature: Within are in NEUTRAL
operation range position {42 ± 10 kg/cm2 }

speed.
Measurement Left work equipment Main relief pressure
Defective adjustment or conditions control lever
3 malfunction of main relief • Hydraulic oil 33.1 to 36.8 MPa
valve temperature: Within Arm IN relief
operation range {338 to 375 kg/cm2 }
If normal oil pressure is not obtained after adjustment, main relief valve
may malfunction (deterioration of spring) or have internal defect
(defective valve seat). Check it directly.
speed.
Measurement Main relief pressure
Control lever
conditions
Malfunction of self-pressure
4 • Hydraulic oil When all control levers 2.84 to 3.4 MPa
reducing valve
operation range position {29 to 35 kg/cm2 }
a Relief valve of self-pressure reducing valve is not adjustable. If it is

defective, replace self-pressure reducing valve assembly.
40-674 PC490LC-10
40 Troubleshooting
mode)

a Be ready with engine stopped, then troubleshoot with engine at low
speed and full speed.
PC-EPC valve output
Engine Control lever pressure
5 Malfunction of PC-EPC valve
2.9 MPa
At low idle When all control levers {30 kg/cm2 }
are in NEUTRAL
position 0.98 MPa
At high idle
{10 kg/cm2 }
speed.
Measured oil pressure Measurement Oil pressure ratio
conditions
Defective adjustment or Pump delivery
6 pressure 1
malfunction of PC valve Swing lock switch: ON
PC valve output Arm IN relief Approx. 0.6 (Approx.
pressure 3/5)
If normal oil pressure is not obtained after adjustment, PC valve may
malfunction (deterioration of spring) or have internal defect (prying or
sticking of PC spool). Check it directly.
speed.
LS-EPC valve output
Travel speed Travel lever pressure
7 Malfunction of LS-EPC valve
2.9 MPa
Lo NEUTRAL
{30 kg/cm2 }
0 MPa
Hi Fine operation
{0 kg/cm2 }
speed.
Operation of levers and oil pressure ratio
Run the track off
Measured oil pressure When all control levers ground.
are in NEUTRAL
position (Lever operated
Defective adjustment or halfway)
8
malfunction of LS valve Pump delivery
pressure 1
Almost same pressure
LS valve out put Approx. 0.6 (Approx.
pressure 3/5)
If normal oil pressure is not obtained after adjustment, LS valve may
sticking of LS spool). Check it directly.
If sensor output voltage shown in Cause 1 is normal, servo piston is
9 Malfunction of servo piston judged to be normal.
Check orifices and filters in pump servo devices for clogging.
If there is no abnormality in above Cause 1 to 9, piston pump may have
10 Defective piston pump problems of performance degradation, malfunction, internal defect, etc.
PC490LC-10 40-675
40 Troubleshooting
mode)
H-2 Engine speed lowers significantly or engine stalls (PC400-FPN-400-A-Z0-A)
Failure • Engine speed lowers extremely or engine stalls.

• If a failure code appears, perform troubleshooting for the corresponding failure
codes (DKR0MA, DKR1MA, DXA8KA, DXA8KB, DXA9KA, DXA9KB, DXE0KA,
DXE0KB).
• For items other than swing, check whether speed becomes normal when swing lock
Related information switch is turned to ON position.
If speed becomes normal, check swash plate sensor of pump in Cause 1 for
malfunction.
If speed does not become normal, perform troubleshooting in Cause 2 and after.
speed.
Control lever
conditions
temperature: Within
operation range
ground 3.54 ± 0.63 V
speed.
Measurement Left work equipment Main relief pressure
Defective adjustment or conditions control lever
2 malfunction of main relief • Hydraulic oil 33.1 to 36.8 MPa
valve temperature: Within Arm IN relief
If normal oil pressure is not obtained after adjustment, main relief valve
may malfunction (deterioration of spring) or have internal defect
(defective valve seat). Check it directly.
a Prepare with engine stopped, then run engine at low speed and at
full speed to perform troubleshooting at each speed.
PC-EPC valve output
Engine Control lever pressure
3 Malfunction of PC-EPC valve
2.9 MPa
At low idle When all control levers {30 kg/cm2 }
are in NEUTRAL
position 0.98 MPa
At high idle
{10 kg/cm2 }
40-676 PC490LC-10
40 Troubleshooting
mode)

speed.
Measured oil pressure Measurement Oil pressure ratio
conditions
Defective adjustment or Pump delivery
4 pressure 1
malfunction of PC valve Swing lock switch: ON
PC valve output Arm IN relief Approx. 0.6 (Approx.
pressure 3/5)
If normal oil pressure is not obtained after adjustment, PC valve may
sticking of PC spool). Check it directly.
speed.
LS-EPC valve output
5 Malfunction of LS-EPC valve
2.9 MPa
Lo NEUTRAL
{30 kg/cm2 }
0 MPa
Hi Fine operation
{0 kg/cm2 }
speed.
Run the track off
Measured oil pressure When all control levers ground.
are in NEUTRAL
position (Lever operated
6
pressure 1
pressure 3/5)
7 Malfunction of servo piston judged to be normal.
Check orifices and filters in pump servo devices for clogging.
If no abnormality is detected in Cause 1 to 7 above, piston pump may
8 Defective piston pump
malfunction or have internal defect, etc.
If no abnormality is detected in Cause 1 to 8 above, there may be
9 Defective engine system degradation of the engine performance. Perform troubleshooting
referring "S Mode".
PC490LC-10 40-677
40 Troubleshooting
mode)
H-3 Any of work equipment, swing and travel does not work (PC400-FT5-400-A-Z1-A)
Failure • All work equipment, travel, and swing systems do not work.
Related information • Perform all troubleshooting with working mode in power mode (P).
speed.
Measurement Solenoid output
Malfunction of PPC lock Lock lever pressure
1 conditions
solenoid valve
• Hydraulic oil at LOCK position 0 MPa {0 kg/cm2 }
temperature: Within 2.84 to 3.43 MPa
operation range at FREE position
{29 to 35 kg/cm2 }
speed.
Measurement Control circuit source
Control lever pressure
conditions
Malfunction of self-pressure
2 reducing valve • Hydraulic oil When all control levers 2.84 to 3.43 MPa
a Relief valve of self-pressure reducing valve cannot be adjusted. If it

is defective, replace self-pressure reducing valve assembly.
Piston pump may malfunction or have internal defect. Check it by
following method.
• Crank the engine with main oil pressure pickup port plug. If oil flows
out, it is in normal.
Pump shaft may not rotate due to some internal defect of damper.
4 Defective damper
Check the damper.
40-678 PC490LC-10
40 Troubleshooting
mode)
H-4 Unusual sound is heard from around hydraulic pump (PC400-BAA-400-A-Z0-A)
Failure • Unusual sound is heard from around hydraulic pump

Related information —
Check hydraulic oil level directly.
1 Lowering of hydraulic oil level (Reference) If the hydraulic oil level is low while no hydraulic oil leaks to
the outside, it is assumed that hydraulic oil may flow in the flywheel
chamber due to a pump shaft seal damage.
2 Defective hydraulic oil Air may mix in hydraulic oil. Check it for bubbles or milky state.
Cap of the hydraulic tank cap may be clogged, causing negative
3 Clogging of hydraulic tank cap
pressure inside the tank. Check the cap.
Clogging of hydraulic tank Strainer in the hydraulic tank may be clogged, causing negative
4 pressure in the suction circuit. Check the strainer.
strainer
Clogging of hydraulic tank Check the return filter in the hydraulic tank may be clogged, especially
5 by metallic materials. Check the return filter.
return filter
If any metallic materials are detected in Cause 4 and 5 above, piston
pump may have internal defect.
PC490LC-10 40-679
40 Troubleshooting
mode)
H-5 Fine control performance or response is poor (PC400-FTB-400-A-Z0-A)
Failure • Fine control performance or response is poor.

• Perform all troubleshooting with working mode in POWER (P) mode.
• If a failure code appears, perform troubleshooting for the codes first (DKR0MA,
Related information DKR1MA, DXE0KA, DAXE0KB).
• Check swash plate sensor voltage using a monitoring code (F pump side: 01138, R
pump side: 01140).
speed.
Control lever
conditions
temperature: Within
operation range
ground 3.54 ± 0.63 V
speed.
LS-EPC valve output
Travel speed Travel lever
2 Malfunction of LS-EPC valve pressure
2.9 MPa
Lo NEUTRAL
{30 kg/cm2 }
Hi Fine operation 0 MPa {0 kg/cm2 }
3 Clogging of LS circuit orifice Orifice in LS circuit may be clogged. Check orifice.
speed.
Run the track off
Measured oil pressure ground.
All levers in NEUTRAL
(Lever operated
4
pressure 1
pressure 3/5)
judged to be normal.
5 Malfunction of servo piston If condition changes even after replacing pump swash sensor with a
new one (or replacing the F side with the R side), servo piston may be
defective.
40-680 PC490LC-10
40 Troubleshooting
mode)
H-6 Speed or power of boom is low (PC400-A8B-400-A-Z0-A)
Failure • Speed or power of boom is low

• If a failure code appears, perform troubleshooting for the codes first (DXE5KB,
DXE6KA, DXE6KB).
• Boom RAISE PPC pressure can also be checked by using the monitor (monitoring
mode: 07400).
Related information • Merge-divider (main) solenoid current can also be checked by using the monitor
(monitoring mode: 08000).
• Merge-divider (LS) solenoid current can also be checked by using the monitor
speed.
Measurement Left work equipment PPC valve output
Malfunction of right PPC valve conditions control lever pressure
1 (boom circuit) • Hydraulic oil NEUTRAL 0 MPa {0 kg/cm2 }
temperature: 40 to
60 °C Boom RAISE 2.84 to 3.43 MPa
• Swing lock switch: Boom Lower {29 to 35 kg/cm2 }
OFF
a If speed of boom is low, check all work equipment speeds. If any
abnormality is detected, perform individual troubleshooting shown
in Cause 2-1 to 2-4 below for merge-divider valve.
Malfunction of pump merge- Measurement Required time (sec.)
2 Control lever
divider valve assembly conditions
• Hydraulic oil Boom RAISE/LOWER Max. 4.8/-
temperature: Within Arm IN/OUT Max. 5.0/4.3
operation range
• High idle Bucket CURL/DUMP Max. 4.3/3.5

speed.
Measurement EPC output pressure
EPC current value
Malfunction of merge-divider conditions
3 Work equipment 0 to 0.49 MPa
main EPC valve
control lever in 0 mA
NEUTRAL {0 to 5 kg/cm2 }
Bucket CURL and Arm 2.84 to 3.43 MPa
IN to hydraulic relief 800 to 1000 mA
{29 to 35 kg/cm2 }
speed.
EPC current value
4 Work equipment 0 to 0.49 MPa
LS-EPC valve
control lever in 0 mA
NEUTRAL {0 to 5 kg/cm2 }
Bucket CURL and Arm 2.84 to 3.43 MPa
IN to hydraulic relief 800 to 1000 mA
{29 to 35 kg/cm2 }
PC490LC-10 40-681
40 Troubleshooting
mode)

a Release remaining pressure in hydraulic tank and piping, then
troubleshoot with engine stopped.
Malfunction of merge-divider • Check merge-divider valve body and main spool for scuffing,
5 main spool sticking, etc. (Spool must move smoothly without hitch).
• Remove main spool from body, then check it for flaw and dirt.
a When restoring, be careful not to let any dirt get in the assembly.
Malfunction of merge-divider • Check merge-divider valve body and LS spool for scuffing, sticking,
6 LS spool etc. (Spool must move smoothly without hitch).
• Remove LS spool from body and check it for flaw and dirt.
Malfunction of boom control • Check control valve body and boom spool for scuffing, sticking, etc.
7 valve (spool) (Spool must move smoothly without hitch).
• Remove boom spool from the valve body, and check it for flaw and
dirt.
speed.
Measurement Measuring point Boom relief pressure
conditions
33.1 to 36.8 MPa
Boom RAISE relief
{338 to 375 kg/cm2 }
• Hydraulic oil at low- 16.47 to 19.6 MPa
temperature: Within Boom pressure
{168 to 200 kg/cm2 }
operation range LOWER to setting
hydraulic at high- 29.2 to 33.3 MPa
relief pressure
setting {298 to 340 kg/cm2 }
Malfunction of boom control
8 valve (pressure compensation
a With engine stopped, check boom cylinder for hydraulic drift.
valve)
Measurement conditions Hydraulic drift
• Hydraulic oil temperature: Within operation If hydraulic drift is
range detected visually, it is
• Bucket with rated load, arm fully IN abnormal.
a While performing hydraulic relief of another work equipment, check
if boom cylinder moves slowly. (If it moves, it is abnormal.)
a If an abnormality is detected in any of the items above, check by
replacing pressure compensation valve in the RAISE side with that
in the LOWER side and watching how condition changes.
(Be sure to restore them to the original position after checking since
their area ratio is different.)
40-682 PC490LC-10
40 Troubleshooting
mode)

• Check control valve body and boom regeneration valve for prying,
Malfunction of boom control sticking, etc. (Spool must move smoothly without hitch).
9 valve (regeneration valve) • Check whether regeneration valve (check valve) has contact with
body (is not hitched halfway). Then, remove it from the body, and
check it for flaw and dirt.
• Check spring of check valve for deterioration or deformation.
speed.
Measurement Arm and boom relief
Measuring point
conditions pressure
• Hydraulic oil Arm IN/OUT and boom 33.1 to 36.8 MPa
temperature: Within RAISE to hydraulic
relief
a If arm OUT and boom RAISE relief pressures are low in the relief
pressure shown above, safety valve may be abnormal. check safety
valve. (*1)
Malfunction of safety valve for (Reference) Since boom RAISE and arm OUT circuits are connected to
10 boom lock valve and safety valve circuit through check valve, if arm side is normal, boom
malfunction of lock valve lock valve is judged defective.
a If safety valve is not abnormal, check lock valve.
• Check whether pilot piston and poppet has contact with body (is not
hitched halfway).
• Check lock valve body, pilot piston, and poppet for scuffing or
sticking.
(Spool must move smoothly without hitch).
• Remove pilot piston and poppet from body, and check them for flaw
and dirt.
• Check poppet spring for deterioration or deformation.
speed.
conditions
33.1 to 36.8 MPa
Boom RAISE relief
{338 to 375 kg/cm2 }
{168 to 200 kg/cm2 }
Malfunction of boom control hydraulic at high- 29.2 to 33.3 MPa
11 valve (suction valve) relief pressure
a If relief pressure is low only in either the boom RAISE or LOWER

side in the relief pressure shown above, suction valve may be
abnormal. Check suction valve.
• Check whether check valve has contact with body (is hitched
halfway).
• Remove check valve body, and check them for flaw and dirt.
PC490LC-10 40-683
40 Troubleshooting
mode)

speed.
conditions
33.14 to 36.77 MPa
Boom RAISE relief
{338 to 375 kg/cm2 }
{168 to 200 kg/cm2 }
Malfunction of boom control hydraulic at high-
12 valve (suction safety valve) 29.2 to 33.34 MPa
relief pressure
a If boom LOWER relief pressure is low in the relief pressures shown

above, suction safety valve may be abnormal. Check it.(*1)
• Check whether suction valve has contact with body of safety valve
(is hitched halfway).
• Push in suction valve, and remove external force. Then, check that
it returns smoothly and has contact with valve body.
(Reference) Boom LOWER safety valve has the machine push-up
function with 2-stage relief setting.
speed.
Measurement LS differential
Measuring point
conditions pressure
When all control levers 4.2 ± 1.0 MPa
Malfunction of boom control • Hydraulic oil are in NEUTRAL
13 valve (LS shuttle valve) temperature: Within position {42 ± 10 kg/cm2 }
operation range 2.65 ± 0.1 MPa
At boom RAISE fine
• Boom RAISE
operation {27 ± 1 kg/cm2 }
a If LS differential pressure is higher than the standard value at the
measuring points above, LS shuttle valve may be defective. Check
check valve (ball) for damage.
14 Defective boom cylinder
a If above item is abnormal, measure leakage through boom cylinder
during boom RAISE to hydraulic relief.
Leakage from boom
Measurement conditions cylinder
Boom RAISE relief Max. 20 cc/min
(*1): As for outside view, check seal materials for damage. (Make sure that no dirt gets into the assembly
when repairing.)
If disassembled, relief pressure cannot be adjusted when mounted on machine. Replace the assembly of
safety valve with suction.
40-684 PC490LC-10
40 Troubleshooting
mode)
H-7 Speed or power of arm is low (PC400-A8C-400-A-Z0-A)
Failure • Speed or power of arm is low

• If any failure code appears, perform troubleshooting for that code first (DHS3MA,
DXE5KA, DXE5KB, DXE6KA, DXE6KB).
• Bucket CURL PPC pressure can also be checked by using the monitor (monitoring
mode: 07200).
speed.
Malfunction of L.H. PPC valve conditions control lever pressure
1 (arm circuit) • Hydraulic oil NEUTRAL 0 MPa {0 kg/cm2}
temperature: 40 to
60 °C Arm IN or 2.84 to 3.43 MPa
• Swing lock switch: arm OUT {29 to 35 kg/cm2}
OFF
a If speed of arm is low, check all work equipment speeds. If any
abnormality is detected, perform individual troubleshooting shown
in Cause 3 to 6 below for merge-divider valve.
2 Control lever
divider valve conditions
operation range

speed.
EPC current value
3 Work equipment lever
main EPC valve 0 mA 0 MPa {0 kg/cm2}
is in neutral
Arm IN and Bucket 2.84 to 3.43 MPa
CURL to hydraulic 800 to 1000 mA
relief {29 to 35 kg/cm2}

speed.
EPC current value
4 Work equipment lever
LS-EPC valve 0 mA 0 MPa {0 kg/cm2}
is in neutral
relief {29 to 35 kg/cm2}

PC490LC-10 40-685
40 Troubleshooting
mode)

Malfunction of arm control • Check control valve body and arm spool for prying, sticking, etc.
• Remove arm spool from body and check it for flaw and dirt.
speed.
Measurement Measuring point Arm relief pressure
conditions
• Hydraulic oil 33.1 to 36.8 MPa
Arm IN/OUT to
temperature: Within
hydraulic relief {338 to 375 kg/cm2}
operation range
a With engine stopped, check arm cylinder for hydraulic drift.
Malfunction of arm control Measurement conditions Hydraulic drift
8 valve (pressure compensation • Hydraulic oil temperature: Within operation If hydraulic drift is
valve) range detected visually, it is
a Relieve another work equipment, and check whether arm cylinder
moves slowly. (If it moves, it is abnormal.)
a If there is abnormality in above item, check by interchanging
pressure compensation valves on IN side and OUT side and
watching how condition changes.
• Check control valve body and arm regeneration valve for scuffing,
Malfunction of arm control sticking, etc. (Smooth and no hitch).
9 valve (regeneration valve) • Check whether regeneration valve (check valve) has contact with
body (is not hitched halfway). Then, remove it from the body, and
40-686 PC490LC-10
40 Troubleshooting
mode)

Malfunction of arm control (*1)
10 valve (quick return valve)
• Check if pilot spool and check valve has contact with body (is
hitched halfway).
• Check quick return valve body, pilot spool, and check valve for
scuffing or sticking
(Spool must move smoothly without hitch).
• Remove pilot spool and check valve from body, and check them for
flaw and dirt.
speed.
conditions
• Hydraulic oil Arm IN/OUT
33.1 to 36.8 MPa
Malfunction of safety valve for temperature: Within Boom RAISE/LOWER
11 arm lock valve or defect of operation range {338 to 375 kg/cm2}
to hydraulic relief
lock valve (if equipped)
a If arm OUT and boom RAISE relief pressures are low in the relief
pressure shown above, safety valve is defective. Check safety
valve. (*3)
(Reference) Safety valve circuit is connected to both the boom RAISE
and arm OUT circuits through check valve. If boom is normal, arm lock
valve is judged to be defective.
speed.
conditions
Malfunction of arm control • Hydraulic oil 33.1 to 36.8 MPa
12 valve (suction valve) Arm IN/OUT to
temperature: Within
operation range
a If arm OUT relief pressure is low in the relief pressure shown above,
check suction valve. (*2)
(*2) For checking, see item 6 (*1).
PC490LC-10 40-687
40 Troubleshooting
mode)

speed.
Malfunction of arm control conditions
13 valve (safety valve with • Hydraulic oil 33.1 to 36.8 MPa
Arm IN/OUT to
suction) temperature: Within
operation range
a If arm IN relief pressure is low in the relief pressure shown above,
check suction safety valve. (*3)
speed.
Measuring point
conditions pressure
Malfunction of arm control temperature: Within are in NEUTRAL
14 valve (LS shuttle valve) position {42 ± 10 kg/cm2}
operation range
• Arm IN/OUT At arm IN/OUT fine 2.65 ± 0.1 MPa
operation operation {27 ± 1 kg/cm2}
15 Defective arm cylinder
during arm IN to hydraulic relief.
Leakage from arm
Arm IN relief Max. 20 cc/min
when repairing.)
40-688 PC490LC-10
40 Troubleshooting
mode)
H-8 Speed or power of bucket is low (PC400-A8D-400-A-Z0-A)
Failure • Speed or power of bucket is low

• If any failure code appears, perform troubleshooting for that code first (DHS4MA,
DXE5KA, DXE5KB, DXE6KA, DXE6KB).
• Bucket CURL PPC pressure can also be checked by using the monitor (monitoring
mode: 07300).
speed.
Measurement Right work equipment PPC valve output
Malfunction of right PPC valve conditions control lever pressure
1 (bucket circuit) • Hydraulic oil NEUTRAL 0 MPa {0 kg/cm2}
temperature: 40 to
60 °C Bucket CURL 2.84 to 3.43 MPa
• Swing lock switch: At bucket DUMP {29 to 35 kg/cm2}
OFF
a If speed of bucket is low, check all work equipment speeds. If any
abnormality is detected, perform individual troubleshooting for
merge-divider valve in H-6 and H-7.
2 Control lever
divider valve conditions
operation range

Malfunction of bucket control • Check control valve body and bucket spool for prying, sticking, etc.
• Remove bucket spool from body and check it for flaw and dirt.
PC490LC-10 40-689
40 Troubleshooting
mode)

speed.
Measurement Measuring point Bucket relief pressure
conditions
Bucket CURL/DUMP
temperature: Within
to hydraulic relief {338 to 375 kg/cm2}
operation range
a With engine stopped, check bucket cylinder for hydraulic drift.
Malfunction of bucket control Measurement conditions Hydraulic drift
4 valve (pressure compensation • Hydraulic oil temperature: Within operation If hydraulic drift is
valve) range detected visually, it is
if bucket cylinder moves slowly. (If it moves, it is abnormal.)
speed.
Malfunction of bucket control conditions
5 valve (safety valve with • Hydraulic oil 33.1 to 36.8 MPa
Bucket CURL/DUMP
suction) temperature: Within
to hydraulic relief {338 to 375 kg/cm2}
operation range
a If bucket CURL relief pressure is low in the relief pressures shown
above, suction safety valve may be abnormal. Check it. (*1)
speed.
Measuring point
conditions pressure
Malfunction of bucket control temperature: Within are in NEUTRAL
6 position {42 ± 10 kg/cm2}
valve (LS shuttle valve) operation range
• Bucket CURL/ At bucket CURL/ 2.65 ± 0.1 MPa
DUMP operation DUMP fine operation {27 ± 1 kg/cm2}
40-690 PC490LC-10
40 Troubleshooting
mode)

a With engine stopped, check bucket cylinder for hydraulic drift.
7 Defective bucket cylinder
a If above item is abnormal, measure leakage through bucket cylinder
during bucket CURL to hydraulic relief.
Leakage from bucket
Bucket CURL relief Max. 20 cc/min
when repairing.)
PC490LC-10 40-691
40 Troubleshooting
mode)
H-9 Work equipment does not move in single operation (PC400-FTC-400-A-Z0-A)
(1) The boom does not move when operated independently.

Failure (2) The arm does not move when operated independently.
(3) Bucket does not move independently.
• If a failure code appears, perform troubleshooting for the codes first (DHS3MA,
DHS4MA, DHS8MA, DHSDMA).
• PPC pressure of each work equipment can also be checked by using the monitor.
Related information Monitoring codes are as follows.
Boom RAISE PPC pressure: 07400
Arm IN PPC pressure: 07200
Bucket CURL PPC pressure: 07300
Bucket DUMP PPC pressure: 07301
speed.
conditions control lever pressure
1 Malfunction of PPC valve
• Hydraulic oil NEUTRAL 0 MPa {0 kg/cm2 }
temperature: 40 to
60 °C 2.84 to 3.43 MPa
Operated
• Swing lock switch: {29 to 35 kg/cm2 }
OFF
Malfunction of control valve • Check bucket control valve body and spool for scuffing, sticking,
2 (spool) etc. (Spool must move smoothly without hitch).
• Remove spool from the valve body, then check it for flaw and dirt.
40-692 PC490LC-10
40 Troubleshooting
mode)
H-10 Hydraulic drift of work equipment is large (PC400-MS8-400-A-Z0-A)
Failure (1) Hydraulic drift of boom is large.

1 Defective boom cylinder
during boom RAISE to hydraulic relief.
Leakage from boom
Boom RAISE relief Max. 20 cc/min
speed.
conditions
Arm IN/OUT
temperature: Within
operation range Boom RAISE relief {338 to 375 kg/cm2 }
Malfunction of safety valve for
2 boom lock valve and a If arm OUT and boom RAISE relief pressure is low in the relief
malfunction of lock valve pressures shown above, safety valve may be abnormal. Check it.
(Reference) Since boom RAISE and arm OUT circuits are connected to
safety valve circuit through check valve, if arm side is normal, boom
lock valve is judged defective.
a If safety valve is normal, check lock valve (For contents to be
checked, see Cause 6 in H-6)
PC490LC-10 40-693
40 Troubleshooting
mode)
Failure (2) Hydraulic drift of arm is large.

1 Defective arm cylinder
during arm IN to hydraulic relief.
Leakage from arm
Arm IN relief Max. 20 cc/min
speed.
conditions
• Hydraulic oil Arm IN/OUT 33.1 to 36.8 MPa
temperature: Within
operation range Boom RAISE relief {338 to 375 kg/cm2 }
Malfunction of safety valve for
2 arm lock valve or malfunction a If arm OUT and boom RAISE relief pressure is low in the relief
of lock valve (if equipped) pressures shown above, safety valve may be abnormal. Check it.
(Reference) Safety valve circuit is connected to both the boom RAISE
and arm OUT circuits through check valve. If boom is normal, arm lock
valve is judged to be defective.
a If safety valve is normal, check lock valve (For contents to be
checked, see Cause 6 in H-7)
A If lock valve (if equipped) is not installed, check following items.
speed.
conditions
Malfunction of arm control Arm IN/OUT to
temperature: Within
3 valve (safety valve with hydraulic relief {338 to 375 kg/cm2 }
operation range
suction)
a If arm IN relief pressures is low in the relief pressure shown above,
suction safety valve (bottom side) may be defective. Check suction
safety valve directly (See H-7).
* This defect can be judged by replacing it with another suction safety
valve and watching how condition changes.
Malfunction of arm control • Check control valve body and arm spool for prying, sticking, etc.
• Remove arm spool from body and check it for flaw and dirt.
40-694 PC490LC-10
40 Troubleshooting
mode)

a Relieve another work equipment, and check whether arm cylinder
moves slowly. (If it moves, it is abnormal.)
Malfunction of arm control a If there is abnormality in above item, check by interchanging
5 valve (pressure compensation pressure compensation valves on IN side and OUT side and
valve) watching how condition changes.
PC490LC-10 40-695
40 Troubleshooting
mode)
Failure (3) Hydraulic drift of bucket is large.

1 Defective bucket cylinder
a If above item is abnormal, measure leakage through bucket cylinder
during bucket CURL to hydraulic relief.
Leakage from bucket
Bucket CURL relief Max. 20 cc/min
speed.
conditions
Malfunction of bucket control Bucket CURL/DUMP
temperature: Within
2 valve (safety valve with to hydraulic relief {338 to 375 kg/cm2 }
operation range
suction)
a If bucket CURL or DUMP relief pressure is low in the relief pressure
items shown above, check safety valve with suction for abnormality.
(See H-8)
Malfunction of bucket control • Check control valve body and bucket spool for prying, sticking, etc.
• Remove bucket spool from body and check it for flaw and dirt.
if bucket cylinder moves slowly. (If it moves, it is abnormal.)
Malfunction of bucket control
4 valve (pressure compensation
valve)
40-696 PC490LC-10
40 Troubleshooting
mode)
H-11 Time lag of work equipment is large (PC400-FTD-400-A-Z0-A)
Failure • Time lag of work equipment is large

Related information • If a failure code appears, perform troubleshooting for the codes first (DXE0KA,
DXE0KB).
speed.
LS-EPC valve output
Approx. 1.37 MPa
Lo NEUTRAL
{Approx. 14 kg/cm2 }
• Check control valve body and boom regeneration valve for prying,
Malfunction of control valve sticking, etc. (Spool must move smoothly without hitch).
2 (regeneration valve) [Boom • Check whether regeneration valve (check valve) has contact with
and arm only] body (is not hitched halfway). Then, remove it from the body, and
a Check relief pressure of each parts of work equipment. If there is
abnormality, suction safety valve of control valve (Boom: Head side,
Malfunction of control valve Arm and bucket: Bottom side) may malfunction. Check suction
3 (suction safety valve) safety valve directly (See H-7).
if bucket cylinder having large time lag moves slowly (If it moves, it
is abnormal).
Malfunction of control valve
4 (pressure compensation a If there is abnormality in above item, check by interchanging
valve) pressure compensation valves between both ports and watching
how condition changes.
PC490LC-10 40-697
40 Troubleshooting
mode)
H-12 Other work equipment moves when one of work equipment is

relieved (PC400-FT4-400-A-Z0-A)
Failure • Other wok equipment moves when one of work equipment is relieved
When performing hydraulic relief of a work equipment and if other work
equipment move, pressure compensation valve on moving work side
Defective sealing for control may malfunction.
1 valve (pressure compensation a Component parts of pressure compensation valve have outer and
valve) inner seals, LS check valve (ball), etc.
Since inner seal has slipper seal, breakage of inside O-ring cannot
be checked from outside.
40-698 PC490LC-10
40 Troubleshooting
mode)
H-13 One-touch power maximizing function does not work (PC400-FGL-400-A-Z1-A)
Failure • One-touch power maximizing function does not work.

Related information • If a failure code appears, perform troubleshooting for the codes first (DWK0KA,
DWK0KB).
speed.
Malfunction of 2-stage relief Swing lock switch Solenoid output pressure
1
solenoid valve OFF 0 MPa {0 kg/cm2 }
2.84 to 3.43 MPa
ON
{29 to 35 kg/cm2 }
speed.
Measurement Work equipment Main relief pressure
conditions control lever
Defective adjustment or Only bucket or arm to 33.1 to 36.8 MPa
Normal relief hydraulic relief
2 malfunction of main relief {338 to 375 kg/cm2 }
valve Only bucket or arm to 35.6 to 39.2 MPa
One-touch relief hydraulic relief {363 to 400 kg/cm2 }
If the oil pressure cannot be set normally by adjustment, the main relief
valve may malfunction.
Check for deterioration of spring and defective valve seat.
PC490LC-10 40-699
40 Troubleshooting
mode)
H-14 Machine push-up function does not work (PC400-FTG-400-A-Z1-A)
Failure • The machine push-up function does not work.

speed.
Machine push-up switch Solenoid valve outlet pressure
Malfunction of machine push-
1 up solenoid valve Min. 2.75 MPa
OFF (solenoid is energized)
{Min. 28 kg/cm2 }
0 MPa
ON (solenoid is de-energized)
{0 kg/cm2 }
speed.
Measurement Right work equipment Main relief pressure
Machine push-up 16.5 to 19.6 MPa
Malfunction of boom control switch OFF Only boom LOWER {168 to 200 kg/cm2 }
2 valve (safety valve and suction to hydraulic relief 29.2 to 33.3 MPa
Machine push-up
valve)
switch ON {298 to 340 kg/cm2 }
Safety valve and suction valves of boom control valve (Lo) (high
pressure set side on head side) may malfunction.
If normal oil pressure is not obtained after adjustment, safety valve may
malfunction (deterioration of spring) or have internal defect (defective
valve seat),etc. Check it directly.
40-700 PC490LC-10
40 Troubleshooting
mode)
H-15 In combined operation of work equipment , equipment having

heavier load moves slower. (PC400-D34-400-A-Z0-A)
Failure • Work equipment loaded more is slower during combined operation
Related information —
Pressure compensation valve for work equipment on low load side may
malfunction.
a Component parts of pressure compensation valve have outer and
inner seals, LS check valve (ball), etc.
Since inner seal has slipper seal, breakage of inside O-ring cannot
be checked from outside.
Combination of
Larger load side Smaller load side
combined operation
Boom RAISE
+ Boom Arm
Malfunction of control valve Arm IN
1 (pressure compensation Boom RAISE
valve) on smaller load side + Arm Boom
Arm OUT
Boom RAISE
+ Boom Bucket
Bucket CURL
Arm OUT
+ Arm Bucket
Bucket CURL
Boom LOWER
+ Arm Boom
Arm OUT
PC490LC-10 40-701
40 Troubleshooting
mode)
H-16 In combined operation of swing and boom RAISE, boom rising

speed is low (PC400-D35-400-A-Z0-A)
Failure • In combined operations of swing and boom RAISE, boom rising speed is low
Related information • If boom raise single operation is also slow, troubleshoot H-6 first.
LS selector valve of swing control valve may malfunction or sealing
Malfunction or its sealing may may be defective.
1 be defectiveing of LS selector
Check LS selector valve for hitch and flaw of piston and deterioration of
valve
spring.
40-702 PC490LC-10
40 Troubleshooting
mode)
H-17 Travel speed drops largely in combined operation of swing and

trave (PC400-D26-400-A-Z0-A)
Failure • Travel speed drops largely in combined operation of swing and travel
Related information • When travel speed is low in the single operation of travel, carry out H-19 check first.
The LS shuttle valve in the right travel control valve or the swing control
Malfunction of LS shuttle valve valve may malfunction.
1 (left travel and swing) Check for flaw of check valve (ball) and check that ball moves
smoothly.
PC490LC-10 40-703
40 Troubleshooting
mode)
H-18 Machine does not travel straight (PC400-FTF-400-A-Z0-A)
Failure • Machine deviates during travel

• If any failure code appears, perform troubleshooting for that code first (DW91KA,
DW91KB, DHS3MA, DXE5KA, DXE5KB, DXE6KA, DXE6KB).
• Travel PPC pressure can also be checked by using the monitor (monitoring code:
Related information 01882).
• Merge-divider (main) solenoid current can also be checked by using the monitor
speed.
Measurement PPC valve output
Travel lever pressure
conditions
NEUTRAL 0 MPa {0 kg/cm2 }
Malfunction of travel PPC When traveling
1
valve forward 2.84 to 3.43 MPa
• Hydraulic oil
temperature: Within When traveling {29 to 35 kg/cm2 }
operation range reverse
Differential output Max. 0.4 MPa
between right and left
{Max. 4 kg/cm2 }
sides
speed.
Malfunction of self-pressure Measurement PPC valve output Control circuit source
2 reducing valve conditions pressure pressure
• Hydraulic oil When all control levers 2.84 to 3.43 MPa

speed.
Malfunction of travel junction Travel lever
3 conditions
solenoid valve Both levers in
• Hydraulic oil 0 MPa {0 kg/cm2 }
NEUTRAL
When either lever is
operating range
operated {29 to 35 kg/cm2 }
Malfunction of travel junction • Check merge-divider valve body and travel junction valve spool for
4 valve (spool) scuffing, sticking, etc. (Spool must move smoothly without hitch).
• Remove travel junction valve spool from body, and check it for flaw
and dirt.
Malfunction of travel control • Check control valve body and travel spool for prying, sticking, etc.
• Remove travel spool from the valve body, then check it for flaw and
dirt.
40-704 PC490LC-10
40 Troubleshooting
mode)

speed.
Measurement Measuring point Travel relief pressure
conditions
Malfunction of travel control • Hydraulic oil Travel system relief
35.6 to 40.7 MPa
6 valve (pressure compensation temperature: Within (Right, left, forward, or
operating range {363 to 415 kg/cm2 }
valve) reverse)
a If there is abnormality in only one of right, left, front, and rear,
pressure compensation valve may malfunction.
Check by interchanging front and rear pressure compensation
valves and watching how condition changes.
Interchange connection ports of right and left hoses connecting swivel
7 Defective center swivel joint
joint and travel motors and check if turning direction changes.
a Check for hydraulic drift of travel on slope.
Measurement conditions Hydraulic drift of travel
• Hydraulic oil temperature: 45 to 55 °C
8 Defective travel brake
• Stop machine on 30 °C slope with sprocket
on upper side. 0 mm
• Measure hydraulic drift of machine for five
minutes.
speed.
Measurement Leakage from travel
9 Defective travel motor Travel lever
conditions motor
• Hydraulic oil
temperature: Within Travel system relief 40 l/min
operating range
10 Defective final drive a Judge by unusual sound, unusual heating, metallic powder in
drained oil, etc.
PC490LC-10 40-705
40 Troubleshooting
mode)
H-19 Travel speed is low (PC400-D20-400-A-Z0-A)
Failure • Travel speed is low

• If a failure code appears, perform troubleshooting for the codes first (DXE0KA,
DXE0KB).
• Pump pressure can also be checked by using the monitor (monitoring code: F pump
Related information pressure 01100, R pump pressure 01101).
01882).
• LS-EPC solenoid current can also be checked by using the monitor (monitoring
mode: 01500).
speed.
conditions
1
• Hydraulic oil
operating range reverse
Differential output Max. 0.4 MPa
between right and left
{Max. 4 kg/cm2 }
sides
speed.
Malfunction of self-pressure Measurement PPC valve output Control circuit source
2 reducing valve conditions pressure pressure
• Hydraulic oil When all control levers 2.84 to 3.43 MPa
operating range position {29 to 35 kg/cm2 }

speed.
LS-EPC valve output
Approx. 2.9 MPa
Lo NEUTRAL
dirt.
Malfunction of travel control
5 valve (pressure compensation a Check by interchanging forward and reverse pressure
valve) compensation valves and watching how condition changes.
40-706 PC490LC-10
40 Troubleshooting
mode)

speed.
conditions
6 valve (suction valve) 35.6 to 40.7 MPa
temperature: Within (Right, left, forward, or
reverse)
If relief pressure of only one port is low after adjustment, suction valve
may malfunction. Check the check valve for flaw, deterioration of
spring, etc.
speed.
Measurement Leakage from travel
7 Defective travel motor Travel lever
conditions motor
• Hydraulic oil
temperature: Within Travel system relief 40 l/min
operating range
8 Defective final drive a This defect can be judged by unusual sound, unusual heating,
metal powder in drained oil, etc.
PC490LC-10 40-707
40 Troubleshooting
mode)
H-20 Machine is hard to steer or travel power is low (PC400-L18-400-A-Z0-A)
Failure • Machine is not steered well or steering power is low

• If any failure code appears, perform troubleshooting for that code first (DW91KA,
DW91KB, DHS3MA, DXE5KA, DXE5KB, DXE6KA, DXE6KB).
• Merge-divider (main) solenoid current can also be checked by using the monitor

speed.
conditions
1
• Hydraulic oil
operation range reverse
Differential output Max. 0.4 MPa{Max. 4
between right and left kg/cm2 }
sides
speed.
Malfunction of travel junction Travel lever pressure
2 conditions
solenoid valve
temperature: Within When either lever is 2.84 to 3.43 MPa
operating range operated {29 to 35 kg/cm2 }
Malfunction of travel junction • Check merge-divider valve body and travel junction valve spool for
3 valve (spool) scuffing, sticking, etc. (Spool must move smoothly without hitch).
• Remove travel junction valve spool from body, and check it for flaw
and dirt.
(Note) If machine deviates largely when work equipment is operated
during travel, perform following troubleshooting.
speed.
Malfunction of merge-divider Measurement EPC output pressure
4 EPC current value
main EPC valve conditions
Work equipment lever 0 to 0.49 MPa
0 mA
is in neutral {0 to 5 kg/cm2 }
relief {25 to 30 kg/cm2 }
40-708 PC490LC-10
40 Troubleshooting
mode)

speed.
EPC current value
5 Work equipment lever 0 to 0.49 MPa
LS-EPC valve 0 mA
is in neutral {0 to 5 kg/cm2 }
relief {25 to 30 kg/cm2 }

dirt.
speed.
conditions
35.6 to 40.7 MPa
9 valve (pressure compensation temperature: Within (Right, left, forward, or
valve) reverse)
a If there is abnormality in only one of right, left, front, and rear,
pressure compensation valve may malfunction.
Check by interchanging front and rear pressure compensation
valves and watching how condition changes.
Interchange connection ports of right and left hoses connecting swivel
10 Defective center swivel joint joint and travel motors and check if turning direction changes.
If both reverse and forward travels of either of right and left travel
motors are abnormal during check in Cause 9, safety valve may be
Defective travel motor (safety defective.
11 valve)
Check by interchanging safety valves of right and left travel motors and
If pressure compensation valve is judged normal by check in Cause 9,
Defective travel motor (check check valve may malfunction.
12 valve)
Check by interchanging check valves from forward and reverse circuit
of one motor and watching how condition changes.
drained oil, etc.
PC490LC-10 40-709
40 Troubleshooting
mode)
H-21 Travel speed does not change, or travel speed is too low or
high (PC400-BQ4-400-A-Z0-A)
Failure • Travel speed does not change or travel speed is too low or high
• Perform all troubleshooting with working mode in POWER (P) mode.
• If a failure code appears, perform troubleshooting for the codes first (DW43KA,
DW43KB).
Related information • LS-EPC solenoid current can also be checked by using the monitor (monitoring
mode: 01500).
• Travel speed selector solenoid (ON, OFF) can also be checked by using the monitor
speed.
Travel speed Travel lever LS-EPC current value
Lo 690 mA (See *)
Mi Fine operation 740 mA
Hi 0 mA
1 Malfunction of LS-EPC valve a Be ready with engine stopped, then troubleshoot with engine at full
speed.
LS-EPC valve output
Approx. 2.9 MPa
Lo NEUTRAL

speed.
Solenoid valve output
Malfunction of travel speed Travel speed Travel lever
2 pressure
solenoid valve
Lo NEUTRAL 0 MPa {0 kg/cm2 }
2.84 to 3.43 MPa
Hi Fine operation
{29 to 35 kg/cm2 }
Malfunction of travel motor If no abnormality is detected in Cause 1 and 2 above, speed selector
3 (speed-select unit) portion of travel motor may malfunction. Check speed selector portion
of travel motor.
*: Travel speed of Low can be adjusted with adjustment function of machine monitor. Therefore, if it has been
changed from initial set value, indicated value changes more or less.
40-710 PC490LC-10
40 Troubleshooting
mode)
H-22 One of tracks does not run (PC400-BG1-400-A-Z0-A)
Failure • Travel system does not work (only one side)

pressure 01100, R pump pressure 01101).
speed.
Malfunction of travel PPC conditions
1 NEUTRAL 0 MPa {0 kg/cm2 }
valve
• Hydraulic oil When traveling
temperature: Within forward 2.89 to 3.43 MPa
operation range When traveling {29 to 35 kg/cm2 }
reverse
If check result of Cause 1 is normal and pump pressure is approx. 4
2 MPa and one of tracks does not run when travel operation is
(spool)
performed, spool may be stuck near neutral position.
speed.
conditions
Travel system relief
Defective travel motor (safety • Hydraulic oil 35.6 to 40.7 MPa
3 valve) temperature: Within (Right, left, forward, or
reverse)
If both reverse and forward travels of either of right or left travel motors
are abnormal, sealing of safety valve may be defective.
Check by interchanging safety valves of right and left travel motors and
If pressure safety valve is judged normal by check in Cause 3, check
Defective travel motor (check valve seat may be defective.
4 valve) Check by interchanging check valves from forward and reverse circuit
of one motor and watching how condition changes.
Defective travel motor (parking When running track idle off ground, if track does not move at relief
5 brake) pressure, parking brake may malfunction.
speed.
Measurement Measuring point Leakage from travel
6 Defective travel motor conditions motor
• Hydraulic oil Travel system relief
temperature: Within (Right, left, forward, or 40 l/min
operating range reverse)
drained oil, etc.
PC490LC-10 40-711
40 Troubleshooting
mode)
H-23 Upper structure does not swing (PC400-L40-400-A-Z0-A)
Failure • (1) Upper structure does not swing in both right and left directions.
Related information DW45KB).
speed.
Measurement Solenoid valve output
Malfunction of swing parking Swing control lever
1 conditions pressure
brake solenoid valve
• Hydraulic oil NEUTRAL 0 MPa {0 kg/cm2}
temperature: Within Left swing 2.84 to 3.43 MPa
operation range Right swing {29 to 35 kg/cm2}
If check result of Cause 1 is normal and upper structure does not swing
Malfunction of swing motor
2 at swing to hydraulic relief, swing brake may malfunction (Judge by
(swing parking brake)
checking pump pressure with monitoring function).
If check results of Causes 1 and 2 are normal and pump pressure is
3 approx. 4 MPa and upper structure does not swing when operated,
(spool)
spool may be stuck near neutral position.
speed.
Measurement Left work equipment Swing relief pressure
Defective swing motor (safety Swing lock Swing to hydraulic 28.4 to 32.9 MPa
4 valve) switch ON relief {290 to 335 kg/cm2}
If right and left swing relief pressures are same and lower than
standard value, sealing of safety valve may be defective.
Safety valve has 2-stage relief function, but both Hi and Lo are set to
same pressure (Relief flow rates are different, however).
speed.
5 Defective swing motor Measurement Left work equipment Leakage from swing
conditions control lever motor
Swing lock Swing to hydraulic
11 l/min
switch ON relief
6 Defective swing machinery a Judge by unusual sound, unusual heating, metallic powder in
drained oil, etc.
40-712 PC490LC-10
40 Troubleshooting
mode)
Failure • (2) Upper structure does not swing in only one direction.
Related information • Swing PPC pressure can also be checked by using the monitor (monitoring code:
Left swing 09001, Right swing 09002).
speed.
Malfunction of swing PPC Swing lever
valve
operation range Operated for swing
{29 to 35 kg/cm2}
If check result of Causes 1 is normal and pump pressure is approx. 4
2 MPa and upper structure does not swing when operated, spool may be
(spool)
stuck near neutral position.
Check by interchanging right and left suction valves of swing motor and
Defective seat of swing motor watching how condition changes.
3 (suction valve)
When removing valves, check them for sticking, flaw, etc.
Check by interchanging right and left check valves of swing motor and
4 (check valve)
PC490LC-10 40-713
40 Troubleshooting
mode)
H-24 Swing acceleration is poor or swing speed is low (PC400-L43-400-A-Z0-A)
• (1) Swing acceleration or swing speed of upper structure is low in both right and left
Failure
directions.
Related information DW45KB).
Malfunction of control valve Swing spool may malfunction.
1 (spool) Check spool for hitch, flaw, etc.
Malfunction of swing motor Malfunction of swing motor (swing parking brake)
2 (swing parking brake) Check piston for prying, and check disc and plate for seizure, flaw, etc.
Malfunction of all control The LS shuttle valve may malfunction.
3 valves (LS shuttle valves) Check shuttle valve (ball) for flaw, etc.
speed.
4 valve) switch ON relief {290 to 335 kg/cm2 }
speed.
11 l/min
switch ON relief
drained oil, etc.
40-714 PC490LC-10
40 Troubleshooting
mode)
Failure • (2) Swing acceleration or swing speed is low in only one direction.
speed.
valve
operating range Operated for swing
{29 to 35 kg/cm2 }
The pressure compensation valve of the swing control valve may
Malfunction of control valve malfunction.
3 (pressure compensation Judge by interchanging right and left pressure compensation valves
valve) and watching how condition changes.
(See H-12)
4 (suction valve)
5 (check valve)
PC490LC-10 40-715
40 Troubleshooting
mode)
H-25 Upper structure overruns excessively when it stops swinging (PC400-

L46-400-A-Z0-A)
Failure • (1) Overrun of upper structure is large in both right and left directions.
Related information • Pump pressure can also be checked by using the monitor (monitoring code: F pump
speed.
1 valve) switch ON relief {283 to 335 kg/cm2 }
speed.
Measurement Left work equipment Leakage from swing
2 Defective swing motor
11 l/min
switch ON relief
40-716 PC490LC-10
40 Troubleshooting
mode)
Failure • (2) Upper structure overruns excessively when it stops swing in only one direction.
speed.
valve
{29 to 35 kg/cm2 }
Swing PPC slow return valve may malfunction.
Clogged swing PPC slow Judge by interchanging right and left slow return valves and watching
2 how condition changes.
return valve
When removing slow return valves, check their strainers for clogging.
4 (suction valve)
5 (check valve)
PC490LC-10 40-717
40 Troubleshooting
mode)
H-26 Shock is large when upper structure stops swinging (PC400-L49-400-A-Z0-A)
Failure • Large shock is made when upper structure stops swinging

speed.
valve
{29 to 35 kg/cm2 }
Swing PPC slow return valve may malfunction.
Clogged swing PPC slow Judge by interchanging right and left slow return valves and watching
2 how condition changes.
return valve
When removing slow return valves, check their strainers for clogging.
Malfunction of swing motor Shockless valve of swing motor may malfunction.
3 (shockless valve) Check spool for hitch and sticking and check deterioration of spring.
40-718 PC490LC-10
40 Troubleshooting
mode)
H-27 Large unusual noise is heard when upper structure stops

swinging (PC400-BAB-400-A-Z0-A)
Failure • Large unusual noise is heard when upper structure stops swinging.
speed.
Malfunction of variable back Swing lever
pressure solenoid valve
operating range Operated for swing
{29 to 35 kg/cm2 }
If check result of cause 1 is normal, back pressure valve of control
Malfunction of back pressure valve may malfunction.
2
valve Check valve for prying, sticking, flaw, etc. and check deterioration of
spring.
Safety valve of swing motor may malfunction.
3 (safety valve) If normal oil pressure is not obtained after adjustment, the safety valve
may have internal defect.
4 (suction valve)
drained oil, etc.
PC490LC-10 40-719
40 Troubleshooting
mode)
H-28 Swing drift on a slope is large (PC400-MS5-400-A-Z0-A)
Failure • (1) Swing drift on a slope is large (while swing parking brake is applied)
• When swing lock switch is in ON position, or swing parking brake cancel switch is in
normal position, swing parking brake is applied and disc brake holds upper
structure.
DW45KB).
speed.
Malfunction of swing parking Swing control lever
brake solenoid valve
temperature: Within Left swing 2.84 to 3.43 MPa
operating range Right swing {29 to 35 kg/cm2}
2 swing parking brake may malfunction. Check it directly.
(swing parking brake)
speed.
11 l/min
switch ON relief
drained oil, etc.
40-720 PC490LC-10
40 Troubleshooting
mode)
Failure • (2) Swing drift on a slope is large (while swing parking brake is released)
Related information • Pump pressure can also be checked by using the monitor (monitoring code: F pump
If check result of Causes 1 is normal and pump pressure is approx. 4
1 MPa and upper structure does not swing when operated, spool may be
(spool)
stuck near neutral position.
The pressure compensation valve of the swing control valve may
Malfunction of control valve malfunction.
2 (pressure compensation Judge by interchanging right and left pressure compensation valves
valve) and watching how condition changes.
(See H-12)
speed.
3 valve) switch ON relief {290 to 335 kg/cm2}
4 (suction valve)
5 (check valve)
Malfunction of swing motor Swing motor reverse prevention valve of swing motor may malfunction.
6 (swing motor reverse
prevention valve) Check spool for hitch and sticking and check deterioration of spring.
PC490LC-10 40-721
40 Troubleshooting
mode)
H-29 Attachment circuit cannot be changed (PC400-HBD-400-A-Z1-A)
Failure • Attachment circuit can not be changed

• For machines with provision for attachment, service circuit changes as shown below
according to selected working mode.
1. In mode ATT: The double-acting circuit (2-way) is selected and the safety valve is
set to the low-pressure setting.
2. In B mode: Single-acting circuit (1-way) is selected and safety valve is set to
Related information
high-pressure setting.
* Setting of the safety valve is changed on only port B side. Setting on port A side is
kept to the low-pressure setting.
• If a failure code appears, perform troubleshooting for the codes first (DWA2KA,
DWA2KB).
speed.
Malfunction of ATT return Working mode
selector solenoid valve
• Hydraulic oil In mode ATT 0 MPa {0 kg/cm2 }
operating range B mode
{29 to 35 kg/cm2 }
If check result of Cause 1 is normal, ATT return selector valve may
Malfunction of ATT return malfunction.
2
selector valve Check valve for prying, sticking, flaw, etc. and check deterioration of
spring.
Safety valve of service valve may malfunction.
Malfunction of service valve
3 (safety valve) If normal oil pressure is not obtained after adjustment, the safety valve
may have internal defect.
40-722 PC490LC-10
40 Troubleshooting
mode)
H-30 Oil flow in attachment circuit cannot be controlled (PC400-HBE-400-A-Z0-A)
Failure • Oil flow in attachment circuit cannot be changed

• For machine equipped with attachment, flow rate of the service circuit depends on
selection in selection mode.
• How to adjust flow rate in ATT mode is different from that in B mode. For details, see
Related information Operation and Maintenance Manual.
• If a failure code appears, perform troubleshooting for the codes first (DXE4KA,
DXE4KB).
speed.
Measurement EPC valve output
Service pedal
conditions pressure
Malfunction of attachment flow NEUTRAL 0 MPa {0 kg/cm2 }
1 • Hydraulic oil
rate adjustment EPC valve 2.75 MPa
temperature: Within
operating range Operated
{28 kg/cm2 }
a If output pressure of EPC valve is 0 MPa, check "Service solenoid
current" with monitoring function (Monitoring code: 01700).
If current is 0.3 to 0.91 A, EPC valve may be defective.
speed.
Measurement EPC valve output
Malfunction of service PPC Service pedal
valve
operating range Operated
{29 to 35 kg/cm2 }
PC490LC-10 40-723
40 Troubleshooting
mode)
H-31 Fan speed is abnormal (high, low, or 0 rpm) (PC400-FTP-400-A-00-A)
Detail of failure • Fan speed is abnormal (high, low, or 0 rpm)

• When engine is started for the first time after hydraulic oil replacement, the fan may
temporarily operate at a higher speed but this is normal.
• If failure codes are displayed, carry out troubleshooting for them first (DLM3MA,
DLM3MB, DWN5KA, DDWN5KB, DWN5KY)
Related • Fan speed can also be checked on the monitor (monitoring code: 10007)
information • Hydraulic oil temperature can also be checked on the monitor (monitoring code: 04401)
• Before performing troubleshooting, check that the hydraulic oil level tank is normal.
• Fan EPC solenoid current can also be checked on the monitor (monitoring code:
31624)
a Start engine and check
Measurement conditions Engine speed
1 Defective engine speed Engine at low idle 975 to 1,025 rpm
* Engine high idle (P-mode) 1,745 to 1,795 rpm
If engine speed is not increased to specification, perform troubleshooting
for "S-5 Engine runs rough or is unstable".
Defective PTO (fan pump
2 Fan pump drive of PTO may be defective. Check it.
drive)
a Prepare with starting switch OFF, then run the engine at full speed
position to perform troubleshooting
Malfunction of self-
3 pressure reducing valve Work equipment control lever Control circuit pressure
2.84 to 3.43 MPa
Neutral
{29 to 35 kg/cm2 }
If no failure is found by check on cause 3 and pressure is at the specified
4 Defective fan EPC valve level, solenoid valve may be defective.
Check that the spool is not stuck in the valve body and moves smoothly.
speed.
Malfunction of fan motor
5 (safety valve) Fan mode Fan motor drive pressure
9.8 to 15.7 MPa
100 %
{100 to 160 kg/cm2 }
If pressure does not reach the specified value after adjustments are made
for cause 5, there may be an internal defect in the fan pump.
6 Defective fan pump
Check if metal particles are adhered to the self-pressure reducing valve
inlet strainer
a Release remaining pressure from hydraulic tank and piping and then
perform troubleshooting
Malfunction of fan motor • Check for stuck or seized spool in direction selector valve body (spool
7 (direction selector valve) should move smoothly)
• Take out direction selector spool from valve body and check for defects
and dirt.
a Be careful not to let foreign matter enter the valve during repair work
If no failure is found by checks on causes 1 to 7, there may be an internal
8 Defective fan motor
defect in the fan motor.
40-724 PC490LC-10
40 Troubleshooting
mode)
H-32 Unusual noise is heard from around fan (PC400-FTQ-400-A-00-A)
Detail of failure • Abnormal sound is heard around the fan.

Related
information
Looseness of mounting
1 portions of fan and fan Check mounting portions of fan and fan motor for looseness and play.
motor
2 Interference of shroud Check shroud and fan for interference.
3 Defect in fan motor Fan motor may have defect in it.
PC490LC-10 40-725
40 Troubleshooting
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode) (ALL-3840-001-A-03-A)
Information mentioned in troubleshooting table (S mode) (PC400-5170-010-A-00-A)
(Rev. 2011/04 125T4)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
Related Information related to the detected failure or troubleshooting
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment
1. Gauze filter for feed pump

a This figure shows the location of gauze filter (1) for the feed pump explained in this manual.
40-726 PC490LC-10
40 Troubleshooting
S-1 When starting switch is turned to START position, engine is not

cranked (PC400-A26-400-A-Z0-A)
Failure When starting switch is turned to START position, engine is not cranked
• See E mode (E-1) for troubleshooting the electrical system.
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy

Defective starting circuit wiring • When starting switch is turned to START
Diagnose and take
1 system position, starting motor pinion is not pushed
remedies for E-1
out
• Grating noise is heard from starting motor
pinion
(When starting switch is turned to START
position, starting motor pinion is pushed
out)
• Starting motor pinion disengages during
operation
Defective starting motor position, starting motor pinion is pushed Diagnose and take
2 (safety relay section) out) remedies for E-1
• Ratting noise is heard and starting motor
does not turn.
position, starting motor pinion is pushed
out)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
• If grating noise is heard from starting motor
3 Broken flywheel ring gear pinion and the starting motor does not Replace if damaged
crank, visually check the flywheel ring gear.
• Remove EGR cooler inlet and outlet gas
piping and check if coolant containing
Cracked EGR cooler antifreeze flows out Replace EGR cooler
4 (Reference: coolant in exhaust and drain water from
gas) a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.
PC490LC-10 40-727
40 Troubleshooting
S-2 The engine cranks but exhaust smoke does not come out (PC400-A27-400-A-Z0-
A)
Failure The engine cranks but exhaust smoke does not come out
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
7 Defective common rail Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
8 Defective supply pump when checking common rail pressure on Replace supply pump
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
• When priming pump is operated, no
9 Defective priming pump Replace priming pump
resistance is felt or it is heavy
Clogging of feed pump gauze • Gauze filter is clogged Clean or replace
10 gauze filter
filter
• Common rail pressure does not go down Loosen injection piping
when when pressure is checked with and high pressure
Improper bleeding of common
11 rail or injection piping monitoring function and then stopped piping mounting nuts
(Code: 36400 Common rail pressure) on common rail and
(pressure will not decrease if air is present) bleed air
40-728 PC490LC-10
40 Troubleshooting
S-3 Fuel is injected but engine does not start (incomplete combustion,
engine seems to start but does not) (PC400-A28-400-A-Z0-A)
Fuel is injected but engine does not start (incomplete combustion, engine seems to start
Failure but does not)
• Specific gravity of electrolyte and voltage of Add electrolyte or
1 Defective battery
battery are low charge battery
cap is clogged
5
drained
Clogging of feed pump gauze Clean or replace
9 • Gauze filter is clogged
filter gauze filter
• Air cleaner dust indicator is at a caution Test and adjust air
10 Clogged air cleaner element
level cleaner element
• During pre-heating operation, intake air
heater mount is cold
• When engine is preheated or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor heater
does not indicate properly
• Check valve clearance
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve Replace valve or
12 Worn valves or rocker arms clearance") rocker arm
• While engine is running, unusual noise is
heard around cylinder head
• Testing compression pressure
Replace piston ring or
13 Defective piston ring (Reference: See Testing and adjusting,
piston
"Testing compression pressure")
Defective injector • When a certain cylinder is cut out, engine
speed does not change
14 (clogged injector, defective Replace Injector
(Note: see "Handling cylinder cutout mode
injection) operation" section of Testing and adjusting)
• Since this is an internal defect, Replace engine
15 Defective engine controller troubleshooting cannot be performed. controller.
PC490LC-10 40-729
40 Troubleshooting
S-4 Engine startability is poor (PC400-A10-400-A-Z0-A)
Failure Engine startability is poor.

• If any failure code is displayed, carry out troubleshooting for it first.
• The common rail fuel injection system (CRI) controls the fuel injection timing
Related information electrically. Accordingly, even if the engine is cranked properly, the engine may not
start until the crankshaft rotates two turns under the most disadvantageous
condition. This phenomenon does not mean a problem, however.
• Specific gravity of electrolyte and voltage of Add electrolyte or
1 Defective battery
battery are low charge battery
• Non-specified fuel is being used.
• Fuel suitable for ambient temperature is not
used Use proper fuel
Improper fuel used (Reference: When engine starts in warm specified in Operation
3
temperatures but not in low temperatures) and Maintenance
• Wax is found when clear bowl of fuel Manual
prefilter is checked (milky)
cap is clogged
6
drained
(CC/min)
above first.
when checking common rail pressure on Replace supply pump
10 Defective supply pump
defective.
filter gauze filter
• Air cleaner dust indicator is at a caution Check, clean air
12 Clogged air cleaner element
level cleaner element
• During pre-heating operation, intake air
heater mount is cold
• When engine is preheated or when Replace intake air
13 Defective intake air heater
temperature is low, preheating monitor heater
does not indicate properly
40-730 PC490LC-10
40 Troubleshooting

• Remove EGR cooler inlet and outlet gas
piping and check if coolant containing
Cracks in EGR cooler antifreeze flows out Replace EGR cooler
14 (Reference: coolant in exhaust and drain water from
gas) a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
15 Defective injector • When a certain cylinder is cut out, engine Replace injector
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
• Measure the compression pressure (see
standard values table)
Defective contact of valve with "Testing compression pressure") Correct or replace
17 • Test the valve clearances
valve seat valve or valve seat
adjusting, "Testing and adjusting valve
clearance")
• Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
"Testing exhaust gas color".) Replace piston ring or
18 Defective piston ring • Measure the compression pressure (see piston
• Check piston rings and piston ring grooves
PC490LC-10 40-731
40 Troubleshooting
S-5 Engine does not pick-up smoothly (PC400-A30-400-A-Z0-A)
Failure Engine does not pick up smoothly

cap is clogged
4
drained
(CC/min)
above first.
Defective supply pump when checking common rail pressure on Replace supply pump
8
defective.
filter gauze filter
• If Crankcase Pressure High Error (failure
code: CA555) is still displayed after KCCV
Abnormally high crankcase filter element is replaced, blow-by pressure Perform
10 pressure may be high due to seizure or damage of troubleshooting for
KVGT (see Testing and adjusting, "Testing cause 10 and after.
blow-by pressure")
• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
12 Seized or broken KVGT Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)
• When engine is cranked, Unusual noise is
13 Incorrect valve clearance generated around cylinder head Adjust valve clearance
40-732 PC490LC-10
40 Troubleshooting

clearance")
clearance")
exhaust gas.
PC490LC-10 40-733
40 Troubleshooting
S-6 Engine stops during operation (PC400-AF0-400-A-Z0-A)
Failure Engine stops during operation

cap is clogged
4
drained
filter gauze filter
• See Testing and adjusting, "Checking fuel Replace supply pump
delivery, return rate and leakage" and pressure limiter
Defective air intake hose
• Visually check the air intake hose for Replace air intake
10 (from air cleaner to KVGT damage hose
inlet)
• Check the intake manifold for internal Replace air intake
11 Defective air intake manifold damage manifold
Defective boost piping and
connections Correct or replace
12 • Air flows out from boost piping
(from KVGT outlet to air intake boost piping
manifold)
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
13 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat shield plate)
• Check valves and rocker arms
Replace valve or
14 Damaged valve or rocker arm (Unusual noise is heard and engine
stopped suddenly) rocker arm
• Metallic powders are found in oil drained
from oil pan
• Remove oil pan and check pistons and
Broken or seized piston or Replace piston or
15 connecting rod connecting rods
connecting rod
(Reference: Unusual noise is heard and
engine stopped suddenly, or stopped after
overheating)
• Metallic powders are found in oil drained
Broken or seized crankshaft from oil pan Replace crankshaft
16 main bearing • Remove oil pan and check crankshaft main main bearing
bearing
• Check engine controller power supply
Correct engine
Defective engine controller wiring
17 power supply wiring controller power
(Reference: See Troubleshooting, Failure
supply wiring
Code [CA441].)
40-734 PC490LC-10
40 Troubleshooting

Defective starting switch Diagnose and take
18 wiring • Check starting switch wiring
remedies for E-1
Malfunction of hydraulic • See H mode, "H-2 Engine speed lowers Diagnose and take
19 system significantly or engine stalls" remedies for H-6
PC490LC-10 40-735
40 Troubleshooting
S-7 Engine runs rough or is unstable (PC400-A40-400-A-Z0-A)
Failure Engine runs rough or is unstable

cap is clogged
4
drained
• Check for leaks from boost system (KVGT Correct or replace
7 Leakage in boost system outlet to aftercooler, aftercooler to air intake parts around boost
manifold) piping
filter gauze filter
• Replace sensor and check if problem is
Defective mass air flow and corrected Replace mass air flow
9 temperature sensor (Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor
40-736 PC490LC-10
40 Troubleshooting
S-8 Engine lacks power (PC400-A60-400-A-Z0-A)
Failure Engine lacks power

cap is clogged
4
drained
"Check fuel circuit for leaking")
• See Testing and adjusting, "Checking fuel Replace supply pump
delivery, return rate and leakage" and pressure limiter
filter gauze filter
Clogged air cleaner element Check, clean air
9 • Air cleaner dust indicator in caution level
cleaner element
• Check air cleaner and airflow screen for Correct or replace air
10 Defective air cleaner
deformation cleaner
Defective air intake hose
• Visually check the air intake hose for Replace air intake
11 (from air cleaner to KVGT damage hose
inlet)
• Check the intake manifold for internal Replace air intake
12 Defective air intake manifold damage manifold
(from KVGT outlet to air intake boost piping
manifold)
Improperly installed boost • Air leaks from boost pressure sensor Correct mounting of
14 pressure sensor mounting boost pressure sensor
exhaust gas leakage
16 Gas leakage from EGR piping • Gas leaks from EGR piping Replace EGR piping
Check intake and exhaust
system • Measure boost pressure
Correct or replace
17 (KVGT outlet to air intake (Reference: See Testing and adjusting,
defective parts
manifold, exhaust manifold to "Testing boost pressure")
KDPF inlet)
18 Seized or broken KVGT Replace KVGT
PC490LC-10 40-737
40 Troubleshooting

• Open the exhaust color inspection hole in
front of KDPF, check the exhaust gas (refer
Excessive soot accumulation standard value table) Clean or replace
19
in KDPF (Note: see "Measuring exhaust gas color" KDPF
section of Testing and adjusting
• KDPF clogging - check exhaust pressure Clean or change
20 Defective KDPF
before KDPF KDPF
generated around cylinder head
21 Incorrect valve clearance Adjust valve clearance
clearance")
troubleshooting cannot be performed. controller.
clearance")
exhaust gas.
25 Defective piston ring
• Measure the compression pressure (see piston
40-738 PC490LC-10
40 Troubleshooting
S-9 KDPF gets clogged in a short time (PC400-AH5-400-A-Z0-A)
Failure KDPF gets clogged in a short time

a If this failure is occurring, it indicates that KCSF may be damaged. After completing
the repair of the problem, check the exhaust gas color according to the following
procedure. Replace the KCSF if the black smoke comes out of the exhaust pipe
Related information outlet.
1. Start the engine, perform the quick acceleration from low idle to high idle two times,
and then keep the engine running at high idle for 5 seconds.
2. Check that the black smoke does not come out of the exhaust pipe outlet during this
quick acceleration and high idling.
Use proper fuel
Improper fuel used • Non-specified fuel is being used. specified in Operation
1
and Maintenance
Manual
2
drained
• Check air cleaner and airflow screen for Correct or replace air
3 Defective air cleaner
deformation cleaner
exhaust gas leakage
Correct charge (boost)
Defective mounting of charge • Air leakage from mounting part of charge
5 pressure sensor
(boost) pressure sensor (boost) pressure sensor
mounting
(From KVGT outlet to air boost piping
intake manifold)
7 Gas leakage from EGR piping • Gas leaks from EGR piping Replace EGR piping
8 KVGT seized or broken Replace KVGT
9 Defective injector • When a certain cylinder is cut out, engine Replace Injector
• Too much fuel is returned when flow is
checked
10 Defective fuel return piping "Checking fuel delivery, return rate and return piping
leakage")
• Check fuel return piping for clogging
• Replace sensor and check if problem is
Defective mass air flow and corrected Replace mass air flow
11 temperature sensor (Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor
generated around cylinder head
• Check valve clearance Adjust valve clearance
12 Incorrect valve clearance
clearance".
PC490LC-10 40-739
40 Troubleshooting

standard values table).
Defective contact of valve with "Testing compression pressure".) Correct or replace
13
valve seat • Test the valve clearances valve or valve seat
clearance".
exhaust gas.
"Testing compression pressure".)
40-740 PC490LC-10
40 Troubleshooting
S-10 Engine oil consumption is excessive (PC400-B10-400-A-Z0-A)
Failure Engine oil consumption is excessive

Dust sucked in from intake • When intake piping between air cleaner Clean or replace
1 system and engine is removed, dust is found intake piping
inside.
• Measured blowby pressure exceeds
standard value.
• Blow-by pressure is still high after KCCV
filter element is replaced Replace or correct
2 Broken or worn piston ring
• Measure the compression pressure (see piston ring
Oil leakage from KCCV oil • Check for oil leaks from KCCV oil return Correct or replace oil
3 return piping piping piping
External leakage of oil from
4 engine • Check for oil leaks Correct oil leaks
Oil leakage from oil filter Reinstall or replace oil

5 • Check for oil leaks from oil filter
filter
Correct or replace oil
6 Oil leakage from oil piping • Check for oil leaks from oil piping
piping
7 Oil leakage from oil drain plug • Check for oil leaks from oil drain plug Retighten oil drain plug
Correct or replace oil
8 Oil leakage from oil pan • Check for oil leaks from oil pan
pan
Correct or replace
9 Oil leakage from cylinder head • Check for oil leaks from cylinder head
cylinder head
• Oil level in clutch chamber or damper Correct or replace rear
10 Worn or damaged rear oil seal
chamber on machine is low. oil seal
• KVGT blower inlet and outlet, and turbine
outlet are dirty with oil.
11 Oil leakage from KVGT • Check if KVGT shaft rotates Replace KVGT
• Oil in coolant
• Remove oil cooler and check for external oil
12 Oil leakage from oil cooler leaks Replace oil cooler
• Check for leaks by applying air pressure to
oil cooler
Oil leakage from EGR valve • When EGR valve is removed, outlet port is
13 Replace EGR valve
stem found to be dirty with oil.
• Check valve guide and stem seal
• Remove cylinder head. Check inside
Worn or damaged valve guide, diameter of guide, and check stem seal for Replace valve guide
14
stem seal damages. and stem seal
(Reference: See "Maintenance standard".)
PC490LC-10 40-741
40 Troubleshooting
S-11 Engine oil becomes contaminated early (PC400-B20-400-A-Z0-A)
Failure Engine oil becomes contaminated quickly.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
2
and Maintenance
Manual.
• Check exhaust gas color at location just Perform
Black exhaust gas color
upstream of KDPF. troubleshooting for "S-
3 checked at location just
(Reference: See Testing and adjusting, 9 Exhaust gas is
upstream of KDPF
"Testing exhaust color".) black".
standard value. Perform following
4 Excessive blowby gas
• Blowby pressure is still high after KCCV checks.
filter element is replaced.
• Rotate KVGT shaft and check for play.
Defective KVGT seal on (Move KVGT vanes with hand in axial and Replace KVGT.
5
turbine side radial directions to make judgement.)
• Remove EGR valve and check stem seal,
guide, and stem.
6 Worn EGR valve guide Replace EGR valve.
• When EGR valve is remove, outlet port is
dirty with oil.
• Check oil level for excessive refilling.
7 Excessive refilling of oil (If oil level is excessive, oil will reach high Refill with oil to correct
temperatures and early deteriorates.) oil level.
• Visually check oil cooler element for
contamination. Clean or replace oil
8 Dirty oil cooler element
(Contaminated oil cooler element can cooler element.
increased oil temperature.)
standard value.
• Blowby pressure is still high after KCCV
filter element is replaced. Replace piston ring or
9 Broken or worn piston ring
• Measure compression pressure (see correct its installation.
Standard value table).
• Check valve guide and stem seal.
• Remove cylinder head, and check inside
Worn or damaged valve Replace valve guide
10 guide or stem seal diameter of guide and stem seal for
damage. and stem seal.
(Reference: See "Maintenance standards".)
40-742 PC490LC-10
40 Troubleshooting
S-12 Fuel consumption is excessive (PC400-B70-400-A-Z0-A)
Failure Fuel consumption is excessive

Replace injector
• Test spill rate from injector
Too much fuel is spilled from (Reference: See Testing and adjusting, There may be
1 injector "Checking fuel delivery, return rate and excessive dust in fuel.
leakage") Confirm quality control
of fuel.
• Check fuel return piping for clogging
Correct or replace fuel
2 Clogged fuel return piping (Injection rate increased due to clogged fuel
return piping
return piping)
Fuel leakage from inside • Check for increased oil level
4 Correct defective parts
cylinder head • Check for smell of diesel fuel
• Check for increased engine oil level and
Fuel leakage from feed pump smell of diesel fuel Replace feed pump oil
5
oil seal • Check feed pump oil seal seal
6 Fuel leakage to outside • Check for fuel leakage to outside of engine. Correct defective parts
7 Fuel leakage from fuel doser • Check fuel doser for fuel leaks Replace fuel doser
PC490LC-10 40-743
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)
Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block
40-744 PC490LC-10
40 Troubleshooting
S-14 Oil pressure drops (PC400-10D-400-A-Z0-A)
Failure Oil pressure drops

Related information • Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
• Oil level in oil pan is low
1 Lack of oil in oil pan • Oil pressure monitor indicates low oil Add oil
pressure when operating on slopes
Defective oil pressure sensor, Replace oil pressure
• Check oil pressure sensor, wiring harness,
2 wiring harness sensor, wiring harness,
and connector
or connector
If oil is contaminated
with fuel, carry out
• Perform oil analysis and check for fuel in oil
3 Fuel in oil troubleshooting for "S-
• Engine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
• Perform oil analysis and check for water in with water, carry out
4 Water in oil oil troubleshooting for "S-
• Oil is milky 16 Water mixes into
engine oil (milky)"
• Check oil filter
(Reference: Oil filter has been used beyond
5 Clogged oil filter the specified period, oil heavily Replace oil filter
deteriorated, etc.)
• Water in oil can cause oil filter blockage
6 Clogged oil strainer • Check oil strainer Clean oil strainer
Crushed or clogged hydraulic Replace hydraulic
7 • Hydraulic piping is crushed or clogged
piping piping
• Check oil pump
8 Defective oil pump (worn or damaged gear) Replace oil pump
• Oil pump rotation is heavy or it has play
Defective regulator valve • Check valve spring for fatigue or damage Replace regulator
9
valve
• Valve and spring of oil pump relief valve is Replace oil pump relief
10 Defective oil pump relief valve fatigued, damaged. valve
Cracks in oil pump suction • Check around oil pump suction piping Replace oil pump
11 piping (cracked piping) suction piping
Defective seal between oil
12 pump and oil pump suction • Check seal Replace seal
piping
Replace boost oil
13 Defective boost oil pump • Check boost oil pump
pump
Defective boost oil pump relief • Check boost oil pump relief valve for fatigue Replace boost oil
14 or damage on valve and spring pump relief valve
valve
Oil leakage from EGR Replace EGR
15 hydraulic piping • Check EGR hydraulic piping
hydraulic piping
• Check main journal bearing
Replace main journal
16 Worn main journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
• Check pin journal bearing
Replace pin journal
17 Worn pin journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
Worn idler bushing, damaged Replace idler bushing
18 idler gear • Check idler bushing and idler gear
or idler gear
Breakage or falling off of Replace piston cooling
19 piston cooling nozzle • Check piston cooling nozzle
nozzle
PC490LC-10 40-745
40 Troubleshooting
S-15 Fuel mixes into engine oil (PC400-B31-400-A-Z0-A)
Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
1 Defective injector • When a certain cylinder is cut out, engine Replace Injector
Fuel leakage from injector or
2 • Check injector or O-ring Replace injector O-ring
O-ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced
40-746 PC490LC-10
40 Troubleshooting
S-16 Water mixes into engine oil (milky) (PC400-B32-400-A-Z0-A)
Failure Water mixes into engine oil (milky)

• If oil mixes into the coolant, perform troubleshooting for "S-13 Oil mixes into coolant"
When engine starting and stopping is frequently repeated in low outside
temperatures, the KCCV may cause condensation of water vapor in the blow-by gas
Related information leading to milky oil or emulsification inside the engine, but this is normal. This is not
a problem if coolant is not leaking.
If coolant leakage is suspected by such as drop of coolant level in a short time, carry
out the following troubleshooting procedures.
• Coolant containing antifreeze flows out
when EGR cooler outlet gas piping are
removed.
(Make sure the water is coolant or not. It
may be condensate water)
1 Cracks in EGR cooler Replace EGR cooler
(Reference: If cracks are found in the EGR
cooler, this may be caused by low coolant
level in the cooling system. When replacing
the EGR cooler, check for leaks from
coolant system piping and radiator.)
• Check oil cooler element and O-ring
Damaged oil cooler element or Replace oil cooler
2 • Pressure-tightness test of oil cooler shows
O-ring element or O-ring
oil leakage
Leakage from water pump • Check for leaks from water pump Replace water pump
3
mechanical seal mechanical seal mechanical seal
Clogged water pump drain • Check water pump drain hole Clean water pump
4
hole drain hole
Replace cylinder head
Broken cylinder head or • Disassemble engine and check cylinder
5 or cylinder head
cylinder head gasket head and cylinder head gasket
gasket
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
6
block or pitting in cylinder block
PC490LC-10 40-747
40 Troubleshooting
S-17 Coolant temperature rises too high (overheating) (PC400-AL0-400-A-Z0-A)
Failure Coolant temperature rises too high (overheating).

information
Clogged radiator core • Check radiator core for clogging, and check
1 Clean radiator core.
fin for crush.
• Thermostat does not open at cracking
temperature.
2 Malfunction of thermostat a Thermostat cracking temperature: 76.5 ± 2 Replace thermostat.
°C
(Full open temperature: 90 °C)
• Error related to coolant temperature is Replace coolant
Defective coolant temperature temperature sensor,
3 displayed, but measured value of radiator
gauge monitor or wiring
coolant temperature is normal.
harness.
Perform
Increased fuel injection rate • Fuel injection rate is high. troubleshooting for "S-
4
12 Fuel consumption is
excessive".
5 Low coolant level • Check coolant level. for lowering. Refill with coolant.
Replace coolant
6 Leakage of coolant • Check water leakage from coolant piping.
piping.
• Visually check water pump.
(Check shaft seal for water leakage,
7 Breakage of water pump Replace water pump.
impeller for damage, and shaft for
breakage.)
Overheating due to increased
EGR ratio (EGR amount Replace mass air flow
against fresh air amount) • Check mass air flow and temperature
8 and temperature
caused by defective mass air sensor.
sensor.
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount
• Check air cleaner and rectifying wire net for Repair or replace air
9 against fresh air amount)
deformation. cleaner.
caused by air cleaner
deformation
Defective cylinder head or • Check radiator coolant for excessive Perform
10 cylinder head gasket bubbles and spurt back. troubleshooting for "S-
13 Oil is in coolant".
• Open exhaust color inspection hole that is
just upstream of KDPF, and check exhaust
gas.
"Testing exhaust color".) Replace piston ring or
11 Defective piston ring • Measure compression pressure (see piston.
• Check piston ring and piston ring groove.
40-748 PC490LC-10
40 Troubleshooting
S-18 Unusual noise is heard (PC400-BA1-400-A-Z0-A)
Failure Unusual noise is heard.

• Check whether noise source is in or outside engine before starting troubleshooting.
• Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
Related • When engine accelerates, it switches into acceleration mode and its sound becomes
information slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
• If any failure code is displayed, perform troubleshooting for that code first.
• Exhaust gas leaks from piping between
cylinder head and exhaust manifold,
Exhaust gas leakage from between exhaust manifold and KVGT, or Repair or replace
1 piping between KVGT outlet and KDPF. defective parts.
• Exhaust gas leaks from EGR piping or air
intake piping.
Vibration of exhaust piping or • Visually check for vibration. Check and retighten
2 piping brackets.
exhaust bellows
• Check whether KVGT shaft rotates.
3 Seized or broken KVGT (Move KVGT vanes with hand in axial and Replace KVGT.
radial directions to make judgement.)
Clean or replace
4 Internal damage of KDPF • Check inside of KDPF.
KDPF.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
5 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
"Handling cylinder cutout mode operation".)
• Check valve clearance.
6 Incorrect valve clearance (Reference: See Testing and adjusting, Adjust valve clearance.
"Testing and adjusting valve clearance".)
Seized pin bushing, front Repair or replace
7 bearing, or main bearing • Check for metal particles in oil pan.
damaged parts.
• If metal particles is found in oil pan or oil
filter, overhaul engine and check piston ring
and cylinder liner.
Worn piston ring or cylinder Replace piston ring or
8 • Measure compression pressure (see
liner cylinder liner.
• Overhaul engine and check valves and Replace valve or
9 Damaged valve or rocker arm rocker arm parts. rocker arm.
10 Damaged idler gear • Overhaul engine and check idler gear parts. Replace idler gear.
PC490LC-10 40-749
40 Troubleshooting
S-19 Vibration is excessive (PC400-BC0-400-A-Z0-A)
Failure Vibration is excessive.

• If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-18
Related Unusual noise is heard", too.
information • If any failure code is displayed, perform troubleshooting for that code first.
• Visually check engine mounting bolts for
Loose engine mounting bolts Retighten bolts or
1 looseness and cushions for cracks and
or defective cushions replace cushions.
hardening.
• Visually check vibration (viscous) damper Replace vibration
2 Damaged vibration damper
for discoloration. damper.
Defective output shaft or • Check output shaft for damage and damper Replace defective
3 internal defect of damper parts.
for internal defect.
Misalignment and facial
• Measure misalignment and facial runout at
runout at connection between Replace defective
4 connection between engine and hydraulic
engine and hydraulic pump parts.
pump.
are out of standard range.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
5 Defective injector Replace injector.
with some cylinder cutout, engine speed
does not change.
"Handling cylinder cutout mode operation".)
Worn main bearing or • If metal particles are found in oil pan or oil Repair or replace
6 connecting rod bearing filter, overhaul engine. damaged parts.
• If metal particles are found in oil pan or oil Repair or replace
7 Stuck valve or rocker arm filter, open cylinder head cover and check damaged parts.
valves and rocker arms.
• If metal particles are found in oil pan or oil
Replace camshaft
8 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings.
bushings.
40-750 PC490LC-10
40 Troubleshooting
S-20 Air cannot be bled from fuel circuit (PC400-A29-400-A-Z0-A)
Failure Air cannot be bled from fuel circuit

Related information • If any error code is displayed, carry out troubleshooting for it first.
• When fuel feed pump switch is turned ON,
1 Insufficient fuel in tank pump operating sound is heard. Add fuel
• Even when fuel feed pump switch is turned
2 Low battery charge level Charge battery
ON, pump operating sound is not heard.
• Check drain valve of fuel prefilter for
Loose drain valve of fuel
3 loosening Close drain valve
prefilter
(Air leaking in due to loose drain valve)
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
4
• When air bleeding operation for fuel system
is performed, air comes out Correct or replace fuel
(Reference: See Testing and adjusting, piping
"Checking fuel system for leakage")
• With fuel feed pump switch ON, voltage to
Replace fuel feed
7 Malfunction of fuel feed pump fuel feed pump is generated but pump does
pump
not operate.
• With fuel feed pump switch ON, voltage to
Malfunction of fuel feed pump Replace fuel feed
8 fuel feed pump is not generatedLamp does
switch pump switch
not light up.
Defective wiring harness of
fuel feed pump and fuel feed • Check wiring harness Replace wiring
9
pump switch harness
PC490LC-10 40-751
40 Troubleshooting
S-21 Active regeneration is executed frequently (PC400-AQ0-400-A-Z0-A)
Failure Active regeneration is executed frequently.

information
Long-term machine operation
Perform Regeneration
with engine at low to medium • Soot can accumulate if machine does not
1 for Service to burn
speeds (exhaust temperature perform heavy-duty work.
away soot completely.
does not rise)
• Open exhaust color inspection hole being Perform
just upstream of KDPF, and check exhaust troubleshooting for "S-
2 Defective exhaust gas color gas (see Standard value table). 9 Exhaust gas is black
(Reference: See Testing and adjusting, (KDPF gets clogged in
"Testing exhaust color".) a short time)".
• If regeneration frequency does not return to
Plugged KDOC resulting from normal after remedies for cause 2 are taken,
3 Clean KDOC.
bad exhaust color KDOC is plugged.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
4
and Maintenance
Manual.
• If regeneration frequency does not return to
Plugged KCSF due to use of
5 normal after remedies for cause 4 are taken, Clean or replace
improper oil KCSF.
KCSF is plugged.
Perform
Coolant leaking into exhaust troubleshooting for "S-
6 system • Check for low coolant level. 16 Water mixes into
Plugged KCSF due to coolant Clean or replace
7 leaking into exhaust system • Check KCSF inlet for plugging.
KCSF.
Use proper fuel
specified in Operation
8 Improper fuel used • Fuel other than specified one is used.
and Maintenance
Manual.
• KDOC is deteriorated by high sulfur content.
Deteriorated KDOC due to (If regeneration frequency does not return to
9 use of improper fuel Replace KDOC.
normal after remedies for causes 1 to 8 are
taken, KDOC is deteriorated.)
• If regeneration frequency is not improved
10 Plugged KDOC after remedies on causes 1 to 9, KDOC is Clean KDOC.
blocked.
11 Damaged KDOC • Check KDOC for damage. Replace KDOC.
40-752 PC490LC-10
40 Troubleshooting
S-22 Active regeneration takes a long time (PC400-AQ1-400-A-Z0-A)
Failure Active regeneration takes a long time

Related information • Since the time required for manual stationary regeneration depends on the
accumulated soot level, see failure code CA2639.
If values of KDOC inlet temperature:
approximately 250°C or below and KVGT
Replace the whole
solenoid current: approximately 1000 mA
KVGT (including
1 Malfunction of KVGT remain unchanged after performing
hydraulic actuator and
regeneration for service, KVGT is defective.
KVGT position sensor).
(Since the time required for manual stationary
regeneration depends on the accumulated soot
level, see failure code CA2639. )
• Open the exhaust gas color measuring hole Carry out
before the KDPF and check the color of the troubleshooting for "S-
2 Exhaust gas color is bad exhaust gas (see standard value table). 9 Exhaust gas is black
(Reference: See Testing and adjusting, (KDPF gets clogged in
"Testing exhaust gas color".) a short time)"
Defective regeneration due to
3 soot accumulation in fuel • Check fuel doser Clean fuel doser
doser
Bad exhaust color causing • If regeneration time is not improved after
4 KDOC face plugging remedies on cause 2, KDOC is blocked. Clean KDOC
Carry out
5 system • Check for low coolant level 16 Water mixes into
engine oil (milky)"
KCSF plugged due to coolant
6 • Check KCSF for plugging Clean KCSF
leaking into exhaust system
Use proper fuel
Improper fuel used • Non-specified fuel is being used. specified in Operation
7
and Maintenance
Manual
• KDOC deteriorated by high sulfur content
KDOC deterioration due to (If regeneration time is not improved after
8 Replace KDOC
improper fuel used remedies on causes 1 to 6, KDOC is
deteriorated.)
• If regeneration duration does not return to
9 Plugged KDOC normal after remedies for causes 1 to 7 are Clean KDOC
taken, KDOC is plugged
10 Damaged KDOC • Check KDOC for damage Replace KDOC
PC490LC-10 40-753
40 Troubleshooting
S-23 White smoke is exhausted during active regeneration (PC400-AQ2-400-A-Z0-A)
Failure White smoke is exhausted during active regeneration.

• White smoke may be observed for a short time immediately after engine is started in cold
Related weather or during regeneration, but this is normal.
information • If any failure code is displayed, perform troubleshooting for that code first.
Perform
1 system • Check for low coolant level. 16 Water mixes into
Plugged KDOC due to • If white smoke problem is not resolved after
coolant leaking into exhaust remedies for cause 1 are taken, KDOC is Clean or replace
2
system plugged. KDOC.
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
3
and Maintenance
Manual.
• KDOC is deteriorated by high sulfur content.
Deteriorated KDOC due to (If white smoke problem is not resolved after
4 Replace KDOC.
use of improper fuel remedies for causes 1 to 3 are taken, KDOC
is deteriorated.)
• If white smoke problem is not resolved after
5 Plugged KDOC remedies for causes 1 to 4 are taken, KDOC Clean KDOC.
is plugged.
6 Damaged KDOC • Check KDOC for damage. Replace KDOC.
7 Damaged KCSF • Check KCSF for damage. Replace KCSF.
40-754 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
50 Disassembly and assembly

7 50 Disassembly and assembly
PC490LC-10 50-1
Table of contents

50 Disassembly and assembly ........................................................................................................... 50-1
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-14
Engine and cooling system ........................................................................................................ 50-19
Removal and installation of supply pump assembly............................................................... 50-19
Removal and installation of injector assembly....................................................................... 50-26
Removal and installation of cylinder head assembly.............................................................. 50-33
Removal and installation of radiator assembly ...................................................................... 50-41
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-44
Removal and installation of aftercooler assembly .................................................................. 50-46
Removal and installation of cooling fan and fan motor assembly ............................................ 50-48
Removal and installation of engine and main pump assembly ................................................ 50-52
Removal and installation of engine front seal ........................................................................ 50-62
Removal and installation of engine rear seal......................................................................... 50-66
Removal and installation of engine hood assembly ............................................................... 50-71
Removal and installation of KDPF assembly......................................................................... 50-72
Removal and installation of KCCV assembly ........................................................................ 50-74
Removal and installation of air cleaner assembly .................................................................. 50-76
Power train system ................................................................................................................... 50-78
Removal and installation of travel motor and final drive assembly ........................................... 50-78
Disassembly and assembly of final drive .............................................................................. 50-79
Removal and installation of swing motor and swing machinery assembly ................................ 50-87
Disassembly and assembly of swing machinery.................................................................... 50-89
Removal and installation of swing circle assembly ................................................................ 50-96
Separation and connection of track shoe assembly ............................................................... 50-97
Removal and installation of sprocket.................................................................................... 50-99
Removal and installation of idler and idler cushion assembly ............................................... 50-100
Disassembly and assembly of idler .................................................................................... 50-101
Disassembly and assembly of idler cushion........................................................................ 50-104
Disassembly and assembly of track roller ........................................................................... 50-106
Disassembly and assembly of carrier roller......................................................................... 50-107
Removal and installation of revolving frame assembly ......................................................... 50-109
Removal and installation of counterweight assembly ............................................................50-111
Hydraulic system .................................................................................................................... 50-113
Removal and installation of center swivel joint assembly ..................................................... 50-113
Disassembly and assembly of center swivel joint ................................................................ 50-115
Removal and installation of hydraulic tank assembly ........................................................... 50-116
Removal and installation of main pump assembly ............................................................... 50-120
Removal and installation of control valve assembly ............................................................. 50-124
Disassembly and assembly of control valve........................................................................ 50-128
Disassembly and assembly of work equipment PPC valve................................................... 50-133
Disassembly and assembly of travel PPC valve.................................................................. 50-135
Work equipment ..................................................................................................................... 50-137
Removal and installation of work equipment assembly ........................................................ 50-137
Disassembly and assembly of work equipment cylinder....................................................... 50-140
Removal and installation of operator's cab assembly........................................................... 50-145
Removal and installation of operator's cab glass (adhered window glass) ............................. 50-150
Removal and installation of front window assembly ............................................................. 50-160
Removal and installation of floor frame assembly................................................................ 50-166
Removal and installation of air conditioner unit assembly..................................................... 50-172
Removal and installation of operator’s seat ........................................................................ 50-176
50-2 PC490LC-10
Table of contents
Removal and installation of seat belt .................................................................................. 50-178

Removal and installation of front wiper assembly ................................................................ 50-179
Removal and installation of air conditioner compressor assembly......................................... 50-186
Removal and installation of air conditioner condenser assembly .......................................... 50-189
Removal and installation of engine controller assembly ....................................................... 50-191
Removal and installation of pump controller assembly......................................................... 50-193
Removal and installation of machine monitor assembly ....................................................... 50-196
Removal and installation of pump swash plate sensor ......................................................... 50-198
Removal and installation of mass air flow and temperature sensor ....................................... 50-199
Removal and installation of KOMTRAX terminal assembly .................................................. 50-201
PC490LC-10 50-3
Related information on disassembly and assembly
Related information on disassembly and assembly (ALL-3851-001-A-00-A)
How to read this manual (ALL-0320-011-A-00-A)

(Rev.2013.05)
Removal and installation of TTTT assembly • The general tools required for "Installation" are
Special tools listed as [1], [2], ..., without description of part
• The special tools required for removal and number, part name, and quantity.
installation work are described in the list as • Marks used in "Installation" section are
symbols such as A1, ..., X1. Part number, part explained below.
name, necessity, and quantity are described. k: This mark shows safety-related precautions
• Mark used in the column of necessity are which must be followed when performing the
explained below. work.
t: Tools are not substituted, must always be
equipped (used). a : This mark gives knowledge or precautions
q: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tools. 4 : This mark shows the weight of the part
• For details and the sketches of the special tools, or equipment.
see "Special tool list" and "Sketches of special
tools." 2 : This mark shows a specific coating
agent to be used.
Removal
• In "Removal" section, the work procedures, 3 : This mark shows the specified
precautions and know-how to do the work, and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark shows the amount of oil or
• The general tools required for "Removal" are coolant to be added.
listed as [1], [2], ..., without description of part • For details of oil or coolant to be
number, part name, and quantity. added after installation, see
• Marks used in "Removal" section are explained Specification "Table of fuel, coolant
below. and lubricants".
k: This mark shows safety-related precautions Disassembly and assembly of TTTT assembly
which must be followed when performing the Special tools
work. • The special tools required for disassembly and
assembly work are described in the list as
a : This mark gives knowledge or precautions
symbols such as A1, ..., X1. Part number, part
when performing the work.
name, necessity, and quantity are described.
[*1]: This mark indicates that knowledge or • Mark used in the column of necessity are
precautions for the assembly installation work are explained below.
given in the "Installation" section. t: Tools are not substituted, must always be
equipped (used).
6 : This mark shows the amount of oil or q: Tools extremely useful if available or tools
coolant to be drained. that can be substituted with commercially
available tools.
4 : This mark shows the weight of the part • For details and the sketches of the special tools,
or equipment. see "Special tool list" and "Sketches of special
Installation tools."
• The work procedure of "Installation" is in the Disassembly
reversed order to removal unless otherwise • "Disassembly" describes the work procedure as
specified. well as the precautions, knowledge, and drain
• For knowledge and precautions required for amounts of oil and coolant required for the work.
"Installation", a [*1] mark is assigned to the • The general tools required for "Disassembly" are
"Removal" work procedure to indicate the work listed as [1], [2], ..., without description of part
item of the installation knowledge or precaution. number, part name, and quantity.
50-4 PC490LC-10
• Marks used in the section of "Disassembly" are

explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.

6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of the part

or equipment.
Assembly
• "Assembly" describes the work procedure as
well as the precautions, knowledge, and drain
amounts of oil and water required for the work.
• The general tools required for "Assembly" are
listed as [1], [2], ..., without description of part
number, part name, and quantity.
• Marks used in the section of "Assembly" are
explained below.
k: This mark shows safety-related precautions
which must be followed when performing the
work.

4 : This mark shows the weight of the part

or equipment.
2 : This mark shows a specific coating
agent to be used.
3 : This mark shows the specified
tightening torque.
5 : This mark shows the amount of oil or

coolant to be added.
• For details of oil or coolant to be
added after installation, see
Specification "Table of fuel, coolant
and lubricants".
PC490LC-10 50-5
Coating materials list (ALL-3540-071-A-00-A)
(Rev.2012.11)
a The coating materials such as adhesives, liquid gasket, and grease used for disassembly and assembly
are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20 g Polyethy- polypropylene, tetrafluoroethylene and
LT-1B 790-129-9050 (contained 2 lene vinyl chloride), rubber, metal, and non-
pieces) container metal parts which require immediate
and strong adhesion.
• Features: Resistance to heat and
Polyethy- chemicals
LT-2 790-129–9180 50 g lene • Use to prevent bolts and plugs from
container coming loose and as sealant.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 Set of adhesive Can plastics.
Hardener:
and hardener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene • Use to seal plugs for blank holes.
container
• Heat-resistant seal used to repair
Holts MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
Polyethy- • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 50 g lene • Use mainly to bond metals, rubbers,
container plastics, and woods.
• Instantaneous adhesive
2g Polyethy- • Quick-curing type (max. strength is
Aron Alpha 201 790-129-9130 (contained 5 lene obtained after 30 minutes)
pieces) container • Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 cc Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
Polyethy- • Features: Resistance to heat and
Loctite 648-50 79A-129-9110 50 cc lene chemicals
container • Use to bond high-temperature fit parts.
50-6 PC490LC-10
Liquid gasket
• Use to seal various threaded parts,
LG-5 Polyethy- pipe joints, and flanges.
790-129-9080 1 kg lene
ThreeBond 1110F • Use to seal taper plugs, elbows, and
container nipples for hydraulic piping.
• Features: Silicon-based heat and cold-
LG-6 resistant sealant.
790-129-9160 250 g Tube • Use to seal flange surface and
ThreeBond 1215 threaded parts.
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
LG-7 sealant
790-129-9170 150 g Tube • Use to seal flywheel housing, intake
ThreeBond 1207C manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
419-15-18131 100 g Tube and shock-resistant sealant.
ThreeBond 1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
790-129-9310 200 g Tube clamped by bolts, gaps in the weld
ThreeBond 1206D which must be caulked, etc.
• Can be coated with paint.
• Use as lubricant or sealant when the
LG-10
790-129-9320 200 g Tube radiator hoses are put on.
ThreeBond 1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission case
and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted
LM-P 09940-00040 200 g Tube parts, and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S 09995-00250 190 g Can metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.
PC490LC-10 50-7
Seizure prevention compound

• Feature: Seizure and galling prevention
compound with metallic super-fine-
LC-G grain, etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.
Grease
SYG2-400LI-A
G2-LI SYGA-16CNLI • Lithium grease with extreme pressure
G0-LI(*) SYG0-400LI-A Various Various lubrication performance, general
*: For cold districts (*) purpose type.
SYG0-16CNLI (*)
• Use for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows- • Do not use this grease for rolling
disulfide grease type bearings like swing circle bearings,
SYG2-400M-A 400 g x 20 container etc. and spline.
LM-G(G2-M) SYGA-16CNM 16 kg Can • Use this grease for work equipment
pins only when installing them, but
do not use it afterward.
Hyper white SYG2-400T • Higher seizure resistance, heat
grease Bellows-
SYG2-16CNT 400 g type resistance, and waterproof than
G2-T molybdenum disulfide grease
SYG0-400T(*) 16 kg container
G0-T(*) • Not conspicuous on machine since
SYG0-16CNT(*) Can color is white.
*: For cold districts
Biogrease
SYG2-400B
G2-B Bellows-
SYGA-16CNB • Since this grease is biodegradable in
G2-BT(*) 400 g type
SYG2-400BT(*) container short period, it has less impact on
*: For use at high 16 kg microorganisms, animals, and plants.
SYGA-16CNBT Can
temperature and
(*)
under high load
• Feature: Silicon-based grease with
wider operating temperature range and
G2-S superior thermal oxidative stability to
— 200 g Tube prevent deterioration of rubber and
ThreeBond 1855 plastic.
• Use for oil seals of the transmission,
etc.
• Feature: Urea (organic) grease with
heat resistance and long life, inclusion
type.
G2-U-S
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
ENS grease
damper.
Caution: Do not mix with lithium
grease.
50-8 PC490LC-10
Primer
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 ml
container instantaneous adhesive.
SUNSTAR Paint • Use as primer for cab side.
Glass (Effective period: 4 months after
Surface Primer 20 ml
container manufacture)
580 SUPER
417-926-3910
SUNSTAR Glass • Use as primer for glass side.
Glass (Effective period: 4 months after
Primer 580 20 ml
For adhered window glass

container manufacture)
SUPER
• Use as primer for painted cab sheet
SUNSTAR Paint metal surface.
Glass
Surface Primer 22M-54-27230 20 ml (Effective period: 4 months after
container
435-95 manufacture)
• Use as primer for black ceramic-
SUNSTAR coated glass surface and for hard
PRIMER 435-41 22M-54-27240 150 ml Steel can polycarbonate-coated surface.
for glass (Effective period: 4 months after
manufacture)
• Use as primer for sash (alumite
SUNSTAR sash Glass surface treatment).
primer GP-402 22M-54-27250 20 ml (Effective period: 4 months after
container
manufacture)
Adhesive
• Use "S" as adhesive for glass in
high temperature months (during

SUNSTAR Polyethy- summer) and "W" in low
Penguin Seal 580 417-926-3910 320 ml lene temperature months (during winter).
SUPER "S" or "W" container (Effective period: 4 months after
manufacture)
• Use as adhesive for glass.
Sika Japan Cartridge (Effective period: 6 months after
20Y-54-39850 310 ml
Sikaflex 256HV manufacture)
SUNSTAR Ecocart • Use as adhesive for glass.
Penguin Super 22M-54-27210 320 ml (special (Effective period: 6 months after
560 container) manufacture)
Caulking material
SUNSTAR • Use to seal glass-to-glass joint.
Penguin Seal 417-926-3920 330 ml Cartridge (Effective period: 4 months after

No.2505 manufacture)
• Use to seal front window.
SEKISUI Silicone Cartridge (Effective period: 6 months after
20Y-54-55130 333 ml
Sealant 83 manufacture)
• Translucent white seal used for joint

GE TOSHIBA seals between glasses
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL381 manufacture)
PC490LC-10 50-9
Special tools list (PC400-3530-061-A-00-A)
a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity:
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tool.
a New/redesign:
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
a Tools marked with Q in the sketch column have the sketches. (See Sketches of special tools)
New/redesign
Necessity
Sketch
Sym- Detail of work,
Q'ty
Work Part number Part name
bol remarks
1 795-799-1131 Gear t 1 Barring

Removal and Standard puller
2 795-630-5500 t 1
installation of supply Separation of gear
pump assembly 3 01010-81090 Bolt t 2
and shaft
4 01643-31032 Washer t 2
Seal puller assembly Removal of engine
5 795-931-1100 q 1
Removal and front seal
installation of engine 6 795T-521-1140 Push tool t 1 Q
t 3 Installation of engine
front seal 7 01010-61650 Bolt
front seal
8 01643-31645 Washer t 9
Seal puller assembly Removal of engine
9 795-931-1100 q 1
rear seal
A 10 795T-421-1340 Push tool t 1 Q Press fitting of
11 01010-61635 Bolt t 3 standard oil seal
12 01643-31645 Washer t 3 (with guide)
Removal and
installation of engine 13 795-931-1220 Push tool t 1
rear seal 14 01010-61650 Bolt t 3
15 01643-31645 Washer t 3 Press fitting of
16 795T-421-1320 Push tool t 1 Q sleeved oil seal
17 01010-61645 Bolt t 3
18 01643-31645 Washer t 9
Removal and
Angle tightening of
installation of cylinder 19 790-331-1110 Wrench q 1 cylinder head bolt
head assembly
Removal and
installation of engine Removal, installation
and main pump B 796T-601-1110 Stopper t 1 Q of engine mounting
assembly bolts
1 796T-627-1630 Push tool q 1 Q Removal of shaft
2 790-201-2350 Push tool t 1 Removal of bearing
Removal and 3 790-201-2510 Push tool t 1 Press fit of bearing
installation of swing
motor and swing D 790-101-5401 Push tool kit t 1
machinery assembly 790-101-5531 • Plate 1
4 Press fit of oil seal
790-101-5421 • Grip 1
01010-51240 • Bolt 1
50-10 PC490LC-10
New/redesign
Necessity
Sketch
Q'ty
bol remarks
t 1 Press fit of bearing

Removal and 5 790-201-2870 Push tool
inner race
installation of swing
D t 1 Press fit of bearing
motor and swing 6 790-201-2770 Push tool
inner race
machinery assembly
7 796T-626-1110 Push tool t 1 Q Press fit of bearing
796-627-1210 Wrench assembly t 1
796-627-1220 • Wrench 1 Removal, installation
1
796-427-1140 • Pin 3 of round nut
01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1
791-122-1130 Plate q 1
Disassembly and
assembly of final drive E 790-101-2550 Leg q 2
Adapter Pressing of bearing
2 790-101-2740 q 2
inner race
790-101-2570 Plate q 4
790-101-2560 Nut q 2
790-101-2102 Puller (294 kN {30 ton}) t 1
790-101-1102 Pump t 1
Installation of
3 796-627-1020 Installer t 1
floating seal
Disassembly and 1 791-430-3230 Installer t 1
assembly of carrier F 2 791-601-1000 Oil pump assembly
roller t 1
assembly of track G Oil refilling
2 791-601-1000 Oil pump assembly t 1
roller
assembly of idler H
791-685-8006 Compressor t 1
791-635-3160 Extension t 1 Disassembly and
1 Cylinder (686 kN {70 assembly of idler
790-101-1600 ton}) t 1 cushion
Disassembly and
assembly of idler J 790-101-1102 Pump t 1
cushion 790-201-1500 Push tool kit t 1
790-201-1660 • Plate 1 Installation of dust
2
790-101-5021 • Grip 1 seal
01010-50816 • Bolt 1
791-650-3000 Remover and installer t 1
Separation and
Cylinder (980 kN {100 Pulling out of master
connection of track K 790-101-1300 ton}) t 1
pin
shoe assembly
790-101-1102 Pump t 1
PC490LC-10 50-11
New/redesign
Necessity
Sketch
Q'ty
bol remarks
796-946-1310 Guide (21.8 mm dia.)

t 1
(For 723-46-40100 and 723-46-40601)
796-946-2110 Guide (20.9 mm dia.)
1 t 1
(For 723-46-44100)
796-946-2210 Guide (20.6 mm dia.)
t 1
(For 723-46-45100 and 723-46-45500)
796-946-1320 Guide
t 1
(For 723-46-40100 and 723-46-40601)
796-946-1420 Guide (21.6 mm dia.)
t 1
(For 723-46-42800) Replacement of
Disassembly and 2
796-946-2120 Guide pressure
assembly of control L t 1
(For 723-46-44100) compensation valve
valve
796-946-2220 Guide seal
t 1
(For 723-46-45100 and 723-46-45500)
796-946-1330 Sleeve
t 1
(For 723-46-40100 and 723-46-40601)
796-946-1430 Sleeve
t 1
(For 723-46-42800)
3
796-946-2130 Sleeve
t 1
(For 723-46-44100)
796-946-2230 Sleeve
t 1
(For 723-46-45100 and 723-46-45500)
790-101-2501 Push-puller t 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly and 791-112-1180 • Nut 1 Disassembly, and
assembly of center 1 790-101-2540 • Washer 1 assembly of center
swivel joint 790-101-2630 • Leg 2 swivel joint
M
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
Disassembly and 2 796T-416-1010 Push tool t 1 Q Disassembly and
assembly of travel 3 796T-416-1030 Push tool t 1 Q assembly of travel
PPC valve 4 796T-416-1020 Push tool t 1 Q PPC valve
Disassembly and
1 790-502-1003 Cylinder repair stand t 1 assembly of work
equipment cylinder
790-102-4300 Wrench assembly t 1 Removal and
2 installation of piston
790-102-4310 Pin t 2 assembly
Disassembly and
assembly of work N 3 790-720-1000 Expander q 1
equipment cylinder Ring (For boom and
796-720-1680 bucket) q 1
Installation of piston
Clamp (For boom and
4 07281-01589 bucket) q 1 ring
796-720-1690 Ring (for arm cylinder) q 1
07281-01919 Clamp (For arm) q 1
50-12 PC490LC-10
New/redesign
Necessity
Sketch
Q'ty
bol remarks
790-201-1702 Push tool kit t 1

790-201-1851 • Push tool (for bucket) 1
790-201-1861 • Push tool (for boom) 1
5 Press fit of bushing
790-201-1871 • Push tool (For arm) 1
790-101-5021 • Grip 1
Disassembly and
01010-50816 • Bolt 1
assembly of work N
equipment cylinder 790-201-1500 Push tool kit t 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
6 Press fit of dust seal
790-201-1660 • Plate (For bucket) 1
790-201-1670 • Plate (for boom) 1
790-201-1680 • Plate (For arm) 1
796-670-1100 Remover q 1
796-670-1110 • Sleeve 1
796-670-1120 • Plate 1
796-670-1130 • Screw 1
Removal and 796-870-1110 • Adapter 1
installation of work P Removal of foot pin
equipment assembly 01643-33080 • Washer 1
01803-13034 • Nut 1
Puller (long)
790-101-4000 q 1
(490 kN {50 ton}
790-101-1102 Pump (294 kN {30 ton}) q 1
Removal and 1 793-498-1210 Lifter (Suction cup) t 2 Removal and
installation of installation of
operator's cab glass Y operator's cab glass
(adhered window 2 20Y-54-13180 Stopper rubber t 2 (adhered window
glass) glass)
Commercially Impact wrench
Removal and q 1 Removal and
available
installation of Socket wrench installation of
–
counterweight Commercially counterweight
assembly (Width across flats: 65 q 1 assembly
available
mm)
PC490LC-10 50-13
Sketches of special tools (PC400-3531-066-A-00-A)
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A6 Push tool
A10 Push tool
50-14 PC490LC-10
A16 Push tool
B Stopper
PC490LC-10 50-15
D1 Push tool
D7 Push tool
50-16 PC490LC-10
E2 Push tool
M2 Push tool
PC490LC-10 50-17
M3 Push tool
M4 Push tool
50-18 PC490LC-10
Removal and installation of supply pump assembly (PC400-AD70-924-K-00-A)
k Park the machine on a level ground, lower 4 Frame (7):

the work equipment to the ground, and stop
the engine. 45 kg
k Set the lock lever in the Lock position.
k Turn the battery disconnect switch to the

OFF position and remove the key.
a Special tools
Necessity
Sym-
Q'ty
Part number Part name
bol
1 795-799-1131 Gear t 1
2 795-630-5500 Standard puller t 1 6. Disconnect connector S50 (8).
A
3 01010-81090 Bolt t 2 7. Remove electric fuel feed pump switch (10)
4 01643-31032 Washer t 2 together with bracket (9).
Removal (PC400-AD70-520-K-00-A)
1. Open engine hood (1).

2. Remove engine hood (2). For details, see
"Removal and installation of engine hood
assembly".
8. Remove the clamp for wiring harness (11).

9. Remove guard (12).

4. Remove reservoir tank (5) and bracket (6).
10.Remove the KCCV assembly. For details, see

"Removal and installation of KCCV assembly".
11.Remove the air cleaner assembly For details,
see "Removal and installation of air cleaner
assembly".
12.Remove tubes (13), hose (14), and intake
5. Lift and remove frame (7). connector (15). [*1]
13.Remove tube (16). [*2]
PC490LC-10 50-19
14.Remove plate (17). 18.Remove bracket (22).
15.Remove plate (18) and hose (19). [*3] 19.Disconnect connectors PCV1 (23), PCV2 (24),
and G (25). Reposition wiring harness (26) out of
the way.
20.Remove overflow tube (27).
21.Remove bolt (28).
22.Remove eyebolt (29).
23.Remove bracket (30).
16.Remove air conditioner compressor belt (20).

[*4]
17.Reposition air conditioner compressor (21) out
of the way.
a Do not disconnect the air conditioner
compressor hoses.
24.Remove plate (31).
50-20 PC490LC-10
25.Remove tube (32). 33.Remove brackets (46) and (47) from bottom of
26.Remove stay mounting bolts on block (33). the supply pump.
27.Remove brackets (34) and (35).
28.Remove tubes (36) and (37). [*5]
34.Remove cover (48).

35.Remove the cover from bottom of the starting
29.Remove eyebolts (38) and (39).[*6] motor, and then install gear A1.
36.Rotate the crankshaft in the normal rotation of
engine by using gear A1, and align the center
point between "2.5 TOP" and "3.4 TOP" stamp
lines on damper (49) with pointer (50).
30.Remove tube (40) and bracket (41).

31.Remove two fuel spray prevention caps (42)
and (43).
32.Remove two clamps and high-pressure pipes
(44) and (45).
PC490LC-10 50-21
37.Make sure that the supply pump drive gear Installation (PC400-AD70-720-K-00-A)
forcing tap is aligned with cover mounting bolt
holes (51). If not aligned, rotate the crankshaft a Note the following points about high-pressure
for another turn. pipes.
38.Remove nut (52). k Be sure to use the Komatsu genuine high-
pressure fuel pipe clamps and observe the
tightening torque.
k Do not bend the fuel high-pressure pipe to

correct before installing.
k Before installing the high-pressure pipe,

check it for the following.
If the high-pressure fuel pipe has any defect,
replace it with a new one since fuel may leak.
• Make sure with visual check that the
joint’s taper seal at part (a) (within 2 mm
39.Install tools A2, A3, and A4. from the end) is free from lengthwise
40.Tighten the center bolt of tool A2 to separate the streaks (b) or spots (c).
supply pump drive gear from the shaft. • Make sure that part (d) (2 mm from the
end of taper seal) is free from the stepped
a To prevent the supply pump drive gear from wear which can be felt with your fingernail.
falling off, leave tools A2, A3, and A4 (Namely, this part must be free from
installed. fatigue.)
41.Remove four supply pump mounting bolts (53),

and then remove supply pump assembly (54).
1. Make sure that shaft key (55) is facing directly
above.
2. While aligning shaft key (55) with keyway (a) on
the gear side, install supply pump assembly
(54).
50-22 PC490LC-10

59 to 74 Nm {6.0 to 7.5 kgm}
10.Tighten two mounting bolts of bracket (46) at the
supply pump side to the specified torque.
3 Supply pump side mounting bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
11.Tighten bolts (56) and (57) in this order.
12.Install fuel spray prevention caps (42) and (43).
a Install with the notch faced as follows.
• Fuel spray prevention cap (43): lower
side
• Fuel spray prevention cap (42):
cylinder block side
13.Install and lightly tighten brackets (58), (59), (60),
(61), and (41) with your hand.
14.Install and lightly tighten clamps (63) and (64)
with your hand.
15.Lightly tighten clamps (63) and (64) with your
hand.
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
16.Tighten mounting bolts (65) of bracket (41) to
the specified torque.
3. Tighten four supply pump mounting bolts (53)
lightly with your hand.
4. Install and tighten brackets (46) and (47) lightly
with your hand.
19.Tighten bolt (68) to the specified torque.
20.Tighten tube (40) to the specified torque.
3 Joint bolt
(Cylinder block side):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
(Supply pump side):
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
5. Install and lightly tighten high-pressure pipes
(44) and (45) with your hand.
6. Install and lightly tighten the above-mentioned
clamps and brackets with your hand.
7. Install and lightly tighten lubrication tube (40)
with your hand.
8. Tighten the sleeve nuts of high-pressure pipes
(44) and (45) to the specified torque.
3 Sleeve nut
(Both the common rail side and
supply pump side):
39.2 to 44.1 Nm {4 to 4.5 kgm}
9. Tighten supply pump mounting bolts (53) to the
specified torque.
PC490LC-10 50-23
• Dimension (b): Min. 5 mm

2 Clamp bolt thread portion (BC):
Lubricant (ThreeBond PANDO 18B or
equivalent)
• If hoses are to be reused
Install the clamp to the clamp mark put on
the hose.
3 Clamp bolt:
Min. 2.9 to 5.9 Nm {0.3 to 0.6 kgm}
• When using a new hose
Tighten the clamp so that dimension (BDG)
is 4 to 7 mm.
23.Perform the following installation in the reverse [*2]

order to removal.
[*1] a Tighten two mounting nuts (c) of tube (16) to the
1. Tighten four mounting nuts (a) of tube (13) to the following torque.
following torque. 3 Nut:
3 Mounting nut: 14.7 to 44.1 Nm {1.5 to 4.5 kgm}
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
[*3]
2. Tighten the MIKALOR clamps at both ends of a Tighten the clamps at both ends of hose (19) to
tube (13) and hose (14) according to the the following torque.
3 Clamp:
a Use new MIKALOR clamps.
10.5 ± 0.5 Nm {107 ± 5 kgcm}
a Impact wrench is not allowed to use. [*4]
a With bridge (BR) set under the clamp bolt, a Adjust the air conditioner compressor belt
tighten the bolt so that bridge (BR) overlaps tension. For details, see Testing and adjusting,
with the band by dimension (b) indicated "Testing and adjusting air conditioner
below. compressor belt tension".
50-24 PC490LC-10
[*5]
a Tighten the eyebolts of tube (36) to the following
torque.
3 Eyebolts of tube (36) (both ends):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*6]
a Tighten eyebolts (38) and (39) to the following
torque.
3 Eyebolt:
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
• Bleeding air
Bleed air from the fuel system. For details, see
circuit".
• Checking for fuel leakage
Check for fuel leakage. For details, see Testing
and adjusting, "Testing fuel circuit for leakage".
PC490LC-10 50-25
Removal and installation of injector assembly (PC400-AE60-924-K-00-A)
k Park the machine on a level ground, lower

the engine.

Removal (PC400-AE60-520-K-00-A)

"Removal and installation of engine hood 6. Disconnect connector S50 (8).
assembly". 7. Remove electric priming pump (10) together with
bracket (9).

4. Remove reservoir tank (5) and bracket (6). 8. Remove the clamp for wiring harness (11).
9. Remove guard (12).
5. Lift and remove frame (7).

10.Remove the KCCV assembly. For details, see
4 Frame (7): "Removal and installation of KCCV assembly".
45 kg 11.Remove intake connector (13) and hose (14).
[*1]
12.Remove hose (15) and tube (16).[*2]
50-26 PC490LC-10
13.Remove plate (17). 20.Lift and remove air intake connector (34).
14.Disconnect connectors VGT-REV (18), SVGT
(19), and DOSER (20). 4 Air intake connector:
15.Remove plate (21). 25 kg
21.Disconnect and reposition harness (35) out of

the way.
a Disconnect the connector according to the
1) Insert the tip of a flat-head screwdriver [1]
into stepped portion (a) and push stopper (b).
2) Move the flat-head screwdriver [1] in
direction (X) and disconnect connector (c).
22.Remove spill tube (36).
23.Remove bracket (37) and the clamp inside.
16.Disconnect connectors SOV2 (22), SOV1 (23),

and PDOSER (24).
17.Remove tubes (25), (26), (27), (28), (29),
and (30).[*3]
18.Remove fuel filter (31) together with head (32).
19.Remove brackets (33).
PC490LC-10 50-27
30.Remove rocker shaft mounting bolt (50) and

24.Remove five brackets (38) and four clamps (39).
remove the rocker arm and shaft assembly (51).
25.Remove fuel spray prevention caps (40) and
(41), six of them each. a Loosen locknut (52) and loosen adjustment
26.Remove six high-pressure pipes (42). screw (53) sufficiently so that an excessive
force will not be applied to the push rod when
a When removing the high-pressure pipe for
the rocker arm is installed.
the No. 6 cylinder, remove oil filter (43) and
head (44).
31.Remove injector assembly (54).

27.Remove cylinder head cover (45). 1) Remove mounting bolt (56) of holder (55).
28.Loose two nuts (46) completely. 2) Insert a tool such as an "L" shaped bar [1]
into inlet connector (a) of injector (54), and
a Loosen the nuts alternately. then pry up the injector.
29.Remove mounting bolt (48) of holder (47) and
then keep injector harness (49) together in one a Never grip the solenoid valve on the top
place. of the fuel injector with pliers, etc. to pull
out.
3) Remove injector assembly (54) together with
holder (55).
50-28 PC490LC-10
5) Insert sleeve nut (61) of the high-pressure

pipe through the high-pressure pipe insertion
part. Set the sleeve nut to injector connector
(a), and tighten it lightly.
a Lightly tighten the common rail side
sleeve nuts also.
Installation (PC400-AE60-720-K-00-A)
1. Install the injector assembly according to the

1) Check that there is not dirt in the injector
assembly mounting hole at the cylinder head
side.
2) Install gasket (57) and O-rings (58) and (59) 6) Tighten holder (55) to the specified torque.
to injector assembly (54). a While pulling the high-pressure pipe in
2 O-ring: the opposite direction of the injector,
tighten mounting bolt (56).
Engine oil
3) Insert holder (55) in injector assembly (54) 3 Injector holder mounting bolt:
and insert the injector assembly into the 58.8 to 73.5 Nm {6.0 to 7.5 kgm}
rocker housing.
4) Install spherical washer (60) to bolt (56) and a After tightening the holder, remove the
lightly tighten holder (55). high-pressure pipe.
2. Install the rocker arm shaft assembly according
2 Spherical washer (60): to the following procedure.
Engine oil 1) Set rocker arm and shaft assembly (51).
a When installing rocker arm shaft (62),
direct its larger mounting hole end down
and its ball plug (63) end forward.
2) Check that the ball of adjustment screw (53)
is fitted in push rod socket (64) and tighten
mounting bolts (50).
a Before installing, clean the oil holes.
3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
3) Adjust the valve clearance. For details, see
Testing and adjusting, “Adjusting valve
clearance”.
PC490LC-10 50-29
k Do not bend the fuel high-pressure pipe

to collect before installing.
k Before installing the high-pressure pipe,

check it for the following defects.
If the high-pressure fuel pipe has any
defect, replace it with a new one since
fuel may leak.
• Make sure with visual check that the
joint’s taper seal at part (a) (within 2
mm from the end) is free from
lengthwise streaks slits (b) or spots
3. Install injector harness (49) according to the (c).
following procedure. • Make sure that part (d) (2 mm from the
1) Tighten holder (47) with bolt (48). end of taper seal) is free from the
stepped wear which can be felt by
3 Bolt (48): your fingernail. (Namely, this part must
27 to 34 Nm {2.8 to 3.5 kgm} be free from fatigue.)
2) Tighten nuts (46) alternately.
3 Nut (46):
2.0 to 2.4 Nm {0.2 to 0.24 kgm}
1) Lightly tighten the sleeve nut of high-

pressure pipe (42) with your hand.
a Loosen all of the high-pressure pipe
4. Install cylinder head cover (45).
clamps.
3 Mounting bolt: 2) Tighten the sleeve nut of high-pressure pipe
9.8 ± 1 Nm {1.0 ± 0.1 kgm} (42) to the specified torque.
3 Sleeve nut (on both sides):
39.2 to 44.1 Nm {4 to 4.5 kgm}
3) Install fuel spray prevention caps (40) and
(41) to each high-pressure tube.
a Install with the slit oriented as follows.
• Injector side: Downward
• Common rail side: Cylinder block side
4) Install and lightly tighten all of the following
clamps and brackets with your hand.
• Clamps (65) (six)
• Brackets (38) (five)
• Brackets (66) and (37)
5. Install the high-pressure pipe according to the
following procedure. 5) Tighten clamps (65) to the specified torque.
3 Mounting bolt:
k Be sure to use the genuine fuel high- 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
pressure pipe clamps and observe the 6) Tighten the bolts for brackets (38) and (66) to
tightening torque. the specified torque.
50-30 PC490LC-10
7) Install and lightly tighten four clamps (39) a Impact wrench is not allowed to use.
with your hand.
a With bridge (BR) set under the clamp bolt,
8) Lightly tighten clamp (67) to bracket (37) with
tighten the bolt so that bridge (BR) overlaps with
your hand and then tighten to the specified
the band by dimension (b) indicated below.
torque.
• Dimension (b): Min. 5 mm
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
9) Tighten bracket (37) to the specified torque. Lubricant (ThreeBond PANDO 18B or
10)Tighten clamps (39) to the specified torque. equivalent)
3 Mounting bolt:
Install the clamp to the clamp mark put on the
11.8 to 14.7 Nm {1.2 to 1.5 kgm} hose.
3 Clamp bolt:
Min. 2.9 to 5.9 Nm {0.3 to 0.6 kgm}
Tighten the clamp so that dimension (BDG) is 4
to 7 mm.
[*2]
a Tighten two mounting nuts (c) of tube (16) and
the hose clamp to the following torque.
3 Nut:
14.7 to 44.1 Nm {1.5 to 4.5 kgm}
a Tighten the clamps for tube (16) and hose (15) to
the following torque.
3 Clamp:
10.5 ± 0.5 Nm {107 ± 5 kgcm}
6. Perform the following installation in the reverse

order to removal.
[*1]
Tighten the MIKALOR clamps at both ends of hose
(14) according to the following procedure.
[*3]
PC490LC-10 50-31
a Tighten the eyebolts for tubes (25), (26), and

(28) to the following torque.
3 Eyebolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a Tighten the eyebolts for tube (29) to the following
torque.
3 Eyebolt
Head side:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
Supply pump side:
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
• Bleeding air
Bleed air from the fuel system. For details, see
circuit".
• Checking for fuel leakage
Check for fuel leakage. For details, see Testing
and adjusting, "Testing fuel circuit for leakage".
50-32 PC490LC-10
Removal and installation of cylinder head assembly (PC400-A100-924-K-00-A)

the engine.

a Special tools
Necessity
Sym-
Q'ty
bol 4) Remove oil filter (6) and head (7).
A19 790-331-1110 Wrench q 1

Removal (PC400-A100-520-K-00-A)
1. Remove the injector assembly For details, see

"Removal and installation of injector assembly".
a Perform the following work in parallel.
1) Remove plate (1).
5) Remove the KVGT side mounting bolts for

tube (8) and clamp mounting bolts. Loosen
the cylinder head side sleeve nuts. [*1]
6) Remove bracket (9).
2) Remove engine hood (2).
4 Engine hood:
35 kg
2. Disconnect connector TIM (10) from the rear of

the air intake manifold.
3. Remove mounting bolt (12) for clamp (11).
3) Remove the mounting bolts of bracket (3),

and then Reposition fuel pre filter (4) and
head (5) aside out of the way.
PC490LC-10 50-33
4. Remove clamp (13) and bracket (14) from the 3) Remove bracket (16).
front of the air intake manifold.
7. Remove tube (20). [*3]

5. Remove air intake manifold (15).
4 Air intake manifold:

30 kg
8. Remove engine hood (21) and frame (22) as a

unit.
4 Engine hood:
6. Remove bracket (16). 40 kg
1) Remove lubrication tubes (17) and (18) of
the EGR valve. [*2]
2) Remove clamp (19).
50-34 PC490LC-10
9. Remove tube (23) and brackets (23a) and (23b) 14.Remove tubes (29) and (30). [*6]
as a unit. [*4]
15.Disconnect hose (31).

10.Remove brackets (24) and (25). 16.Remove cover (32).
17.Remove tube (33).
11.Disconnect hose (26). [*5]

12.Remove guard (27). 18.Disconnect fuel doser side of tube (34). [*7]
13.Remove tube (28).
PC490LC-10 50-35
19.Disconnect the KVGT side of tubes (35) and (36).

[*8]
20.Remove KVGT assembly (37). [*9]
4 KVGT Ass'y:
35 kg
21.Remove tubes (38) and (39). [*10]
26.Remove tube (48). [*12]
22.Remove tubes (40), (41), (42), (43), and (44).

[*11]
23.Remove mounting bolt for tube (45) from below
the EGR cooler.
24.Remove EGR cooler (46).
27.Remove exhaust manifold (49). [*13]
4 Exhaust manifold:
25 kg
50-36 PC490LC-10
28.Remove bracket (50). 33.Remove cylinder head assembly (55).

29.Remove head cover (51).
4 Cylinder head assembly:
a The head cover has been removed in
"Removal and installation of injector 20 kg
assembly" however, it is temporarily installed
to prevent entry of foreign matter.
Installation (PC400-A100-720-K-00-A)
1. Install the cylinder head assembly.

30.Remove push rods (52). [*14]
31.Remove crossheads (53). [*15] a Place the gasket on the cylinder block after
checking that there is no dust or foreign
material on the cylinder head mounting face
and inside the cylinders.
a When installing the gasket, check that the
grommets are not fall off or lost.
2. Tighten the cylinder head mounting bolts.
1) Check for the following conditions. If any bolt
is applicable, do not use it but replace it with
a new one.
• The bolt has been tightened for six times
(five punch marks).
• Stem length of bolt (a): Min. 171.4 mm
32.Remove rocker housing (54). [*16]
PC490LC-10 50-37
a When not using tool A19, make marks (b)

on the cylinder head and bolt with paint
and then tighten the bolt by 90 to 120 °
(target: 120 ° ).
3) Put a punch mark (c) on the bolt head to
indicate the number of tightening times.
a When a new bolt is used, do not make a
punch mark on its head.
2) Tighten the mounting bolts in the numeric

order shown below.
2 Cylinder head mounting bolt:
Molybdenum disulphide lubricant
(LM-P)
3 Cylinder head mounting bolt:
1st time: 98 ± 9.8 Nm {10 ± 1 kgm}
2nd time: 166.6 to 176.4 Nm {17 to 4) Tighten cylinder head auxiliary bolts (7).
18 kgm}
3 Cylinder head mounting auxiliary
(Target: 176.4 Nm {18 kgm})
bolt:
3rd time: Using tool A19, retighten
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
the bolt by 90 to 120 ° .
(Target: 120 ° )
3. Perform the following installation in the reverse

order to removal.
[*1]
a Tighten the cylinder block side sleeve nut for
tube (8) to the following torque.
3 Sleeve nut:
24 to 27 Nm {2.4 to 2.7 kgm}
[*2]
a Tighten tube (17) to the following torque.
3 Eyebolts (both ends):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a Tighten tube (18) to the following tightening
torque.
50-38 PC490LC-10
3 Front cover side sleeve nut: 3 Mounting bolt:

35 to 63 Nm {3.5 to 6.5 kgm} 59 to 74 Nm {6 to 7.5 kgm}
3 EGR valve side eyebolt: [*5]
34.3 to 44.1 Nm {3.5 to 4.5 kgm} a Tighten the clamps for hose (26) to the following
[*3] torque.
a Tighten the MIKALOR clamps at both ends of 3 Hose clamp:

tube (20) according to the following procedure. 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
a Use new MIKALOR clamps. [*6]
a Impact wrench is not allowed to use. a Tighten tubes (29) and (30) to the following
torque.
a With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) overlaps with 3 Front cover side sleeve nut:
the band by dimension (b) indicated below. 24 to 27 Nm {2.4 to 2.7 kgm}
• Dimension (b): Min. 5 mm 3 KVGT side eyebolt:
2 Clamp bolt thread portion (BC): 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
Lubricant (ThreeBond PANDO 18B or [*7]
equivalent)
a Tighten the fuel doser side eyebolt for tube (34)
to the following torque.
hose. 3 Eyebolt:
3 Clamp bolt: 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
Min. 2.9 to 5.9 Nm {0.3 to 0.6 kgm} [*8]
• When using a new hose a Tighten the KVGT side sleeve nut for tube (35) to
Tighten the clamp so that dimension (BDG) is 4 the following torque.
to 7 mm.
3 Sleeve nut:
35 to 65 Nm {3.5 to 6.5 kgm}
[*9]
a Tighten the KVGT assembly mounting nuts to
2 Mounting bolt:
3 Mounting nut:
68.6 to 73.5 Nm {7 to 7.5 kgm}
[*10]
a Tighten the eyebolts for tubes (38) and (39) to
[*4]
a Tighten the KDPF side mounting bolt for tube
3 Eyebolt (38):
(23) to the following torque.
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
2 Mounting bolt:
3 Eyebolt (39):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Mounting bolt:
[*11]
78.5 to 88.3 Nm {8.0 to 9.0 kgm}
a Tighten tube (40) to the following torque.
a Tighten brackets (23a) and (23B) to the following
torque. 3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
2 Mounting bolt:
Seizure prevention compound (LC-G) a Tighten the eyebolts for tubes (41) and (42) to
PC490LC-10 50-39
3 Eyebolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*12]
a Tighten the eyebolt for tube (48) to the following
torque.
3 Eyebolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*13]
a Installation procedure for exhaust manifold
1. Screw in all of the exhaust manifold
mounting bolts two to three turns by hand. [*16]
2. After tightening mounting bolts [1] to [3] to
3 Rocker housing mounting bolt:
the specified torque, tighten the other
mounting bolts. 58.8 to 73.5 Nm {6.0 to 7.5 kgm}
3 Mounting bolt:
58.8 to 73.5 Nm {6 to 7.5 kgm}
[*14]
a Check that the push rod is in the cam follower.
[*15]
a Adjust the crosshead according to the following
procedure.
1. Loosen lock nut (56) and back off adjustment
screw (57).
2. While pressing the top of crosshead (53)
lightly, tighten the adjustment screw.
3. When adjustment screw (57) touches the
valve stem, tighten it further by 20 ° .
4. While keeping this condition, tighten lock nut
(56).
2 Crosshead guide and top of crosshead:
Engine oil
3 Locknut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
50-40 PC490LC-10
Removal and installation of radiator assembly (PC400-B220-924-K-00-A)

the work equipment to the ground completely,
and stop the engine.
k Release the remaining pressure in the

hydraulic circuit. For details, see Testing and
adjusting, "Releasing remaining pressure
from hydraulic circuit".

7. Remove fan guards (6) and (7).
Removal (PC400-B220-520-K-00-A)
1. Drain coolant from bottom of the radiator.
6 Radiator:
44 l
2. Remove the engine hood. For details, see
"Removal and installation of engine hood".
3. Remove undercover (2).
8. Remove hose clamps and disconnect the

following hoses.
• (8): Aeration hose
• (9): Reservoir hose
• (11): Radiator inlet hose
9. Remove step plate (12).
4. Remove reservoir tank (3).

5. Remove reservoir tank mounting bracket (4).
10.Remove fan guards (13) and (14).

11.Remove stay (15).
6. Lift and remove radiator frame (5).
4 Radiator frame (5):

45 kg
PC490LC-10 50-41
13.Disconnect fan motor connector CN-A16 (17) 19.Disconnect hydraulic oil cooler tube (23).
from the bottom.
a Plate (26) interferes with the cooler tube.
14.Remove sponge (18) with its plate.
20.Remove nine mounting bolts (24) and four wing
nuts (25).
15.Disconnect the following hoses from the bottom.

• (19): Hose (Port TC: from hydraulic tank)
• (20): Hose (Port T: to hydraulic oil cooler) 22.Lift and remove radiator assembly (27).
• (21): Hose (Port P: from fan pump)
• (21a): Hose (Radiator outlet) 4 Radiator assembly (27):
a Place an oil container under the hoses. 40 kg
16.Sling cooling fan and fan motor assembly (22).

17.Remove a total of twelve mounting bolts from
Installation (PC400-B220-720-K-00-A)
four places. Perform installation in the reverse order to removal.

18.Lift and remove the cooling fan and fan motor • Refilling of coolant (radiator)
assembly (22). Add the coolant through the coolant filler port to
the specified level. Run the engine to circulate
4 Cooling fan and fan motor assembly the coolant through the system. Then, check the
(22): coolant level again.
220 kg
50-42 PC490LC-10
5 Radiator (coolant):
44 l (For details, see "Table of fuel,
coolant and lubricants")
PC490LC-10 50-43
Removal and installation of hydraulic oil cooler assembly (PC400-B8P0-924-K-00-A)

lower the work equipment to the ground and
stop the engine.

adjusting, "Releasing residual pressure from
hydraulic circuit".

6. Sling and remove radiator frame (3c).
Removal (PC400-B8P0-520-K-00-A)
4 Radiator frame (3c):
"Removal and installation of engine hood". 220 kg
7. Open side cover (4) on the right side.

3. Loosen drain plug (3) at bottom of the hydraulic 8. Remove cover (5) from top of the hydraulic oil
tank to drain the oil. cooler.
9. Remove mounting bolt (8) on the right top of the
6 Hydraulic tank: hydraulic oil cooler.
248 l
10.Disconnect hydraulic oil cooler outlet tube (7).

4. Remove reservoir tank (3a). a Fix the outlet tube (7) so that it does not
5. Remove reservoir tank mounting bracket (3b). interfere with the hydraulic oil cooler.
11.Remove hydraulic oil cooler upper (front)
mounting bolts (8).
50-44 PC490LC-10
a Check that the heat insulation material (sponge)

on the hydraulic oil cooler periphery is not
damaged.
a If the heat insulating material (sponge) is
damaged, replace it with a new one.
a When installing the hydraulic oil cooler assembly,
carefully lower it to avoid the heat insulation
material (sponge) on the periphery from being
damaged.
a Check that the convex parts (A) at the bottom of
the hydraulic oil cooler properly fits with the
12.Loosen the plug (9) located under hydraulic oil concave parts (B) of the machine from the
cooler inlet tube (10) and drain oil. [*1] bottom side.
a Place an oil container under the hydraulic oil
cooler inlet tube (10).
• Refilling of oil (hydraulic tank)

Add hydraulic oil through the oil filler port to the
specified level. Run the engine to circulate the
13.Sling and remove hydraulic oil cooler assembly oil through the piping. Then, check the oil level
(11). [*2] again.
4 Hydraulic oil cooler assembly (11): 5 Hydraulic tank (hydraulic oil):
45 kg 248 l (specified capacity: 472 l )
For details, see "Table of fuel, coolant
and lubricants".
• Bleeding air (hydraulic system)
Bleed air from the hydraulic pump circuit. For
details, see Testing and adjusting, "Bleeding air
from hydraulic system".
Installation (PC400-B8P0-720-K-00-A)
Perform installation in the reverse order to removal.

[*1]
a Before supplying oil, check that the oil cooler
drain plug is securely tightened.
[*2]
PC490LC-10 50-45
Removal and installation of aftercooler assembly (PC400-A9A0-924-K-00-A)


Removal (PC400-A9A0-520-K-00-A)

a A gas cylinder is attached to engine hood (1).
5. Open radiator front cover (4).
a Apply the lock firmly. 6. Disconnect outlet air hose (5). [*1]
2. Sling and open engine hood (1a).
a Apply the lock firmly.
7. Disconnect inlet air hose (6). [*2]
8. Sling aftercooler assembly (7).

9. Remove upper mounting bolts (8) and lower
4. Remove cover (3) from the bottom. mounting bolts (9).
50-46 PC490LC-10
11.By using lifting tool [1], lift and remove

aftercooler assembly (7).
4 Aftercooler assembly (7):

30 kg
Installation (PC400-A9A0-720-K-00-A)

[*1], [*2]
• Tighten the hose clamps according to the
1. Referring to the drawing below, set the
bridge under the bridge band.
2. Tighten the clamp so that dimension (a) is as
follows.
Dimension (a): 8 to 10 mm
(b): Overlapping length of bridge and band
(c): Bridge
(d): Punch hole
2 Clamp bolt thread portion:
Lubricant (ThreeBond PANDO 18B
or equivalent)
3 Clamp bolt:
16 to 17 Nm {1.6 to 1.7 kgm}
PC490LC-10 50-47
Removal and installation of cooling fan and fan motor assembly (PC400-B5L0-
924-K-00-A)



Removal (PC400-B5L0-520-K-00-A)

7. Remove hose clamps and disconnect the

following hoses.
3. Remove reservoir tank (3). • (10): Aeration hose
4. Remove reservoir tank mounting bracket (4). • (11): Radiator inlet hose
8. Remove step plate (12).
5. Lift and remove radiator frame (5).

10.Remove stay (15).
4 Radiator frame (5):
45 kg
50-48 PC490LC-10
12.Disconnect fan motor connector CN-A16 (17) 18.Remove mounting bolt (23) and lock plate (24).
from the bottom. 19.Remove mounting nut (25).[*1]
13.Remove sponge (18) with its plate.
20.Using tool [1], remove fan (27) together with

14.Disconnect the following hoses from the bottom. boss (26).
• (19): Hose (Port TC: from hydraulic tank) a To prevent boss (26) from popping out,
• (20): Hose (Port T: to hydraulic oil cooler) mounting nut (25) must be screwed in for
• (21): Hose (Port P: from fan pump) three to four turns.
a Place an oil container under the hoses. a Do not use a hammer to remove boss (26).
15.Sling cooling fan and fan motor assembly (22).

21.Disconnect fan motor connectors CN-V17 (28)
16.Remove a total of 12 mounting bolts from four and CN-P50 (29).
places.
17.Lift and remove the cooling fan and fan motor a Also remove the harness clamps.
assembly (22). 22.Remove three mounting bolts (30) and plate
(31).
4 Cooling fan and fan motor assembly a Pull out grommet (32) from its mounting hole
(22): and remove the wiring harness from plate
220 kg (31).
23.Remove fan guard (33).
PC490LC-10 50-49
24.Disconnect harness clamp (34). 29.Remove key (40) from fan motor assembly (38).
25.Disconnect the following tubes and hoses.
• (35): Tube (Port TC: from hydraulic tank)
a Reposition tube (35) aside after
disconnecting it out of the way.
• (36): Hose (Port T: to hydraulic oil cooler)
• (37): Hose (Port P: from fan pump)
Installation (PC400-B5L0-720-K-00-A)

[*1]
a Thoroughly clean and degrease tapered
surfaces of fan motor (38) shaft and boss (26).
26.Reverse fan motor assembly (38) and loosen • Install boss (26) with its position matched to key
four mounting bolts (39). (40).
• Tighten lock plate (24) according to the following
procedure.
1. Tighten mounting nut (25).
3 Mounting nut (25):
858.0 Nm {87.5 kgm}
2. Place lock plate (24) on mounting nut (25).
3. Among the two holes in lock plate (24) and two
bolt holes in boss (26), select the holes at
locations requiring the smallest retightening
angle to turn the nut.
4. Retighten mounting nut (25), and align mounting
holes in lock plate (24).
27.Reverse fan motor assembly (38) again and Specified retightening angle: Max. 15 °
remove four mounting bolts (39) from the a Do not align holes by turning lock plate (24)
bottom. in the loosening direction.
28.Lift and remove fan motor assembly (38). 5. Install lock plate mounting bolt (23).
4 Fan motor assembly (38): 2 Lock plate mounting bolt (23):

40 kg Adhesive (LT-2)
50-50 PC490LC-10
• Refilling (hydraulic tank)

oil through the piping. Then, check the oil level
again.
5 Hydraulic tank (hydraulic oil):

Refilling only (For details, see "Table
of fuel, coolant and lubricants")
PC490LC-10 50-51
Removal and installation of engine and main pump assembly (PC400-R400-924-K-

00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
B 796T-601-1110 Stopper t 1


6. Disconnect connector CN-P57 (5).

Removal (PC400-R400-520-K-00-A)

7. Disconnect the following KCCV hoses. [*1]

• (6): Coolant inlet hose
• (7): Blow-by gas outlet hose
• (8): Oil drain hose
• (9): Blow-by gas inlet hose
• (10): Coolant outlet hose
a Place an oil container under the piping.
8. Remove KCCV assembly (11) together with the
bracket.
6 Radiator:
44 l
4. Disconnect connector CN-S50 (3).
5. Remove electric priming pump assembly (4)
together with the bracket.
9. Remove window washer tank (11a).
50-52 PC490LC-10
10.Open left side cover (12). 14.Remove cover (14) from top of the turbocharger.
11.Remove cover (12a) from above the hydraulic
pump.

16.Remove tubes (16) and (17) between the
12.Remove cover (12b) and frame (12c) from under turbocharger and aftercooler. [*2]
the KDPF.
a Put marks on the hose end and tube to
indicate their installing positions.
13.Remove pre-filter assembly (13) together with

the bracket.
a Fix pre-filter assembly (13) to the machine 18.Remove fan guard (19).
side.
PC490LC-10 50-53

19.Remove step plate (19a).
24.Disconnect mass air flow and temperature

sensor connector CN-P55 (24).
25.Loosen mounting band (25a) and remove air
cleaner case (25). [*4]
20.Remove air cleaner case cover (20).

21.Remove air cleaner element (21).
22.Remove box (22).
26.Remove engine compartment partition (25a).

27.Remove air hose (25b). [*5]
28.Disconnect connectors CN-E01 (26), CN-EGR

(27), and CN-SEGR (28) at the left side of the
engine.
29.Disconnect air intake connector (29). [*6]
23.Remove U-bolts (23a) and disconnect tube (23)

from between the aftercooler and intake
connector. [*3]
50-54 PC490LC-10
30.Remove U-bolt (30a), and disconnect tube (30) 33.Disconnect fuel return hose (32) from the left
from between the turbocharger and air cleaner side of the engine.
and. [*7]
34.Remove air conditioner compressor assembly

(36) according to the following procedure. [*8]
1) Disconnect air conditioner compressor
31.Remove cover (31) from top of the turbocharger. electromagnetic clutch connector CN-M34
(35).
2) Loosen bracket mounting bolt (37), bolt (38),
adjustment nut (39), and then move air
conditioner compressor assembly (36) in the
loosening direction.
3) Loosen the air conditioner compressor belt
(40) tension and remove the belt.
4) Remove bracket mounting bolt (37), and then
remove air conditioner compressor assembly
(36) with the bracket and fasten them to the
machine side.
a Remove the assembly with the hoses
installed.
32.Disconnect connector CN-E27 (31a) at the left
of the engine.
PC490LC-10 50-55
35.Disconnect the wiring of engine controller

assembly according to the following procedure.
[*9]
a Thoroughly clean the surrounding area to
remove mud and other contamination to
prevent them from entering the connector.
1) Remove bracket (41) and cover (42).
2) Disconnect connector CN-M37 (43).
3) Disconnect connectors CN-CE03 (44), CN-
CE01 (45), and CN-CE02 (46).
a To disconnect connectors CN-CE03 (44),
CN-CE01(45), and CN-CE02 (46), loosen 37.Disconnect alternator harness terminals CN-
the hexagon socket head bolt (4 mm) at the M18 (50), CN-M21 (51), and CN-M22 (52).
center of the connectors.
a Fasten wiring harness (47) to the machine
side.
38.Remove hose clamps and disconnect the

following hoses.
• (56): Radiator inlet hose
• (57): Radiator outlet hose
36.Disconnect starting motor harness terminals

CN-SB (48) and (49).
a Terminals CN-SB (48) and (49) are tightened
together.
50-56 PC490LC-10
39.Disconnect connectors CN-E25 (58) and CN- 40.Remove partition (60).

E26 (59) according to the following procedure.
1) Remove harness clamps.
41.Loosen drain plug (61) at bottom of the hydraulic

tank to drain the oil.
2) Slide the lever (red) of the connector in the
direction of the arrow to unlock. 6 Hydraulic tank:
248 l
3) While pressing the knob on the upper portion

of the connector, pull out the connector in the 42.Disconnect the following connectors.
direction of the arrow. (62): CN-V12
(63): CN-V11
(64): CN-V19
(65): CN-P27
(66): CN-V13
(67): CN-P28
PC490LC-10 50-57
46.Using tool B, remove right and left front engine

mount bolts (80) and right and left rear engine
mount bolts (81).
a If the nuts are heated with gas, the bolts are
removed easily.
43.Disconnect the following hydraulic hoses.

(68): PDIR case drain port
(69): PLSR rear pump load pressure input port
(70): PBR rear pump pressure input port
(71): To front pump LS valve
(72): To front pump PC valve
(73): PEPC EPC source pressure input port
(74): PEPC EPC source pressure input port
(75): PBF front pump pressure input port
(76): PLSF front pump load pressure input port
(77): PFS pump suction port
(78): PFEPC EPC valve source pressure input
port
(79): PFI pump discharge port
47.Lift and remove the engine and hydraulic pump

assembly (82).
a Ensure that all the wiring, piping, clamps, etc.
are disconnected before removing.
4 Engine and hydraulic pump assembly

(82):
44.Disconnect connector CN-P22 (79a). 2,000 kg
45.Disconnect suction tube (79b). [*10]
a Place an oil container under suction tube
(79b).
Installation (PC400-R400-720-K-00-A)
• Perform installation in the reverse order to

removal.
50-58 PC490LC-10
a Remove dirt etc. sticking to the wiring harness 3 Hose mounting clamp:
connectors before connecting them. 10.5 ± 0.5 Nm {107 ± 5 kgcm}
[*1] [*5]
3 Mounting clamp for blow-by gas outlet 3 Air hose (25b) mounting clamp:
hose (7):
17.6 to 21.6 Nm {1.8 to 2.2 kgm}
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*7]
[*2] [*3] [*6]
3 Tube (30) for air hose mounting clamp:
Install the disconnected air tube according to the
following procedure. 10.5 ± 0.5 Nm {107 ± 5 kgcm}
a Use new MIKALOR clamps. 3 U-bolt (30a):

1. Install the hose to the original position (marked 14.7 to 44.1 Nm {1.5 to 4.5 kgm}
position). [*8]
a Reference a See Testing and adjusting, "Checking and
Air hose inserted depth: 80 mm (on each adjusting air compressor belt tension".
side) 3 Adjustment nut (39):
2. With bridge (BR) set under the clamp bolt,
156.8 to 196.0 Nm {16 to 20 kgm}
tighten the bolt so that bridge (BR) overlaps with
the band by dimension (b) indicated below.
Dimension (b): Min. 5 mm
Lubricant (ThreeBond PANDO 18B or
equivalent)
a Impact wrench is not allowed to use.
hose.
3 Clamp bolt:
Min. 2.9 to 5.9 Nm {0.3 to 0.6 kgm}
[*9]
Tighten the clamp so that dimension (BDG) 3 Hexagonal socket head bolt (4 mm) at
is as follows. center of connectors CN-CE03 (44), CN-
Dimension (BDG): 7 to 10 mm CE01 (45), and CN-CE02 (46):
2.6 to 3.1 Nm {0.27 to 0.32 kgm}
3 U-bolt (23a): [*10]

Min. 10.8 to 26.5 Nm {1.1 to 2.7 kgm} 1. Install the suction tube according to the following
[*4] procedure.
3 Mounting band (25a): 1) Apply adhesive to the inserted portion (j) of
17.6 to 21.6 Nm {1.8 to 2.2 kgm} the suction hose (hatched area).
PC490LC-10 50-59
2 Inserted portion (j) of the suction Dimension (b): Min. 5 mm

hose (hatched area):
Adhesive (THREEBOND 4314 or
Lubricant (THREEBOND PANDO 18B
equivalent)
or equivalent)
hose.
3 Clamp bolt:
Min. 2.9 to 5.9 Nm {0.3 to 0.6 kgm}
is as follows.
Clamps at (k): 15 to 18 mm
Clamps at (m): 10 to 13 mm
2) Install and adjust the positions of the suction Clamps at (n): 3 to 9 mm
tube and suction hose as shown in the
following figure.
3) Tighten the hose clamps in the following

order.
(a)o(b)o(c)o(d)o(e)o(f)o(g)o(h)
• Refilling of coolant (radiator)

Add the coolant through the coolant filler port to
the specified level. Run the engine to circulate
the coolant through the system. Then, check the
coolant level again.
2. Install the MIKALOR clamp according to the
following procedure. 5 Radiator (coolant):
• With bridge (BR) set under the clamp bolt, • Refilling (hydraulic tank)
tighten the bolt so that bridge (BR) overlaps Add hydraulic oil through the oil filler port to the
with the band by dimension (b) indicated specified level. Run the engine to circulate the
below.
50-60 PC490LC-10

again.

248 l (specified capacity: 472 l ) (For
details, see "Table of fuel, coolant and
lubricants")
PC490LC-10 50-61
Removal and installation of engine front seal (PC400-A350-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
5 795-931-1100 Seal puller assembly q 1

6 795T-521-1140 Push tool t 1
A
7 01010-61650 Bolt t 3
8 01643-31645 Washer t 9

and stop the engine. 4. Remove air conditioner compressor belt (7)
according to the following procedure. [*1]
k Set the lock lever in the Lock position. 1) Loosen mounting bolts (3), (4) and
adjustment nut (5), and then move air
k Release the remaining pressure in the conditioner compressor assembly (6) for
hydraulic circuit. For details, see Testing and ease of removal.
adjusting, "Releasing remaining pressure 2) Loosen the air conditioner compressor belt
from hydraulic circuit". (7) tension and remove the belt.

a Note connector numbers and installed positions

before disconnecting wiring and hoses.
a Fit a plug or flange to the disconnected hydraulic
hose to prevent oil from flowing out.
Removal (PC400-A350-520-K-00-A)
1. Remove the engine hood assembly. For details,

see "Removal and installation of engine hood
assembly".
2. Remove undercover (1). 5. Remove alternator belt (8) according to the
following procedure. [*2]
1) Apply a wrench [1] to portion (a) (width
across flats: 12.7 mm) of tensioner assembly
(9).
2) Turn the wrench in the direction opposite to
the winding-up direction to remove alternator
belt (8).
k Firmly set wrench [1] on tensioner

assembly (9) at portion (a) before
applying turning force to the wrench.
(The spring of tensioner assembly (9)
is strong. If the wrench is loosely
3. Remove the cooling fan and fan motor assembly inserted, the wrench can accidentally
(2). For details, see "Removal and installation of come off and this is extremely
cooling fan and fan motor assembly". dangerous.)
k After removing alternator belt (8),

slowly and carefully restore tensioner
assembly (9).
50-62 PC490LC-10
k Be careful not to get your finger

caught between the pulley and
alternator belt (8) during work.
7. Engine front oil seal [*4]

a Before removing, tap engine front oil seal
(12) to unstick it.
a Take care not to damage the oil seal contact
surfaces on front cover (11) and crankshaft
(13).
a If it is difficult to remove engine front oil seal
(12), remove it according to the following
procedure.
1) Drill several holes about 3 mm in diameter in
engine front oil seal (12).
a Remove all the chips.
2) Replace the tip of tool A5 with the drill type
one, and insert the tool into holes made in
6. Damper and pulley assembly [*3] the previous step.
1) Using lifting tools [2], sling the damper and 3) Pull slide hammer [SH] of tool A5 to apply
pulley assembly (10). impact and remove engine front oil seal (12).
2) Remove six mounting bolts, and then pull out a Perform the above procedure evenly at
the dowel pin portion. several places so that engine front oil
3) Using guide bolt [3], pull out, sling and seal (12) is not slanted.
remove damper and pulley assembly (10).
4 Damper and pulley assembly (10):

25 kg
• Tool A5
PC490LC-10 50-63
Installation (PC400-A350-720-K-00-A) a Adjust the alternator belt tension. For details,

see Testing and adjusting, "Testing and
a Perform installation in the reverse order to adjusting alternator belt tension".
removal.
[*3]
[*1]
a There are two kinds of damper and pulley
a Adjust the air conditioner compressor belt assembly (10) mounting bolts.
tension. For details, see Testing and adjusting,
"Testing and adjusting air conditioner 3 Mounting bolt (width across flats: 22 mm,
compressor belt tension". 1 piece):
[*2] 157 to 196 Nm {16 to 20 kgm}
a Install alternator belt (8) according to the 3 Mounting bolt (width across flats: 24 mm,
following procedure. 5 pieces):
1. Apply a wrench [1] to part (a) (width across flats: 245 to 309 Nm {25.0 to 31.5 kgm}
12.7 mm) of tensioner assembly (9). [*4]
2. Turn wrench [1] in the direction opposite to the
a Install engine front oil seal (12) according to the
winding-up direction to install alternator belt (8).
k Firmly set wrench [1] on tensioner a Before installation, check that crankshaft end
assembly (9) at portion (a) before surface corners, sliding surfaces of oil seal lip,
applying turning force to the wrench. (The and front cover are free from flaws, burrs, rust,
spring of tensioner assembly (9) is strong. etc.
If the wrench is loosely inserted, the 1. Set engine front oil seal (12) to front cover (11),
wrench can accidentally come off and this and then use a plastic hammer to install it until
is extremely dangerous.) oil seal lip (b) is inserted in crankshaft (13).
a Be careful not to install engine front oil seal
k Afterinstalling alternator belt (8), slowly
(12) in the wrong direction.
and carefully restore tensioner assembly
(9). a Tap evenly on all around the engine front oil
seal (12) to drive it in place while using care
k Be careful not to get your finger caught not to deform the seal.
between the pulley and alternator belt (8) a Take care not to let oil seal lip (b) get caught
during work. in crankshaft (13).
2 Engine front oil seal (12) (50 to 80% of
lip space volume):
Grease (G2-LI)
50-64 PC490LC-10
a Press fitted depth (d) of engine front oil seal

(12) from end surface of crankshaft (13): 9.2
(+1/0) mm

again.

2. Install tool A6 and tighten three tools A7 (bolts) • Bleeding air (hydraulic system)
evenly until they bottom, to press fit engine front Bleed air from the hydraulic pump circuit. For
oil seal (12) into front cover (11). details, see Testing and adjusting, "Bleeding air
a Do not install tools A8 (washers) to tools A7
(bolts) at this time.
3. Remove three tools A7 (bolts), and then install
three tools A8 (washers) to each of tools A7
(bolts).
4. Install three tools A7 (bolts) again, and tighten
them evenly until end surface of tool A6 comes
in contact with end surface of front cover (11), to
press fit engine front oil seal (12).
a Press fitted depth (c) of engine front oil seal
(12) from end surface of front cover (11): 16
(+1/0) mm
PC490LC-10 50-65
Removal and installation of engine rear seal (PC400-A510-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
Seal puller
9 795-931-1100 assembly q 1
10 795T-421-1340 Push tool t 1
11 01010-61635 Bolt t 3
12 01643-31645 Washer t 3
A 13 795-931-1220 Push tool t 1
14 01010-61650 Bolt t 3
2. Remove the main pump assembly. For details,
15 01643-31645 Washer t 3 see "Removal and installation of main pump
16 795T-421-1320 Push tool t 1 assembly".
17 01010-61645 Bolt t 3 3. Remove eight damper mounting bolts (1).
18 01643-31645 Washer t 9 4. By using guides [1], pull out damper assembly
A10 to A12: For standard seals (2).
5. By using lifting tool [2], lift and remove damper
A13 to A15: For sleeved seals assembly (2).
A16 to A18: For sleeved seals
k Park the machine on a level ground, lower 4 Damper assembly (2):
the work equipment to the ground completely, 15 kg



Removal (PC400-A510-520-K-00-A)
1. Loosen drain plug (1a) at bottom of the hydraulic

6 Hydraulic tank:
248 l
6. Flywheel [*1]
1) By using eyebolt [3], sling flywheel (3).
2) Remove six mounting bolts (4), and then pull
out the dowel pin portion.
3) Using guide bolt [4], pull out, sling and
remove flywheel (3).
50-66 PC490LC-10
4 Flywheel (3):
45 kg
2) Removal of sleeved oil seal

1] Replace the tip of tool A9 with the hook
type one, and hook the tool on outer case
7. Engine rear oil seal [*2]
(a) of engine rear oil seal (5).
a Before removing, tap engine rear oil seal (5) 2] Pull slide hammer [SH] of tool A9 to apply
to unstick it. impact and remove engine rear oil seal
(5).
a Take care not to damage the oil seal contact
surfaces on flywheel housing (6) and a Perform the above procedure evenly
crankshaft (7). at several places so that engine rear
oil seal (5) is not slanted.
a If it is difficult to remove engine rear oil seal
3] Cut and remove sleeve (8) by using a
(5), remove it according to the following
chisel and a hammer.
procedure.
1) Removal of standard oil seal a Take care not to damage crankshaft
(7) and flywheel housing (6).
1] Drill several holes about 3 mm in
diameter in engine rear oil seal (5). a Remove all the chips.
a Remove all the chips.
2] Replace the tip of tool A9 with the drill
type one, and insert the tool into holes
made in the previous step.
3] Pull slide hammer [SH] of tool A9 to apply
impact and remove engine rear oil seal
(5).
a Perform the above procedure evenly
at several places so that engine rear
oil seal (5) is not slanted.
a Perform installation in the reverse order to

removal.
[*1]
a Install flywheel (3) according to the following
procedure.
1. Using eyebolt [3], sling flywheel (3) and install it
while aligning the dowel pin portion by using
guide bolt [4].
• Tool A9
4 Flywheel (3):
45 kg
PC490LC-10 50-67

Engine oil (SAE30-DH or equivalent)
2. Tighten mounting bolts (4) according to the
a Impact wrench is allowed to use.
1st time: 147 ± 19. 6 Nm {15 ± 2.0
kgm}
2nd time: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
[*2]
a Install engine rear oil seal (5) according to the
1. Selecting oil seal
a Regarding the Teflon seal (laydown lip seal),
check the wear of the crankshaft and select
"standard oil seal" or "sleeved oil seal" to be
installed depending on the wear.
a If the wear condition of the crankshaft is
glossy and no scratches (when touched by a
finger, wear depth is 10 mm or less), install a
"standard oil seal". Otherwise install a
sleeved oil seal.
a The left one in the following figure shows the
standard oil seal and the right one shows the
sleeved oil seal.
3. Using dial gauge [5], measure the facial runout

and radial runout.
a Facial runout: Max. 0.20 mm
a Radial runout: Max. 0.15 mm
2. Installation of standard oil seal

a Clean, degrease, and dry the contacting
surface against the flywheel housing.
a Before installing the oil seal, check that the
end corner and oil seal lip sliding contact
surface of the crankshaft (7) and the housing
are free from flaw, burr, and rust.
a When installing the engine rear oil seal, do
not apply oil or grease to the crankshaft and
the hatched area of oil seal lip (b). Also,
thoroughly wipe off oil or grease from the
crankshaft.
50-68 PC490LC-10
a Mounting guide (9) adheres to engine rear oil 4) Install tool A10 and tighten three tools A11
seal (5) when it is supplied as a spare part. (bolts) evenly until they bottom, to press fit
Do not remove this guide until the engine engine rear oil seal (5).
rear oil seal is to be installed.
a Do not install tools A12 (washers) to tools
A11 (bolts) at this time.
a Take care not to damage the oil seal lip
with tools, etc. when press-fitting the
engine rear oil seal.
5) Remove tools A11 (bolts), and then install
one tool A12 (washer) to each of tools A11
(bolts).
6) Install three tools A11 (bolts) to tool A10
again, and tighten them evenly until end
surface of tool A10 comes in contact with
end surface of crankshaft (4), to press fit
engine rear oil seal (5).
1) Put the large inside diameter side (c) of a Press fitted depth (d) of engine rear oil
mounting guide (9) on engine rear oil seal (5) seal (5) from end surface of crankshaft
to the end of crankshaft (7). (7): 16.3 ± 0.2 mm
a Be careful not to install engine rear oil a Take care not to damage the oil seal lip
seal (5) in the wrong direction. with tools, etc. when press-fitting engine
rear oil seal (5).
a After press-fitting engine rear oil seal (5),
remove the red sealant layer from its
periphery.
2) Push in the outer case end surface of engine

rear oil seal (5) evenly.
3) Push in engine rear oil seal (5) partially until
it doesn't come off, and then remove
mounting guide (9).
3. Installation of sleeved oil seal
a When removing mounting guide (9), take
a Clean, degrease, and dry the contacting
care not to damage the oil seal lip.
surface against the flywheel housing.
a Check that the end corner and oil seal lip
sliding surface of the crankshaft, and the
housing are free from flaw, burr, sharp fin,
rust, etc.
a Do not apply oil or grease to the crankshaft,
inside surface of sleeve (8), and the hatched
area of engine rear oil seal lip (b). Also,
thoroughly wipe off oil or grease from the
crankshaft.
a Handle the engine rear oil seal and sleeve
(8) as an assembly and never separate them
from each other.
PC490LC-10 50-69
a Do not install tools A18 (washers) to tools

A17 (bolts).
4) Remove tools A17 (bolts), and then install
three tools A18 (washers) to each of tools
A17 (bolts).
5) Install three tools A17 (bolts) to tool A16
again, and tighten them evenly until end
surface of tool A16 comes in contact with
end surface of crankshaft (7), to press fit
sleeve and engine rear oil seal assembly (5).
a Press fitted depth (e) of sleeve and
engine rear oil seal assembly (5) from
end surface of crankshaft (7): 16.3 ± 0.2
1) Set sleeve and engine rear oil seal assembly mm
(5) to tool A13.
a Take care not to damage the oil seal lip
2 Inside surface of sleeve: with tools, etc. when press-fitting engine
Liquid gasket (LG-7) rear oil seal (5).
a After press-fitting sleeve and engine rear
oil seal assembly (5), remove the red
sealant layer from its periphery.
2) Place sleeve (8) of the sleeve and engine

rear oil seal assembly (5) to the end face of
crankshaft (7), and tighten the three tools
A14 (bolts) of tool A13 evenly to press fit
sleeve and rear oil seal assembly (5). • Refilling (hydraulic tank)
a Install one tool A15 (washer) to each of specified level. Run the engine to circulate the
tools A14 (bolts), and then tighten tools oil through the piping. Then, check the oil level
A14 (bolts) until they bottom. again.

248 l (specified capacity: 472 l ) (For
details, see "Table of fuel, coolant and
lubricants")
3) Remove tool A13 and replace with tool A16,

and then tighten three tools A17 (bolts)
evenly to press fit sleeve and engine rear oil
seal assembly (5) at this time.
50-70 PC490LC-10
Removal and installation of engine hood assembly (PC400-H540-924-K-00-A)
Removal (PC400-H540-520-K-00-A)
4 Engine hood (6):
1. Remove engine hood (1) according to the 55 kg
1) Open engine hood (1).
a It is necessary to open engine hood (1)
first to open the radiator side engine
hood.
2) Sling engine hood (1) and remove lock bar
(2).
3) Remove two gas cylinders (3).
a Gas cylinders (3) are installed to engine
hood (1) only.
4) Remove the mounting bolts, and then sling
and remove engine hood (1).
Installation (PC400-H540-720-K-00-A)
4 Engine hood (1):
30 kg
removal.
2. Remove engine hood (4) according to the

1) Sling and open engine hood (4).
2) Remove lock bar (5).
3) Remove the mounting bolts, and then sling
and remove engine hood (4).
4 Engine hood (4):

35 kg
3. Remove the mounting bolts, and then sling and

remove engine hood (6).
PC490LC-10 50-71
Removal and installation of KDPF assembly (PC400-A9H0-924-K-00-A)
k Turn the battery disconnect switch to the 2) Slide the lever (red) of the connector in the
OFF position and remove the key. direction of the arrow to unlock.
k Since the temperature of KDPF or KDOC

becomes 500 °C or higher, take care not to
get burn injury.
k Stop the engine and wait until the

temperature of piping around engine drops,
then remove KDPF.
k Check for and remove any accumulated dirt

and combustibles (dead leaves, twigs, etc.)
around the KDPF.
k KDPF is fragile against shock such as falling, 3) While pressing the knob on the upper portion
handle with care, and never use damaged of the connector, pull out the connector in the
part. direction of the arrow.
k Keep the record for each KDPF unit to

monitor the life, and never use the KDPF
exceeded its life.
Removal (PC400-A9H0-520-K-00-A)
1. Remove engine hood assembly (1). For details,

see "Removal (and installation) of engine hood
assembly".
3. Sling KDPF assembly (4) and remove mounting

bolts for exhaust pipe (4a) and bracket (5). [*1]
4. With bracket (5) attached, sling and remove
KDPF assembly (4).
4 KDPF assembly (4):

110 kg
2. Disconnect connectors CN-E25 (2) and CN-E26

(3) according to the following procedure.
1) Remove the clamp for the wiring harness.
5. Remove mounting nuts (7) and (6) and U-bolt (8).

[*2]
6. Remove mounting bolts (9) and bracket (5).
7. Remove tail pipe (10). [*3]
50-72 PC490LC-10
Installation (PC400-A9H0-720-K-00-A)

removal.
a Before installing, remove dirt etc. sticking to the
wiring harness connectors.
[*1]
• Install exhaust pipe (4a) according to the
1. Install KDPF assembly (4) and exhaust pipe (4a)
loosely.
2. Before tightening exhaust pipe (4a), make sure [*2]
that clearance (a) and difference in level (b) are
3 Mounting nut (6):
as follows.
Clearance (a) between flanges: less than 2 mm 14.7 to 34.3 Nm {1.5 to 3.5 kgm}
(without gasket) 3 Mounting nut (7):
Difference in level (b) of flanges: less than 1 mm
21 to 49 Nm {2.1 to 5.0 kgm}
3. Install gasket and install exhaust pipe (4a).
a Make sure that distances (c) from U-bolt (8) end
a Use a new gasket.
to mounting nut (7) are even at both sides.
4. Positioning adjustment of KDPF assembly (4)
1) Adjustment in fore/aft and right/left directions
1] Loosen mounting bolts (11).
2] Move bracket (5) in fore/aft and right/left
directions to set it at a reasonable
position.
2) Up/down adjustment
1] Loosen U-bolt (8) mounting nuts (7) and
(6).
2] Loosen four mounting bolts (13) at the
side.
3] By using height adjustment bolt (12),
move bracket (5) up or down to set it at a
reasonable position. [*3]
3) When adjustments are complete, tighten • Install gasket and install tail pipe (10).
mounting bolts (4b), (11), and (13).
5. After tightening exhaust pipe (4a), make sure a Use a new gasket.
that clearance (a) and difference in level (b)
between flanges are as follows.
Axial clearance (a): Max. (with gasket)
Difference in level (b) of flanges: Max. 1 mm
a Measure clearance (a) and difference in level (b)
at four sides.
PC490LC-10 50-73
Removal and installation of KCCV assembly (PC220-A180-924-K-00-A)

position, and remove the key.
k After the engine is operated, the parts are

very hot. Wait until all parts are cooled down.
k If hoses are wrongly installed, it may result

in engine damage. So be careful when
installing hoses.
Removal (PC400-A180-520-K-00-A)

a Gas cylinder is installed to engine hood (1). Installation (PC400-A180-720-K-00-A)
a Be sure to lock them. • Perform installation in the reverse order to
removal.
a If oil drain hose (6) and coolant inlet hose (4) are
wrongly installed, the engine may be damaged.
So be careful not to install hoses wrongly.
a Remove dirt, etc. sticking to the connectors
before connecting harness connector.
[*1]
3 Mounting clamp for coolant inlet hose
(4):
3.3 ± 0.49. Nm {0.34 ± 0.05 kgm}
2. Disconnect connector P57 (3). 3 Mounting clamp for blowby gas outlet
hose (5):
4.4 ± 0.49. Nm {0.45 ± 0.05 kgm}
a For the installed dimension of hoses, see the
following figure.
3. Disconnect following KCCV hoses. [*1]

• (4): Coolant inlet hose
• (5): Blowby gas outlet hose
• (6): Oil drain hose
• (7): Blowby gas inlet hose
• (8): Coolant outlet hose
a Prepare oil container under the piping.
4. Remove KCCV assembly (9) together with
bracket.
50-74 PC490LC-10
a When check valve (6a) at the bottom of oil drain

hose (6) is removed, install check valve (6a) with
its black side (b) downward.
• (k): KCCV ventilator side (gray)
• (b): Cylinder block side (black)
PC490LC-10 50-75
Removal and installation of air cleaner assembly (PC400-A910-924-K-00-A)


Removal (PC400-A910-520-K-00-A)

2. Sling and open engine hood (2).
8. Disconnect mass air flow and temperature

sensor connector CN-P55 (8).
9. Loosen mounting band (9) and remove air
cleaner case (10). [*1]
3. Remove step plate (3). a Put marks on the hose end and tube to
indicate their fitting positions.
4. Open the right side cover (4).

5. Remove air cleaner case cover (5).
6. Remove air cleaner element (6).
7. Remove box (7). • Perform installation in the reverse order to

removal.
a Remove dirt etc. sticking to the wiring harness
connectors before connecting them.
[*1]
3 Mounting band (9):
17.6 to 21.6 Nm {1.8 to 2.2 kgm}
50-76 PC490LC-10
3 Hose mounting clamp:

10.5 ± 0.5 Nm {107 ± 5 kgcm}
PC490LC-10 50-77
Power train system
Power train system (ALL-C100-001-K-50-A)
Removal and installation of travel motor and final drive assembly (PC400-DF10-
924-K-00-A)
Removal (PC400-DF10-520-K-00-A)
4 Final drive assembly:
1. Remove the sprocket referring to the section 700 kg
"Removal and installation of sprocket".
k Park the machine on level ground and

lower the work equipment to the ground
and stop the engine, and set the lock
lever to LOCK position.
k Loosen the hydraulic tank cap slowly to


Installation (PC400-DF10-720-K-00-A)

removal.
[*1]
3 Mounting bolt:
490 to 608 Nm {50 to 62 kgm}
• Refilling of oil (hydraulic tank)
Add hydraulic oil through oil filler port to the
oil through the system. Then check the oil level
again.
3. Disconnect drain hose (2), travel speed selector 5 Hydraulic tank (hydraulic oil):
hose (3), and motor hoses (4) and (5).
a Also remove the nipple. of fuel, coolant and lubricants")
• Bleeding air (travel motor)
Bleed air from the travel motor. For details, see
part".
4. Remove the 24 mounting bolts, and sling and

remove final drive assembly (6). [*1]
a Take care no to damage the nipple sealing
surface on the hose mounting block.
a When slinging the final drive assembly, do
not use a tapped hole for slinging the cover.
50-78 PC490LC-10
Power train system
Disassembly and assembly of final drive (PC400-DF10-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol

796-627-1220 • Wrench 1
1
796-427-1140 • Pin 3
01314-20612 • Screw 3
796T-627-1230 Push tool t 1
790-101-2510 Block q 1
791-122-1130 Plate q 1 3. Spacer
E 790-101-2550 Leg q 2 Remove spacer (2).
790-101-2740 Adapter q 2
2
790-101-2570 Plate q 4
790-101-2560 Nut q 2
Puller
790-101-2102 t 1
(294 kN {30 ton})
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1
Disassembly (PC400-DF10-530-K-00-A)
1. Oil draining
Remove the drain plug to drain the oil from the
final drive case.
4. No. 1 carrier assembly
6 Final drive case:
1) Remove No. 1 carrier assembly (3).
11 l
2. Cover
1) Place the final drive on blocks [1], and then
remove the mounting bolts.
2) Disassemble No. 1 carrier assembly

1] Driven pin (5) into shaft (6) to remove
shaft (5) from carrier (7).
2) Remove cover (1) using eyebolts [2}.
a After removing shaft (6), remove pin
(5).
2] Remove thrust washer (8), planetary gear
(9), bearing (10), and thrust washer (11).
PC490LC-10 50-79
Power train system
5. Sun gear 2) Disassemble No. 2 carrier assembly

Remove spacer (4), No. 1 sun gear (12), and No. according to the following procedure.
2 sun gear (13). 1] Drive pin (16) into shaft (17) to remove
shaft (17) from carrier (18).
a After removing shaft (17), remove pin
(16).
2] Remove thrust washer (19), planetary
gear (20), bearing (21), and thrust washer
(22).
6. Thrust washer
Remove thrust washer (14) from No. 2 carrier
assembly (15).
8. Nut
1) Remove lock plate (23) from lock nut (24).

1) Using wire ropes, etc., sling and remove
No.2 carrier assembly (15).
2) Using tool E1, remove the lock nut.
50-80 PC490LC-10
Power train system
9. Hub assembly 3] Remove bearings (28) and (29).

1) Using eyebolts [3], remove hub assembly
(25) from the travel motor.
3) Remove floating seal (30) from travel motor

(31).
2) Disassemble hub assembly (25) according to
1] Remove bearing (26) from hub (32).
4) Use puller [4] to remove bearing (34) and

collar (33) together.
a These may remove without using puller
2] Remove floating seal (27) from hub (32). [4].
PC490LC-10 50-81
Power train system
Assembly (PC400-DF10-710-K-00-A)
3) Install collar (33) and bearing (34) to travel
motor (31).
a Clean the parts completely and inspect them for
any foreign materials or damage. Apply power
train oil (TO30 or equivalent) to the sliding
surface before assembly.
1. Hub assembly
1) Use push tool to press fit bearing (28) and
(29).
4) Using tool E3, install floating seal (30)

(hidden behind tool E3) to travel motor (31).
a Install floating seal (30) after degreasing
and drying the O-ring and the O-ring
contacting surface completely.
a After installing floating seal (30), check
2) Using tool E3, install floating seal (27) to hub the inclination of the seal. It must be 1
(32) mm or less.
a Install floating seal (27) after degreasing a After floating seal (30) installation, apply a
and drying the O-ring and the O-ring thin coat of power train oil (TO30 or
contacting surface completely. equivalent) to the sliding surfaces.
a After installing floating seal (27), check

the inclination of the seal. It must be 1
mm or less.
a After floating seal (27) installation, apply a
thin coat of power train oil (TO30 or
equivalent) on the sliding surfaces.
5) Using eyebolts [3], place hub assembly (25)

to the travel motor. Then tap the bearing
lightly using the push tool to press-fit it.
50-82 PC490LC-10
Power train system
2. Nut 10)Measure the tangential force of the hub

1) Rotate the hub two to three times. against the motor case in the rotation
2) Using tool E2, press the bearing inner race. direction using push-pull scale [5].
a Pressing force: 29.4 to 38.2 kN {3.0 to a Tangential force: Max. 764 N {78 kg}
3.9 ton} a The tangential force denotes the
3) While pressing the bearing, turn the hub five maximum force at start of the rotation.
turns or more in one direction.
4) Release the pressing force.
5) Press the bearing again.
a Pressing force: 14.7 to 18.6 kN {1.5 to
1.9 ton}
11)Install lock plate (23) so that its splines are

the splines of the motor are in full contact.
2 Mounting bolt thread:
Adhesive (LT-2)
6) Measure dimension (a) under the condition 3 Mounting bolt:
described in 5) above. 59 to 74 Nm {6.0 to 7.5 kgm}
7) Measure thickness (b) of nut (24) only. 3. No. 2 carrier assembly

8) Calculate a – b = c. 1) Assemble the No. 2 carrier assembly
9) Tighten nut (24) using tool E1 dimension (c) according to the following procedure.
is as shown.
a Dimension (c): c(+0.07/-0.03) mm
PC490LC-10 50-83
Power train system
a There is trace of punching on the end

face of carrier side hole (h) which was
caused when the pin was inserted and
locked. Before pin installation, remove
the protrusion in the pin hole as a result of
punching.
1] Install bearing (21) to planetary gear (20).
Fit upper and lower thrust washers (19)
and (22), and then set the planetary gear
assembly to carrier (18).
4. Thrust washer
Install thrust washer (14) to No. 2 carrier
assembly (15).
2] Align the pin holes on shaft (17) and the

carrier, and install shaft (17) by tapping it
lightly with a plastic hammer.
a Install shaft (17), while rotating
planetary gear (20) with care not to
damage the thrust washers.
3] Insert pin (16).
5. No. 2 sun gear
a After inserting pin (16), punch the pin Install spacer (4) and No. 2 sun gear (13).
portion on the carrier.
a After assembling the carrier assembly,
check that planetary gear (20) rotates
smoothly.

1) Assemble the No. 1 carrier assembly
2) Install No. 2 carrier assembly (15). according to the following procedure.
a Align the four gear shaft ends of carrier a There is trace of punching on the end
assembly (15) with the four dimples on face of carrier side hole (h) which was
the motor case end face to install. caused when the pin was inserted and
locked. Before pin installation, remove
the protrusion in the pin hole as a result of
punching.
1] Install bearing (10) to planetary gear (9).
Fit upper and lower thrust washers (8)
and (11), and then set the planetary gear
assembly to carrier (7).
50-84 PC490LC-10
Power train system
2] Align the pin holes on shaft (6) and the

a After installing spacer (2), measure
carrier, and install shaft (6) by tapping it
dimension (j) from the upper end face of
lightly with a plastic hammer.
planetary gear (9) to that of hub assembly
a Install shaft (6), while rotating (25) to check for the correct assembly
planetary gear (9) with care not to condition.
damage the thrust washers.
a If dimension (j) is less than 1.2 mm or the
3] Install pin (5).
upper end face of planetary gear (9) is
a After inserting pin (5), punch the pin projected from that of hub assembly (25), the
portion on the carrier. parts are not assembled correctly. Recheck.
a After assembling the carrier assembly,
check that planetary gear (9) rotates
smoothly.
9. Cover
Using eyebolts [2], install cover (1) and tighten
the bolts.
2) Install No. 1 carrier assembly (4). 2 Cover mounting face:
Liquid gasket (LG-6)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
7. No. 1 sun gear shaft

Install No. 1 sun gear shaft (12).
8. Spacer
Install spacer (2).
PC490LC-10 50-85
Power train system
• Refilling (final drive case)

a Tighten the drain plug and add oil through the
oil filler port.
5 Final drive case (power train oil):

11 l (specified capacity: 11 l )
(For details, see "Table of fuel,
a Do a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.
50-86 PC490LC-10
Power train system
Removal and installation of swing motor and swing machinery

assembly (PC400-J120-924-K-00-A)


3. Lift and remove the swing motor and swing
a Note connector numbers and installed positions machinery assembly (9).
4 Swing motor and swing machinery
a Fit a plug or flange to the disconnected hydraulic assembly (9):
550 kg
Removal (PC400-J120-520-K-00-A)
a When lifting the swing motor and swing
1. Remove the following swing motor hoses. machinery assembly (9) for removal, lift
• (1): Attachment hose slowly so that the surrounding hoses will not
• (2): Attachment hose be damaged.
• (3): Drain hose (port T) a Lift the swing motor and swing machinery
• (4): Pilot hose for releasing swing brake assembly (9) very carefully until the faucet
• (5): Between swing motor and control valve joint portion is completely disconnected.
(port MA)
• (6): Between swing motor and control valve
(port MB)
• (7): Suction hose (port S)
• (8): Between swing motor and control valve
(port PU) (disconnect at destination)
Installation (PC400-J120-720-K-00-A)

[*1]
3 Swing motor and swing machinery
2. Remove mounting bolts, and then disconnect assembly (9):
the swing motor and swing machinery assembly 824 to 1,030 Nm {84 to 105 kgm}
(9), using forcing screw [1]. [*1] • Refilling (hydraulic tank)
again.
PC490LC-10 50-87
Power train system

50-88 PC490LC-10
Power train system
Disassembly and assembly of swing machinery (PC400-J120-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
1 796T-627-1630 Push tool q 1

2 790-201-2350 Push tool t 1
3 790-201-2510 Push tool t 1
790-101-5531 • Plate 1
D 4
790-101-5421 • Grip 1
01010-51240 • Bolt 1
5 790-201-2870 Push tool t 1 4. No. 1 carrier assembly
6 790-201-2770 Push tool t 1 1) Remove No. 1 carrier assembly (3).
7 796T-626-1110 Push tool t 1
Disassembly (PC400-J120-530-K-00-A)
1. Oil draining
Loosen the drain plug to drain the oil from the
swing machinery case.
6 Swing machinery case:

20 l
2. Swing motor assembly
1) Set the swing motor and swing machinery
assembly on block [1].
2) Remove ten mounting bolts, and sling and
remove swing motor assembly (1). 2) Disassemble No. 1 carrier assembly
4 Swing motor assembly: Remove snap ring (4), then remove shaft (5),
110 kg planetary gear (6), bearing (7), thrust washer
(8), and plate (9).
3. No. 1 sun gear

5. Ring gear
Remove No. 1 sun gear (2).
Remove the mounting bolts and ring gear (10).
PC490LC-10 50-89
Power train system
6. No. 2 sun gear 2) Disassemble the No. 2 carrier assembly

Remove No. 2 sun gear (11). according to the following procedure.
1] Push in pin (14) and drive out shaft (15)
from carrier (16).
a After removing the shaft, remove pin
(14).
2] Remove thrust washer (17), planetary
gear (18), bearing (19), and thrust washer
(20).
3] Remove plate (21).
7. Bolt
Remove mounting bolt (12) for No. 2 carrier
assembly (13).
9. Shaft assembly
1) Reverse case and pinion assembly (24) and
remove 12 mounting bolts (23) of cover
assembly (22).

1) Sling and remove No. 2 carrier assembly
(13).
2) Reverse case and pinion assembly (24) and

place them on the press stand.
50-90 PC490LC-10
Power train system
3) Remove pinion shaft assembly (25) using a Push tool to be set in contact with bearing
push tool [2] and tool D1. (30): Tool D2
a Place wooden blocks under the press so
that pinion shaft assembly (25) is not
damaged when it comes off.
a Rough standard: 245 kN {25 ton}
Assembly (PC400-J120-710-K-00-A)
a Clean the parts completely and inspect them for

any foreign material or damage. Apply power
train oil (TO30 or equivalent) to the sliding
4) Disassemble the pinion shaft assembly surface before assembly.
according to the following procedure. a Replace the bearing and oil seal with new ones.
1] Using the push tool, remove cover 1. Bearing
assembly (22) and bearing (26) from Using push tool [4] and tool D3, press fit bearing
shaft (27). (26) to case (31).
a Rough standard: 294 kN {30 ton} a Rough standard: 49 kN {5 ton}
2] Remove oil seal (28) from cover (29).
2. Cover assembly
1) Using tool (push tool kit) D4, press fit oil seal
(28) to cover (29).
2 Outer periphery of oil seal (28):
a Take care that the liquid gasket (LG-6)
does not stick to the oil seal (28) lip and
shaft at the time of press-fitting.
10.Bearing
Using push tool [3], remove bearing (30) from
case (31).
PC490LC-10 50-91
Power train system
2) Install cover assembly (22) to case (31) and

tighten mounting bolts (23).
3) Bearing
a Match the oil path of cover assembly (22) Using tool D7, press fit bearing (30).
with the drilled hole of case (31).
a Press the bearing inner race and outer
2 Mounting surface of cover (22): race simultaneously when press fitting
Liquid gasket (LG-6) the bearing. (Do not press only the inner
race.)
98 to 123 Nm {10.0 to 12.5 kgm}
a After press-fitting the bearing, ensure that
2 Oil seal lip:
the case rotates smoothly.
Grease (G2-LI)
3. Case assembly 4. No. 2 carrier assembly

1) Reverse case assembly (32) and set it to Assemble the No. 2 carrier assembly according
shaft (27). to the following procedure.
2) Press fit the bearing inner race by using push a There is trace of punching on the end face of
tool [5] and tools D5 and D6. carrier side hole (a) which was caused when
a When setting case assembly (32) to shaft the pin was inserted and locked. Before pin
(27), take care not to damage the oil seal. installation, remove the protrusion in the pin
hole as a result of punching.
1) Install plate (21) to carrier (16).
2) Install bearing (19) to planetary gear (18). Fit
upper and lower thrust washers (17) and (20),
and then set the planetary gear assembly to
carrier (16).
3) Align the pin holes on the shaft and the
carrier, and install shaft (15) by tapping it by
using a plastic hammer.
a Install the shaft, while rotating the
planetary gear with care not to damage
the thrust washers.
50-92 PC490LC-10
Power train system
4) Insert pin (14). 2 Mounting bolt thread:

Adhesive (LT-2)
3 Mounting bolt:
343 to 427Nm {34.0 to 43.5 kgm}
3) Install the O-ring to the case.

6. No. 2 sun gear
Install No. 2 sun gear (11).
a When inserting pin (14), do not allow the

three claws (part a) on the outer
periphery to be placed on the thin wall
part of the carrier (part b).
The thin wall part may be on the opposite
side depending on carriers, however.
Check each carrier and avoid setting any
claw of the pin to the thin wall part. 7. Ring gear
a After inserting pin (14), punch the pin Using eyebolts (M12 x 1.75), install ring gear
portion of the carrier. (10).
5. Install No. 2 carrier assembly (13) according to

a When installing ring gear (10), match its
match mark (d) with convex part (c) of the
1) Set No. 2 carrier assembly (13) to the case. case flange as shown in the following figure.
2) Tighten bolt (12).
a Degrease the mating faces of ring gear (10)
and the case.
PC490LC-10 50-93
Power train system
a Do not deposit liquid gasket on the mating

faces of ring gear (10) and case.
3 Mounting bolt:
245 to 309 Nm {25.0 to 31.5 kgm}
a Add oil at this time.
5 Swing machinery case (power train

oil):
2) Install No. 1 carrier assembly (3).

1) Assemble the No. 1 carrier assembly 9. No. 1 sun gear assembly
according to the following procedure. Install No. 1 sun gear (2).
1] Press fit shaft (5) to the carrier in the
direction of the arrow until the snap ring
groove is seen.
2] After installing snap ring (4), push it back
from the opposite side until snap ring (4)
contacts tightly with face (P) of the carrier.
a Take care not to push too hard.
3] After installing plate (9), install thrust
washer (8), bearing (7), planetary gear (6),
and snap ring (4).
50-94 PC490LC-10
Power train system
a When installing the No. 1 sun gear, its side

closer to the teeth (e) must face down.
10.Swing motor assembly

Install swing motor assembly (1) to the ring gear.
a When installing the swing motor assembly,
position the relief valve (f) and the projection
of the case (c) as shown in the following
figure.
a Degrease the mating faces of swing motor
assembly (1) and the ring gear.
2 Mating faces of swing motor
assembly (1) and ring gear:
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
4 Swing motor assembly:

115 kg
• Refilling (swing machinery case)

Tighten the drain plug and add oil through
the oil filler port.
5 Swing machinery case (power train

oil):
PC490LC-10 50-95
Power train system
Removal and installation of swing circle assembly (PC400-J110-924-K-00-A)
k Park the machine on a level ground, lower 3 Swing circle mounting bolt:
the work equipment to the ground completely, 1,180 to 1,470 Nm {120 to 150 kgm}
Target: 1,325 Nm {135 kgm}
k Set the lock lever in the Lock position. a Position the soft zone position (S) mark of an
inner race and the soft zone position (P) mark of
k Release the remaining pressure in the outer race in the R.H. side of the machine as
hydraulic circuit. For details, see Testing and shown below and install it on the track frame.
2 Amount of grease filled in grease bath:
Grease (G2-LI) 33 l

Removal (PC400-J110-520-K-00-A)
1. Remove the revolving frame assembly. For

details, see "Removal and installation of
revolving frame assembly".
2. Sling swing circle assembly (1) by 3-point lifting.
3. Remove 46 mounting bolts, and then lift swing
circle assembly (1) to remove. [*1]
4 Swing circle assembly (1):

700 kg
Installation (PC400-J110-720-K-00-A)

removal.
[*1]
2 Swivel circle mating surface:
2 Swing circle mounting bolt threaded
portion:
Adhesive (LT-2)
50-96 PC490LC-10
Separation and connection of track shoe assembly (PC400-DTL0-924-K-00-A)
a Special tools 5. Move the master pin forward and place block [1]
under the track in front of the idler.
Necessity
6. Remove tool K.
Sym-
Q'ty
bol
Remover and
791-650-3000 t 1
installer
K Cylinder
790-101-1300 t 1
(980 kN {100 ton})
790-101-1102 Pump t 1
Separating track (PC400-DTL0-520-K-00-A)
1. Start the engine and move the master pin to

above the idler.
2. Remove track shoes (2) which are connected by
master pin (1). [*1] 7. Move the machine back slowly to spread the
3. Lower the work equipment to the ground and track. [*4]
loosen lubricator (3) to decrease track tension.
[*2]
Connecting track (PC400-DTL0-720-K-00-A)
• Perform connection in the reverse order to

k Since the internal pressure of the separation.
adjustment cylinder is very high, do not [*1]
loosen the lubricator more than one turn. 2 Mounting bolt:
If the grease does not come out
Seizure prevention compound
sufficiently, move the machine backward
(MARUZEN MOLYMAX No. 2 or
and forward.
equivalent)
3 Mounting bolt: Tighten the 4 bolts first to
588 ± 59 Nm {60 ± 6 kgm}.
Check that the mating faces are fitted,
then retighten each bolt by 120 ° ± 10 ° .
[*2]
a See Testing and adjusting, “Testing and
adjusting track shoe tension”.
3 Tightening torque for lubricator:
58.8 to 88.3 Nm {6 to 9 kgm}
[*3]
4. Using tool K, remove master pin (1). [*3]
a Apply grease to master pin (1). (in the area
where bushing (4) and master pin (1) come
contact: shown hatched)
PC490LC-10 50-97
2 Between bushing and master pin

(hatched area):
Grease
NIGTIGHT LYK-2 from Nippon Grease
Co., Ltd.: part no. 44392708 or equivalent
[*4]
a Set the track shoe and sprocket (6) as shown in
the following figure. (on both right and left sides)
a Using the tool, press fit the master pin, so that

the protrusion amount (a) of the master pin is the
dimension designated below.
Protrusion amount (a) of master pin: 4.4 ± 2 mm
a Apply grease to the contact faces of dust seal (5)

and bushing (4) (all over the end face of the dust
seal or bushing) (portions marked Q). Do not
apply grease to the pars marked (X), however.
2 Contact surface between bushing and
dust seal:
Grease
NIGTIGHT LYK-2 from Nippon Grease
Co., Ltd.: part no. 44392708 or equivalent
R: Detail of regular pin position
M: Detail of master pin position
(Pins are not inserted, however))
50-98 PC490LC-10
Removal and installation of sprocket (PC400-DT60-924-K-00-A)
Removal (PC400-DT60-520-K-00-A)
1. Separate the track shoe assembly. For details,

see "Separation and connection of track shoe
assembly".
2. Swing the work equipment 90 ° , then push up
the chassis with the work equipment and place
block [1] between the track frame and the track.
3. Remove 26 mounting bolts, and sling and

remove sprocket (1). [*1]
4 Sprocket:
70 kg
Installation (PC400-DT60-720-K-00-A)

removal.
[*1]
2 Threads of sprocket mounting bolt:
Adhesive (LT-2)
3 Sprocket mounting bolt:
640 to 785 Nm {65 to 80 kgm}
PC490LC-10 50-99
Removal and installation of idler and idler cushion assembly (PC400-DTA0-924-K-00-

A)
Removal (PC400-DTA0-520-K-00-A)
1. Separate track shoe assembly. For details, see

"Separation and connection of track shoe
assembly".
a Remove lubricator (1).
Installation (PC400-DTA0-720-K-00-A)

removal.
2. Lift idler and idler cushion assembly (2), and pull

it forward to remove.
4 Idler and idler cushion assembly:

570 kg
3. Disconnect idler cushion assembly (4) from idler

assembly (3).
4 Idler assembly:
290 kg
4 Idler cushion assembly:

390 kg
50-100 PC490LC-10
Disassembly and assembly of idler (PC400-DT90-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
1 791-575-1520 Installer t 1
H
Disassembly (PC400-DT90-530-K-00-A)
5. Remove nut (8), pull out bolt (9), and then

remove support (10) from shaft (11).
6. Remove bushing (12) from idler (5).
1. Remove nut (1) and pull out bolt (2) to remove

support (3).
2. Remove floating seal (4) from support (3) and
idler (5).
3. Remove idler (5) from shaft and support Assembly (PC400-DT90-710-K-00-A)
assembly (6).
1. Press fit bushings (12) to idler (5) (on both
a It is filled with 375 ± 10 cc of oil, so drain the sides).
oil at this point.Lay a cloth to prevent the 2. Install the O-ring, and then install support (10) to
area from becoming dirty. shaft (11) by using the bolt, and then tighten nut
4. Remove floating seal (7) on the other side from (8).
idler (5) and assembly (6) of the shaft and
support.
PC490LC-10 50-101
4. Install assembly (6) of the shaft and support to

a Install the shaft with the UP mark up.
idler (5).
3. Using tool H1, install floating seal (7) to idler (5)

5. Similarly, using tool H1, install floating seal (4) to
and assembly (6) of the shaft and support.
idler (5) and support (3).
a When installing the floating seal, completely

a Apply oil to the sliding surfaces of the floating
clean, degrease, and dry the contact
seal, and take care not to have any dirt stuck
surfaces (hatched area shown in the figure)
on it.
of the O-ring and floating seal. Also take care
not to have any dirt stuck on the contact a Degrease the contact surfaces of the O-ring
faces of the floating seal. and the floating seal.
6. Install the O-ring, and then install support (3),
a Be sure to use tool (installer) H1 to insert the
install bolt (2), and tighten nut (1).
floating seal assembly in the housing.
7. Using tool H2, add oil and tighten the plug.
a After inserting the floating seal, check that
the inclination of the seal is less than 1 mm 5 Idler (engine oil):
and that the protrusion shown as (a) in the 375 ± 10 cc(EO30-DH)
illustration is within the range shown below.
Protruding amount of the seal(a): 7 to 11 mm
50-102 PC490LC-10
3 Plug:
130 to 180 Nm {13 to 18 kgm}
PC490LC-10 50-103
Disassembly and assembly of idler cushion (PC400-DTBP-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
1 Cylinder
790-101-1600 t 1
(686 kN {70 ton})
J 790-101-1102 Pump t 1
790-201-1660 • Plate 1
2 2) Apply hydraulic pressure gradually to
790-101-5021 • Grip 1
compress the spring and remove lock plate
01010-50816 • Bolt 1 (3) and nut (4).
Disassembly (PC400-DTBP-530-K-00-A) a Compress the spring until the nut
becomes loose.
a Release the hydraulic pressure slowly to
release the tension of the spring.
a Free length of spring: 845.3 mm
3) Remove yoke (6), cylinder (7), collar (8), and
dust seal (9) from spring (5).
3. Further disassembly of piston assembly
1) Remove lock plate (11) from piston (10), and
then remove valve (12).
2) Remove snap ring (13), then remove U-
packing (14) and ring (15).
1. Remove piston assembly (2) from idler cushion

assembly (1).
2. Disassembling idler cushion assembly
1) Set tool J1 to idler cushion assembly (1).
k Since the load at installed length of the

spring is large and dangerous, set the
spring securely to the tool.
a Load at installed length of spring:
239 kN {24 ton}
50-104 PC490LC-10
Assembly (PC400-DTBP-710-K-00-A)
3) Apply hydraulic pressure slowly to compress

the spring, and then tighten nut (4) so that
the installed length of the spring is dimension
(a) and secure it with lock plate (3).
a Installed length (a) of spring: 690 mm
1. Assembly of piston
4) Remove idler cushion assembly (1) from tool
1) Install ring (15) and U-packing (14) to piston J1.
(10), and secure them with snap ring (13). 3. Install piston assembly (2) to idler cushion
2) Tighten valve (12) lightly, and secure it with assembly (1).
lock plate (11).
2. Assembly of idler cushion 2 Sliding surface of cylinder:
1) Using tool J2, install dust seal (9) to cylinder Grease (G2-LI)
(7). 2 Wear ring:
Grease (G2-LI)
a Install the piston assembly with the valve
installed position facing outward.
a Pump 320 cc of grease (G2-LI) into the
cylinder and bleed air. Check that the grease
comes out of the grease hole.
2) Install cylinder (7), collar (8), and yoke (6) to

spring (5), and then install the assembly to
tool J1.
2 Sliding surface of cylinder:
Grease (G2-LI)
PC490LC-10 50-105
Disassembly and assembly of track roller (PC400-DTD0-926-K-00-A)
a This section explains only the precautions for

assembling the track roller assembly.
a Special tools
Necessity
Sy-
Q'ty
mb- Part number Part name
ol
1 791-630-1780 Installer t 1
G 2 791-601-1000 Oil pump assembly t 1
Assembly (PC400-DTD0-710-K-00-A)
• Floating seal
a Using tool G2, fill the track roller assembly with
oil and tighten the plug.
clean, degrease, and dry the contact surfaces
(hatched area shown in the figure) of the O-ring
and floating seal. Also take care not to have any 5 Single track roller (engine oil):
dirt stuck on the contact faces of the floating 300 to 330 cc (EO30-DH)
seal. 3 Plug:
a Be sure to use tool (installer) G1 to insert the 10 to 20 Nm {1 to 2 kgm}
a After inserting the floating seal, check that the
inclination of the seal is less than 1 mm and that
the protrusion shown as (a) in the illustration is
within the range shown below.
Protruding amount of the seal (a): 7 to 11 mm
• Track roller
a Using tool G2, apply the standard pressure to
the oil filler port to check the oil seal for air
leakage.
a Keep the following standard pressure for 10
seconds and check that the pointer of the gauge
does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
50-106 PC490LC-10
Disassembly and assembly of carrier roller (PC400-DTJ0-926-K-00-A)
a This section explains only the precautions for a After inserting the floating seal, check that the
assembling the carrier roller assembly. inclination of the seal is less than 1 mm and that
the protrusion shown as (a) in the illustration is
a Special tools
within the range shown below.
Necessity
Protruding amount of the seal (a): 7 to 11 mm
Sym-
Q'ty
bol
1 791-430-3230 Installer t 1
F
Assembly (PC400-DTJ0-710-K-00-A)
• Press-fitting of support (2)

Using push tool [1], press fit support (2) to shaft
(1).
Press-fitting dimension (b) of shaft: 90 mm
Press-fitting force: 21.6 to 24.5 kN {2.2 to 2.5
ton}
• Carrier roller
a Using tool F1, apply the standard pressure to the
oil filler port to check the oil seal for air leakage.
a Keep the following standard pressure for 10
seconds and check that the pointer of the gauge
does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
a Using tool F2, fill the carrier roller assembly with

oil and tighten the plug.
5 Carrier roller (Engine oil):

• Floating seal 190 to 200 cc (EO30-DH)
clean, degrease, and dry the contact surfaces
(hatched area shown in the figure) of the O-ring
and floating seal. Also take care not to have any
dirt stuck on the contact faces of the floating
seal.
a Be sure to use tool (installer) F1 to insert the
PC490LC-10 50-107
50-108 PC490LC-10
Removal and installation of revolving frame assembly (PC400-H110-924-K-00-A)
k Extend the arm and bucket cylinder piston

rods fully, lower the work equipment to the
ground, and set the work equipment lock
lever to the LOCK position.
Park the machine on a level ground, lower



Removal (PC400-H110-520-K-00-A)
1. Remove the work equipment assembly. For

details, see "Removal and installation of work
6. Disconnect seven hoses (5) and (11).
equipment assembly."
2. Remove the counterweight assembly. For • (5): Between center swivel joint (Port D) and
details, see "Removal and installation of Swing motor (Port T)
counterweight assembly." • (6): Between center swivel joint (Port D) and
3. Disconnect four boom cylinder hoses (1). Hydraulic tank
• (7): Between center swivel joint (Port E) and
a Install an oil stopper to the hose. Solenoid valve
• (8): Between center swivel joint (Port B) and
Left travel control valve (Port B2)
• (9): Between center swivel joint (Port D) and
Right travel control valve (Port B5)
• (10): Between center swivel joint (port A) and
Left travel control valve (port A2)
• (11): Between center swivel joint (port C) and
Right travel control valve (port A5)
7. Remove pin (12) on the center swivel joint side
and disconnect the lock plate from the center
swivel joint.
4. Sling boom cylinder assembly (2).

5. Remove plate (3) and pin (4), and sling and
remove boom cylinder assembly (2).
a Remove the boom cylinder on the opposite
side in the same manner.
4 Boom cylinder assembly:

360 kg
PC490LC-10 50-109
8. Remove 34 mounting bolts (13), leaving three 2 Threads of revolving frame mounting
each at the front and rear sides. bolt:
Adhesive (LT-2)
3 Revolving frame mounting bolt
2. Tighten the four bolts marked with * in the
following order.
1) Tighten each bolt to 392 Nm {40 kgm} first.
2) Then tighten the bolts turning by 90 ± 5 ° .
• Put a mark on the bolt head with a marker
pen.
(to check the angle)
3) The tightening torque of the bolt tightened in
2) above must be 1,176 Nm {120 kgm} or
larger.
9. Using a lever block, sling the revolving frame
3. Tighten the other bolts (208-25-41180)
assembly, adjusting the longitudinal and lateral according to the above procedure, steps 1) to 3).
balance of it. If the tightening torque reaches 2,254 Nm {230
a Place wood material at the rear side of the kgm} before completing the above steps and the
frame. tightening angle is 35 to 95 ° , however, stop
• Rough standard length of sling: tightening.
Front: 8 m in total a Marks (P) and (S) are the soft zone positions.
Rear: 6 m
a If the engine hood interferes with the sling,
erect the engine hood, referring to “Removal
and installation of radiator assembly”.
10.Remove the remaining 6 mounting bolts, then
sling and remove revolving frame assembly (14).
k When removing the revolving frame

assembly, take care not to let it hit against
the center swivel joint assembly.
4 Revolving frame assembly:

10,300 kg
• Perform the subsequent installation in the
reverse order to removal.
Add oil through oil filler port to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

Installation (PC400-H110-720-K-00-A) part".
1. Match the soft zone position (P) of the outer race
and the soft zone position (S) of the inner race.
2 Mating face of swing circle:
50-110 PC490LC-10
Removal and installation of counterweight assembly (PC400-H700-924-K-00-A)
a Special tools
4 Counterweight assembly (3):
Necessity
9,950 kg
Sym-
Q'ty
bol
Commercially Impact wrench

q 1
available
– Socket wrench
Commercially
(Width across flats: q 1
available
65 mm)
a Use the impact wrench and socket wrench with

the torque capacities enough for tightening the
counterweight mounting bolts.
3 Counterweight mounting bolt (width
across flats 65 mm):
3,430 to 4,212 Nm {350 to 430 kgm}

Removal (PC400-H700-520-K-00-A)
1. Disconnect rear working lamp connector CN- Installation (PC400-H700-720-K-00-A)

A15 (1) and camera connector CN-A40 (2). • Perform installation in the reverse order to
removal.
a If heat insulation cover (11) of the engine
compartment is flattened, replace it.
2. Using lifting tools [1], sling counterweight

assembly (3).
3. Remove four mounting bolts (4) from under
portion of the counterweight.[*1]
4. Sling and remove counterweight assembly (3). a Precautions in tightening mounting bolts
[*2]
Tighten the mouting bolts lightly by hand until
a Check the locations of shim. the counterweight mounting faces seat to the
a Take care not to bump it against the engine frame.
or radiator or cooler assembly. Then, tighten the mounting bolts to the specified
torque by using impact wrench, etc.
[*1]
PC490LC-10 50-111
3 Mounting bolt (width across flats: 65

mm):
3,430 to 4,212 Nm {350 to 430 kgm}
[*2]
a Installing and adjusting of counterweight
1. Adjust the level difference (vertical
clearance) among the exterior parts with
shims. (Shim adjustment must be limited to
max. 2 mm)
• Kinds of shim thickness: 0.5 mm, 1 mm
2. Install the counterweight so that the
clearance between the door and
counterweight and that between the
revolving frame and counterweight are even
and within the limit of 10 ± 5 mm.
a The horizontal difference (a) in right to left
direction between revolving frame (5) and
counterweight (3) must be the following.
Difference (a): Max. 5 mm
a The vertical difference (b) between upper cover
(6) and counterweight (3) must be the following.
Difference (b): Max. 5 mm
50-112 PC490LC-10
Hydraulic system
Removal and installation of center swivel joint assembly (PC400-J8E0-924-K-00-A)
k Park the machine on a level ground, lower swing motor (T port)

the work equipment to the ground completely, • (10): Between center swivel joint (port D) and
and stop the engine. hydraulic tank
• (11): Between center swivel joint (port E) and
k Set the lock lever in the Lock position. solenoid valve
• (12): Between center swivel joint (port B) and
k Release the remaining pressure in the L.H. travel control valve (B2 port)
hydraulic circuit. For details, see Testing and • (13): Between center swivel joint (port D) and
adjusting, "Releasing remaining pressure R.H. travel control valve (B5 port)
from hydraulic circuit". • (14): Between center swivel joint (port A) and
L.H. travel control valve (A2 port)
k Turn the battery disconnect switch to the • (15): Between center swivel joint (port C) and
OFF position and remove the key. R.H. travel control valve (A5 port)
3. Remove pin (16) on the side of center swivel
a Note connector numbers and installed positions joint and remove the lock plate from the center
before disconnecting wiring and hoses. swivel joint.
Removal (PC400-J8E0-520-K-00-A)
1. Disconnect six hoses (1) through (6) between

travel motor and center swivel joint.
• (1): Between center swivel joint (port T) and
L.H. travel motor (port T)
• (2): Between center swivel joint (port T) and
R.H. travel motor (port T)
• (3): Between center swivel joint (port B) and
L.H. travel motor (port PA)
• (4): Between center swivel joint (port D) and
R.H. travel motor (port PB) 4. Remove four mounting bolts (17).
• (5): Between center swivel joint (port A) and
L.H. travel motor (port PB)
• (6): Between center swivel joint (port C) and
R.H. travel motor (port PA)
5. Sling and remove center swivel joint assembly

(18). [*1]
4 Center swivel joint assembly:

2. Disconnect nine hoses (7) through (15). 40 kg
L.H. travel motor (port P)
R.H. travel motor (port P)
• (9): Between center swivel joint (port D) and
PC490LC-10 50-113
Hydraulic system
a Do not remove plate (19) on which center swivel • Refilling (hydraulic tank)
joint assembly is installed. Add hydraulic oil through the oil filler port to the
a When removing plate (19) on which center specified level. Run the engine to circulate the
swivel joint assembly is installed, mark the oil through the piping. Then, check the oil level
installing direction and location beforehand. [*2] again.

part".
Installation (PC400-J8E0-720-K-00-A)

removal.
[*1]
Install the center swivel joint facing in the direction
shown in the figure. (The figure shows the machine
as seen from above)
[*2]
Install plate (19) on which center swivel joint
assembly is installed, four mounting bolts (20), eight
washers (21), and four nuts (22) by adjusting the
dimensions according to the following figure.
50-114 PC490LC-10
Hydraulic system
Disassembly and assembly of center swivel joint (PC400-J8E0-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
790-101-2501 Push-puller t 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
M 1 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
Assembly (PC400-J8E0-710-K-00-A)
1. Install slipper seal (8) and O-ring (7) to swivel

Disassembly (PC400-J8E0-530-K-00-A)
rotor (4).
2. Install seal (6) to swivel shaft (5).
3. Place swivel shaft (5) on the block. Using the
push tool, install swivel rotor (4) to the shaft
while tapping the swivel rotor lightly with a
plastic hammer.
2 Contact surfaces on swivel rotor (4)
and swivel shaft (5):
Grease (G0-LI or G2-LI)
a When installing swivel rotor (4), take care not
to damage slipper seals (8) and O-rings (7).
4. Install ring (3) and secure it with snap ring (2).
5. Install the O-ring and cover (1).
3 Cover (1) mounting bolt:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}

2. Remove snap ring (2).
3. Using tool M1, pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
4. Remove seal (6) from swivel shaft (5).
5. Remove O-ring (7) and slipper seal (8) from
swivel rotor (4).
PC490LC-10 50-115
Hydraulic system
Removal and installation of hydraulic tank assembly (PC400-PM30-924-K-00-A)

the engine.

adjusting, "Releasing residual pressure from
hydraulic circuit".
a Note the connector numbers and installed

positions before disconnecting wiring and hoses.
hose to prevent oil from flowing out. 6. Remove undercover (24) from bottom of the
Removal (PC400-PM30-520-K-00-A)
hydraulic tank.

7. Loosen drain plug (25) at bottom of the hydraulic

2. Remove handrail (3) and foot barrier (3a). 6 Hydraulic tank:

3. Remove cover (4) from the rear of the operator's 248 l
cab.
4. Disconnect overflow hose (5).
8. Remove hydraulic tank cover (7).

9. Remove frame (8).
5. Open left side cover (6).
50-116 PC490LC-10
Hydraulic system
13.Disconnect hydraulic oil temperature sensor

connector CN-P22 (26).
14.Disconnect suction tube (27).
(27).
10.Disconnect hydraulic hoses (9), (10), (11), (12),

(13), and (14) at the upper side of the hydraulic
tank.
15.Sling the hydraulic tank and remove six

mounting bolts (28) from bottom of the hydraulic
tank.
11.Disconnect hydraulic hoses (15), (16), (17), (18),

(19), (20), and (21) at the lower side of the
hydraulic tank.
16.Sling and remove hydraulic tank assembly (29).
4 Hydraulic tank assembly (29):

230 kg
12.Remove hose clamps (22) and (23).
17.Remove suction tube (30) from hydraulic tank

assembly (29). [*1]
PC490LC-10 50-117
Hydraulic system
(a) o (b) o (c) o (d) o (e) o (f) o (g) o (h)
Installation (PC400-PM30-720-K-00-A)
• Perform installation in the reverse order to 2. Install the MIKALOR clamp according to the
removal. following procedure.
[*1]
1. Install the suction tube according to the following
procedure. • With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) laps over
1) Apply adhesive to the inserted portion (j) of with the band by dimension (b) indicated
the suction hose (hatched area). below.
hose (hatched area): 2 Threaded portion of clamp bolt (BC):
Adhesive (ThreeBond 4314 or Lubricating oil (ThreeBond PANDO
equivalent) 18B or equivalent)
a Do not use an impact wrench.
Install the clamp to the clamp mark made on
the hose.
3 Clamp bolt:
Min. 2.9 to 5.9 Nm {0.3 to 0.6 kgm}
Tighten until dimension (BDG) becomes as
follows.
Clamp (k): 12 to 15 mm
Clamp (m): 7 to 10 mm
Clamp (n): 0 to 3 mm
2) Install and adjust the positions of the suction
following figure.

order.
50-118 PC490LC-10
Hydraulic system

again.

PC490LC-10 50-119
Hydraulic system
Removal and installation of main pump assembly (PC400-C200-924-K-00-A)
k Park the machine on a level ground, swing

the upper structure by 45 ° clockwise, lower
the work equipment to the ground stably, and
stop the engine.


OFF position and remove the key. 6. Remove undercover (12).

Removal (PC400-C200-520-K-00-A)

"Removal (and installation) of engine hood".
7. Loosen drain plug (13) at bottom of the hydraulic

6 Hydraulic tank:
248 l
2. Open left side cover (2).

3. Remove cover (3) from top of the hydraulic
pump.
4. Remove frame (4).
8. Disconnect the following connectors.

• (14): CN-V12 rear PC-EPC valve
• (15): CN-V11 front PC-EPC valve
• (16): CN-V19 LS-EPC valve
• (17): CN-P27 front pump swash plate sensor
• (18): CN-V13 fan pump
• (19): CN-P28 rear pump swash plate sensor
5. Remove partition plate (11).
50-120 PC490LC-10
Hydraulic system
9. Disconnect the following hydraulic hoses. 12.Loosen drain plug (34) at bottom of the damper
• (20): PDIR case drain port case to drain the oil.
• (21): PLSR rear pump load pressure input
port 6 Damper case:
• (22): PBR rear pump pressure input port 1.6 l
• (23): To front pump LS valve
• (24): To front pump PC valve
• (25): PEPC EPC source pressure input port
• (26): PEPC EPC source pressure input port
• (27): PBF front pump pressure input port
• (28): PLSF front pump load pressure input
port
• (29): PFS pump suction port
• (30): PFEPC EPC valve source pressure
input port
• (31): PFI pump discharge port
13.Remove clamp (34) and damper case oil filler

pipe (35).
14.Sling the main pump assembly and remove 12
mounting bolts (36).
10.Disconnect hydraulic oil temperature sensor

connector CN-P22 (32).
11.Disconnect suction tube (33). [*1]
(33).
15.Sling and remove main pump assembly (37).
[*2]
4 Main pump assembly (37):

320 kg
PC490LC-10 50-121
Hydraulic system
(a) o (b) o (c) o (d) o (e) o (f) o (g) o (h)
Installation (PC400-C200-720-K-00-A)
• Perform installation in the reverse order to 2. Install the MIKALOR clamp according to the
removal. following procedure.
[*1]
1. Install the suction tube according to the following
procedure. • With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) laps over
1) Apply adhesive to the inserted portion (j) of with the band by dimension (b) indicated
the suction hose (hatched area). below.
hose (hatched area): 2 Clamp bolt thread portion (BC):
Adhesive (ThreeBond 4314 or Lubricant oil (ThreeBond PANDO 18B
equivalent) or equivalent)
the hose.
3 Clamp bolt:
Min. 2.9 to 5.9 Nm {0.3 to 0.6 kgm}
is as follows.
Clamp (k): 12 to 15 mm
Clamp (m): 7 to 10 mm
Clamp (n): 0 to 3 mm
2) Install and adjust the positions of the suction
following figure.

order.
50-122 PC490LC-10
Hydraulic system
[*2]
2 Main pump involute splines:
Molybdenum disulfide grease (LM-G)
2 Mating face on main pump case:
again.

• Refilling (damper case)
Add oil through the oil filler to the specified level.
5 Damper case:
1.6 l
PC490LC-10 50-123
Hydraulic system
Removal and installation of control valve assembly (PC400-C030-924-K-00-A)
k Park the machine on a level ground, swing 4. Remove undercover (5).

the upper structure by 45 ° clockwise, lower
stop the engine.


5. Loosen drain plug (5a) at bottom of the hydraulic
a Note the connector numbers and installed tank to drain the oil.
a Fit a plug or flange to the disconnected hydraulic 6 Hydraulic tank:
hose to prevent oil from flowing out. 248 l
Removal (PC400-C030-520-K-00-A)
• In this section, only the 9-spool valve is

explained.
6. Remove partition (13), covers (13a) and (13b) of

the engine compartment.
3. Remove plate (4).
7. Disconnect hydraulic hoses (14), (15), and (16).

8. Sling and remove attachment accumulator
mounting bracket (17).
4 Attachment accumulator mounting

bracket (17):
200 kg
50-124 PC490LC-10
Hydraulic system
9. Disconnect the following solenoid valve hoses. 11.Disconnect the following hoses on the front of
• (18): Port PX1 (to control valve) control valve.
• (19): To attachment circuit selector valve • (36): Port PLS2 (to rear pump LS valve)
• (20): Port BP5 (to control valve (boom)) • (37): Port PLS1 (to front pump LS valve)
• (21): Port PU (to swing motor 2-stage relief • (38): (disconnect at the destination)
valve) • (39): (disconnect at the destination)
• (22): To port PPC valve • (40): (disconnect at the destination)
• (23): Port PST (to control valve) • (41): (disconnect at the destination)
• (24): Port Pi (to travel motor) • (42): (disconnect at the destination)
• (25): Port B (to swing motor) • (43): (disconnect at the destination)
• (26): To attachment circuit selector valve • (44): (disconnect at the destination)
• (27): Port PX2 (to control valve) • (45): (disconnect at the destination)
10.Disconnect the following connectors. 12.Disconnect the following hoses on the right of
• (28): CN-V08 2-stage relief solenoid valve control valve.
• (29): CN-V05 swing holding brake solenoid • (46): Port P-4 (service port)
valve • (47): Port P2 (bucket)
• (30): CN-V03 travel junction solenoid valve • (48): Port P4 (L.H. travel)
• (31): CN-V01 PPC source pressure solenoid • (49): Port P6 (boom)
valve • (50): Port P8 (swing)
• (32): CN-V02 swing cut-off solenoid valve • (51): Port P10 (R.H. travel)
• (33): CN-V04 travel speed solenoid valve • (52): Port P12 (arm)
• (34): CN-V06 machine push-up solenoid • (53): Port TSW (from swing motor)
valve (disconnect at the destination)
• (35): CN-V07 attachment return select
solenoid valve
PC490LC-10 50-125
Hydraulic system
• (68): F pump pressure sensor connector CN-

P25
• (71): R pump pressure sensor connector CN-
P26
15.Disconnect the following hoses on the rear of
control valve.
• (66): Port T (to tank)
• (67): Port PP2 (from front pump)
• (69): Port PP2 (from rear pump)
• (70): Port PPS2 (to rear pump LS valve)
13.Disconnect the following hoses from the left side

of control valve.
• (54): Port PX1 (from 2-stage relief solenoid
valve)
• (55): Port P-5 (service port)
• (56): Port P-3 (service port)
• (57): Port PPC (pilot source pressure)
• (58): Port P1 (bucket)
• (59): Port P3 (L.H. travel)
• (60): Port P5 (boom)
• (61): Port BP5 (machine push up solenoid
16.Sling the control valve assembly and remove
valve)
four mounting bolts (72) from the bottom.
• (62): Port P7 (swing)
• (63): Port P9 (R.H. travel)
• (64): Port P11 (arm)
• (65): Port PX2 (from 2-stage relief solenoid
valve)
17.Sling and remove control valve assembly (73).
4 Control valve assembly (73):

270 kg
a Lift control valve assembly (73) while
keeping it horizontal.
a Check that all wiring harness connectors and
hoses are disconnected.
14.Disconnect the following connectors on the rear

of the control valve.
50-126 PC490LC-10
Hydraulic system
Installation (PC400-C030-720-K-00-A)

removal.
again.

PC490LC-10 50-127
Hydraulic system
Disassembly and assembly of control valve (PC400-C030-926-K-00-A)
a This section explains only the precautions for

assembling the compensation valve and control
valve assembly.
a Special tools
Necessity
Sym-
Q'ty
bol
796-946-1310 Guide (21.8 mm dia.)

(For 723-46-40100 and 723-46- t 1
40601)
796-946-2110 Guide (20.9 mm dia.)
1 t 1 a Many types of pistons are used.
(For 723-46-44100)
796-946-2210 Guide (20.6 mm dia.) a Thoroughly clean the pressure compensation
(For 723-46-45100 and 723-46- t 1 valve.
45500)
a Install seal rings (5) by using the tool as
796-946-1320 Guide
t 1 shown in the figure below.
(For 723-46-40100 and 723-46-
40601) 3. Install O-ring (6) to piston (2).
4. Place tool L1 to piston (2), put seal ring (5) on
796-946-1420 Guide (21.6 mm dia.)
t 1 tool L1, and then push the seal ring (5) down
For 723-46-42800)
2 slowly in such a way that it expands evenly to
796-946-2120 Guide install it in.
L t 1
(For 723-46-44100)
a You may push seal ring (5) down to the flat
796-946-2220 Guide
t 1 part of tool L1, and then place tool L1 with
(For 723-46-45100 and 723-46-
45500) seal ring (5) on piston (2) to install seal ring
(5) in position.
796-946-1330 Sleeve
(For 723-46-40100 and 723-46- t 1
40601)
796-946-1430 Sleeve
t 1
(For 723-46-42800)
3
796-946-2130 Sleeve
t 1
(For 723-46-44100)
796-946-2230 Sleeve
(For 723-46-45100 and 723-46- t 1
45500)
Procedures for replacing pressure

compensation valve seal rings (PC400-
L6D4-924-K-00-A)
5. Repeat the same process to install another seal
a Since many types of pressure compensation ring (5). Place tool L2 on the same end of piston
valve are used in the machine, put a mark and (2). Slowly push seal ring (5) down in such a
note the installed position when removing it. way that it expands evenly to install it in position.
1. Remove piston (2), plug (3) and spring (4) from
pressure compensation valve (1).
2. Remove seal rings (5) and O-rings (6) from
piston (2).
50-128 PC490LC-10
Hydraulic system
a You may push seal ring (5) down to the flat a After the installation, push piston (2) by hand
part of tool L2, and then place tool L2 with and check that piston (2) returns only with
seal ring (5) on piston (2) to install seal ring spring force.
(5) in position.
Assembly of control valve

6. Install settling tool L3 on piston (2) and keep it
installed for approx. one minute so that seal ring
assembly (PC400-C030-710-K-00-A)
(5) fit in. • Apply engine oil (EO30-DH or equivalent) to the
sliding surfaces on the parts before assembling
a Check seal ring (5) for protrusion and cut. them.
• When installing spools (7) and (8) into the
cylinder, ensure that its drilled holes (a) and (b)
face in the direction of cylinder ports (c) and (d).
7. Install plug (3) and spring (4) to piston (2), and

then install pressure compensation valve (1) to
complete the assembly of the valve.
a When it is difficult to install the piston, do not
push it in forcibly but install it to settling tool
L3 again to settle the seal ring (5) and then
install piston (2) to the sleeve.
PC490LC-10 50-129
Hydraulic system
Boom hydraulic drift prevention valve

Variable back pressure valve
Control valve upper cover
Control valve lower cover
3 Merge-divider valve (11) mounting bolt:
156.9 to 176.5 Nm {16 to 18 kgm}
• Install filters (9) mounted at the bottom of ports

(PLS1) (e) and (PLS2) (f) in the direction shown
in the figure below.
• Apply liquid gasket (LOCTITE 222 or equivalent)

to the mating surfaces of each block before
installation. However, do not apply to the
following components.
Boom hydraulic drift prevention valve
Boom Hi check valve
Variable back pressure valve
Arm hydraulic drift prevention valve
• Install two washers to mounting bolts (10) for the
control valve top cover.
• Tighten the mounting bolts for the following
components in the order shown in the figure
below. (AoDoCoB)
Merge-divider valve
Boom Hi check valve
50-130 PC490LC-10
Hydraulic system
3 Mounting bolts for control valve upper

and lower covers:
156.9 to 176.5 Nm {16 to 18 kgm}
• When slinging the control valve assembly, use

tapped holes (g) or (h).
Tapped hole (g): M10 x 1.5 mm
Tapped hole (h): M12 x 1.75 mm
PC490LC-10 50-131
Hydraulic system
• Pressure compensation valve

a Install each pressure compensation valve,
checking the identification mark that was put
when removing it.
• Main relief valve
After installing the main relief valve to the control
valve, see Testing and adjusting, "Measuring
and adjusting oil pressure in work equipment,
swing, and travel circuits".
3 Main relief valve assembly:

49 to 58.8 Nm {5 to 6 kgm}
50-132 PC490LC-10
Hydraulic system
Disassembly and assembly of work equipment PPC valve (PC400-PL28-926-K-00-A)
• This section explains only the precautions for

disassembling and assembling the work
equipment PPC valve assembly.
Disassembly (PC400-PL28-530-K-00-A)
a Each of spring (4) and (5) consists of two springs

having different load at installed length. Note
their installed positions (hydraulic ports) and
identify them with tags to ensure correct
installation.
Assembly (PC400-PL28-710-K-00-A)
a Before assembly, thoroughly clean the parts and a Before installing piston (6), apply grease (G2-LI)
check them for dirt, rust, or damage to prevent to the periphery of the piston and the bore in the
failure. valve body.
a Install spring (3) with its small diameter end 2 Periphery of piston (6) and inside of hole
facing shim (2). in body:
• Diameter of spring (3) end turn (inside diameter) Grease (G2-LI)
Small diameter end: 4.9 mm
Large diameter end: 5.55 mm
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a When installing springs (4) and (5), note that
their installed positions are determined by the a When installing joint (10) to valve body (1), apply
hydraulic ports. adhesive (Loctite No. 262 or equivalent)
• Installed height (for all springs): 31.9 mm
• Load at installed length: 1. When installing joint (10), apply a drop
(approximately 0.02 g) of adhesive (LOCTITE
Spring (4) (P1, P2): 35.3 N {3.6 kg}
No. 262 or equivalent) to two places at threaded
Spring (5) (P3, P4): 21.6 N {2.2 kg} hole (a) in the valve body. Before installing joint
PC490LC-10 50-133
Hydraulic system
(10), thoroughly degrease and dry its male

threads and the threaded hole (a) in the valve
body.
2. Drop adhesive (LOCTITE No. 262 or equivalent)
to area (b).
Dimension (b): 5 to 7 mm
2 Threaded hole (a) in valve body:
Apply adhesive (LOCTITE No. 262 or
equivalent) and then install.
3 Joint (10):
39 to 49 Nm {4 to 5 kgm}
a Apply grease (G2-LI) to the rocking parts of joint

(10) and to the contact surfaces on disc (11) and
piston (6).
2 Rocking part of joint (10):
Grease (G2-LI) (2 to 4 cc/entire periphery)
2 Contact parts of disc (11) and piston (6):
Grease (G2-LI) (0.3 to 0.8 cc/part)
a Install disc (11) according to the following
procedure.
1. Adjust the disc so that the play at the lever
end is within the following range.
Play at lever end:
0.5 to 3.0 mm (at 200 mm from lever pivot
point)
2. Tighten nut (12) to the following torque.
3 Nut (12):
69 to 88 Nm {7 to 9 kgm}
3. Adjust the play of the lever. For details, see
Testing and adjusting, "Adjusting play of work
equipment PPC valve".
50-134 PC490LC-10
Hydraulic system
Disassembly and assembly of travel PPC valve (PC400-C6V0-926-K-00-A)
• This section explains only the precautions for

disassembling and assembling the travel PPC
valve assembly.
Disassembly (PC400-C6V0-530-K-00-A)
1. Remove screw (17) to remove damper assembly

(13).
2. Remove mounting bolts (18) to remove case
(10) and shaft assembly (12).
3. Remove mounting bolt (16) to remove plate (19).
a Note the thickness and installed position of
each washer (15).
a Remove pin (20) from valve body (1).
4. Remove seal (9) and collar (8).
5. Remove pistons (7) to remove retainers (6),
springs (5) and (4) and shims (3).
a Note the installed position, quantity and
thickness of each pack of shims (3) and keep
them.
6. Remove valves (2) from valve body (1).
Assembly (PC400-C6V0-710-K-00-A)
a Before assembly, thoroughly clean the parts and a Before installing piston (7), apply grease (G2-LI)
check them for dirt, rust, or damage to prevent to the periphery of the piston and the bore in the
failure. valve body.
PC490LC-10 50-135
Hydraulic system
a Install spring (4) with its small diameter end

facing shim (3).
• Diameter of spring end turn (Inside diameter)
Small diameter end: 4.9 mm
Large diameter end: 5.55 mm
a Apply grease (G2-LI) to the rocking parts of shaft
(12), contact surfaces on lever (11) and piston
(7), and contact surfaces on damper (13) and
pin (14).
2 Rocking parts of shaft (12):
Grease (G2-LI) (4 to 8 cc/part)
2 Contact parts of lever (11) and piston (7):
2 Contact parts of damper (13) and pin (14):
a For washer (15), install the one 1.6 mm in
thickness.
If the difference in the lever angle between right
and left when the lever is at full stroke position,
exceeds 0.7 degree, adjust the thickness of the
washer to make the difference 0.7 degree or
smaller.
(If the thickness of the washer is reduced by 0.3
mm, the full stroke angle of the lever increases
by 0.39 ° )
• Thickness of washer (15):
1.0, 1.3, 1.6, 1.9, 2.2 mm
a Tighten each part to the following torques.
27 to 34 Nm {2.8 to 3.5 kgm}
3 Screw (17):
0.441 to 0.588 Nm {0.045 to 0.06 kgm}
25 to 31 Nm {2.5 to 3.2 kgm}
50-136 PC490LC-10
Work equipment
Removal and installation of work equipment assembly (PC400-L410-924-K-00-A)
a Special tools a Lower the cylinder head on a stand with the

piston rod tied by using wire to prevent it
Necessity
from coming out, or support the cylinder
Sym-
Q'ty
Part number Part name head with a block to prevent it from lowering.
bol
When supporting it with a block etc., remove
the grease nipple at the cylinder bottom.
796-670-1100 Remover q 1
796-670-1110 • Sleeve 1 a Remove the boom cylinder on the other side
796-670-1120 • Plate 1 in the same manner.
796-670-1130 • Screw 1 a If bumping of the lifting hook against the work
796-870-1110 • Adapter 1 equipment lamp is anticipated in lifting the
P 01643-33080 • Washer 1 work equipment, the lamp must be removed.
01803-13034 • Nut 1 5. Disconnect intermediate connector A42 (6) for
Puller (long) the working lamp.
790-101-4000 q 1 6. Disconnect three arm cylinder hoses (7) and two
(490 kN {50 ton})
bucket cylinder hoses (8).
Pump (294 kN {30
790-101-1102 ton}) q 1
a Plug the hose and then fix it to the valve side
with rope.
Removal (PC400-L410-520-K-00-A)
k Extend the arm and bucket cylinder rods

fully, lower the work equipment to the ground,
and set the work equipment lock lever to the
LOCK position.

adjusting, “Releasing remaining pressure in
hydraulic circuit”.
1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (2) and remove
the lock bolt and nut (3). [*1]
3. Remove plate (4) and remove head pin (5). 7. Sling the work equipment assembly.
[*2] 8. Remove cover (9).
9. Remove step (10).
a Shims are installed, so note their quantity
and thickness.
4. Start the engine and then retract the piston rod.
PC490LC-10 50-137
Work equipment
10.Remove plate (11). Installation (PC400-L410-720-K-00-A)

11.Remove boom foot pin (12), then sling and
remove work equipment assembly (13). [*3] • Perform installation in the reverse order to
removal.
[*1]
a When tightening the lock nut, tighten so that
clearance (a) between the plate and nut is as
shown below.
Clearance (a): 0.5 to 1.5 mm
• Removal by using tool P

1) Sling and set tool P.
2) Remove boom foot pin (12) by using tool P,
then sling and remove work equipment
assembly (13).
a Shims are installed, so note their quantity
and thickness.
[*2]
12.Sling and remove work equipment assembly
(13). 2 Inner surface of bushing when installing
pin: Anti-friction compound (LM-P)
4 Work equipment assembly (13):
2 Pin after installed in position: Grease
PC490LC-10: 8,000 kg (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust clearance (b) between cylinder rod (14)

and plate (4) to the following value by using
shimming.
Clearance (b): max. 1.5 mm
Standard shim thickness: 1.0, 2.0 mm
50-138 PC490LC-10
Work equipment
[*3]
2 Inner surface of bushing when installing
pin: Anti-friction compound (LM-P)
2 Pin after installed in position: Grease
(LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the clearance (c) between the foot end

face of boom (15) and bracket (16) to the
following value by using shimming.
Clearance (c): max. 1 mm
Standard shim thickness: 2.0, 2.5, 3.0, 3.5 mm

Add oil through oil filler port to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.

Bleed air from the hydraulic system. For details,
see Testing and adjusting, "Bleeding air from
each part".
PC490LC-10 50-139
Work equipment
Disassembly and assembly of work equipment cylinder (PC400-PPZ0-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
1 790-502-1003 Cylinder repair stand t 1

2
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Ring
796-720-1680 (for boom and q 1
bucket)
Clamp 4) Disassemble the piston rod assembly
07281-01589 q 1 according to the following procedure.
(for boom and
4 bucket) 1] Install piston rod assembly (2) to tool N1.
Ring (for arm
796-720-1690 cylinder) q 1
Clamp
07281-01919 q 1
(For arm)
N • Push tool
790-201-1851 (for bucket) 1
• Push tool
790-201-1861 (for boom) 1
5
• Push tool
790-201-1871 (For arm) 1
790-101-5021 • Grip 1
01010-50816 • Bolt 1
2] Remove piston assembly lock screw (3).
790-101-5021 • Grip 1 a This step is common in the
01010-50816 • Bolt 1 disassembly work of the boom, arm,
• Plate and bucket.
6 790-201-1660 (for bucket) 1
Screw size: M12 x 1.75 mm
• Plate
790-201-1670 (for boom) 1
• Plate
790-201-1680 (For arm) 1
Disassembly (PC400-PPZ0-530-K-00-A)
1. Piston rod assembly

1) Remove the piping from the cylinder
assembly.
2) Remove the mounting bolts and disconnect
head assembly (1).
3) Pull out piston rod assembly (2).
a Place a container under the cylinder to
collect oil from the cylinder.
50-140 PC490LC-10
Work equipment
a If screw (3) is punched too firmly to be • Only for arm cylinders

loosened, tighten the screw further in
a Since cap (8) is made of nylon, tighten
and apply a tap on the threads to
a screw into it and pull it out with
remove it.
pliers.
3] Using tool N2, remove piston assembly

(4). 2. Disassembly of piston assembly
• When tool N2 is not available, use the 1) Remove ring (11).
drill holes (f10: 2 places) to loosen 2) Remove wear rings (12).
the piston assembly (in which the pins 3) Remove piston ring (13).
of N2 are inserted in the following 4) Remove O-ring and backup rings (14).
figure).
4] Remove plunger (5).
• Only for boom, arm cylinders
5] Remove collar (6).
6] Remove head assembly (7).
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16), then remove dust
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove snap ring (21).
6) Remove bushing (20).
7] Remove cap (8), remove out eleven balls

(9), and then remove plunger (10).
PC490LC-10 50-141
Work equipment
Assembly (PC400-PPZ0-710-K-00-A)
a Be careful not to damage the packing, dust seal,

and O-ring during the assembly work.
a Clean each parts. After installing them, cover the
piping ports and pin holes to prevent dirt from
entering.
a Before installing the backup ring, warm it in hot
water of approximately 50 to 60 °C . Do not
attempt to force it into position.
3) Install backup ring and O-ring (14).

4) Install wear ring (12).
5) Install ring (11).
a Be careful not to open the closed gap of
the ring excessively.
2 Ring groove:
Grease (G2-LI)
1. Assembly of head assembly

1) Using tool N5, press fit bushing (20).
2) Install buffer ring (19).
3) Install rod packing (18).
4) Using tool N6, install dust seal (17) and
secure it with snap ring (16).
5) Install backup ring and O-ring (15).
6) Install snap ring (21).
3. Piston rod assembly

1) Place the piston rod on tool N1.
2) Install head assembly (7) to the piston rod.
3) Install the O-ring and backup ring to collar
(6).
4) Install plunger (5).
2. Assembly of piston assembly

1) Using tool N3, expand piston ring (13).
a Place the piston ring on tool N3 and turn
the handle eight to ten turns to expand
the piston ring.
2) Using tool N4, compress piston ring (13).
50-142 PC490LC-10
Work equipment
5) Place plunger (10) on the piston rod. Install a After tightening the piston, check that
11 balls (9) and secure them with cap (8). there is play in plunger (5).
a After installing the plunger, check that • Only for boom, arm cylinders
there is a little play at its end.
• Only for arm cylinders
3] Drill a screw hole to install screw (3).

a With a drill aligned with V-groove
6) Assemble piston assembly (4) according to where the threads of piston (4) and
the following procedure. rod (2) are mated, drill a hole straight.
• When reusing the rod and piston a The cylinder with bottom cushion (arm
assembly (4) cylinder) must not be machined in the
1] Screw in piston assembly (4). Then, cushion plug position.
using tool N2, tighten piston assembly (2)
• Dimensions of screw hole (mm)
until the screw holes are aligned.
Tap drill diameter Tap
a Any burrs or sharp edges on threaded
10.3 12 x 1.75
portions must be removed using files.
Go to 4). Tap drill hole Screw hole
depth depth
Bucket, boom 27 20
Arm 36 29
• When replacing either or both of

the rod and piston assembly (4)
with new ones
4] Tighten screw (3).
a If the cylinder has the bottom cushion,
put a mark on the rod end face to a Clean and degrease the threads
indicate the tightening position of the thoroughly to remove metal chips and
cushion plug. dust, etc.
• Only for arm cylinders 2 Threaded part (b) of screw:
2] Screw in piston assembly (4) until it
Adhesive (LT-2)
comes into contacts with end surface (c)
of the rod, then use tool N2 to tighten. 3 Screw (3):
3 Piston assembly: 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
5] Punch screw part (a) at four peripheral
294 ± 29.4 Nm {30 ± 3.0 kgm}
places.
PC490LC-10 50-143
Work equipment
7) Install piston rod assembly (2).

a Set the assembly with the ring closed gap
horizontally (sideways) and install the
assembly whit aligning it with the axial
center of the cylinder tube.
a After installing the piston rod, check that
the ring is not broken and has not come
out, then fit it fully.
8) Tighten the mounting bolts of cylinder head

assembly (7).
3 Mounting bolt:
Cylinder Tightening torque
bucket 530 ± 78.5 Nm {54.0 ± 8 kgm}
Arm 892 ± 137 Nm {91.0 ± 14 kgm}
Boom 530 ± 78.5 Nm {54 ± 8 kgm}
9) Install the piping.
50-144 PC490LC-10
Removal and installation of operator's cab assembly (PC400-K000-924-K-00-A)
k Park the machine on a level ground, swing

the upper structure by 90 ° , lower the work
equipment to the ground stably, and stop the
engine.


a Positions of the controllers are shown below.
• A: Pump controller assembly
• B: Air conditioner controller assembly 5. Remove box (9) (five bolts).
• C: KOMTRAX terminal
a Disconnect the hose located under box (9).
6. Remove box (10) (three bolts).
a Be careful about connectors (11) and (12)
located behind box (10) (for machines
equipped with 12 V power socket).
• Connector (11): 12 V power socket
intermediate harness (M13A)
intermediate harness (M13B)
7. Remove cover (13) (three bolts).
Removal (PC400-K000-520-K-00-A)
1. Remove the machine monitor assembly. For

details, see "Removal and installation of
machine monitor assembly".
2. Remove the floor mat.
3. Remove cover (1) first, and then remove cover
(2).
4. Remove cover and duct assembly (3).
a Remove harness (4) by passing it through
the space between cover (5) and duct (6).
8. Remove cover (14) (seven bolts).

a Disconnect connector (15) located behind
cover (14).
• Connector (15): Cigarette lighter (M04)
PC490LC-10 50-145
9. Remove duct (16). 13.Remove ducts (23) and (24).

10.Remove cover (17). 14.Disconnect connector (25).
a Disconnect connectors (18) and (19) located • Connector (25): Room lamp (L03)
behind cover (17). a Cut the cable ties holding the ducts and
• Connector (18): R.H. console connectors.
intermediate harness (H14)
• Connector (19): R.H. console
intermediate harness (H15)
15.Disconnect connectors (26) to (29) from

KOMTRAX terminal (C).
• Connector (26): Communication antenna
(GPS)
• Connector (27): Machine main harness
(CK01).
(CK02).
a Neatly arrange and place the disconnected
connectors on the floor apart from the
operator's cab.

12.Pull up lock pin (21) to unlock and remove duct
(22).
50-146 PC490LC-10
16.Remove connector (30) from the clip at the

operator's cab.
• Connector (30): L.H. console intermediate
harness (H16)
a Neatly arrange and place the disconnected
connector on the floor apart from the
operator's cab.
17.Release connectors (31) to (35) from the clips at
the operator's cab and disconnect the
connectors.
intermediate harness (M10) (for machines
20.Disconnect connectors (38) to (40) from air
equipped 12 V power socket)
conditioner controller assembly (B).
• Connector (32): Handsfree microphone
intermediate harness (M46) (for machines • Connector (38): Air conditioner compressor
equipped handsfree microphone) electromagnetic clutch relay (R21)
• Connector (33): AUX intermediate connector • Connector (39): Machine main harness
(M01B) (AC02)
• Connector (34): Operator's cab roof • Connector (40): Machine main harness
intermediate connector (H09) (AC01)
• Connector (35): Loudspeaker intermediate a Air conditioner controller assembly (B) can
connector (H08) be easily removed after the above
a Neatly arrange and place the disconnected connectors are disconnected.
connectors on the floor apart from the a Neatly arrange and place the disconnected
operator's cab. connector on the floor apart from the
18.Disconnect radio antenna (36). operator's cab.
a Cut the cable ties holding the antenna. 21.Remove two bolts (41) and remove air
conditioner controller assembly (B). Neatly
a Neatly arrange and place the disconnected arrange and place the assembly on the floor
radio antenna parts on the floor apart from apart from the operator's cab.
the operator's cab.
22.Remove ducts (42) and (43).

19.Remove four bolts (37) and remove pump
controller assembly (A). Neatly arrange and a Cut the cable ties holding the ducts.
place the assembly on the floor apart from the 23.Disconnect connector (44).
operator's cab. • Connector (44): Front window wiper motor
(M05)
PC490LC-10 50-147
24.Remove ducts (45) to (47). 28.Remove bolt (53) from under the rear left side of
the operator's cab, and then remove lock plate
(54). [*1]
29.Remove cab tipping stopper (55) (width across
flats: 46 mm). [*2]
25.Remove clamp (49).
30.Remove operator's cab mounting bolts (56) and

nuts (57). [*3]
a Bolt (56): 6 places
a Nut (57): 4 places
26.Disconnect window washer hose (50).

27.Cut cable ties (52) holding window washer hose
(50) and harness (51).
a Arrange them neatly and place window
washer hose (50) and harness (51) on the
floor.
31.Remove cover (58) from the hydraulic tank.
50-148 PC490LC-10
3 Cab tipping stopper (55) (width across

flats: 46 mm):
245 to 309 Nm {25.0 to 31.5 kgm}
[*3]
3 Operator's cab mounting bolt (56):
98.1 to 122.6 Nm {10.0 to 12.5 kgm}
32.Remove cover (59) from the rear of the

operator's cab.
33.Sling and remove operator's cab assembly (60).

a Lift up the operator's cab little by little while
checking that every hose, connector, and
clamp is disconnected.
4 Operator's cab assembly (60):

530 kg
Installation (PC400-K000-720-K-00-A)

removal.
[*1]
3 Lock plate mounting bolt (53):
98 to 123 Nm {10.0 to 12.5 kgm}
[*2]
PC490LC-10 50-149
Removal and installation of operator's cab glass (adhered window

glass) (PC400-K183-924-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
bol
1 793-498-1210 Lifter (Suction cup) t 2

Y
2 20Y-54-13180 Stopper rubber t 2
a Although some of the figures depict another

model, the replacement procedure is basically
the same.
a Among the glass panes on the four sides of the
operator's cab, five panes (1) to (4) and (18) are
adhered.
a In this section, the procedures for replacing the
adhered window glass are explained.
a When replacing front window glass (4), remove
front window assembly (5). (It is impossible to
replace only the front window glass while the
front window assembly is installed to the
operator's cab.)
a For the procedure for replacing the front window
assembly, see "Removal and installation of front
window assembly".
a Figure of structure
50-150 PC490LC-10
(1): Right side window glass

(2): Left side rear window glass
(3): Door lower window glass
(4): Front window glass
(5): Front window assembly (front window glass and front frame)
(6): Dam rubber
(17): Center trim seal
(18): Rear window glass
PC490LC-10 50-151
Removal (PC400-K183-520-K-00-A)
a Remove the window glass to be replaced

1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet) (8).
a If the glass is broken in small pieces, it may

be removed with knife [4] and a flat-head
screwdriver.
a Widening the cut with a flat-head screwdriver,
cut the adhesive and dam rubber with knife
[4].
2. Remove the window glass.

1. Using a knife and scraper [5], remove the

remaining adhesive and dam rubber from the
sheet metal (adhesion surfaces) of the
operator’s cab.
a Remove the adhesive and dam rubber to a
degree that they will not affect adhesion of
the new adhesive. Take care not to scratch
the painted surfaces. (If the painted surfaces
are damaged, adhesion will be lowered.)
(The figure shows the operator’s cab of a wheel
loader.)
2. Remove oil, dust, dirt, etc. from the adhesion
surfaces on cab (8) and glass (9) with white
gasoline.
50-152 PC490LC-10
a If the adhesion surfaces are not cleaned well,

the glass may not be stuck perfectly.
a Clean all the black part on the back of the
window glass.
a After cleaning the adhesion surfaces, leave
them for at lease 5 minutes to dry.
(The following figure shows the operator's cab of
a wheel loader.)
3) Evenly apply the painted surface primer to

the surfaces on operator’s cab (8), the
surface where dam rubber (6) is bonded on
and its outside surfaces where the adhesive
is applied to.
2 Primer for painted surface:
SUNSTAR PAINT PRIMER580
SUPER
3. Apply primer (10). a Do not apply the primer more than two
times. (Applying primer more than twice
a The primer is good for is four months after will degrade the performance.)
the date of manufacture. Do not use the
primer after the expiration date.
a Use the primer within two hours after opening
container.
a Even if the container of the primer is capped
again just after it is opened, use it out within
24 hours after it is opened for the first time.
(Discard the primer which is left unused 24
hours after it is opened.)
1) Stir the primers for painted surface and glass
sufficiently before using them.
a If the primer is stored in a refrigerator,
leave it at the room temperature for at a Places to apply: Apply over the entire
least half a day before stirring it. (If the circumferential area of dimension (a).
primer is opened just after taken out of • Primer applying dimension (a): 30 mm
the refrigerator, water will be condensed.
Accordingly, leave the primer at the room
temperature for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and contaminants.
a Prepare respective brushes for the
painted surface primer and glass primer.
a In addition to the above places, apply

primer to right side window glass (1) and
lower door window glass (3).
PC490LC-10 50-153
• Area to apply additional primer for right a Places to apply: Apply the primer to
side window glass (1): (b) adhesion surface (d) on window glass (9)
• Area to apply additional primer for lower along its circumference, which is
door window glass (3): (c) determined by the installed position of
dam rubber (6) and operator’s cab (8).
a After applying the primer, leave it in air for
at least 5 minutes (maximum 8 hours) to • Primer applying dimension (d): 30 mm
dry. a Do not apply the primer to the boarder
about 5 mm wide between the black
portion and transparent portion of the
glass.
a After applying the primer, leave it in air for
at least 5 minutes (maximum 8 hours) to
dry.
a Never apply wrong primer. If painted
surface primer, etc. is applied by mistake,
wipe it off with white gasoline.
4. Stick dam rubber (double-sided adhesive) (6) to

the operator's cab according to the following
procedure.
a Never apply wrong primer. If the glass
primer, etc. is applied by mistake, wipe it a Do not remove the release tape of dam
off with white gasoline. rubber on the glass sticking side before
4) Evenly apply the glass primer on the sticking the window glass.
adhesion surfaces of glass (9). a When sticking the dam rubber, do not touch
2 Primer for glass: the cleaned surface.
SUNSTAR GLASS PRIMER 453-41 a Care should be taken not to slacken the dam
a Do not apply the primer more than two rubber of each sticking corner.
times. (Applying primer more than twice
will degrade the performance.)
50-154 PC490LC-10
a When sticking dam rubber (6) all around, do 3) Stick dam rubber (6) for door lower window
not overlap the ends. Or, provide a clearance glass (3) to the position as shown in the
of approximately 5 mm between ends (e). figure.
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
a Stick additional dam rubber (6b) for door

lower window glass (3)
• Positions to stick additionally dam
a Stick additional dam rubber (6a) for right rubber for door lower window glass:
side window glass (1). (j): 110 mm
• Positions to stick additional dam rubber (k): 90 mm
for right side window glass: (m): 200 mm
(f): 50 mm
(g): 90 mm
(h): 250 mm
4) Stick dam rubber (6) for front window glass

(4) to the position as shown in the figure.
2) Stick dam rubber (6) for left side rear window

glass (2) to the position as shown in the
figure.
PC490LC-10 50-155
a Stick dam rubber (6c) of the lower side of

the front window glass along the outside
edge of the lower frame, differently from
other dam rubber (6). (If it is stuck along
the inside, it will be seen through the
transparent portion of the glass.)
a When positioning front window glass (4)

• Set right and left installing positions to
the frame width.
• And set its vertical position to make
the height difference (p) between the
5. Position the new window glass. frame top and front window glass (4)
will be 3 mm.
1) Check the clearance between the window
glass and the operator’s cab (8) on the right,
left, upper, and lower sides, and then position
the window glass so that it is centered.
2) Stick tapes [6] between window glass (9) and
operator’s cab (8). Draw positioning line (n)
on each tape.
a For accurate positioning, stick tape [6]
across the left, right, and bottom edges of
the right side window glass, left side rear
window glass, and door lower window
glass.
3) Cut the tape between window glass (9) and
operator’s cab (8) with a knife, etc. and then 6. Apply adhesive.
remove the window glass.
a Use either of two types of adhesives
a Do not remove the tapes left on the according to the season.
window glass and operator’s cab (8)
before installing the window glass. 2 Adhesive (summer):
SUNSTAR penguine seal 580 super
"S" or equivalent
2 Adhesive (winter season):
SUNSTAR penguine seal 580 super
"W" or equivalent
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use the
adhesive after the period.
a Keep the adhesive in a dark place where the
temperature is below 25 °C .
a Never heat the adhesive higher than 30 °C .
a When reusing the adhesive, remove all the
hardened part from the nozzle tip.
1) Remove aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
50-156 PC490LC-10
2) Cut the tip of the adhesive nozzle (14) so that

a Adjacent to dam rubber (6) on operator’s
dimensions (q) and (r) are as follows.
cab (8), apply adhesive (15) in
• Dimension (q): 10 mm dimensions (s) and (t) as shown in the
• Dimension (r): 15 mm figure.
• Dimension (s): 10 mm
• Dimension (t): 15 mm
a Apply adhesive (15) thicker than dam
rubber (6).
a Apply the adhesive evenly in height.
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
a Apply adhesive (15) adjacent to

additional dam rubber (6a) for right side
window glass and additional dam rubber
(6b) for lower door window glass.
4) Remove the release tape from the dam

rubber on the glass adhesive side.
5) Apply adhesive (15) to the outside of dam
rubber (6) of the operator’s cab.
PC490LC-10 50-157
a After installing front window glass (4), fill

the clearances between it and center trim
seal (16) with caulking material in range
(s) with dimensions (t) and (u).
a After applying the primer to the part of
window glass (4) shown in section A-A,
apply the adhesive as caulking material.
• Caulking dimension (t): 2 mm
• Caulking dimension (u): 5 mm
a When caulking, apply masking to the
window glass and form the adhesive with
7. Install the window glass. a rubber spatula as shown in the figure.
1) Install window glass (9) while aligning the a Wipe off the squeezed adhesive.
lines down on the positioning tapes in Step 5.
2 Primer for glass:
a Since the window glass cannot be SUNSTAR GLASS PRIMER 580
removed and installed again, install it with SUPER
utmost caution.
2 Adhesive:
a Install the window glass within 5 minutes
Sikaflex 250-2
after applying the adhesive.
2) After installing window glass (9), press entire
circumferential area until it adheres firmly to
the dam rubber.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently by

pulling window glass (9) from inside of the
operator's cab using tool (lifter) Y1.
8. Fix the glass.

1) After installing right window glass (1) to the
operator's cab, insert tool Y2 to two places
(v) at the bottom of the glass to fix the glass.
50-158 PC490LC-10
14 hours, at least 24 hours in total, before

operating the machine actually.
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and dam
rubber to bond them completely.
9. After installing the window glass, remove any

excess of the primer and adhesive on the
operator’s cab and window glass.
a Using white gasoline to wipe off the
remaining adhesive before it dries up.
a When cleaning the glass, do not give an
impact on it.
10.Cure the stuck window glass.
1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for ten
hours as a curing period. (at temperature of
20 °C and humidity 60%)
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
PC490LC-10 50-159
Removal and installation of front window assembly (PC400-K181-924-K-00-A)

the engine.
k Removal and installation work must be done

by a pair of two workers.
a To replace the front window glass, the front

window assembly must be removed from the
operator's cab.
Removal (PC400-K181-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling

and lock it. 4. Release the lock of front window assembly (1).
a Make sure that the assembly is certainly

locked.
2. Remove front lower window (2).
3. Remove bracket (3) at the left corner (two

screws) and bracket (4) at the right corner (two
screws). [*1]
a Leave mounting screws (5) and washers (6)
for bracket (3) at the left corner in position.
They are used to hook the pull-up assist
cable in Step 6.
5. Carefully slide front window assembly (1) down

until the lower part of front window assembly (1)
is detached from the operator’s cab through the
ends from which the corner brackets are
removed in Step 2 (rail missing ends) and
support the lower part of the front window
assembly.
a Right and left rollers (7) and (8) are insertion-
fitted so they easily become detached.
Handle them carefully.
50-160 PC490LC-10
7. Lower front window assembly (1) completely.

a Take care not to let front window assembly
(1) touch machine monitor (12).
6. Remove pin (9). [*2]

a Removal of pin (9) allows plate (11) at the
end of pull-up assist cable (10) to come off.
a Hook plate (11) on screw (5) of left corner 8. Carefully slide front window assembly (1) down
bracket (3) to hold the plate (used washer (6) to detach the top of the front window assembly
as well). from the operator’s cab through the ends from
which the left and right corner brackets are
removed in Step 2 (rail missing ends).
k Pull-up assist cable (10) is under a return
load of 58.8 N {6 kg} that is working a Right and left rollers (13) and (14) are
toward the rear of the operator's cab. So insertion-fitted, so they easily become
be fully careful when removing pin (9) detached. Handle them carefully.
during the disconnection of the cable.

removal.
[*1]
PC490LC-10 50-161
• Adjust opening and closing of front window a There must be no level difference on rolling
assembly (1) according to the following surface (R) for the roller.
procedure.
1. Open and close front window assembly (1) to
check that it does not interfere with the rails and
the rollers are not caught.
2. If there is any problem in opening or closing of
front window assembly (1), loosen mounting
bolts (16) of roller positioning adjustment bracket
(15) to adjust the condition of the front window,
and tighten the mounting bolts again.
a Make sure that bracket (15) is not slanted
when mounted.
3 Mounting bolt (16) of bracket (15):
19.6 to 25.0 Nm {2.0 to 2.5 kgm}
5. Install left corner bracket (3).
3. Pull up front window assembly (1) to the ceiling a Tighten lightly for the meantime. Bolts are
and lock it. tightened to the specified torque after
adjusting the locks for the front window
a Make sure that the assembly is certainly assembly (1) in its "closed" position in the
locked. following Step 6.
4. Install right corner bracket (4).
a Install left corner bracket (3) so that
a Tighten lightly for the meantime. Bolts are clearance (b) between rail (18) and left
tightened to the specified torque after corner bracket (3) becomes 0 to 2.0 mm.
adjusting the locks for the front window
assembly (1) in its "closed" position in the a There must be no level difference on rolling
following Step 6. surface (R) for the roller. (Same as the right
corner bracket.)
a Install right corner bracket (4) so that
clearance (a) between rail (17) and right
corner bracket (4) becomes 0 to 2.0 mm.
6. Adjust the locks for the front window assembly

(1) in its "closed" position according to the
50-162 PC490LC-10
1) Install left and right corner brackets (3) and

(4) in roughly right positions so that front
window glass (19) is closely attached to
operator's cab side trim seal (20).
7. After the adjustment, splash water heavily over

the front window glass and check that the water
does not leak into the cab.
8. Adjust the lock for front window assembly (1) in
its "open" position.
2) Check the working condition of right and left
locks (22) and (21) when opening and 1) After adjusting the locks for the front window
closing front window assembly (1). assembly (1) in its "closed" position in Steps
6 and 7, pull up front window assembly (1) to
a If right and left locks (22) and (21) rattle; the ceiling.
1] Loosen lock fixing bolt (23) inside the 2) Check the locks at the rear right and left of
cover , move lock (21) forward, and then the operator’s cab on the following items with
tighten the bolt again. (The same applies front window assembly (1) in its "open"
to the right side). position.
2] After moving the lock, check the contact • Check the working condition of right and
between front window glass (19) and left locks (21) and (22) (as explained
operator's cab side trim seal (20) which above)
was checked in Step 1). • Front window assembly (1) must be in
3] Repeat the work in Steps 1] and 2] until contact with right and left rubber stoppers
the contact of front window glass (19) and (24), and furthermore, must be pressing
the working condition of right and left them backward by 1.5 to 3.0 mm.
locks (21) and (22) are both acceptable, • Make sure that front window assembly (1)
and then tighten the mounting bolts of the is pressing limit switch (25) 4 to 7 mm
right and left corner brackets. (tighten to backward.
the specified torque)
4] a Since position of limit switch (25) cannot
be adjusted, the "open" position of front
window assembly (1) is decided within
the functioning range of this switch.
a Limit switch (25) prohibits wiper operation
if the wiper switch is turned ON by
mistake while the front window assembly
is "open".
a The wiper falls into the operator's cab and
breaks if operated when front window
assembly (1) is open.
PC490LC-10 50-163
a To check whether limit switch (25) is • Front window assembly (1) (locked in
working, turn the starting switch to ON "open" position) must be pushing limit
position and see that, even if the wiper switch (25) backward by 4 to 7 mm.
switch is turned on, the wiper does not • Working condition of lock (31)
operate when front window assembly (1)
is in the "open" position.
6) Adjustment of right and left rubber stoppers

(24)
• When adjustment is needed after • Bring right and left rubber stoppers (24)
peforming check in Step 8; into contact with front window assembly
3) Close front window assembly (1). (1) (locked in "open" position).
4) Loosen lock nut (26) of right and left rubber
stoppers (24), and move stoppers (24)
backward so that front window assembly (1)
does not touch stoppers (24) when it is
locked in its "open" position.
• Close front window assembly (1).

• Turn right and left rubber stoppers (24) to
the left one and a half rotation
a One turn of rubber stopper (24) to the left
is equivalent to squashing the rubber by
5) Loosen right and left lock nuts (27) and
approximately 1.5 mm.
adjust position of their striker bolts (28).
• Striker bolt (28): M10
• Diameter of hole in plate (29): 14.5 mm
50-164 PC490LC-10
a When front window assembly (1) is

locked in "open" position, front window
assembly (1) must be pushing right and
left rubber stopper (24) by 1.5 to 3.0 mm.
10.Check the latching efforts of front window

assembly (1).
a After finishing the adjustment of Steps 6 to 9,
check that latching efforts of both right and
• Tighten lock nuts (26) of right and left left locks (31) and (32) are even.
rubber stoppers (24).
a Also check the latching efforts of right and

9. Adjust anti-vibration stopper (30) of front window left locks (33) and (34) for the front window
assembly (1). assembly in its "closed" position (at front side
1) Adjust and lock anti-vibration stoppers (30) at of operator's cab).
both sides so that surface (d) of stopper (D)
is in contact with surface (c) of anti-vibration
stopper (30) when front window assembly (1)
is pulled up.
2)
[*2]
3 Pin (9):
27 to 34 Nm {2.8 to 3.5 kgm}
2 Threaded portion of pin (9):
Adhesive (LT-2)
PC490LC-10 50-165
Removal and installation of floor frame assembly (PC400-H1H0-924-K-00-A)
k Park the machine on a level ground, lower a Refrigerant to be collected:

the work equipment to the ground, and stop 1,000 ± 50 g
the engine. 3. Remove undercover (2).


k If you drain the coolant or disconnect the

heater hose when the coolant is still hot, you
may be scalded. Wait until the coolant
temperature drops before starting the work.
4. Loosen drain valve (3) at the bottom of the
k If refrigerant gas (R134a) gets in your eyes, radiator to drain the coolant. (Drain hose: inside
you may lose your sight. And if it touches diameter f7 mm)
your skins, you may suffer from frostbite.
Accordingly, put on the protective
6 Radiator:
eyeglasses, gloves and working suits with
long sleeves while you are collecting or 44 l
filling refrigerant (R134a).
a Never release the refrigerant (R134a) to the

atmosphere.
a Ask a qualified person for collection, adding, and
filling operations of the refrigerant (R134a).
a Fit a plug or flange in the place where a
hydraulic hose is disconnected from to prevent
oil from flowing out.
Removal (PC400-H1H0-520-K-00-A) 5. Remove under cover (4).
1. Remove operator's cab assembly (1), referring

to "Removal and installation of operator's cab
assembly".
6. Disconnect ground cables (5).
2. Collect the refrigerant (R134a) from the air

conditioner circuit. [*1]
50-166 PC490LC-10
a The hose bands are colored as follows:

• Hose (18): Black (port (P1))
• Hose (19): Brown (port (P2))
7. Disconnect connectors (7) to (10) from travel

PPC valve (6).
• Connector (7): L.H. travel reverse oil
pressure sensor (P10) 11.Disconnect connectors (21) and (22) from 1-way
• Connector (8): L.H. travel forward oil attachment PPC valve (20). (for machines
pressure sensor (P09) equipped with attachment)
• Connector (9): R.H. travel forward oil • Connector (21): Pedal rear inclination oil
pressure sensor (P11) pressure switch (P14)
• Connector (10): R.H. travel reverse oil • Connector (22): Pedal front inclination oil
pressure sensor (P12) pressure switch (P15)
8. Disconnect hoses (11) to (14) from travel PPC 12.Disconnect hoses (23) and (24) from 1-way
valve (6). attachment PPC valve (20). (for machines
a The hose bands are colored as follows: equipped with attachment)
• Hose (11): Red (L.H. travel forward port a The hose bands are colored as follows:
(P2)) • Hose (23): Yellow (port (P1))
• Hose (12): Without band (L.H. travel • Hose (24): Without band (port (P2))
reverse port (P1)) 13.Disconnect connectors (25) and (26). (for
• Hose (13): Blue (R.H. travel reverse port machines equipped with attachment)
(P3)) • Connector (25): Attachment oil flow rate
• Hose (14): Green (R.H. travel forward adjuster EPC valve (V30)
port (P4)) • Connector (26): Intermediate connector
(P13) of attachment oil pressure switch
a Cut all cable ties that hold the harnesses to
the floor frame.
9. Disconnect connectors (16) and (17) from 2-way

attachment PPC valve (15). (for machines
equipped with attachment)
• Connector (16): Pedal front inclination oil
14.Disconnect clamps (27) (two bolts).
pressure switch (P16)
• Connector (17): Pedal rear inclination oil
pressure switch (P30)
10.Disconnect hoses (18) and (19) from 2-way
attachment PPC valve (15). (for machines
PC490LC-10 50-167
a Disconnect work equipment PPC valve

hoses (P) from the relay block. (See Step
34.)
15.Disconnect ground cables (28).

a Ground cable arrangement (from left to right):
(T04), (T05), (T06), (T07), (T09), (T10)
16.Remove clamps (29) and (30). 19.Disconnect hose (35).
• Hose (35): Port (T) (drain circuit to the
hydraulic tank)
20.Disconnect connector (36).
• Connector (36): Dual pressure switch (P17)
of air conditioner
a Cut all cable ties that hold the harnesses to
the floor frame.
21.Remove bolt (37), then disconnect tubes (38) of
the air conditioner. [*2]
22.Remove clamp (39) (one bolt) fastening tubes
(38).
23.Disconnect heater core hoses (40). [*3]
17.Pull connectors (31) to (33) out of the clips. 24.Remove clamp (41) (one bolt) (with a spacer)
• Connector (31): Intermediate connector fastening hoses (40).
(A41) (for machines equipped with a 2nd
camera)
• Connector (32): Intermediate connector
(A42) (for machines equipped with a 3rd
camera)
• Connector (33): Intermediate connector
(A08) (for machines equipped with
attachment)
18.Disconnect hose (34).
• Hose (34): Port (P) (circuit from PPC
hydraulic lock solenoid valve)
25.Remove clamps (42) and (43) (two bolts each).

26.Cut cable tie (44).
27.Remove clamp (45) (one bolt). (for machines
50-168 PC490LC-10
28.Disconnect connector (46) and remove air 30.Disconnect ground cable (T01) (50).
conditioner controller (B) from the main harness. 31.Disconnect all clamps that fasten main harness
• Connector (46): Machine main harness (51) to the floor frame.
(AC04) a Separate the pump controller assembly and
main harness from the floor frame and move
them toward the boom.
29.Disconnect connectors (47) to (49).

• Connector (47): R.H. console intermediate
harness (H14) 32.Open engine hood (52) and remove cover (52a).
harness (H15)
• Connector (49): L.H. console intermediate
harness (H16)
33.Remove clamps (53) to (55) fastening the

hoses.
a Move the hoses toward the control valve to
allow disconnecting the work equipment
PPC valve hoses from the relay block.
PC490LC-10 50-169
a Cut the cable ties holding the hoses. 36.Sling and remove floor frame assembly (66).
a Lift the operator's cab little by little while
checking that every hose, connector, and
clamp is disconnected.
4 Floor frame assembly (66):

290 kg
34.Disconnect work equipment PPC valve hoses

(57) to (64) from relay block (56).
a Be sure to place a container to receive
hydraulic oil before disconnecting the hoses.
a The hose bands are colored as follows:
• Hose (57): White (bucket CURL circuit)
Reference: Precautions for removing work
• Hose (58): Brown (boom LOWER circuit)
equipment lever
• Hose (59): Without band (swing RIGHT
circuit) Using a flat-head screwdriver and the like, push lock
• Hose (60): Blue (arm IN circuit) (69) of resin frame (68) in boot (67) to remove boot
• Hose (61): Black (bucket DUMP circuit) (67) from console resin cover (70).
• Hose (62): Green (boom RAISE circuit) a Do not forcibly pull out any parts other than lock
• Hose (63): Red (swing LEFT circuit) (69) of resin frame (68) when performing this
• Hose (64): Yellow (arm OUT circuit) operation. Doing so may damage the resin
frame.
35.Open the left side cover of the machine and pull

out hose assembly (65).
50-170 PC490LC-10
a When installing the hoses of heater core, make

Installation (PC400-H1H0-720-K-00-A)
white line (marking) of heater hoses straight to
• Perform installation in the reverse order to prevent kink of heater hoses.
removal. Reference: Precautions for installing cab mount
[*1]
a The type of damper differs by the installed
• Filling air conditioner circuit with refrigerant
position. Note the identification labels before
(R134a)
removing them. (See Structure and Function,
Fill the air conditioner circuit with refrigerant
"Cab mount and cap tipping stopper.")
(R134a).
a Cab mounts must be installed with the mount
a Filling quantity:
rubber groove (1) oriented as shown in the figure.
1,000 ± 50 g (Top view. Left side of figure is the front side of
• Refilling of air compressor oil machine)
For details, see Others, "Filling compressor oil".
Add coolant through the coolant filler to the
coolant through the system. Then, check the
5 Radiator (coolant):
[*2]
a When installing the air conditioner hoses and
tubes, take care so that dust, dirt or water does
not enter them.
a When connecting the air conditioner hoses and
tubes, check that O-rings are fitted to their joints.
a Do not reuse an O-ring since it is deformed and
deteriorated once it is used.
a When removing O-rings, use a soft tool to avoid
damaging hoses and tubes.
a Check that there is no defect or deterioration on
the O-ring.
a Apply compressor oil (Denso: ND-OIL8) for
R134a refrigerant to O-rings.
3 Hose clamp (M6 bolt):

8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
PC490LC-10 50-171
Removal and installation of air conditioner unit assembly (PC400-K540-924-K-00-A)
k Park the machine on a level ground, swing 3. Pull up front window assembly (1) to the ceiling
the upper structure by 90 ° , lower the work and lock it.
equipment to the ground stably, and stop the
a Make sure that the assembly is certainly
engine.
locked.
5. Remove floor mat (3).
k If you drain the coolant or disconnect the

heater hose when the coolant is still hot, you
may be scalded. Wait until the coolant
temperature drops before starting the work.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. And if it touches
long sleeves while you are collecting or
6. Remove box (8) (five bolts).
a Never release the refrigerant (R134a) to the a Disconnect the hose located under box (8).
atmosphere. 7. Remove box (9) (three bolts).
a Ask a qualified person for collection, adding, and a Be careful about connectors (10) and (11)
filling operations of the refrigerant (R134a). located behind box (9) (for machines
a Note the connector numbers and installed equipped with 12 V power socket).
positions before disconnecting wiring and hoses. • Connector (10): 12 V power socket
intermediate harness (M13A)
a Positions of the controllers are shown below.
• A: Pump controller assembly intermediate harness (M13B)
• B: Air conditioner controller assembly 8. Pull up cover (12) (three bolts) to remove.
a The connectors and harnesses at the rear
must not be caught.
Removal (PC400-K540-520-K-00-A)

a Refrigerant to be collected: 1,000 ± 50 g
(Drain hose: inside diameter f7 mm)
6 Radiator:
44 l
50-172 PC490LC-10
9. Remove cover (13) (seven bolts). 12.Remove plate (19) (two bolts).
13.Pull up lock pin (20) to unlock and remove duct
a Disconnect connector (14) located behind
(21).
cover (13).
14.Remove ducts (24) to (28). [*2]
10.Remove duct (15) (two bolts). a Cut the cable ties holding the ducts.
11.Remove cover (16) (three bolts) and bracket
(41) (two bolts).
a Disconnect connectors (17) and (18) located
behind cover (16).
harness (H14)
harness (H15)
15.Remove cable tie (39) of the left console wiring

harness.
PC490LC-10 50-173
16.Remove cable tie (40) of the floor wiring 19.Disconnect connectors (42) to (45).
harness. • Connector (42): Communication antenna
(GPS)
(CK01).
(CK02).
20.Remove KOMTRAX terminal (C) (four bolts).
17.Remove four bolts (29) and remove pump

controller assembly (A). Arrange the assembly
neatly and place it on the floor apart from the
operator’s cab.
18.Disconnect connectors (30) to (32) from air

conditioner controller assembly (B).
(AC01)
• Connector (31): Machine main harness 22.Remove bolt (34), then disconnect tubes (35) of
(AC02) the air conditioner. [*3]
• Connector (32): Air conditioner unit harness 23.Disconnect heater core hoses (36). [*4]
(AC04)
50-174 PC490LC-10
a Since the mounting bolts of cover (48) are

hidden by cover (47), remove cover (47) first.
24.Remove six mounting bolts (37) and remove air

conditioner unit assembly (38).
[*3]
not enter them.
tubes, check that O-rings are fitted to their joints.
deteriorated once it is used.
a When removing O-rings, use a soft tool to avoid
damaging hoses and tubes.
Installation (PC400-K540-720-K-00-A) a Check that there is no defect or deterioration on
the O-ring.
removal. a Apply compressor oil (Denso: ND-OIL8) for
[*1] R134a refrigerant to O-rings.
(R134a)
(R134a).
a Filling quantity: 1,000 ± 50 g
• Refilling of air compressor oil
Add coolant through the coolant filler to the
coolant through the system. Then, check the
5 Radiator (coolant): 3 Hose clamp (M6 bolt):

44 l (For details, see "Table of fuel, 8 to 12 Nm {0.8 to 1.2 kgm}
coolant and lubricants") [*4]
[*2]
a When installing the hoses of heater core, make
Removing cover (48) makes easier to install ducts white line (marking) of heater hoses straight to
(24) and (26). prevent kink of heater hoses.
PC490LC-10 50-175
Removal and installation of operator’s seat (PC400-K2Q0-924-K-00-A)

stop the engine.



Removal (PC400-K2Q0-520-K-00-A) 3. Pull lever (1) again and move operator's seat (2)
1. Pull lever (1) and move operator's seat (2) forward and fold the backrest forward.
backward. 4. Remove two bolts (5) (with hexagonal socket)
and two reinforcing plates (7), on the seat rail at
the rear side of operator's seat. [*1]
5. Disconnect connector (6) of the operator's seat.
• Connector (6): Seat belt caution switch (S19)
2. Remove two bolts (3) (with hexagonal socket)

and two reinforcing plates (4), on the seat rail at
the front side of operator's seat.[*1]
50-176 PC490LC-10
a For the heated seat a Place washer (17) between adjusters (11),
Remove wiring harness fixing band (8) and (12) and base (16).
disconnect connector (9). 3. Slide adjusters (11) and (12) forward and install
them loosely to base (16) using two bolts (15).
(Connector (9) is located under the seat rail
mounting frame.) 3 Mounting bolt (15):
• Connector (9): Heated seat (M35) 49 Nm {5.0 kgm}
4. Slide adjusters (11) and (12) backward and
forward approximately three times to make sure
that they slide smoothly.
5. Make sure that they are locked at the midpoint of
the sliding move, then tighten four bolts (13).
49 Nm {5.0 kgm}
6. Slide the seat assembly backward and forward
approximately three times. After making sure
that they are locked in the rearmost position,
tighten two bolts (15) of the front side.
3 Mounting bolt (15) (front side):
6. Remove the operator's seat.
49 Nm {5.0 kgm}
7. Slide the seat assembly backward and forward
4 Operator's seat:
approximately three times again. After making
21 kg sure that they are locked in the rearmost position,
Installation (PC400-K2Q0-720-K-00-A) tighten two bolts (15) of the rear side.
• Perform installation in the reverse order to 3 Mounting bolt (15) (rear side):
removal. 49 Nm {5.0 kgm}
[*1] 8. If the operating effort is excessive (should be 15
kg or less), redo the adjustment and check that
3 Mounting bolts (3) and (5) of operator's
the right and left locks work in each position.
seat (hexagonal socket head):
25.5 Nm {2.6 kgm}
Reference: Assembly and adjustment procedure
for operator’s seat adjuster
1. Using four bolts (13), install adjusters (11) and
(12) loosely to frame (10). At the same time,
install two wires (14) for releasing slide lock.
a Check that right and left locks work properly.
2. Slide adjusters (11) and (12) backward and

install them loosely to base (16) using two bolts
(15).
PC490LC-10 50-177
Removal and installation of seat belt (PC400-K2Q3-924-K-00-A)

the engine.



Removal (PC400-K2Q3-520-K-00-A) 6. Remove operator's seat (2).
1. Pull lever (1) and move operator's seat (2)
backward. 4 Operator's seat (2):
21 kg
7. Remove seat belt mounting bolts (6) (one on
each side) and remove seat belt (7). [*2]
2. Remove two hexagonal socket head bolts (3)

from the seat rails. [*1]
3. Pull lever (1) again and move operator's seat (2)

forward and fold the backrest forward. Installation (PC400-K2Q3-720-K-00-A)
4. Remove two hexagonal socket head bolts (4)
from the seat rails. [*1] • Perform installation in the reverse order to
5. Disconnect connector (5). removal.
[*1]
• Connector (5): Seat belt caution switch (S19)
3 Mounting bolts (3) and (4) of operator's
seat (2) (hexagonal socket head):
25.5 Nm {2.6 kgm}
[*2]
3 Mounting bolt (6) of seat belt (7):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
50-178 PC490LC-10
Removal and installation of front wiper assembly (PC400-K710-924-K-00-A)

the engine.
k Set the work equipment lock lever in the

LOCK position.

Removal (PC400-K710-520-K-00-A)
1. Check that wiper blade (1) is at stowed position

(to the R.H. stay).
2. Pull lever (3) to release the lock while holding

handle (2) at right and left of upper part of front
window.
3. Hold lower handle (4) with left hand and upper

handle (5) with right hand, and pull up the front
window, and push it against lock cap (6) at the
rear of cab to lock.
4. Check lever (3) is securely locked.

a Check that the position of arrows on lock
case (7) and lever (3) match.
PC490LC-10 50-179
a One of four mounting screws is covered with

cap (13).
5. Remove lower window (9) by pulling up at knobs

(8).
8. Disconnect connector P31 (14) inside cover
(12).
6. Remove cover (10) and floor mat (11).
9. Remove covers (15) and (16).

a Insert a flat-head screwdriver in slit (18) at
left bottom, and pull it upward to remove
cover (12) while releasing lug (19).
50-180 PC490LC-10
13.Move wiring harness (23) and remove connector

M05 (24).
14.Open cap (25), remove nut (26) and remove

wiper arm (27).
15.Remove cap (28), nut (29), washer (30) and
packing (31).
11.Remove duct (20).
16.Remove six mounting bolts (32) and remove

wiper motor assembly (33).
12.Remove the mounting bolts of bracket (21) and

keep the bracket with machine monitor (22) at
rear side.
a Ii is not necessary to disconnect the
connectors of machine monitor.
1. Install wiper motor assembly (33).
PC490LC-10 50-181
2 Mounting bolt (32): 3 Nut (26):

Adhesive (LT-2) 11.8 to 15.7 Nm {1.20 to 1.60 kgm}
2. Install packing (31), washer (30) and tighten nut

(29) to the specified torque.
a Install washer (30) with its chamfered face
toward cab front.
3 Nut (29):
10.8 to 12.7 Nm {1.10 to 1.30 kgm}
3. Install cap (28) and wiper arm (27).

a Install wiper arm (27) so that clearance (a)
between washer nozzle (34) and wiper blade
(35) becomes the following dimension.
• Dimension (a): 7 mm
4. Tighten nut (26) and close cap (25).
5. Check the operation of the wiper arm according
to the following procedure.
1) Connect connector M05 (24) and P31 (14).
50-182 PC490LC-10
2) Install lower window (9) by holding knobs (8).
5) When the bottom of front window touches the

3) Pull lever (3) down to release the lock while top of lower window, push the upper portion
holding handle (2) at right and left of front of front window against lock catcher (36) at
window stowed in the ceiling. the front of the cab to lock.
4) Hold lower handle (4) with left hand and 6) Check lever (3) is securely locked.
upper handle (5) with right hand securely,
and push down the window forward slowly.
PC490LC-10 50-183
a Check that the position of arrows on lock

case (7) and lever (3) match.
7) Turn the battery disconnect switch to the ON

position.
8) Check that the work equipment lock lever is
in the LOCK position, and then start the
engine.
9) Check the operation of wiper arm while the
front window is dry.
1] Push wiper switch (37) 3 times
consecutively, check that wiper arm (27)
makes one round trip and then be stowed
to the R.H. stay.
10)Check the operation of wiper arm while the
2] Repeat Step 1] again.
front window is wet with washing fluid.
a Rotating direction of motor crank 1] Keep pushing window washer switch (39)
defers between Step 1] and Step 2]. for few seconds to wet the front window
Accordingly, check twice. throughout, then hand off the switch.
3] Push wiper switch (37), and check 2] Check that wiper arm (27) makes two
clearance (b) with trim seal (38) becomes round trips and then be stowed to the R.H.
the following dimension when the tip of stay
wiper blade (35) reaches to the highest 3] Repeat Step 1] again.
point. 4] Check that wiper arm (27) makes round
• Dimension (b): Max. 130 mm trips in odd number and then be stowed
to the R.H. stay
5] Keep pushing window washer switch (39)
to operate the wiper, and check following.
a No interference between wiper slider
(40) and stopper (41) when the tip of
wiper blade (35) reaches to the
highest point. (If interferes, click
sound is heard.)
50-184 PC490LC-10
a No interference between wiper blade

(35) and front window seal (42) when
the tip of wiper blade (35) reaches to
the lowest point.
11)If any abnormality is found in the above

checks, perform the installation adjustment
of wiper arm in Step 3.
6. Perform the subsequent installation in the
reverse order to removal.
PC490LC-10 50-185
Electrical system
Removal and installation of air conditioner compressor assembly (PC400-

K590-924-K-00-A)
k Turn the battery disconnect switch to the conditioner compressor assembly (9) in the
OFF position and remove the key. loosening direction.
2) Loosen the tension on air conditioner
k If refrigerant gas (R134a) gets in your eyes, compressor belt (6) and remove the belt.
you may lose your sight. And if it touches 3) Remove bracket mounting bolt (8), and then
your skins, you may suffer from frostbite. remove air conditioner compressor assembly
Accordingly, put on the protective (9) with the bracket.

atmosphere.
filling operations of the refrigerant (R134a).
Removal (PC400-K590-520-K-00-A)

a Refrigerant to be collected: 7. Disconnect air conditioner grounding (10).
1,000 ± 50 g 8. Remove four mounting bolts (11), and then
2. Referring to "Removal (and installation) of remove air conditioner compressor assembly (9)
supply pump assembly", remove parts to the from bracket (12).
condition shown in the following figure.
3. Remove air intake tube (1) and air tube (2).
[*2]
indicate their fitting positions.
4. Disconnect air conditioner compressor
electromagnetic clutch connector CN-M34 (3).

removal.
[*1]
(R134a)
5. Disconnect air conditioner hoses (4) and (5). [*3] Fill the air conditioner circuit with refrigerant
(R134a).
a Plug the hose to prevent any dirt, dust and
water from entering. a Filling quantity:
a Take care not to damage or lose the O-rings. 1,000 ± 50 g
6. Remove air conditioner compressor assembly • Refilling of air compressor oil
(9) according to the following procedure. [*4] For details, see Others, "Filling compressor oil".
[*2]
1) Loosen bracket mounting bolt (8), bolt (7),
adjustment nut (7a), and then move air
50-186 PC490LC-10
Electrical system
Connect the disconnected air intake tube (1) and air a When installing the air conditioner hoses and
tube (2) according to the following procedure. tubes, take care so that dust, dirt or water does
1. Set the hose to the original position (marked not enter them.
position). a When connecting the air conditioner hoses and
a Reference tubes, check that O-rings are fitted to their joints.
Hose fitting length: a Do not reuse an O-ring since it is deformed and
Air intake tube (1): 80 mm deteriorated once it is used.
Air tube (2): 50 mm a When removing O-rings, use a soft tool to avoid
2. Install the hose clamp (MIKALOR clamp) for air damaging hoses and tubes.
intake tube (1) according to the following
a Check that there is no defect or deterioration on
procedure.
the O-ring.
a Use a new MIKALOR clamp.
a Apply compressor oil (Denso: ND-OIL8) for
With bridge (BR) set under the clamp bolt, R134a refrigerant to O-rings.
tighten the bolt so that bridge (BR) overlaps
with the band by dimension (b) indicated 3 Hose clamp (M6 bolt):
below. 8 to 12 Nm {0.8 to 1.2 kgm}
Dimension (b): Min. 5 mm
Lubricant (THREEBOND PANDO 18B)
the hose.
3 Clamp bolt:
16 to 17 Nm {1.6 to 1.7 kgm}
is as follows. [*4]
Dimension (BDG): 4 to 7 mm
• a See Testing and adjusting, "Checking and
adjusting air compressor belt tension".
3 Adjustment nut (7a):
156.8 to 196.0 Nm {16 to 20 kgm}
24.5 to 29.4 Nm {2.5 to 3.0 kgm}
3. Air tube (2)

3 Air tube hose (2) clamp bolt:
10 to 11 Nm {1.02 to 1.12 kgm}
3 Air tube (2) mounting U bolt:
14.7 to 44.1 Nm {1.5 to 4.5 kgm}
[*3]
PC490LC-10 50-187
Electrical system
50-188 PC490LC-10
Electrical system
Removal and installation of air conditioner condenser assembly (PC400-K580-

924-K-00-A)

k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. And if it touches

atmosphere.
filling operations of the refrigerant (R134a). • Perform installation in the reverse order to
removal.
Removal (PC400-K580-520-K-00-A)
[*1]
1. Remove six mounting bolts, then remove right • Filling air conditioner circuit with refrigerant
cover (1a). (R134a)
(R134a).
a Filling quantity:
1,000 ± 50 g
• Refilling of air compressor oil
[*2]
not enter them.
2. Collect the refrigerant (R134a) from the air tubes, check that O-rings are fitted to their joints.
a Refrigerant to be collected: deteriorated once it is used.
1,000 ± 50 g a When removing O-rings, use a soft tool to avoid
3. Referring to "Removal (and installation) of damaging hoses and tubes.
radiator assembly", remove parts to the
condition shown in the following figure. a Check that there is no defect or deterioration on
4. Disconnect air conditioner hoses (1) and (2). [*2] the O-ring.
a Plug the hose to prevent any dirt, dust and a Apply compressor oil (Denso: ND-OIL8) for
water from entering. R134a refrigerant to O-rings.
a Take care not to damage or lose the O-rings. 3 Hose clamp (M6 bolt):
5. Remove mounting bolts (3) and air conditioner 8 to 12 Nm {0.8 to 1.2 kgm}
condenser assembly (4). [*3]
a When removing air conditioner condenser
assembly (4), take care not to damage the
core part.
PC490LC-10 50-189
Electrical system
[*3]
a Mount air conditioner condenser assembly (4)
by inserting cushions in place.
a Do not degrease the thread portion of air
conditioner condenser assembly mounting bolt
(3).
3 Air conditioner condenser assembly
mounting bolt (3):
9.0 to 11.8 Nm {0.96 to 1.24 kgm}
50-190 PC490LC-10
Electrical system
Removal and installation of engine controller assembly (PC400-AP70-924-K-00-A)

the engine.


Removal (PC400-AP70-520-K-00-A)

5) Remove two stud bolts (11). [*2]

6) Disconnect grounding connector T12 (12).
7) Remove two mounting nuts (13), then
remove bracket (14) and engine controller
assembly (15). [*3]
3. Remove engine controller assembly according
to the following procedure.
a Thoroughly clean the surrounding area to
remove mud and other contamination to
prevent them from entering the connector
hole.
1) Remove hose clamp (2) and spacer (3).
2) Remove bracket (4) and loosen five
mounting bolts to remove cover (5).
3) Disconnect connector M37 (6).
4) Disconnect connectors CE03 (7), CE01 (8)
and CE02 (9). [*1]
a To disconnect connectors CE03 (7), Installation (PC400-AP70-720-K-00-A)
CE01 (8) and CE02 (9), loosen their
hexagon socket head bolts (4 mm) on the
removal.
center of the connectors.
a Fix wiring harness (10) to the machine.
wiring harness connectors of the engine
controller assembly.
[*1]
3 Hexagon socket head bolts (4 mm) on the
center of the connectors CE03 (7), CE01
(8) and CE02 (9):
2.6 to 3.1 Nm {0.27 to 0.32 kgm}
PC490LC-10 50-191
Electrical system
[*2]
3 Stud bolt (11):
27 to 34 Nm {2.8 to 3.5 kgm}
[*3]
3 Mounting nut (13):
27–34 Nm {2.8 ± 3.5 kgm}
50-192 PC490LC-10
Electrical system
Removal and installation of pump controller assembly (PC400-C3V1-924-K-00-A)

the engine.


a The position of the pump controller is shown in
the following figure.
• A: Pump controller
3. Disconnect connectors (4) and (5) according to
a While pressing lock (L1), move lock (L2) to
the other side.
a Slider (B) comes out and the lock is
released.
• Connector (4): Pump controller (CP01)
• Connector (5): Pump controller (CP02)
4. Remove four bolts (6) to remove pump controller
(A).
Removal (PC400-C3V1-520-K-00-A)
1. Pull up cover (1) (three bolts) to remove.

a The connectors and wiring harnesses at the
rear must not be caught.
2. Remove bolt (2) to remove plate (3).
Installation (PC400-C3V1-720-K-00-A)

removal.
Reference: How to remove connector cover (1)
1. Cut and remove cable tie (2).
2. Move lever (3) upward.
PC490LC-10 50-193
Electrical system
3. Lightly press part (A) on both sides of connector

a Right and left sliders (4) are pushed in as far
cover (1) to release tabs (B).
as they go. (See the left figure shown below.)
4. Arc connector cover (1) around tab (C) to
2. Move lever (3) on connector cover (1) from the
remove the cover.
top position to the left position (locked position)
as shown in the following figure.
a (B), (C): Tab
a If the sliders and lever are not set as shown
in the following figure, the connector is not
disconnected or locked securely with the
lever. Accordingly, check their positions
again.
a The figure below shows the connector

without connector cover (1).
3. Set tab (C) to the connector and place connector

cover (1).
a Take care that wiring harness (5) is not
caught.
Reference: Procedure for installing connector

cover (1)
1. Push in right and left sliders (4) as far as
possible.
4. Put tabs (B) in to install connector cover (1).
50-194 PC490LC-10
Electrical system
5. Using new cable tie (2), bind connector cover (1)

and wiring harness (6).
PC490LC-10 50-195
Electrical system
Removal and installation of machine monitor assembly (PC400-Q180-924-K-00-A)

the engine.


Removal (PC400-Q180-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling

and lock it.
5. Remove connector (6) and then remove cover
a Check that the front window is securely (4).
locked.
• Connector (6): Sunlight sensor (P31)
•
3. Remove rubber panel (3) (two bolts). 6. Remove duct (10) (one bolt).
4. Remove three mounting screws of cover (4). 7. Insert a flat-head screwdriver in slit (7) and pull it
a One of the three screws is covered with cap upward to remove cover (9) while releasing lug
(5). (8).
50-196 PC490LC-10
Electrical system
10.Disconnect connectors (13) to (16).

a Hook (17) beneath cover (9) unites cover (9).
a Disconnecting connector (15) first makes
easier to disconnect the other connectors.
• Connector (13): Machine monitor (CM01)
• Connector (14): Machine monitor (CM02)
• Connector (15): Machine monitor (not used)
(CM03)
• Connector (16): Machine monitor (for camera
connection) (CM04)
•
8. Loosen mounting bolts (19) of cover and duct

assembly (18).
a Loosening mounting bolts (19) first makes
easier to remove machine monitor mounting
bolts.
9. Remove four mounting bolts (11) of machine

monitor (12).
Installation (PC400-Q180-720-K-00-A)

removal.
PC490LC-10 50-197
Electrical system
Removal and installation of pump swash plate sensor (PC400-C3WG-924-K-00-A)

the engine.


Removal (PC400-C3WG-520-K-00-A)

Installation (PC400-C3WG-720-K-00-A)

removal.
3 Pump swash plate sensor mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
• Adjust the pump swash plate sensors. For
details, see Testing and adjusting, "Special
function of machine monitor", "Adjustment (front
pump swash plate sensor calibration)" and
"Adjustment (rear pump swash plate sensor
calibration)".
2. Open left side cover (2) and remove cover (3).
3. Disconnect connectors CN-P27 (4) and CN-P28

(5).
• Connector (4): Front pump swash plate
sensor (CN-P27)
• Connector (5): Rear pump swash plate
sensor (CN-P28)
4. Remove front pump swash plate sensor (6) and
rear pump swash plate sensor (7).
50-198 PC490LC-10
Electrical system
Removal and installation of mass air flow and temperature sensor (PC400-
A96H-924-K-00-A)


Removal (PC400-A96H-520-K-00-A)

2. Sling and open engine hood (2).
8. Disconnect mass air flow and temperature

sensor connector P55 (8).
9. Remove two mounting screws to remove mass
air flow and temperature sensor (9).
3. Remove step plate (3). a Be careful not to let dust enter air cleaner
(10).
4. Open the right side cover (4).

5. Remove air cleaner case cover (5).
6. Remove air cleaner element (6).
Installation (PC400-A96H-720-K-00-A)
7. Remove box (7). • Perform installation in the reverse order to

removal.
wiring harness connectors.
a When installing the sensor, check that the
sensor is free from dirt or dust.
PC490LC-10 50-199
Electrical system
3 Mass air flow and temperature sensor

mounting screw (11):
0.98 to 1.27 Nm {0.1 to 0.13 kgm}
50-200 PC490LC-10
Electrical system
Removal and installation of KOMTRAX terminal assembly (PC400-Q210-924-K-00-A)

the engine.


a The position of the KOMTRAX terminal is shown
below.
a Be careful about connector (7) located
behind box (6).
Removal (PC400-Q210-520-K-00-A)
1. Remove box (1) (five bolts).

a Disconnect the hose under box (1).
2. Remove box (2) (three bolts).
5. Remove KOMTRAX terminal (C) (four bolts).
a Be careful about connectors (3) and (4) 6. Disconnect connectors (8) to (11).
located behind box (2) (for machines • Connector (8): Communication antenna
equipped with 12 V power socket). (GPS)
• Connector (3): 12 V power socket • Connector (9): Machine main harness
intermediate harness (M13A) (CK01).
• Connector (4): 12 V power socket • Connector (10): Machine main harness
intermediate harness (M13B) (CK02).
3. Remove cover (5) (three bolts). • Connector (11): Communication antenna
PC490LC-10 50-201
Electrical system
Installation (PC400-Q210-720-K-00-A)

removal.
50-202 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
60 Maintenance standard
8 60 Maintenance standard
PC490LC-10 60-1
Table of contents

60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Cooling fan pump ................................................................................................................. 60-5
Cooling fan motor................................................................................................................. 60-7
Power train system ..................................................................................................................... 60-8
Swing circle ......................................................................................................................... 60-8
Swing machinery ................................................................................................................. 60-9
Final drive ......................................................................................................................... 60-11
Sprocket............................................................................................................................ 60-13
Idler .................................................................................................................................. 60-16
Track roller ........................................................................................................................ 60-18
Carrier roller ...................................................................................................................... 60-19
Track shoe ........................................................................................................................ 60-20
Main pump ........................................................................................................................ 60-23
Control valve ..................................................................................................................... 60-25
Swing motor ...................................................................................................................... 60-36
Travel motor ...................................................................................................................... 60-38
PPC valve ......................................................................................................................... 60-41
Solenoid valve ................................................................................................................... 60-48
Attachment circuit selector valve ......................................................................................... 60-49
Center swivel joint .............................................................................................................. 60-50
Work equipment ....................................................................................................................... 60-51
Work equipment................................................................................................................. 60-51
Work equipment cylinder .................................................................................................... 60-60
60-2 PC490LC-10
Engine mount
Engine mount (PC400-H320-034-K-00-A)
PC490LC-10 60-3
Cooling system
Cooling system (PC400-B000-034-K-00-A)
60-4 PC490LC-10
Cooling fan pump
Cooling fan pump (PC400-B450-034-K-00-A)
PC490LC-10 60-5
Cooling fan pump
Servo valve (PC400-B4H0-034-K-00-A)
60-6 PC490LC-10
Cooling fan motor
Cooling fan motor (PC400-B5L0-034-K-00-A)
PC490LC-10 60-7
Swing circle
Power train system (ALL-C100-001-K-60-A)
Swing circle (PC400_10-J110-034-K-00-A)
Unit: mm
No. Item Criteria Remedy
Axial clearance of bearing Standard clearance Allowable clearance
1 Replace
(when installed on machine) 0.5 to 1.6 3.2
60-8 PC490LC-10
Swing machinery
Swing machinery (PC400_10-J130-034-K-00-A)
PC490LC-10 60-9
Swing machinery
Unit: mm
Backlash between No.2 sun Standard clearance Allowable clearance
1 gear and No.2 planetary gear 0.16 to 0.55 0.90
Backlash between No. 2
2 planetary gear and ring gear 0.17 to 0.60 1.00
Backlash between No. 1 sun
4 gear and No. 1 planetary 0.15 to 0.51 1.00
gear
Backlash between swing
5 motor shaft and No. 1 sun 0.18 to 0.28 –
gear
Replace
6 planetary carrier and No. 2 0.40 to 0.75 1.20
sun gear
Clearance between plate and
7 2.6 ± 0.71 –
No. 2 sun gear
Clearance between plate and
8 0.83 ± 0.26 –
No. 2 planetary carrier
9 planetary carrier and swing 0.08 to 0.25 –
pinion
Backlash between swing
10 pinion and swing circle 0 to 1.21 2.00
Standard Repair limit
Tolerance Repair by hard
Outside diameter of oil seal dimension
11 contact surface of spacer chrome-plating
0
150 – or replace
-0.100
60-10 PC490LC-10
Final drive
Final drive (PC400_10-DF10-034-K-00-A)
PC490LC-10 60-11
Final drive
Unit: mm
Backlash between No. 2 Standard clearance Allowable clearance
1 planetary carrier and travel
0.06 to 0.24 –
motor
3 planetary gear and No. 2 0.15 to 0.51 1.00
sun gear
Replace
5 planetary gear and No. 1 0.15 to 0.54 1.10
sun gear shaft
6 planetary carrier and No. 2 0.15 to 0.54 –
sun gear
Amount of wear on sprocket Repair limit: 6
7 Rebuild by
tooth
Repair limit build-up welding
Standard dimension
8 Width of sprocket tooth or replace
90 ± 2.5 84
60-12 PC490LC-10
Sprocket
Sprocket (PC400-DT60-034-K-00-A)
Unit: mm
Standard dimension Repair limit
1 Wear of tooth tip
355 343 Rebuild by
2 Thickness of tooth root 21.8 15.8 build-up
3 Width of tooth 90 84 welding or
Repair limit: 6 (use a full-scale drawing of sprocket tooth replace
4 Wear of tooth shape shape to judge)
PC490LC-10 60-13
Sprocket
Full-scale drawing of sprocket tooth shape
a This figure is reduced to 61% of the original size. Before using, enlarge it to 164% of the current size to
restore the original size and duplicate the drawing to the transparency sheet. Check the sprocket tooth
shape by putting the transparency sheet on the sprocket.
60-14 PC490LC-10
Track frame and idler cushion (PC400-DT20-034-K-00-A)
Unit: mm
Repair
limit
Height of idler Track +3
1 guide 107 111
frame -1 Rebuild by
Idler build-up
support 105 ±0.5 103
welding or
Track +4 replace
250 255
frame -1
2 Width of idler guide
Idler
247.4 – 245.4
support
Repair
Standard dimension
limit
Free Load at
length x Installed installed Free Free
3 Recoil spring Outside length length of length length Replace
diameter spring
239.0 kN 217.7 kN
845.3 x {24,375 {22,200
690 656
237 kg} kg}
PC490LC-10 60-15
Idler
Idler (PC400-DT90-034-K-00-A)
60-16 PC490LC-10
Idler
Unit: mm
Outside diameter of Standard dimension Repair limit
1 protrusion
704 –
2 Outside diameter of tread 660 648
3 Depth of tread 22 28 Rebuild by
4 Thickness of tread 24 15 build-up
5 Overall width 209.2 – welding or
6 Width of tread 52.1 – replace
Clearance between bushing
7 and support 0.46 to 0.86 –
(Total of both sides)
Standard Tolerance Standard Allowable
Clearance between shaft dimension Shaft Hole clearance clearance
8 and bushing
-0.120 +0.360 0.340 to
100
-0.207 +0.220 0.567 Replace
Tolerance Standard Allowable bushing
Standard
interfer- interfer-
Interference between idler dimension Shaft Hole
9 and bushing ence ence
+0.087 -0.027 0.054 to
107.6 –
+0.037 -0.062 0.149
PC490LC-10 60-17
Track roller
Track roller (PC400-DTD0-034-K-00-A)
Unit: mm
1 Outside diameter of flange
250 –
3 Thickness of tread 59.2 53.2
– Rebuild by
4 Overall width 291.2
build-up welding
5 Width of tread 58.2 – or replace
6 Width of flange 37.4 –
Clearance between
7 bushing and collar 0.45 to 0.98
(Total of both sides)
Clearance between shaft dimension Shaft Hole clearance clearance
8 and bushing
-0.250 +0.174 0.279 to
84 –
-0.350 +0.029 0.524 Replace
Tolerance Allowable bushing
Standard Standard
interfer-
Interference between roller dimension Shaft Hole interference
ence
9 and bushing
+0.087 +0.022 0.015 to
91.6 –
+0.037 -0.013 0.100
60-18 PC490LC-10
Carrier roller
Carrier roller (PC400-DTJ0-034-K-00-A)
Unit: mm
1 Outside diameter of flange
194 –
3 Width of tread 53.9 –
4 Thickness of tread 37 30
5 Width of flange 19 –
dimen-
Clearance between shaft Shaft Hole clearance clearance
6 and bushing sion Replace
-0.250 +0.100 0.286 to
57 –
-0.280 +0.036 0.380
dimen- interfer- interfer-
Interference between roller sion Shaft Hole ence ence
7 and bushing
+0.117 +0.030 0.057 to
64 –
+0.087 0 0.117
Standard clearance Allowable clearance
8 Play in axial direction
0.5 to 0.7 –
PC490LC-10 60-19
Track shoe
Track shoe (PC400-DTL0-034-K-00-A)
a Part P shows the link on the side where the bushing is press-fitted.
Unit: mm
1 Link pitch
228.9 231.9
Turn 180 deg.
2 Outside diameter of bushing or replace
76 71
3 Thickness of bushing 13.3 8.3
4 Link height
133 123 Repair or
Thickness of link (bushing replace
5 press fit part) 35.3 25.3
6 184
7 Shoe bolt pitch 144 Replace
8 76.2
60-20 PC490LC-10
Track shoe
Unit: mm
Inside
9 106
width
Overall Repair or
10 Link 55.2 replace
width
Tread
11 48.4
width
12 Protrusion of pin 4.4
Protrusion of regular
13 bushing 5.25
Adjust or
14 Overall length of pin 258 replace
15 Overall length of bushing 167.9
16 Thickness of spacer –
17 Bushing 127 to 333 kN {13 to 34 ton}
Regu-
18 Press fitting force 198 to 510 kN {20 to 52 ton}
larpin –
19 Mater-
147 to 412 kN {15 to 42 ton}
(*) pin
Tightening torque Retightening angle
a.
(Nm {kgm}) (deg.)
Regular
link Triple grouser 588 ± 59
{60 ± 6} 120 ± 10
shoe
20 Shoe bolt Retighten
Tightening Lower limit
b. torque Retightening angle torque
Master (degree)
(Nm {kgm}) (Nm {kgm})
link
– – –
Standard Tolerance Standard
Interference between dimension Shaft Hole interference
21 bushing and link
+0.494 +0.074
73.5 0.380 to 0.494
+0.454 0
Interference between +0.184 -0.268
22 regular pin and link 48.8 0.302 to 0.514
+0.034 -0.330
Clearance between regular dimension Shaft Hole clearance
23 pin and bushing
+0.184 +0.864 Adjust or
48.8 0.180 to 0.830 replace
+0.034 +0.364
24 Interference between master dimension Shaft Hole interference
(*) pin and link +0.03 -0.218
48.75 0.218 to 0.310
0 -0.280
25 Clearance between master dimension Shaft Hole clearance
(*) pin and bushing -0.2 +0.914
48.75 0.614 to 1.318
-0.4 +0.414
*: Dry type track link
PC490LC-10 60-21
Track shoe
Triple-grouser shoe (PC400-DTL8-034-K-00-A)
Unit: mm
1 Grouser height
37 22
2 Overall shoe height 52 37
3 Plate thickness 15 Rebuild by
4 33 build-up welding
Grouser bottom length or replace
5 27
6 25.5
7 Grouser tip length 17.5
8 23.5
60-22 PC490LC-10
Main pump
Main pump (PC400-C200-034-K-00-A)
PC490LC-10 60-23
Main pump
60-24 PC490LC-10
Control valve
Control valve (PC400-C030-034-K-00-A)
PC490LC-10 60-25
Control valve
60-26 PC490LC-10
Control valve
Unit: mm
Free length Installed Load at Load at
Free
x Outside installed installed
1 Spool return spring length length
diameter length length
120.6 N 326 N
54.5 x 34.8 53.5 –
{12.3 kg} {33.2 kg}
139.3 N 315 N If damaged or
2 Spool return spring 54.6 x 34.8 53.5 – deformed,
{14.2 kg} {32.1 kg}
replace spring.
94.1 N 300 N
3 Spool return spring 54.2 x 34.8 53.5 –
{9.6 kg} {30.6 kg}
33.4 N 336 N
{3.4 kg} {34.3 kg}
362 N
{36.9 kg}
PC490LC-10 60-27
Control valve
60-28 PC490LC-10
Control valve
Unit: mm
Free
1 Suction valve spring length length If damaged or
5.5 N 4.4 N deformed,
46.8 x 7.5 40.6 – replace spring.
{0.56 kg} {0.45 kg}
1.47 N 1.2 N
2 Check valve spring 11.5 x 4.6 8.5 –
{0.15 kg} {0.12 kg}
PC490LC-10 60-29
Control valve
60-30 PC490LC-10
Control valve
Unit: mm
Free
Return spring for variable x Outside installed installed
1 back pressure valve length length
14.7 N 11.8 N {1.2
59.62x16.8 43 –
{1.5 kg} kg} If damaged or
Check valve spring for deformed,
35.3 N replace spring.
2 hydraulic drift prevention 33 x 12 26 –
{3.6 kg}
valve
13.7 N 11 N {1.12
3 Check valve spring 33.8 x 6 29 {1.4 kg}
–
kg}
Check valve spring for 6.2 N 4.71 N
4 regeneration circuit 31.5 x 10.3 19.5 –
{0.63 kg} {0.48 kg}
PC490LC-10 60-31
Control valve
60-32 PC490LC-10
Control valve
Unit: mm
Free
Merge-divider valve (for LS) x Outside installed installed
1 length length
spring diameter length length
120.5 N 96.5 N
36.4 x 21.8 33.0 –
{12.3 kg} {9.84 kg}
199.8 N 200 N
2 Sequence valve spring 70.9 x 18.0 59.0 –
{20.4 kg} {20.4 kg}
If damaged or
Merge-divider valve (for 177.5 N 142 N
3 64.5 x 32.3 63.0 – deformed,
main) spring {18.1 kg} {14.5 kg}
replace spring.
Hydraulic drift prevention 35.3 N 28.2 N
4 33.0 x 12.0 26.0 –
valve check valve spring {3.6 kg} {2.88 kg}
13.7 N 11.0 N
5 Check valve spring 33.8 x 6.0 29.0 –
{1.4 kg} {1.12 kg}
Check valve spring for 5.1 N 4.71 N
6 31.5 x 10.3 21 –
regeneration circuit {0.53 kg} {0.48 kg}
50.0 N 40.0 N
7 Travel junction valve spring 30.7 x 20.5 23 –
{5.1 kg} {4.08 kg}
PC490LC-10 60-33
Control valve
60-34 PC490LC-10
Control valve
Unit: mm
Free
Boom RAISE check valve x Outside installed installed
1 spring length length If damaged or
deformed,
36.3 N 96.5 N replace spring.
33 x 12 26.1 –
{3.7 kg} {9.84 kg}
Arm quick return valve 35.3 N 200 N
2 spring 33 x 12 26 –
{3.6 kg} {20.4 kg}
PC490LC-10 60-35
Swing motor
Swing motor (PC300-J610-034-K-00-A)
60-36 PC490LC-10
Swing motor
Unit: mm
Load at Load at
Free length x Installed installed Free installed If
Outside length length of length length of damaged
1 Check valve spring diameter spring spring or
6.96 N 5.59 N deformed,
66.5 x 25.6 45.0 – replace
{0.71 kg} {0.57 kg} spring.
7.46 N 5.98 N
2 Shuttle valve spring 24.5 x 11.6 14.5 –
{0.76 kg} {0.61 kg}
PC490LC-10 60-37
Travel motor
Travel motor (PC400-C400-034-K-00-A)
60-38 PC490LC-10
Travel motor
PC490LC-10 60-39
Travel motor
Unit: mm
Free
1 Regulator piston spring length length
If damaged or
98.1 N 78.5 N{8.0
55.0 x 9.0 50.0 – deformed,
{10.0 kg} kg}
replace spring.
3.04 N 2.45 N
2 Check valve spring 62.5 x 20.0 39.0 {0.31 kg}
–
{0.25 kg}
427 N{43.5 341 N{34.8
3 Spool return spring 62.5 x 32.0 42.0 kg}
–
kg}
60-40 PC490LC-10
PPC valve
PPC valve (ALL-CW10-001-P-00-A)

Work equipment and swing PPC valve (PC300-PL28-034-K-00-A)
PC490LC-10 60-41
PPC valve
60-42 PC490LC-10
PPC valve
Unit: mm
Free
Centering spring x Outside installed installed
1 length length
(for ports P3 and P4) diameter length length
17.7 N 13.7 N If damaged or
42.5 x 15.5 34.0 -
{1.80 kg} {1.40 kg} deformed,
replace spring
Centering spring 29.4 N 23.5 N
2 44.5 x 15.5 34.0 -
(for ports P1 and P2) {3.0 kg} {2.40 kg}
16.7 N 13.7 N
3 Metering spring 26.5 x 8.15 24.9 -
{1.70 kg} {1.40 kg}
Travel PPC valve (PC-C6V0-034-K-00-A)
PC490LC-10 60-43
PPC valve
Unit:mm
Free height Installed Load at Load at
x Outside installed Free height installed If damaged
1 Centering spring height
diameter length length or deformed,
48.57 x 108 N 86.3 N replace
32.5 ‐
15.5 {11 kg} {8.8 kg} spring
26.53 x 16.7 N 13.3 N
2 Metering spring 24.9 ‐
8.15 {1.7 kg} {1.36 kg}
60-44 PC490LC-10
PPC valve
1st-line attachment PPC valve (with EPC valve) (PC-PL29-034-K-00-A)
(if equipped)
PC490LC-10 60-45
PPC valve
Unit:mm
x Outside installed Free length installed If damaged
1 Centering spring length
diameter length length or deformed,
125 N 100 N replace
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg} spring
16.7 N 13.3 N
2 Metering spring 22.7 x 8.10 22.0 —
{1.70 kg} {1.36 kg}
EPC valve (PC300-PL2B-034-K-00-A)

(if equipped)
60-46 PC490LC-10
PPC valve
Unit: mm
Reme-
No. Item Criteria dy
Standard dimension Repair limit If
Load at Load at da-
Installed Free maged
Free length installed installed
length length or
1 Metering spring length length
de-
3.1 N 2.5 N formed,
9.5 8.4 - replace
{0.32 kg} {0.26 kg}
spring
PC490LC-10 60-47
Solenoid valve
Solenoid valve (PC400-PQPT-034-K-00-A)
a The figure shows the type for a machine ready for installing attachments.
60-48 PC490LC-10
Attachment circuit selector valve (PC300-PQJ3-034-K-00-A)
(if equipped)
Unit: mm
Reme-
No. Item Criteria dy
Standard dimension Repair limit If
Load at Load at da-
Free length Installed installed Free installed maged
x Outside length length of length length of or
1 Spool return spring diameter de-
spring spring
formed,
834 N 667 N replace
132 x 29 114.5 –
{85.0 kg} {68.0 kg} spring.
PC490LC-10 60-49
Center swivel joint
Center swivel joint (PC300-J8E0-034-K-00-A)
Unit: mm
Standard Standard Allowable
1 Clearance between rotor and shaft dimension clearance clearance Replace
80 0.056 to 0.105 0.111
60-50 PC490LC-10
Work equipment
Work equipment (PC400-L410-034-K-00-A)
PC490LC-10 60-51
Work equipment
60-52 PC490LC-10
Work equipment
Unit: mm
Clearance between pin and dimension clearance clearance
Shaft Hole
1 bushing connecting
revolving frame and boom -0.036 +0.173 0.137 to
120 1.0
-0.090 +0.101 0.263
Clearance between pin and -0.036 +0.173 0.137 to
2 bushing connecting boom 120 1.0
-0.090 +0.101 0.263
and arm
3 bushing connecting arm and 100 1.0 Replace pin or
-0.090 +0.101 0.263
link bushing
4 bushing connecting arm and 100 1.0
-0.090 +0.355 0.499
bucket
5 bushing connecting link and 100 1.0
-0.090 +0.259 0.419
bucket
6 bushing connecting link and 100 1.0
-0.090 +0.259 0.419
link
PC490LC-10 60-53
Work equipment
Unit: mm
Greasing Remedy
No. Item Criteria
interval
Width of boss Width of hinge
Standard
Standard Standard
Connecting Tolerance Tolerance clearance
dimension dimension Adjust
part of -0.5 +3
778 782 3.5 to 6.0 clearance to be
7 revolving
-1.0 0 1.0 mm or less
frame and
L7: Adjust with the combination of shim thickness 2.0 with shims
boom
(*2) mm (2), 2.5 mm (1), 3.0 mm (1), and 3.5 mm (1).
R7: Insert 2.0 mm thickness shim (1).
(*1) +1.5
116 ±2 119 1.0 to 6.5
Connecting 0 Adjust
part of clearance to be
8 revolving L8: Insert 1.0 mm thickness shim (1).
1.5 mm or less
frame and (*2) R8: Adjust with the combination of shim thicknesses of with shims
boom 1.0 mm (1) and 2.0 mm (2).
cylinder
+2
865 ±2.9 867 1.0 to 4.9
-1
Connecting L9-1: Adjust with the combination of shim thicknesses of Adjust
part of boom 1.0 mm (1) and 2.0 mm (2). clearance to be
9 and boom
L9-2: Insert 1.0 mm thickness shim (1). 1.5 mm or less
cylinder (*2) with shims
R9-1: Insert 1.0 mm thickness shim (1).
R9-2: Insert 1.0 mm thickness shim (1).
+1.5
Connecting 126 ±1.2 129.3 2.1 to 6.0 Adjust
0
part of boom clearance to be
10 and arm L10: Adjust with the combination of shim thicknesses of
1.0 mm (1) and 2.0 mm (2). 1.5 mm or less
cylinder (*2) with shims
-0.3 +0.5
351 355 4.3 to 5.3 Adjust
Connecting -0.8 0
L11: Insert 2.0 mm thickness shim (1). clearance to be
11 part of boom
1.0 mm or less
and arm (*2) R11: Adjust with either shim with thickness 2.0 mm (2) or with shims
2.5 mm (1) or 3.0 mm (1).
Connecting +1.5
126 ±1.2 129.3 2.1 to 6.0
part of arm 0
12 Replace shim
cylinder and L12: Insert 1.0 mm thickness shim (1).
arm (*2)
+1.5
Connecting 116 ±1.2 119.3 2.1 to 6.0 Adjust
0
part of arm clearance to be
13 and bucket L13: Insert 1.0 mm thickness shim (1).
1.5 mm or less
cylinder (*2) R13: Adjust with the combination of shim thicknesses of with shims
1.0 mm (1) and 2.0 mm (2).
+1
Connecting 370 ±0.5 371 0.5 to 2.5
0 –
14 part of link
(*3) L14: –
and bucket
50 hours R14: –
60-54 PC490LC-10
Work equipment
Unit: mm
Greasing Remedy
No. Item Criteria
interval
Width of boss Width of hinge
Standard
Standard Standard
Connecting Tolerance Tolerance clearance
dimension dimension
15- part of bucket +1.0 –
a cylinder and 116 ±1.2 120 2.3 to 3.8
-0.5
link
(*3) L15a: –
50 hours R15a: Insert 1.5 mm thickness shim (1).
370 ±0.5 – – – Adjust
Connecting L15b: –
15- clearance to be
part of link (*3)
b R15b: Adjust with the combination of shim thickness 0.8 1.0 mm or less
and link 50 hours mm (1) and 1.5 mm (3). with shims
+0.5
370 – – – Adjust
Connecting 0
clearance to be
16 part of arm L16: Adjust with the combination of shim thickness 0.8
(*3) 1.0 mm or less
and link mm (1) and 1.5 mm (3).
50 hours with shims
R16: –
+1
370 ±0.5 371 – Adjust
Connecting 0
L17: – clearance to be
17 part of arm
(*4) 0.5 to 1.0 mm
and bucket R17: Adjust with the combination of shim thickness 0.5
50 hours with shims
mm (4) and 1.0 mm (18).
*1: The criteria indicates R.H. boom cylinder. The position for shim adjustment of L.H. boom cylinder becomes
opposite to that of R.H. boom cylinder.
*2: Use plastic shims (with flange).
*3: Use iron shims (without flange).
*4: Use separated iron shims.
a The number in ( ) next to the shim thickness shows the quantity of shims to be prepared.
PC490LC-10 60-55
Work equipment
Dimensions of arm (PC400-L412-034-K-00-A)
60-56 PC490LC-10
Work equipment
Unit: mm
PC490LC-10
No. Measurement point Tolerance
Standard dimension
Shaft Hole
-0.036 +0.1
1 – f110
-0.090 0
+1.5
Arm side 129.3
2 0
Cylinder head side 126 ±1.2
+0.5
Boom side 355
0
3
-0.3
Arm side 351
-0.8
-0.036 +0.1
4 – f120
-0.090 0
5 – 514.8 –
6 – 195 –
7 – 1,038 –
8 – – –
9 – 2,977.5 –
10 – 502 –
11 – 720 –
12 – 719 –
13 – 537.1 –
14 – 1,850 –
-0.036 +0.1
15 – f100
-0.090 0
+1
Bucket side 371
16 -0
Link side 370 ±0.5
-0.036 +0.1
17 – f100
-0.090 0
0
Arm boss (without bushing) 355
-0.5
18
Arm boss (with bushing press-
370 –
fitted)
Min. 1,870 –
19
Max. 3,140 –
PC490LC-10 60-57
Work equipment
Dimensions of bucket (PC400-LBK0-034-K-00-A)
60-58 PC490LC-10
Work equipment
Unit: mm
PC490LC-10
No. Measurement point
1 – 534.1 ±0.5
2 – 56.3 ±0.5
3 – 96 deg.1' –
4 – 537.1 –
5 – 1,839 –
6 – 190 –
7 – – –
8 – 60 deg.1' –
+0.1
9A – f140.1
0
+0.063
9B – f130
0
+0.1
9C – f100
0
+1
10 – 371
0
11A – 57 –
11B – 72
12 – 144 –
+0.5
13 – 562.5
-2.5
14 – f26 –
15A – f165 –
15B – – –
16 – f230 –
17 – 146.1 –
18 – 137.6 –
19 – R115 –
20 – R85 –
21 – 410 ±1
22 – 64 –
PC490LC-10 60-59
Work equipment cylinder
Work equipment cylinder (ALL-PPZ0-001-K-00-A)
Boom cylinder (PC400-L541-034-K-00-A)
Unit: mm
dimen-
Clearance between piston Shaft Hole clearance clearance Replace
1 rod and bushing sion
bushing
-0.036 +0.261 0.083 to
110 0.451
-0.090 +0.047 0.351
Clearance between piston -0.036 +0.210 0.111 to
2 rod support shaft and 110 1.0
bushing -0.071 +0.075 0.281
Replace pin or
Clearance between cylinder bushing
-0.036 +0.190 0.106 to
3 bottom support shaft and 100 1.0
bushing -0.090 +0.070 0.280
Tightening torque of cylinder 530 ± 78.5 Nm {54.0 ± 8.0 kgm}
4
head bolt
Tightening torque of cylinder
5 piston 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
6 piston lock screw 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
60-60 PC490LC-10
Arm cylinder (PC400-L950-034-K-00-A)
Unit: mm
dimen-
bushing
-0.036 +0.263 0.084 to
120 0.453
-0.090 +0.048 0.353
Clearance between piston
-0.036 +0.210 0.111 to
bushing -0.090 +0.075 0.300
Replace pin or
-0.036 +0.210 0.111 to
bushing -0.090 +0.075 0.300
Tightening torque of cylinder 892 ± 137 Nm {91.0 ± 14 kgm}
4
head bolt
Bucket cylinder (PC400-LCD0-034-K-00-A)
PC490LC-10 60-61
Unit: mm
dimen-
bushing
-0.036 +0.261 0.083 to
110 0.451
-0.090 +0.047 0.351
Clearance between piston -0.036 +0.457 0.406 to
bushing -0.090 +0.370 0.547
Replace pin or
-0.036 +0.190 0.106 to
bushing -0.090 -0.070 0.280
Tightening torque of cylinder 530 ± 78.5 Nm {54.0 ± 8.0 kgm}
4
head bolt
60-62 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
80 Appendix
9 80 Appendix
PC490LC-10 80-1
80 Appendix
Table of contents

80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller ..................................................................................................... 80-18
Compressor....................................................................................................................... 80-19
Condenser ........................................................................................................................ 80-20
Receiver drier .................................................................................................................... 80-21
Sunlight sensor .................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Input and output signals of the air conditioner controller ......................................................... 80-29
Parts and connectors layout................................................................................................ 80-31
Layout of air conditioner related parts and connectors ........................................................... 80-32
Testing air leakage (duct) .................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-39
Testing vent (mode) changeover.......................................................................................... 80-41
Testing FRESH/RECIRC air changeover.............................................................................. 80-43
Testing sunlight sensor ....................................................................................................... 80-44
Testing (dual) pressure switch for refrigerant......................................................................... 80-45
Testing relays .................................................................................................................... 80-47
Failure code list related to air conditioner.............................................................................. 80-53
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-54
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-55
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-56
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-58
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-60
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-61
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-62
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-64
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-65
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-66
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-67
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-69
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-72
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-74
Troubleshooting with gauge pressure................................................................................... 80-76
Connection of service tool................................................................................................... 80-79
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-81
Handling of compressor oil.................................................................................................. 80-83
80-2 PC490LC-10
80 Appendix
Precautions for refrigerant
Air conditioner components (ALL-K500-001-K-02-A)
Precautions for refrigerant (ALL-K512-012-K-00-A)
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
PC490LC-10 80-3
80 Appendix
Air conditioner component
Air conditioner component (PC400-K500-04D-K-00-A)
80-4 PC490LC-10
80 Appendix
1. Compressor
2. Condenser
3. Receiver drier
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Air conditioner controller
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
A. Front vent
B. Rear air vent
C. Foot air vent
D. Defroster air vent
E. Recirculation air inlet
F. Fresh air inlet
PC490LC-10 80-5
80 Appendix
Specification (PC400-K500-030-K-00-A)
Refrigerant R134a
Refrigerant refilling level (g) 950 ± 50
80-6 PC490LC-10
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle (ALL-K500-042-K-00-A)
Cycle Compression Condensation Expansion Evaporation

(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator's cab In operator's cab
Engine
Location compartment Front of radiator (Built in air conditioner (Built into air
unit) conditioner unit)
Circulates Lowers temperature
By evaporating
refrigerant gas and Condenses and pressure of
refrigerant, absorb
increases its refrigerant to refrigerant liquid and
heat from the air
temperature and discharge heat gas for easy
around the evaporator,
Function pressure so that it absorbed in evaporation with
and cools the
can be liquefied evaporator. throttle. Controls flow
surrounding air.
easily in condenser. (condensation of rate, too.
(Evaporation of
(Compression of refrigerant) (Throttle action of
refrigerant)
refrigerant) refrigerant)
Gas o gas Gas o liquid Liquid, gas o gas
State of Liquid o liquid, gas
refrigerant Adiabatic Constant pressure Constant pressure
Adiabatic expansion
compression change change
PC490LC-10 80-7
80 Appendix
Outline of refrigeration cycle
Outline of refrigeration cycle (ALL-K500-04A-K-00-A)
• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
Compression (Compressor)
• The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
• The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
• The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
• The heat released to the outside from the condenser is called condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency.
• In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
(The condensation pressure varies depending on the condensation temperature of the refrigerant)
Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
• The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
*1: Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
• The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
• The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
Relationship between refrigerant and defective air conditioning

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
80-8 PC490LC-10
80 Appendix
Outline of refrigeration cycle
• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
• If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.
PC490LC-10 80-9
80 Appendix
Air conditioner unit
Air conditioner unit (ALL-K540-041-K-00-A)
a This air conditioner unit is auto temperature control type.
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
80-10 PC490LC-10
80 Appendix
C: Hot water inlet

D: Hot water outlet
E: Recirculation air hole
F: Fresh air hole
G: Front air vents
H: Rear air vents
J: Foot level air vents
K: Defroster vents
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan, blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor
Vent (mode) changeover door
8. Rear door
9. Foot door
10. Defroster door
11. FRESH/RECIRC air changeover servomotor
12. FRESH/RECIRC air changeover door
13. Power transistor
14. Evaporator temperature sensor
15. Insidel air temperature sensor
a The door is the same as the damper.
Function (ALL-K540-042-K-00-A)
• The air conditioner unit consists of evaporator (1) and heater core (2), and is used to cool down or warm
up the air in the cab.
Temperature control
• When the temperature control switch on the machine monitor is operated, the set temperature data is sent
to the air conditioner controller that is located at the rear of the operator's seat.
• The air conditioner controller controls air mix servomotor (5) to change the angle of air mix door (6) so that
the set temperature is reached
Over-cooling (Freezing) prevention

• Evaporator temperature sensor (14) varies the resistance of its resistor according to temperature.
• The air conditioner controller converts the change in resistance of evaporator temperature sensor (14) into
the change in voltage to determine the temperature of evaporator (1).
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: For details of compressor clutch relay, see "Parts and connectors layout".
Air flow adjustment

• When the air flow adjusting switch on the machine monitor is operated, the set air flow data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) by using power transistor
(13) in order to adjust the air flow.
Vent (mode) changeover

• When a vent switch on the machine monitor is operated, mode data is sent to the air conditioner controller.
The air conditioner controller controls mode changeover servomotor (7) to adjust the opening and closing
angles of mode changeover doors (8) to (10) so that the selected vents are available.
PC490LC-10 80-11
80 Appendix
FRESH/RECIRC air changeover

• When the FRESH/RECIRC air selector switch on the machine monitor is operated, the set data of
FRESH/RECIRC air changeover is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (11) to open or close FRESH/RECIRC air
changeover door (12).
Automatic mode of air conditioner

• Inside air temperature sensor (15) detects the temperature inside operator's cab based on changes in
resistance. The air conditioner controller converts the change in resistance of inside air temperature
sensor (15) into the change in voltage to determine the room temperature.
The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the
room temperature so that it matches the setting made on the machine monitor.
The air conditioner controller also takes into consideration data from the sunlight sensor and the outer
sensor (outside air temperature sensor) when adjusting the room temperature.
Changeover pattern of the vent (mode) changeover door
Rear door (8) Foot door (9) Defroster door (10)
Opening Opening Opening
and closing Angle and closing Angle and closing Angle
door door door
Front Close 0 Close 0 Close 0
Front and rear Open 25 Close 0 Close 0
Front, rear and Open Open
25 35 Close 0
Air vent foot
mode Foot Open 25 Open 53 Close 0
Foot and Open Open Open
25 23 38
defroster
Defroster Open 25 Open 0 Open 38
Selection pattern of air mix door (6)
Set temperature Opening and closing door Angle (deg.)
Max. Cool Close 0
Max. Hot Open 80
80-12 PC490LC-10
80 Appendix
Functions of major components (ALL-K540-001-K-00-A)
a For details of the numbers in the following sentence, see “Air conditioner unit”.
Evaporator (ALL-K549-042-K-00-A)
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3).
• Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.
Heater core (ALL-K547-042-K-00-A)

• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through fins of the heater core (2).
Evaporator temperature sensor (ALL-K5FF-042-K-00-A)

• Evaporator temperature sensor (14) is installed to evaporator (1) with the holder. Its resistance changes in
accordance with the temperature change of the evaporator. The air conditioner controller determines the
temperature of evaporator (1) from voltage changes of evaporator temperature sensor (14) to prevent
freeze of the evaporator.
PC490LC-10 80-13
80 Appendix
Servomotor (ALL-K5D2-042-K-00-A)
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.
• When a switch on the machine monitor is operated, the air conditioner controller applies 24V power
between servomotor terminal B (6) and servomotor terminal A (7). (Rotation direction switches according
to the polarity of supply voltage.) )
• The servomotor contains a variable resistor, and its resistance value changes as the motor rotates.
• The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor
rotation angle from the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the air conditioner controller cannot recognize the potential difference that corresponds to the
command to the servomotor, it generates a air conditioner failure code to inform the machine monitor of
failure in air conditioner system. Failure code [879EMC] or [879FMC] is displayed on the electrical system
failure record screen of the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
a Do not try to drive a servomotor by supplying power directly between servomotor terminals (6) and (7)
during inspection.
80-14 PC490LC-10
80 Appendix
Expansion valve (ALL-K548-041-K-00-A)
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Structure
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).
• The expansion valve (1) converts high-pressure and high-temperature liquid refrigerant from the receiver
drier to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).
Operation (ALL-K548-044-K-00-A)
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
PC490LC-10 80-15
80 Appendix
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).
When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve
(1a) is moved rightward by the reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)
80-16 PC490LC-10
80 Appendix
Dual pressure switch
Dual pressure switch (ALL-K5FG-044-K-00-A)
a The dual pressure switch is mounted on the air conditioner hose under the floor.
• The dual pressure switch turns "OFF" when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay "OFF". As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function (ALL-K5FG-042-K-00-A)
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC490LC-10 80-17
80 Appendix
Air conditioner controller
Air conditioner controller (ALL-K5G4-041-K-00-A)
a See "System Diagrams" for details regarding input/output signals.
80-18 PC490LC-10
80 Appendix
Compressor
Compressor (ALL-K590-041-K-00-A)
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Specification (ALL-K590-044-K-00-A)
Number of cylinders - Bore x Stroke (mm) 10 - 32 x 20.8

Piston capacity (cc/rev) 157.3
Max. allowable speed (rpm) 6,000
Compressor oil DENSO: ND-OIL8 (For R134a)
Compressor oil refill capacity (cc) 180
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When magnetic clutch (2) is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.
PC490LC-10 80-19
80 Appendix
Condenser
Condenser (PC400-K580-041-K-00-A)
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to receiver drier)
Specification (PC400-K580-030-K-00-A)
Fin pitch (mm) 4.0

Height x width x thickness (mm) 357 x 540 x 16
Max. working pressure (MPa {kg/cm2}) 3.6 {36}
Function (PC400-K580-042-K-00-A)
• The condenser cools and liquefies the high pressure and high temperature misty refrigerant sent from the
compressor.
a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction
of refrigerant becomes impossible.
If the heat exchange efficiency is reduced, pressure in the refrigerant circulation circuit will be increased,
applying extra load to the engine or reducing the cooling effect. Take extreme care not to crush or damage
the fins when hangling it or performing daily inspection.
80-20 PC490LC-10
80 Appendix
Receiver drier
Receiver drier (PC400-K5E2-041-K-00-A)
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to air conditioner unit)
Function (PC400-K5E2-042-K-00-A)
• The receiver drier temporarily stores the high pressure and high temperature liquid refrigerant from the
condenser so that it can be supplied to the evaporator according to the need of cooling.
• It sends the stored refrigerant from its bottom to the evaporator, allowing the refrigerant to be liquefied
completely ever when it contains bubbles due to the lower heat dissipation of the condenser.
• The built-in filter and desiccating agent eliminate foreign substances in the circulation circuit and water
content in the refrigerant.
Specification (PC400-K5E2-044-K-00-A)
Effective volume (cc) 370

Weight of desiccating agent (g) 290
PC490LC-10 80-21
80 Appendix
Sunlight sensor
Sunlight sensor (ALL-K5FH-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K5FH-042-K-00-A)
• The sunlight sensor is mounted on top of the machine monitor.

• It detects the strength of incident sunlight and sends signals to the air conditioner controller.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
80-22 PC490LC-10
80 Appendix
Outer temperature sensor (outside air temperature
sensor)
Outer temperature sensor (outside air temperature sensor) (ALL-K55C-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K55C-042-K-00-A)
• The outside (air) temperature sensor is installed in the cooling unit.

• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller detects the ambient temperature by converting the changes in the resistance
of the outside air temperature sensor into voltage changes.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the outside (air) temperature sensor in order to adjust the
temperature and air flow.
PC490LC-10 80-23
80 Appendix
Procedure for testing and troubleshooting
Procedure for testing and troubleshooting (ALL-K500-422-K-00-A)
The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air
conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air
conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with
the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
80-24 PC490LC-10
80 Appendix
Procedure for testing and troubleshooting
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no
refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC490LC-10 80-25
80 Appendix
Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins (PC400-K500-051-K-02-A)
80-26 PC490LC-10
80 Appendix
Circuit diagram and arrangement of connector pins
a Diffuser servomotor means vent (mode) changeover servomotor.

a SERVOMOTOR OF INSIDE/OUTSIDE AIR means FRESH/RECIRC air changeover servomotor.
a Frost sensor means evaporator temperature sensor.
PC490LC-10 80-27
80 Appendix
System diagram
System diagram (PC220-K5F0-051-K-00-A)
a This air conditioner unit is auto temperature control type.
80-28 PC490LC-10
80 Appendix
Input and output signals of the air conditioner controller
Input and output signals of the air conditioner controller (ALL-K5G4-03C-K-00-A)
Controller connector: AMP 025 - 32PM

Wiring harness connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply (5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA Fresh/recirculated air servomotor terminal A Output
14 MRFB Fresh/recirculated air servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
Function (ALL-K5G4-042-K-00-A)
• Operation of air conditioner controller

1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
PC490LC-10 80-29
80 Appendix
Input and output signals of the air conditioner controller
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the air conditioner controller controls the inside (air)
temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor,
the outside air temperature sensor, and the inside air temperature sensor.
8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the controller
notifies it to the machine monitor by the CAN communication. Then, failure code [879***] is displayed on
the "Electrical Systems" screen of the electrical system on the machine monitor.
80-30 PC490LC-10
80 Appendix
Parts and connectors layout
Parts and connectors layout (PC220-K500-055-K-00-A)
• Three fuses related to the air conditioner are in the fuse box at the right rear of the operator's seat.
• The air conditioner unit is mounted inside the rear cover of the operator's seat.
k Park the machine on a level surface, swing the upper structure by 90 degrees, lower the work
equipment to the ground so that it is stable, and stop the engine.
k Turn the battery disconnect switch to the "OFF" position and pull out the key.
a Note the connector numbers and installed positions before disconnecting wiring and hoses.
Connector Reference
Remarks Location
No. item
AC01 Intermediate connector Right rear of cab 2.
AC02 Intermediate connector Right rear of cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Air conditioner controller Rear of cab 2.
CM01* Machine monitor Front of cab 5.
CM02 Machine monitor Front of cab 5.
F01 Fuse box Right rear of cab 1.
Dual pressure switch
P17 Under cab 6.
a Swing upper structure 90 deg.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear of cab 2.
[2] Power transistor Air conditioner unit 3.
[5]* FRESH/RECIRC air changeover
Air conditioner unit 3.
servomotor
[6]* Inside air temperature sensor Air conditioner unit 3.
Evaporator temperature sensor
[7]* Air conditioner unit 3.
(Frost sensor)
*: Connector that does not appear during troubleshooting
PC490LC-10 80-31
80 Appendix
Layout of air conditioner related parts and connectors
Layout of air conditioner related parts and connectors (PC400-K500-04D-K-01-A)
1. Each fuse in fuse box F01: Open the cover of the fuse box at the right rear of the operator's cab.
• No. 10 (20 A): Fuse for the power supply of blower (fan) and the air conditioner compressor
• No. 14 (5 A): Fuse for the primary power supply of the air conditioner unit, air conditioner controller,
and the air conditioner compressor electromagnetic clutch relay
• No. 19 (5 A): Fuse for the power supply (backup power supply) of the air conditioner controller
2. Air conditioner controller: *1

• AC01: Intermediate connector
• AC02: Intermediate connector
• ACECU: Air conditioner controller connector
• R21: Connector for air conditioner compressor electromagnetic clutch relay

a Connectors [2], [5], [6], and [7] do not have labels.
80-32 PC490LC-10
80 Appendix
a Rear side of air conditioner unit (Only connector [2] can be removed while installed on machine)
[2]: Power transistor (*2) connector
[5]: FRESH/RECIRC air changeover servomotor connector
[6]: Inner temperature sensor (inside air temperature sensor) connector
[7]: Evaporator temperature sensor connector
*2: Power transistor
4. Sunlight sensor
P31: Sunlight sensor connector
5. Machine monitor
• CM01 to CM04: Machine monitor connector
a Connector CM03: (Not used)
a Connector CM04: (For camera connection)
6. Dual pressure switch

a Rotate cab undercover 90 degrees and remove it.
• P17: Dual pressure switch connector
PC490LC-10 80-33
80 Appendix
7. Air conditioner compressor

a Open the engine hood.
• AC03: Air conditioner compressor connector
*3: Air conditioner compressor ground
8. Outside air temperature sensor

P18: Outside (air) temperature sensor connector
80-34 PC490LC-10
80 Appendix
Testing air leakage (duct)
Testing air leakage (duct) (ALL-K5D0-001-K-00-A)
k Place the machine on a level ground, lower the work equipment to the ground and stop the engine.
k Turn the battery disconnect switch to the OFF position and remove the key.
a Note the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Check (ALL-K5D0-360-K-00-A)
1. Lift front window assembly (1) to the ceiling and lock it.
a Check that the front window is securely locked.
3. Remove floor mat (3).
4. Remove cover (4) first, and then remove cover (5).
6. Remove cap (7-1).

a Disconnect the sunlight sensor connector from the rear of cover (7).
8. Remove drink box (8) (five bolts).

a Disconnect the hose under drink box (8).
9. Remove magazine box (9) (three bolts).
a Be careful about connectors (10) and (11) behind magazine box (9). (for machines equipped with 12 V
power socket)
• Connector (10): 12 V power socket intermediate harness (M13A)
• Connector (11): 12 V power socket intermediate harness (M13B)
10.Pull up cover (12) (three bolts) to remove.
a The connectors and wiring harnesses at the rear must not be caught.
PC490LC-10 80-35
80 Appendix
11.Remove cover (13) (seven bolts).

a Be careful about connector (14) behind cover (13).
12.Check the following ducts and pins for disconnection.

• Front duct (15)
• Defroster duct (16)
• Rear duct (17)
• Fresh air inlet duct (18) and pin (19)
80-36 PC490LC-10
80 Appendix
PC490LC-10 80-37
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function (ALL-Q19Y-001-K-00-A)
Testing outline (ALL-Q19Y-360-K-00-A)
The air conditioner controller performs various self-diagnosis such as inside air temperature sensor, outside
air temperature sensor, evaporator temperature sensor, temperature control system, vent (mode) changeover
system, sunlight sensor, and refrigerant pressure with the dual pressure switch. If an error is detected on the
temperature control system, vent (mode) changeover system, or refrigerant, the machine monitor
momentarily shows a warning screen and then "Air conditioner system state monitor" lights up continuously.
a The machine monitor displays the system state monitor "!" when an error occurs in the communication
between the machine monitor and the air conditioner controller.
a The system performs self-diagnosis of various sensors. If any failure is detected, a failure code is
displayed on the "Electrical Systems Abnormality Record" screen in the service mode of the machine
monitor.
a Once a failure is detected in the self-diagnosis, the error condition is not canceled even if the failed part
returns to normal.
Turning the starting switch "OFF" clears a failure.
a FRESH/RECIRC air changeover servomotor is not checked in the self-diagnosis.
80-38 PC490LC-10
80 Appendix
How to open the electrical system abnormality record
screen in service mode of the machine monitor
How to open the electrical system abnormality record screen in service

mode of the machine monitor (PC220-Q19Y-100-K-00-A)
• Overview of machine monitor operating procedure
Standard screen
Press [1], [2], and [3] in this order while holding down O [4].
Service menu (Mode)
Press O [F3] twice. Press [F6].
03 Abnormality Record
Press O [F3] once. Press [F6].
02 Electrical systems abnormality record screen
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. Validate the selection by pressing [F6].
3. Press [F3] twice on the Service Menu screen to select 03 "Abnormality Record".
5. Press [F3] once on the Failure Record screen to select 02 "Electrical System Abnormality Record".
PC490LC-10 80-39
80 Appendix
How to open the electrical system abnormality record
screen in service mode of the machine monitor
a For details, see the failure code list related to air conditioner.
Failure code Failure (Displayed on screen) Remarks
Air Conditioner Inner Sensor Open
879AKA
Circuit
*
Air Conditioner Inner Sensor Short
879AKB
Circuit
Air Conditioner Outer Sensor Open
879BKA
Circuit
Air Conditioner Outer Sensor Short
879BKB
Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
Sunlight Sensor Open or Short
879DKZ
Circuit
879EMC Ventilation Damper Abnormality *
879FMC Air Mix Damper Abnormality *
879GKX Refrigerant Abnormality
Air Conditioner Model Selection
DAZ9KQ Abnormality See Chapter 40, "Troubleshooting
CAN2 Disconnection (Air by failure code" **
DAZQKR Conditioner ECU)
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector
cannot be checked.
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The ventilation damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
80-40 PC490LC-10
80 Appendix
Testing vent (mode) changeover
Testing vent (mode) changeover (ALL-K5FR-001-K-00-A)
Testing (ALL-K5FR-360-K-00-A)
1. Remove drink box (1) (five bolts).

a Disconnect the hose under drink box (1).
2. Remove magazine box (2) (three bolts).
a Be careful about connectors (3) and (4) behind magazine box (2). (for machines equipped with 12 V
power socket).
• Connector (3): 12 V power socket intermediate harness (M13A)
• Connector (4): 12 V power socket intermediate harness (M13B)
3. Remove cover (5) (three bolts).

a Be careful about connector (7) behind cover (6).
PC490LC-10 80-41
80 Appendix
Testing vent (mode) changeover
5. Remove ducts (8) and (9).
6. Turn the battery disconnect switch to the "ON" position.

7. Start the engine and turn the air conditioner power "ON".
8. Operate the vent changeover switch on the machine monitor.
9. Check the opening/closing operation of rear door (11) and defroster door (12) of air conditioner unit (10).
10.After finishing the inspection, turn the starting switch to the OFF position.
80-42 PC490LC-10
80 Appendix
Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover (ALL-K5D2-001-K-00-A)
Testing (ALL-K5D2-360-K-00-A)
1. Open outside air filter cover (1) and remove outside air filter (2).
2. Start the engine and turn the air conditioner power "ON".
3. Operate the FRESH/RECIRC air selector switch on the machine monitor.
4. Check the opening/closing operation of FRESH/RECIRC air changeover rear door (3) through the fresh
air inlet on the left side of the cab.
5. After finishing the inspection, turn the starting switch to the OFF position.
PC490LC-10 80-43
80 Appendix
Testing sunlight sensor
Testing sunlight sensor (PC220-K5FH-001-K-00-A)
Testing (PC220-K5FH-360-K-01-A)
1. Remove the machine monitor cover. For details, see "Testing air leakage (duct)", Steps 6 and 7.
2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.)
3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals
on the sensor side using a circuit tester in voltage range.
• Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
80-44 PC490LC-10
80 Appendix
Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant (PC220-K5FG-001-K-00-A)
Testing (PC400-K5FG-360-K-00-A)
• If [879GKX] "Refrigerant Abnormal" is displayed by the self-diagnosis (on "Air-conditioning System"

screen of "Abnormality Record" in the machine monitor), test the dual pressure switch connector P17.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
• The dual pressure switch is ON when the refrigerant pressure is normal, and OFF when it is abnormal.
a If ambient temperature drops to 0°C or below, refrigerant pressure will also subsequently decrease.
Accordingly, there is a possibility that the dual pressure switch is OFF. In such a case, the dual
pressure switch unit is not defective but normal.
1. Perform swing of 90 deg.
2. Remove the cab undercover.
3. Disconnect the dual pressure switch connector P17.
4. Check if the resistance between the switch-side terminals of connector P17 are shorted (ON). (If not
shorted (OFF), dual pressure switch is detecting an abnormal refrigerant pressure.)
a If the dual pressure switch is OFF, attach a pressure gauge to the high-pressure line of the air
conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and
"Troubleshooting with gauge pressure".
a If the refrigerant pressure is normal, the dual pressure switch is defective.
• (Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2 }

LB: 0.02 MPa {0.2 kg/cm2 }
HA: 3.14 MPa {32 kg/cm2 }
HB: 0.59 MPa {6 kg/cm2 }
PC490LC-10 80-45
80 Appendix
Testing (dual) pressure switch for refrigerant
k When replacing the dual pressure switch, refrigerant must be collected in advance.
a If resistance between the switch-side terminals from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant system".
80-46 PC490LC-10
80 Appendix
Testing relays
Testing relays (PC220-K5FE-001-K-00-A)
Testing (PC220-K5FE-360-K-03-A)
1. Check contact R21 of connector (for disconnection).

2. Turn the starting switch ON (do not start the engine), turn the main power of the air conditioner ON, and
turn the air conditioner switch. If the compressor relay is normal, it is turned ON. Check whether it clicks.
a The air conditioner controller will not turn on the compressor clutch relay in the following cases.
1) When the evaporator temperature is below 3 °C (depending on the input voltage from the evaporator
temperature sensor).
2) When the pressure switch detects abnormality (it is turned OFF).
• Checking relay unit

a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil
actually.
Compressor clutch relay (CCRL), connector (AC04)
1. The coil resistance between terminals (1) and (2) is approximately 370 to 530 z.
2. While voltage (DC 20 to 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are
connected.
3. While voltage (DC 20 to 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (5) are
connected.
PC490LC-10 80-47
80 Appendix
Troubleshooting chart 1
Troubleshooting chart 1 (PC220-3840-421-A-00-A)
Numbers in T represent the item numbers in the troubleshooting quick reference table.
1. Lowered cooling performance
2. Lowered heating performance
80-48 PC490LC-10
80 Appendix
Troubleshooting chart 2 (PC220-3840-421-A-01-A)
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check the connector for disconnection. Repair broken parts
Wire breakage or defective and connect
connection See "Parts and connectors layout". correctly
Operate the fan switches in order and check the fan
Defective blower fan motor speed. Replace
See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check duct joints.
Repair
joints See "Testing air leakage (duct)".
Obstruction at evaporator Check evaporator for stain and obstruction Remove obstruction
inlet and clean
Defective evaporator Evaporator is frozen.
temperature sensor, Sensor fixing clip inspection, sensor contaminated
defective contact of Repair or replace
evaporator temperature Inspect the air conditioner hose around the pressure
switch for frost.
sensor, defective expansion
valve* (when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass. refrigerant again
Specifically, perform checking with the gauge manifold Collect refrigerant,
connected. then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/
cm2 }
Judgment by pressure at See Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2 with gauge pressure
}
Temperature in operator's cab: 30 to 35 °C , Engine
speed: Approx. 1,500 rpm
PC490LC-10 80-49
80 Appendix
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
part
Deflection of belt is large.
Compressor See "Checking and adjusting air
belt
Slack of belt conditioner compressor belt tension" in Adjust tension
the "Testing and adjusting" in Chapter
30.
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 to 20 z) Replace
Magnet
Check ground cable and joints.
clutch Wire breakage or defective
connection of ground wire See "Troubleshooting for compressor Repair
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging.
engine coolant Bleed air and correct
(Hose, pipe and core)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
See "Replacing fan belt" in "Testing and adjusting" in
Fan speed is low Replace
Chapter 30.
80-50 PC490LC-10
80 Appendix
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Select manual mode and change temperature setting.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible. and heating
FRESH/RECIRC air cannot
See "Testing FRESH/RECIRC air changeover".
be changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
PC490LC-10 80-51
80 Appendix
Information in troubleshooting table
Information in troubleshooting table (ALL-5170-421-A-03-A)

Information in troubleshooting table
Failure Failure symptom that appears on machine
Related information Information on occurred failure or troubleshooting
[Information described]
• Procedure
• Measuring location
1
a "Between A and B" denotes measuring voltage or resistance, etc.
Probable cause of failure between A and B.
(Perform troubleshooting • Criteria to determine probable causes
according to these.) • Remarks for judgment of Good or No good
[Notes on troubleshooting]
2 (1) pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) tester leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (-) lead to a pin or harness indicated in the
rear.
3 Defective — (2) Example of troubleshooting done by testing multiple items
a Normal in 1 but abnormal in 2
At this time, "Defective component" shown at left 3 is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit
accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with another independent wire. (poor
insulation at connector and others)
Related circuit diagram

This is the extracted circuit diagram related to failure
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location
• The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
• N.C.: Normally closed (Normally ON)
• [1], [2], ... are numbers of unlabeled connectors.
• The arrow (io) indicates their rough installation position on the machine.
80-52 PC490LC-10
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner (ALL-K500-441-K-00-A)

Compo-
Failure Failure (Displayed on screen) nent in Action Category
Remarks
code charge level of record
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON –
Circuit system performed while the controller
is mounted on the machine
A/C Inner Sensor Short Electrical
879AKB MON – since the connector cannot
Circuit system
be checked.
A/C Outer Sensor Open Electrical
879BKA MON –
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON –
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot
Circuit system
be checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Short Circuit system
Ventilation Dumper Electrical Troubleshooting cannot be
879EMC Abnormality MON L01 system performed while the controller
Electrical
879FMC Air Mix Dumper Abnormality MON L01 since the connector cannot
system
be checked.
Electrical
879GKX Refrigerant Abnormality MON L01 system
A/C Model Selection Electrical
DAZ9KQ Abnormality MON –
system See Chapter 40,
"Troubleshooting by failure
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01 code"
system
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The vent damper means the vent (mode) changeover damper (door).
a The Air Mix Damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes is explained after failure code
[879GKX].
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover
PC490LC-10 80-53
80 Appendix
Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKA] A/C Inner sensor Open Circuit (PC220_10-879AKA-400-A-00-A)
Action Air conditioner inside air temperature sensor disconnection

Failure code
level Failure
— (Machine monitor system)
879AKA
Details of • Air conditioner controller detected disconnection in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a disconnection in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
80-54 PC490LC-10
80 Appendix
Failure code [879AKB] A/C Inner sensor Short Circuit
Failure code [879AKB] A/C Inner sensor Short Circuit (PC220_10-879AKB-400-A-00-A)
Action Air conditioner inside air temperature sensor short circuit

Failure code
level Failure
879AKB
Details of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
2
conditioner unit
PC490LC-10 80-55
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit (PC220_10-879BKA-400-A-00-A)
Action Air conditioner outside air temperature sensor disconnection

Failure code
level Failure
879BKA
Details of • Air conditioner controller detected disconnection in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since the air conditioner outside temperature sensor has a disconnection, outside
Problem on temperature is not counted in automatic mode.
machine (The air conditioner is not affected in manual mode)
electrical system in the service mode of the machine monitor.
• For connectors and other parts, see "Parts and connectors layout".
• Since connector ACECU of the air conditioner controller has small pins and does not
Related have a T-adapter, carry out troubleshooting by using the intermediate connector
information (Although the intermediate connector does not have a T-adapter either, it does have large
pins).
• If the air conditioner wiring harness between connector ACECU of the air conditioner
controller and the intermediate connector needs to be replaced, the air conditioner unit
must be replaced.
1. Turn starting switch to "OFF" position.
Defective outside
1 air temperature
sensor Between P18
Resistance 25°C Approx 1.7 kz
(male) (1) and (2)
Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
a If cause 2 is not the cause for the failure, this check is not required.
Breaking of 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors P18 and AC01.
3 (Wire breakage or Between AC01 (female) (7) and P18
defective contact of (female) (1) Max. 1 z
connectors) Resistance
Between AC01 (female) (8) and P18
5
conditioner unit
80-56 PC490LC-10
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit
Circuit diagram related to air conditioner outside air temperature sensor
PC490LC-10 80-57
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit (PC220_10-879BKB-400-A-00-A)
Action Air conditioner outside air temperature sensor short circuit

Failure code
level Failure
879BKB
Details of • Air conditioner controller detected short circuit in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since air conditioner outside temperature sensor has short circuit, outside temperature is
Problem on not counted in automatic mode.
pins).
must be replaced.
1. Turn starting switch to "OFF" position.
Defective outside
1 air temperature
sensor Between P18
(male) (1) and (2)
Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
a If cause 2 is not the cause for the failure, this check is not required.
Short-circuiting of 1. Turn starting switch to OFF position.
3 2. Disconnect connectors P18 and AC01.
harness
Between AC01 (female) (7) and (8), or
Resistance between P18 (female) (1) and (2) Min. 1 Mz
Ground fault in 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors P18 and AC01.
4
(Contact with GND Between ground and AC01 (female) (8)
circuit) Resistance or P18 (female) (1) Min. 1 Mz
6
conditioner unit
80-58 PC490LC-10
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit
Circuit diagram related to air conditioner outside air temperature sensor
PC490LC-10 80-59
80 Appendix
Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKA] Ventilating sensor Open Circuit (PC220_10-879CKA-400-A-00-A)
Action Evaporator temperature (frost) sensor disconnection

Failure code
level Failure
879CKA
Details of • Air conditioner controller detected disconnection in evaporator temperature (frost) sensor.
failure
• Th air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a disconnection in the evaporator
machine temperature (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
2
conditioner unit
80-60 PC490LC-10
80 Appendix
Failure code [879CKB] Ventilating sensor Short Circuit
Failure code [879CKB] Ventilating sensor Short Circuit (PC220_10-879CKB-400-A-00-A)
Action Evaporator temperature (frost) sensor short circuit

Failure code
level Failure
879CKB
Details of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
2
conditioner unit
PC490LC-10 80-61
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit (PC220_10-879DKZ-

400-A-00-A)
Action Sunlight sensor disconnection or short circuit
Failure code
level Failure
879DKZ
Details of • Air conditioner controller detected disconnection or short circuit in sunlight sensor.
failure
• The air conditioner controller sends information about sunlight sensor disconnection or
Action of short circuit to the machine monitor via CAN communication.
controller • Continues control of the air conditioner in automatic mode, ignoring sunlight sensor data.
• Since the air conditioner sunlight sensor has a disconnection or short circuit, sunlight
Problem on strength is not counted in automatic mode.
pins).
must be replaced.
1. See "Testing sunlight sensor".
Defective sunlight Direct sunlight Approx. 0.55 V
1 Between sunlight
sensor Voltage Cloudy Approx. 0.45 V
sensor terminals
Indoor Approx. 0.4 V
Breaking of 2. Disconnect connector P31.
harness a See "Testing sunlight sensor".
2 (Wire breakage or Between P31 (female) (1) and AC01
defective contact of (female) (10) Max. 1 z
connectors) Resistance
Between P31 (female) (2) and AC01
4
conditioner unit
80-62 PC490LC-10
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
PC490LC-10 80-63
80 Appendix
Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879EMC] Ventilating Damper Abnormality (PC220_10-879EMC-400-A-00-A)
Action Abnormality in vent (mode) changeover damper servomotor

Failure code
level Failure
(Machine monitor system)
L01 879EMC
Details of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
2
conditioner unit
80-64 PC490LC-10
80 Appendix
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality (PC220_10-879FMC-400-A-00-A)
Action Abnormality in air mix (temperature regulation) damper

Failure code
level Failure servomotor
L01 879FMC (Machine monitor power train control system)
Details of • The air conditioner controller judged from the potentiometer voltage of the servomotor
failure that the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
• Method of reproducing failure code: Turn starting switch ON position.
Related
information
• Troubleshooting cannot be performed since the connector part of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
2
conditioner unit
PC490LC-10 80-65
80 Appendix
Failure code [879GKX] Refrigerant Abnormality
Failure code [879GKX] Refrigerant Abnormality (PC220_10-879GKX-400-A-00-A)
Action Refrigerant (dual) pressure switch abnormality

Failure code
level Failure
(Machine monitor system)
L01 879GKX
Details of • Air conditioner controller detected that dual pressure switch was OFF (abnormal).
failure
• The air conditioner controller sends information about the refrigerant pressure
abnormality to the machine monitor via CAN communication.
Action of • The air conditioner controller turns OFF compressor clutch relay, since refrigerant
controller pressure is abnormal.
(The air conditioner compressor stops)
Problem on • The air conditioner (cooling) does not operate.
machine
• For each connector and other parts, see "Parts and connectors layout".
pins).
must be replaced.
Defective 1. See "Testing (dual) pressure switch for refrigerant".
1 refrigerant (dual)
k When replacing the dual pressure switch, be sure to collect refrigerant in
pressure switch
advance. See "Precautions for refrigerant".
Breaking of
2. Disconnect connector AC01 and P17.
harness
Between P17 (female) (1) and AC01
2 (Wire breakage or (female) (6) Max. 1 z
defective contact of Resistance Between P17 (female) (2) and ground
connectors) Max. 1 z
a Looseness and rust of T06
4
conditioner unit
Circuit diagram related to (dual) pressure switch for refrigerant
80-66 PC490LC-10
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)
A-1 Troubleshooting for power supply system (Air conditioner does not
operate) (PC400-FJ0-400-A-Z0-A)
Failure • Air conditioner does not operate due to power supply system failure.
Problem on • [DAZQKR] is displayed on the operation screen of machine monitor.
machine • No air blows out (Blower motor does not rotate).
• If failure code [DAZQKR] is displayed on the machine monitor, perform this
troubleshooting first.
a The machine monitor, engine controller, power train controller, and air conditioner
controller are connected via CAN communication.
• [DAZQKR] is displayed on the operation screen of machine monitor in the following
cases. 1. and 2. of these will be covered here.
1. The air conditioner controller is receiving no power.
2. The air conditioner controller is malfunctioning.
3. No communication is possible between the air conditioner controller and the machine
monitor.
a For 3., see failure code [DAZQKR].
• Turn the starting switch ON, and check whether failure code [DAZQKR] for an abnormality
Related in CAN communication is displayed. An abnormality in CAN communication refers to the
information state in which CAN communication between the air conditioner controller on the air
conditioner unit and the machine monitor is disabled.
• Referring to "Parts and connectors layout", ensure that fuse No.14 (5A) in fuse box F01 is
not blown.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• For each connector, see "Parts and connectors layout".
• In cases where fuses are blown when the A/C switch is pressed, see "A-2
Troubleshooting for compressor and refrigerant system."
• Since T-adapter is not provided for the connector ACECU of the air conditioner controller
and the pin size is small, use the intermediate connector for troubleshooting (T-adapter is
also not provided for the intermediate connector, however, the pin size is larger).
• When replacing the air conditioner wiring harness between connector ACECU of the air
conditioner controller and the intermediate connector, you must replace the entire air
conditioner unit.
Defective wiring harness 2. Set battery disconnect switch to OFF position.
1 (ground) 3. Disconnect connector AC02.
Between wiring harness side (1) (black) of
Resistance AC02 and chassis ground Max. 1 z

2 Blown fuse 2. Referring to "Parts and connectors layout", check fuse No.14 (5A) in
fuse box F01.
a If fuse described in related information is blown, replace it.
2. Set battery disconnect switch to OFF position.
3. Disconnect connector AC02.
3 Defective wiring harness 4. Set battery disconnect switch to ON position.
Between AC02 (female) (4) (red) and (1) 20 to 30
Voltage V
(black)
PC490LC-10 80-67
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

a If a fuse is blown again in the above test, perform the following
procedure.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
4 2. Set battery disconnect switch to OFF position.
(contact with ground circuit) 3. Disconnect connector AC02.
4. Remove fuse No.14 in fuse box F01.
Between ground and AC02 (female) (4) (red) or Min. 1
Resistance
F01-14. Mz
2. Set battery disconnect switch to OFF position.
5 Open circuit in wiring harness 3. Disconnect connector AC02.
4. Remove fuse No.14 of fuse box F01.
Resistance Between AC02 (female) (4) (red) and F01-14. Max. 1 z
Defective air conditioner Replace the air conditioner controller.
6
controller
If no failure is found by the above checks, the air conditioner unit may
7 Defective air conditioner unit
be defective.
8 Defective machine monitor If no failure is found by above checks, machine monitor is defective.
Circuit diagram related to power supply system
80-68 PC490LC-10
80 Appendix
A-2 Troubleshooting for compressor and refrigerant
system (Air is not cooled)
A-2 Troubleshooting for compressor and refrigerant system (Air is not

cooled) (PC400-FKE-400-A-Z0-A)
Failure Air is not cooled due to compressor or refrigerant system failure.
• When engine is started and A/C switch is pressed on air conditioner screen of machine
Problem on monitor, air is not cooled as displayed on screen.
machine • Air conditioner compressor does not operate.
• Referring to inspection by self-diagnosis function, display the "Electrical Systems" screen
on the machine monitor to check whether an inappropriate refrigerant is being used by
confirming that failure code [879GKX] is displayed. If an inappropriate refrigerant is being
used, the compressor will not be turned on, and air will not be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the
dual pressure switch is not grounded".
• In certain cases, the air conditioner will not turn on at 3°C or lower (normal).
Related • When air does not come out, see "Troubleshooting of blower motor system".
information • For each connector and fuse, see "Parts and connectors layout".
a A T-adapter is provided only for the connector AC03.
conditioner unit.
a This troubleshooting is performed when failure code [879GKX] is
displayed on the "Electrical Systems" screen of the machine monitor.
See failure code [879GKX].
Defective dual pressure a In certain cases, the dual pressure switch may be operating normally and
1 switch system set to OFF position, therefore, if abnormality is indicated (i.e., switch OFF),
attach a pressure gauge to the air conditioner compressor and check the
refrigerant pressure. (See "Troubleshooting with gauge pressure".)
k Before replacing pressure switch, collect refrigerant.
2. Disconnect the connector AC03 from the air conditioner compressor and
connect a T-adapter to the male side.
Defective air conditioner a Ensure connection of air conditioner compressor ground cable (E).
2 compressor (See "Parts and connectors layout".)
Between connector AC03 (male) (1) and the
Approx. 15
Resistance chassis ground (i.e., air conditioner compressor coil
resistance) z
• Referring to "Testing relays", check sound when compressor clutch relay
is turned ON.
Clicking sound is heard. — A
a When A above is abnormal and B below is abnormal and C is normal (if
the relay is normal), go to cause 4.
Defective compressor 2. Disconnect connector R21.
3 clutch relay (does not 3. Use a wire to short-circuit (3) (white) and (5) (red line on yellow base) of
turn ON) connector R21 (wiring harness side). (This forces the compressor to
operate without using the relay.)
Air is cooled. — B
2. Disconnect connector R21.
Between R21 (male) (1) and (2) (coil Approx. 370
Resistance resistance) C
to 530 z
PC490LC-10 80-69
80 Appendix

a Make sure that result of check of cause 2 is normal (air conditioner
compressor is normal).
Between connector R21 (female) (5) and F01-10
Open circuit in wiring Max. 1 z
4 (When dual pressure switch is ON.)
harness
Between connector R21 (female) (3) and chassis
Approx. 15
Resistance ground z
(Air conditioner compressor coil resistance)
Between F01-14 and AC01 (female) (4) 370 to 530
a Relay coil resistance z
Ground fault in wiring a If the fuse is not blown, skip troubleshooting.

5 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the
circuit) female side of AC03.
Resistance Between AC03 (female) (1) and chassis ground Min. 1 Mz
2. Disconnect connectors AC01, AC02, and R21.
6 a Ensure that test result for cause 2 is normal.
harness
Between wiring harness side (2) of connector R21
Resistance and AC02 (female) (2), (3)*, and (4) Min. 1 Mz

Defective air conditioner 4. Display the air conditioner operation screen on the machine monitor and
7
controller press the A/C switch.
Voltage Between connector R21 (female) (2) and ground Max. 1 V
Defective machine 1. Turn starting switch to ON position.

8 monitor 2. Display the air conditioner operation screen on the machine monitor.
(Defective switch) Press A/C switch. "A/C ON" is displayed.
Defective air conditioner If no failure is found by the above checks, the air conditioner unit may be
9
unit defective.
*: For details of pin 3 of AC02, see "A-1 Troubleshooting for power supply system (Air conditioner does not
operate)".
80-70 PC490LC-10
80 Appendix
Circuit diagram related to compressor and refrigerant system
PC490LC-10 80-71
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal) (PC400-FK3-400-A-Z0-A)
Failure • No air comes out or air flow is abnormal due to blower motor system failure.
• LCD of machine monitor on air conditioner operation screen lights up normally but air does
Problem on not come out.
machine • Air flow does not match fan switch setting on air conditioner operation screen.
• This failure is not checked with self-diagnosis function.
• In cases where the blown-air volume begins to behave in an unpredictable manner after a
certain while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1. Defective compressor clutch relay (remains turned ON) (see Item 3-A of "A-2
Troubleshooting for compressor and refrigerant system")
2. Evaporator temperature sensor mounting holder has come off (replace air conditioner
unit).
3. Improper adjustment of expansion valve (replace air conditioner unit)
• When air comes out, fuses and motor are normal, and failure of wiring harness is unlikely.
• For each connector and power transistor, see "Parts and connectors layout".
Related a Since the power transistor is located at the rear of the air conditioner unit, its
information troubleshooting or troubleshooting by disconnecting connector (2) is not available while it
is installed on the machine.
• When air comes out but air flow is abnormal during heating, the power transistor is
defective. In this case replace the air conditioner unit.
a The power transistor and blower motor cannot be replaced unless the air conditioner unit is
once removed.
conditioner unit.
Defective fuse No. 10 in If fuse is blown, circuit probably has ground fault.
1
fuse box F01
Defective power 2. Replace power transistor.
2
transistor a a If air comes out and air flow can be adjusted, the original power
transistor is defective.
Breaking of harness 1. Turn starting switch to OFF position.
(Wire breakage or 2. Disconnect connector AC02.
3
defective contact of 3. Remove fuse No. 10 of fuse box F01.
connectors) Resistance AC02 (female) (2) and F01-10 Max. 1 z
Ground fault in harness 1. Turn starting switch to OFF position.
2. Disconnect connectors AC02 and AC04.
4 (contact with ground
3. Remove fuse No. 10 of F01.
circuit)
Resistance Between AC02 (female) (2) or F01-10 and ground Max. 1 z
If no failures are found by the above checks, the air conditioner controller
Defective air conditioner may be defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)
Defective air conditioner If no failure is found by the above checks, the air conditioner unit may be
6
unit defective.
80-72 PC490LC-10
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
Circuit diagram related to blower motor system
PC490LC-10 80-73
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
A-4 Troubleshooting for FRESH/RECIRC air changeover (PC400-FKF-400-A-Z0-A)
Failure • FRESH/RECIRC air changeover does not work.

• When FRESH/RECIRC air selector switch of machine monitor is operated, recirculated or
Problem on fresh air does not change over.
machine (FRESH/RECIRC air changeover door (damper) does not rotate)
• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Operate FRESH/RECIRC air selector switch and check operation of FRESH/RECIRC air
changeover door (damper). For details, see "Testing FRESH/RECIRC air changeover".
• For each connector, see "Parts and connectors layout".
a The T-adapter is not prepared for the connector.
Related also not provided for the intermediate connector, however, the pin size is larger).
information • When replacing the air conditioner wiring harness between connector ACECU of the air
conditioner unit.
• Check whether this failure code is displayed on the electrical system abnormality record
screen in service mode of the machine monitor.
• Troubleshooting cannot be performed since the connector portion of the servomotor
cannot be checked while it is installed on machine.
Defective fuse No. 19 in fuse If fuse is blown, circuit probably has ground fault.
1
box F01
a Connector [5] installed on machine cannot be disconnected since it
is on the rear side of the air conditioner unit.
2 (wire breakage or defective 2. Disconnect connector AC02.
contact of connector) 3. Remove fuse No. 19 of fuse box F01.
Resis- Between F01-19 and AC02 (female) (3)
Max. 1 z
tance
Ground fault in wiring harness 2. Disconnect connector AC02.
3 3. Remove fuse No. 19 of fuse box F01.
Resis- Between ground and F01-19 or AC02 (female)
(3) Min. 1 Mz
tance
If no failures are found by the above checks, the air conditioner
Defective air conditioner controller may be defective. (Since this is an internal defect,
4
controller troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit
5 Defective air conditioner unit may be defective. (Since this is an internal defect, troubleshooting
Defective machine monitor 2. Display the air conditioner operation screen on the machine
6 monitor.
(defective switch)
Display of Recirc/
Press FRESH/RECIRC air selector switch. Fresh changes.
80-74 PC490LC-10
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
PC490LC-10 80-75
80 Appendix
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure (PC220-3840-362-A-00-A)
Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• Pressure of high-pressure line is too high: Min. approx. 2.5 MPa {25 kg/cm 2}
• Pressure of high-pressure line is too low: Max. approx. 1 MPa {10 kg/cm 2}
• Pressure of low-pressure line is too high: Min. approx. 0.3 MPa {3 kg/cm 2}
• Pressure of low-pressure line is too low: Max. approx. 0.05 MPa {0.5 kg/cm 2}
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-pressure line is abnormal.
[Measurement condition for pressure]
Item Condition value
Ambient temperature 25 to 50 °C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Cool-Max
• Dual pressure switch
a The switch is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-76 PC490LC-10
80 Appendix
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If any problem (poor cooling) is recognized, the cause
is in other system.
Pressure is normal Pressure of high-pressure line: Approx. 1.5 to -1.7 ―
MPa {15 to 17 kg/cm2}
Pressure of low-pressure line: Approx. 0.13 to 0.2
MPa {1.3 to 2.0 kg/cm2}
Collect refrigerant, then fill
Bubbles can be seen
Insufficient refrigerant up with proper quantity of
through sight glass. *1, *3
refrigerant again. *2
Temperature difference is
recognized between inlet
Clogging of receiver drier and outlet pipes of Replace *2
receiver drier.
Tank is frosty.
Clogging of expansion Expansion valve is frosty. Clean or replace *2
valve
Gas leakage at
<Pressure of both high- Low-pressure line gauge Replace *2
thermoprobe of expansion
pressure and low- reads vacuum.
valve
pressure lines are too
Evaporator is frozen.
low>
Flow rate of refrigerant is Repair or replace
Low-pressure line gauge Defective evaporator
reduced due to freezing.
reads vacuum temperature sensor or Replace receiver drier.
defective contact of (If air conditioner is set to
sensor (coming off of Cool Max. and HI fan
up with proper quantity of
mounting clip) speed modes, later its
cooling performance
lowers.)
Piping between receiver
drier and compressor is
clogged or crushed.
Clogged or crushed piping Clean or replace *2
If clogged completely, low-
pressure line gauge reads
vacuum
Filling of too much
Connect gauge manifold. up with proper quantity of
refrigerant
Check condenser for dirt, Clean condenser, repair
Defective cooling of fins for clogging or fins, or repair or replace
condenser crushing, and cooling fan cooling fan *2
<Pressure of both high- for defective rotation.
pressure and low- Defective adjustment of
pressure lines are too expansion valve Bubbles can be seen
high> Replace *2
(Valve is excessively through sight glass. *3
opened.)
Evacuate air from air
Air sucked in cooling Bubbles can be seen conditioner and then fill up
cycle parts through sight glass. *3 with proper quantity of
PC490LC-10 80-77
80 Appendix
Indicated gauge pressure Cause Check method Remedy

<Pressure of high- Piping between Remarkable temperature Clean inside of cooling
pressure line is too high compressor and difference is recognized cycle parts or replace
and that of low-pressure condenser is Clogged or across clogged part. them.*2
line is too low> crushed.
Pressures of high-
pressure and low-
<Pressure of high- pressure lines are almost
Defective compressor
pressure line is too low the same while
(compression trouble of Replace *2
and that of low-pressure compressor is running.
compressor)
line is too high>
Compressor has seized
and is extremely hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for
refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant.
*3: Sight glass is on the air conditioner hose near the condenser.
80-78 PC490LC-10
80 Appendix
Connection of service tool
Connection of service tool (PC400-S100-730-P-00-A)
k Place the machine on a level surface, lower the work equipment to the ground so that it is stable,
k Turn the battery disconnect switch to OFF position, and remove the key.
a Following service tool kit is used for work with refrigerant R134a.
Symbol Part No. Part name
X 799-703-1200 Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): Red high-pressure line charging hose
(3): Blue low-pressure line charging hose
(4): Large diameter quick joint (for high-pressure line)
(5): Small diameter quick joint (for low-pressure line)
(a): Note that the threads are coarse and the hoses are relatively easy to loosen.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect red high-pressure line charging hose (2) to the gauge manifold (1) (HI side) and blue low-
pressure line charging hose (3) to the gauge manifold (1) (LO side).
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
PC490LC-10 80-79
80 Appendix
Connection of service tool
A: From operator's cab

B: To condenser
80-80 PC490LC-10
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
Precautions for disconnecting and connecting air conditioner

piping (PC300-K5B0-924-K-00-A)
Precautions for disconnecting
k Collect the refrigerant (Air conditioner gas: R134a) from air conditioner circuit before
disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or
receiver drier and so on.
a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working cloth
with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
• When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches.
Use one wrench to fix and use the other one to loosen the nuts.
Precautions for connecting
• When connecting piping, apply compressor oil (ND-OIL8) for R134a to its O-rings. (See item 4 of
"Handling compressor oil")
Do not apply oil to the threads of a bolt, nut or union, however.
• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it,
use a soft tool (such as a toothpick) so that the piping will not be damaged.
• Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers.
• Be sure to use two wrenches to tighten each nut. Use one wrench to fix and tighten the nut with the other
wrench to the specified torque (Use a torque wrench for tightening).
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
3.9 to 6.9 {0.4 to 0.7} (Receiver drier)
M6 x 1.0
8 to 12 {0.8 to 1.2} (Air conditioner unit and compressor)
M16 x 1.5 12 to 15 (1.2 to 1.5)
M22 x 1.5 20 to 25 {2.0 to 2.5}
M24 x 1.5 30 to 35 {3.1 to 3.6}
PC490LC-10 80-81
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
80-82 PC490LC-10
80 Appendix
Handling of compressor oil
Handling of compressor oil (PC300-K594-212-K-00-A)

1. Compressor oil management (DENSO: ND-OIL8 for R134a)
Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following
types of problem can occur if the amount in the system is too high or too low.
Condition Content
Insufficiency of oil Lubrication trouble and seizure of compressor
Cooling trouble (Excessive oil stick to parts and lower heat exchange
Excess of oil performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2. Filling compressor oil

k Refrigerant is potentially hazardous to health and to the environment. Before disconnecting air
conditioner hoses, therefore, refrigerant should be collected in accordance with "Precautions for
connecting air conditioner piping."
a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized.
Be sure to use an oil suitable for R134a (DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic, and therefore, the cap must be immediately closed after
use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (except
a baked finish) as it may dissolve these plastics.
Check compressor oil in the following cases, and then add new oil if necessary.
• When much refrigerant is discharged because of leakage.
• When the compressor is troubled and replaced.
(See 3 below)
• When a cycle parts such as condenser, receiver drier, evaporator unit, etc. is replaced.
• Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (between M24 joint and cab) Approx. 20
Hose (compressor to M24 joint) Approx. 10
Hose (compressor to M22 joint) Approx. 30
Hose (between M22 joint and condenser) Approx. 10
Hose (Condenser – Receiver dryer) Approx. 5
Hose (Cab – Receiver drier) Approx. 20
PC490LC-10 80-83
80 Appendix
Handling of compressor oil
3. Replacement of compressor
• In case of compressor seizure or breakage.
Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
In this case, flush the air conditioner circuit and replace the compressor and receiver drier.
The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new
compressor with the oil of the specified quantity (180 cc) filled in it.
• Other cases
a New compressor contains compressor oil of 180 cc in it.
1. Prepare an oil container and drain oil from the old compressor.
2. Measure the quantity of the drained oil with a measuring cylinder, and note the quantity or mark the level.
3. Drain below-mentioned quantity of oil from the new compressor.

Quantity to be drained = 180 cc - "Noted quantity"
Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new
compressor would be 150 cc (i.e., 180 - 30 cc).
4. Applying compressor oil to O-rings

Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in order to
prevent the leakage of refrigerant.
80-84 PC490LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC490LC-10
Model Serial Number
90 Diagrams and drawings

10 90 Diagrams and drawings
PC490LC-10 90-1
Table of contents

90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram .............................................................................................................. 90-11
Symbols in electric circuit diagram ....................................................................................... 90-11
Electrical circuit diagram ..................................................................................................... 90-15
Electric circuit diagram for air conditioner unit ....................................................................... 90-27
90-2 PC490LC-10
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram (ALL-C000-001-K-90-A)
Symbols in hydraulic circuit diagram (PC220-0000-007-K-00-A)
(Rev. 2013/09)
Symbols Substances
Main piping line
Pilot or drain line
Flexible pipe (hose etc.)
Lines intersecting without jointing
Lines jointing (junction with a black dot)
Direction of flow
Throttle in passage
Variable
Electricity
Spring
Take-off port
Take-off port and pressure gauge
PC490LC-10 90-3
Symbols Substances
Check valve
Suction (with strainer)
Tank and return pipe
Filter
Oil cooler
Stop valve
Drive shaft (unidirectional)
Drive shaft (bidirectional)
Hydraulic pump
Note: Black triangle shows outlet port
Variable capacity hydraulic pump
Hydraulic motor
Note: Two black triangles in the figure show direction of oil entering
hydraulic motor depending on the oil entry port, the direction of rotation is
reversed.
Servo piston
PPC valve
90-4 PC490LC-10
Symbols Substances
Control valve
Single-acting solenoid valve
Single-acting proportional solenoid valve
Hydraulic pilot valve
Hydraulic two-stage pilot valve
Lock valve
Drain valve
Pressure regulator valve, Safety valve, Abnormal pressure prevention

valve
Pressure regulator valve, Safety valve, Abnormal pressure prevention

valve
(when the figure shows air pressure, being released to atmosphere)
Bypass valve
Accumulator
PC490LC-10 90-5
Symbols Substances
Cylinder
Component group
90-6 PC490LC-10
Hydraulic circuit diagram (1/2) Hydraulic circuit diagram (1/2)
PC490-10, PC490LC-10
PC490-10, PC490LC-10
a This figure shows PC490-10, PC490LC-10. As for the control valve portion, however, see"Hydraulic circuit diagram (2/2)".
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC490-10, PC490LC-10 90-7

Hydraulic circuit diagram (2/2) Hydraulic circuit diagram (2/2)
PC490-10, PC490LC-10
PC490-10, PC490LC-10
a This figure shows PC490-10, PC490LC-10.
PC490-10, PC490LC-10 90-9

Symbols in electric circuit diagram
Electric circuit diagram (ALL-0000-001-K-90-A)
Symbols in electric circuit diagram (PC220-0000-008-K-00-A)
(Rev. 2013/09)
Symbols Substances
Electric wire
Electric wire (wires intersecting without connecting)
Electric wire (wires intersecting and connecting (junction) with a black

dot)
Electric wire (bundled drawing style)
Terminal
Chassis ground
Chassis ground using terminal
Contact, Switch
Push-button type switch (N.O. type)

N.O.: Normally Open
Push-button type switch (N.C. type)

N.C.: Normally Close
Pull-button type switch (N.O. type)

N.O.: Normally Open
Pull-button type switch (N.C. type)

PC490LC-10 90-11
Symbols Substances
Variable
Resistor
Variable resistor
Diode
Light emitting diode (LED)
Photo diode
Constant voltage diode (zener diode)
Transistor (PNP type)
Transistor (NPN type)
Coil
Battery
Fuse
Connector
Note:
• Concave side of connecting portion (left in figure): female
• Convex side of connecting portion (right in figure): male
a Figure shows a line disconnection status
90-12 PC490LC-10
Symbols Substances
Plug and receptacle type connector (left: male, right: female)

a Figure shows a line connection status
Solenoid
Motor
Lamp
Pressure switch (N.O. type)

N.O.: Normally Open
Pressure switch (N.C. type)

Potentiometer, Fuel control dial
Temperature sensor
Starting switch
Back up alarm
Horn
Buzzer
Antenna
PC490LC-10 90-13
90-14 PC490LC-10
Electrical circuit diagram (1/6) Electrical circuit diagram (1/6)
PC490-10, PC490LC-10
PC490-10, PC490LC-10
PC490-10, PC490LC-10 90-15

PC490-10, PC490LC-10
PC490-10, PC490LC-10
PC490-10, PC490LC-10 90-17

PC490-10, PC490LC-10
PC490-10, PC490LC-10
PC490-10, PC490LC-10 90-19

PC490-10, PC490LC-10
PC490-10, PC490LC-10
PC490-10, PC490LC-10 90-21

PC490-10, PC490LC-10
PC490-10, PC490LC-10
PC490-10, PC490LC-10 90-23

PC490-10, PC490LC-10
PC490-10, PC490LC-10
PC490-10, PC490LC-10 90-25

Electrical circuit diagram for air conditioner unit Electrical circuit diagram for air conditioner unit
PC490-10, PC490LC-10
PC490LC-10
a In the drawing, full line shows air conditioner wiring harness, and dashed line shows cab and chassis wiring harness. (For the detail of cab and chassis harness, see "Electrical circuit diagram")
a In the drawing, dot and dash line shows machine monitor wiring, and using twisted line (AVS 0.5 x 2, pitch 45 mm or less).
PC490-10, PC490LC-10 90-27

INDEX
INDEX
A D
A-2 Troubleshooting for compressor and Disassembly and assembly of carrier roller ... 50-107
refrigerant system (Air is not cooled) ............. 80-69 Disassembly and assembly of center swivel
A-1 Troubleshooting for power supply system joint.......................................................... 50-115
(Air conditioner does not operate) ................. 80-67 Disassembly and assembly of control valve .. 50-128
A-3 Troubleshooting for blower motor system Disassembly and assembly of final drive......... 50-79
(No air comes out or air flow is abnormal) ...... 80-72 Disassembly and assembly of idler............... 50-101
A-4 Troubleshooting for FRESH/RECIRC air Disassembly and assembly of idler cushion .. 50-104
changeover ................................................ 80-74 Disassembly and assembly of swing
Accumulator ............................................... 10-199 machinery .................................................. 50-89
Adjusting mirrors........................................... 30-78 Disassembly and assembly of track roller ..... 50-106
Adjusting play of work equipment and swing Disassembly and assembly of travel PPC
PPC valves ................................................ 30-63 valve ........................................................ 50-135
Adjusting rearview camera angle ................. 30-150 Disassembly and assembly of work equipment
Air conditioner component ............................... 80-4 cylinder .................................................... 50-140
Air conditioner controller ................................ 80-18 Disassembly and assembly of work equipment
Air conditioner unit ........................................ 80-10 PPC valve ................................................ 50-133
Attachment circuit selector valve ........ 10-194, 60-49 Dual pressure switch..................................... 80-17
B E
Bleeding air from fuel system ......................... 30-26 E-1 Engine does not start (Engine does not
Bleeding air from hydraulic circuit ................... 30-74 crank) ...................................................... 40-584
Breather....................................................... 10-61 E-2 Manual preheater does not operate ........ 40-590
E-3 Automatic preheater does not operate .... 40-593
E-4 While preheater is operating, engine
C preheating monitor does not light up ........... 40-595
Cab mount and cab tipping stopper .............. 10-203 E-5 While starting switch is turned ON,
Carrier roller ................................................. 60-19 machine monitor displays nothing............... 40-597
Center swivel joint............................. 10-197, 60-50 E-6 While starting switch is turned to ON
Check sheet ............................................... 30-159 position (with engine stopped), engine oil
Checking cab tipping stopper......................... 30-77 level monitor lights up in yellow .................. 40-600
Checking engine speed................................... 30-8 E-7 While starting switch is turned to ON
Checking fan pump EPC current .................... 30-67 position (with engine stopped), radiator
Checks before troubleshooting....................... 40-13 coolant level monitor lights up in yellow ....... 40-601
Circuit diagram and arrangement of connector E-8 Engine coolant temperature monitor lights
pins ........................................................... 80-26 up in white while engine is running.............. 40-602
Classification and procedure for E-9 Hydraulic oil temperature monitor lights up
troubleshooting ........................................... 40-38 in white while engine is running .................. 40-603
CLSS........................................................... 10-63 E-10 Charge level monitor lights up in red while
Coating materials list....................................... 50-6 engine is running....................................... 40-604
Compressor ................................................. 80-19 E-11 Fuel level monitor lights up in red while
Condenser ................................................... 80-20 engine is running....................................... 40-605
Configuration and function of refrigeration E-12 Air cleaner clogging monitor lights up in
cycle ............................................................ 80-7 yellow while engine is running .................... 40-606
Connection of service tool ............................. 80-79 E-13 Engine coolant temperature monitor
Connection table of fuse box........................ 40-101 lights up in red while engine is running ........ 40-607
Connector contact identification ..................... 40-57 E-14 Hydraulic oil temperature monitor lights
Connector list and layout ............................... 40-46 up in red while engine is running................. 40-608
Control valve ...................................... 10-91, 60-25 E-15 Engine oil pressure monitor lights up in
Conversion table .......................................... 00-60 red while engine is running......................... 40-609
Cooling fan motor .................................10-39, 60-7 E-16 Fuel gauge display does not move from
Cooling fan pump .................................10-29, 60-5 minimum or maximum ............................... 40-610
Cooling system.....................................10-26, 60-4 E-17 Display of fuel gauge differs from actual
fuel level................................................... 40-611
PC490LC-10 1
INDEX
E-18 Engine coolant temperature gauge E-46 When window washer switch is operated,
display does not move from minimum or window washer does not operate................ 40-648
maximum ................................................. 40-612 E-47 Boom LOWER indicator is not displayed
E-19 Display of engine coolant temperature properly with monitoring function ................ 40-649
gauge differs from actual coolant temperature ...40- E-48 Arm OUT indicator is not displayed
613 properly with monitoring function ................ 40-650
E-20 Hydraulic oil temperature gauge display E-49 Arm IN indicator is not displayed properly
does not move from minimum or maximum . 40-614 with monitoring function ............................. 40-651
E-21 Display of hydraulic oil temperature E-50 Boom RAISE indicator is not displayed
gauge differs from actual oil temperature..... 40-616 properly with monitoring function ................ 40-652
E-22 Machine monitor does not display E-51 Bucket CURL indicator is not displayed
partially .................................................... 40-617 properly with monitoring function ................ 40-653
E-23 Function switch does not operate ......... 40-618 E-52 Bucket DUMP indicator is not displayed
E-24 Automatic warm-up system does not properly with monitoring function ................ 40-654
work (in cold weather)................................ 40-619 E-53 Swing indicator is not displayed properly
E-25 When auto-decelerator switch is with monitoring function ............................. 40-655
operated, auto-decelerator monitor does not E-54 Travel indicator is not displayed properly
light up or does not go off........................... 40-620 with monitoring function ............................. 40-656
E-26 Auto-decelerator is not operated or E-55 Service indicator is not displayed properly
canceled with lever.................................... 40-621 with monitoring function ............................. 40-657
E-27 When working mode switch is operated, E-56 Attachment hydraulic circuit cannot be
working mode selection screen is not changed ................................................... 40-659
displayed.................................................. 40-622 E-57 KOMTRAX system does not operate
E-28 When working mode is changed, setting properly.................................................... 40-660
of engine and hydraulic pump is not changed ....40- E-58 Machine push-up function cannot be
623 canceled .................................................. 40-662
E-29 When travel speed switch is operated, E-59 Machine push-up function does not
travel speed monitor does not change......... 40-624 operate .................................................... 40-664
E-30 When travel speed selection is changed, EGR cooler .................................................. 10-16
actual travel speed does not change........... 40-625 EGR system circuit diagram .......................... 10-13
E-31 Alarm buzzer cannot be canceled......... 40-626 EGR system piping drawing........................... 10-11
E-32 When starting switch is turned OFF, EGR valve ................................................... 10-14
service meter is not displayed .................... 40-627 Electric circuit diagram for air conditioner unit .. 90-27
E-33 Machine monitor cannot be set in service Electrical circuit diagram................................ 90-15
mode ....................................................... 40-628 Electrical control system.............................. 10-205
E-34 All of work equipments, swing, and travel Engine controller......................................... 10-243
mechanism do not move............................ 40-629 Engine mount ................................................. 60-3
E-35 All of work equipment, swing, and travel Engine-related parts........................................ 10-3
mechanism do not lock .............................. 40-631 Explanation of terms for maintenance standard ...00-
E-36 When swing brake cancel switch is set to 23
CANCEL position, machine cannot swing ... 40-632
E-37 Swing brake does not operate while
swing parking brake cancel switch is set to
F
NORMAL position ..................................... 40-634 Failure code [879AKA] A/C Inner sensor Open
E-38 One-touch power maximizing function Circuit ........................................................ 80-54
does not operate properly, or indicator not Failure code [879AKA] A/C Inner Sensor Open
displayed on monitor ................................. 40-636 Circuit ...................................................... 40-117
E-39 One-touch power maximizing function is Failure code [879AKB] A/C Inner sensor Short
not cancelled ............................................ 40-638 Circuit ........................................................ 80-55
E-40 Alarm does not sound during travel....... 40-639 Failure code [879AKB] A/C Inner Sensor Short
E-41 Alarm does not stop sounding while Circuit ...................................................... 40-118
machine is stopped ................................... 40-641 Failure code [879BKA] A/C Outer Sensor
E-42 Horn does not sound ........................... 40-642 Open Circuit ............................................. 40-119
E-43 Horn does not stop sounding ............... 40-644 Failure code [879BKB] A/C Outer Sensor Short
E-44 When wiper switch is operated, wiper Circuit ...................................................... 40-120
monitor does not light up or go off ............... 40-645 Failure code [879CKA] Ventilating sensor
E-45 When wiper switch is operated, Open Circuit ............................................... 80-60
windshield wiper does not operate .............. 40-646 Failure code [879CKA] Ventilating Sensor
Open Circuit ............................................. 40-121
2 PC490LC-10
INDEX
Failure code [879CKB] Ventilating sensor Failure code [CA1691] Regeneration

Short Circuit ............................................... 80-61 Ineffective................................................. 40-237
Failure code [879CKB] Ventilating Sensor Failure code [CA1695] Sens supply 5 volt high
Short Circuit ............................................. 40-122 error......................................................... 40-240
Failure code [879DKZ] Sunlight Sensor Open Failure code [CA1696] Sens supply 5 volt low
Or Short Circuit ......................................... 40-123 error......................................................... 40-241
Failure code [879EMC] Ventilating Damper Failure code [CA1843] Crankcase Pressure
Abnormality ................................................ 80-64 Sensor High Error ..................................... 40-243
Failure code [879EMC] Ventilation Damper Failure code [CA1844] Crankcase Press
Abnormality .............................................. 40-124 Sensor Low Error ...................................... 40-245
Failure code [879FMC] Air Mix Damper Failure code [CA187] Sensor 2 Supply Volt
Abnormality .................................... 40-125, 80-65 Low Error ................................................. 40-165
Failure code [879GKX] Refrigerant Failure code [CA1879] KDPF Delta Pressure
Abnormality .............................................. 40-126 Sensor High Error ..................................... 40-247
Failure code [989L00] Engine Controller Lock Failure code [CA1881] KDPF Delta Pressure
Caution 1 ................................................. 40-127 Sensor Low Error ...................................... 40-249
Failure code [989M00] Engine Controller Lock Failure code [CA1883] KDPF Delta Pressure
Caution 2 ................................................. 40-128 Sensor In Range Error............................... 40-251
Failure code [989N00] Engine Controller Lock Failure code [CA1921] KDPF Soot Load High
Caution 3 ................................................. 40-129 Error 1...................................................... 40-254
Failure code [A1U0N3] HC Desorb Request 1 .....40- Failure code [CA1922] KDPF Soot Load High
130 Error 2...................................................... 40-257
Failure code [A1U0N4] HC Desorb Request 2 .....40- Failure code [CA1923] Dosing Fuel Valve 1
132 High Error................................................. 40-262
Failure code [AA10NX] Air Cleaner Clogging. 40-134 Failure code [CA1924] Dosing Fuel Valve 1
Failure code [AB00KE] Charge Voltage Low . 40-136 Low Error ................................................. 40-264
Failure code [B@BAZG] Eng Oil Press Low .. 40-138 Failure code [CA1925] Dosing Fuel Valve 1 In
Failure code [B@BAZK] Eng Oil Level Low ... 40-139 Range Error.............................................. 40-266
Failure code [B@BCNS] Eng Water Overheat .....40- Failure code [CA1927] Dosing Fuel Press
140 Sens High Error ........................................ 40-268
Failure code [B@BCZK] Eng Water Level Low ....40- Failure code [CA1928] Dosing Fuel Press
141 Sens Low Error ......................................... 40-270
Failure code [B@HANS] Hyd Oil Overheat.... 40-143 Failure code [CA1942] Crankcase Press Sens
Failure code [CA1117] Persistent Data Lost In Range Error .......................................... 40-272
Error ........................................................ 40-233 Failure code [CA1963] Dosing Fuel Valve 1
Failure code [CA115] Eng Ne and Bkup Speed Servo Error............................................... 40-273
Sens Error ................................................ 40-144 Failure code [CA1977] Fuel Doser Open/Short
Failure code [CA122] Chg Air Press Sensor Error ........................................................ 40-276
High Error................................................. 40-145 Failure code [CA1993] KDPF Delta Pressure
Failure code [CA123] Chg Air Press Sensor Low Error ................................................. 40-278
Low Error ................................................. 40-147 Failure code [CA2185] Throt Sensor Sup Volt
Failure code [CA131] Throttle Sensor High High Error................................................. 40-280
Error ........................................................ 40-149 Failure code [CA2186] Throt Sensor Sup Volt
Failure code [CA132] Throttle Sensor Low Low Error ................................................. 40-282
Error ........................................................ 40-151 Failure code [CA221] Ambient Press Sens
Failure code [CA135] Eng Oil Press Sensor High Error................................................. 40-167
High Error................................................. 40-153 Failure code [CA222] Ambient Press Sens Low
Failure code [CA141] Eng Oil Press Sensor Error ........................................................ 40-169
Low Error ................................................. 40-155 Failure code [CA2249] Rail Press Very Low
Failure code [CA144] Coolant Temp Sens High Error 2...................................................... 40-284
Error ........................................................ 40-157 Failure code [CA2265] Fuel feed pump open
Failure code [CA145] Coolant Temp Sens Low circuit error ............................................... 40-285
Error ........................................................ 40-159 Failure code [CA2266] Fuel feed pump short
Failure code [CA153] Chg Air Temp Sensor circuit error ............................................... 40-287
High Error................................................. 40-161 Failure code [CA227] Sensor 2 Supply Volt
Failure code [CA154] Chg Air Temp Sensor High Error................................................. 40-171
Low Error ................................................. 40-163 Failure code [CA2271] EGR Valve Pos Sens
Failure code [CA1664] KDOC Malfunction .... 40-234 High Error................................................. 40-289
PC490LC-10 3
INDEX
Failure code [CA2272] EGR Valve Pos Sens Failure code [CA331] Inj #2(L#2) Open/Short
Low Error ................................................. 40-291 Error ........................................................ 40-187
Failure code [CA234] Eng Overspeed........... 40-172 Failure code [CA332] Inj #4(L#4) Open/Short
Failure code [CA2349] EGR Valve Solenoid Error ........................................................ 40-189
Open Error ............................................... 40-293 Failure code [CA343] ECM Critical Internal
Failure code [CA2353] EGR Valve Solenoid Failure ..................................................... 40-191
Short Error................................................ 40-295 Failure code [CA351] Injectors Drive Circuit
Failure code [CA2357] EGR Valve Servo Error ....40- Error ........................................................ 40-192
297 Failure code [CA352] Sensor 1 Supply Volt
Failure code [CA238] Ne Speed Sensor Low Error ................................................. 40-193
Supply Volt Error ....................................... 40-173 Failure code [CA356] Mass Air Flow Sensor
Failure code [CA2381] KVGT Pos Sens High High Error................................................. 40-195
Error ........................................................ 40-298 Failure code [CA357] Mass Air Flow Sensor
Failure code [CA2382] KVGT Pos Sens Low Low Error ................................................. 40-197
Error ........................................................ 40-300 Failure code [CA386] Sensor 1 Supply Volt
Failure code [CA2383] KVGT Solenoid Open High Error................................................. 40-199
Error ........................................................ 40-302 Failure code [CA441] Battery Voltage Low
Failure code [CA2386] KVGT Solenoid Short Error ........................................................ 40-200
Error ........................................................ 40-304 Failure code [CA442] Battery Voltage High
Failure code [CA2387] KVGT Servo Error ..... 40-306 Error ........................................................ 40-202
Failure code [CA239] Ne Speed Sens Supply Failure code [CA449] Rail Press Very High
Volt High Error .......................................... 40-174 Error ........................................................ 40-203
Failure code [CA2555] Grid Htr Relay Open Failure code [CA451] Rail Press Sensor High
Circuit Error .............................................. 40-307 Error ........................................................ 40-204
Failure code [CA2556] Grid Htr Relay Short Failure code [CA452] Rail Press Sensor Low
Circuit Error .............................................. 40-309 Error ........................................................ 40-206
Failure code [CA2637] KDOC Face Plugging 40-311 Failure code [CA515] Rail Press Sens Sup Volt
Failure code [CA2639] Manual Stationary High Error Failure code.............................. 40-208
Regeneration Request............................... 40-313 Failure code [CA516] Rail Press Sens Sup Volt
Failure code [CA271] IMV/PCV1 Short Error . 40-175 Low Error ................................................. 40-210
Failure code [CA272] IMV/PCV1 Open Error . 40-176 Failure code [CA553] Rail Press High Error 1 40-212
Failure code [CA273] PCV2 Short Error ........ 40-177 Failure code [CA555] Crankcase Press High
Failure code [CA2732] Dosing Fuel Valve 2 Error 1...................................................... 40-213
High Error................................................. 40-316 Failure code [CA556] Crankcase Press High
Failure code [CA2733] Dosing Fuel Valve 2 Error 2...................................................... 40-214
Low Error ................................................. 40-318 Failure code [CA559] Rail Press Low Error ... 40-215
Failure code [CA274] PCV2 Open Error........ 40-178 Failure code [CA595] Turbo Speed High Error
Failure code [CA2741] Dosing Fuel Valve 2.............................................................. 40-219
Swap Error ............................................... 40-320 Failure code [CA687] Turbo Speed Low Error .....40-
Failure code [CA2765] Inj Trim Data Error ..... 40-321 220
Failure code [CA2878] Dosing Fuel Valve 2 Failure code [CA689] Eng Ne and Speed
Servo Error............................................... 40-322 Sensor Error ............................................. 40-222
Failure code [CA2881] Dosing Fuel Pressure Failure code [CA691] Intake Temperature
Low Error 1............................................... 40-325 Sensor High Error ..................................... 40-224
Failure code [CA3133] KDPF Outlet Pressure Failure code [CA692] Intake Temperature
Sensor High Error ..................................... 40-330 Sensor Low Error ...................................... 40-226
Failure code [CA3167] Fuel Doser Degradation...40- Failure code [CA697] ECM Internal Temp
338 Sensor High Error ..................................... 40-228
Failure code [CA322] Inj #1(L#1) Open/Short Failure code [CA698] ECM Int Temp Sensor
Error ........................................................ 40-179 Low Error ................................................. 40-229
Failure code [CA323] Inj #5(L#5) Open/Short Failure code [CA731] Eng Bkup Speed Sens
Error ........................................................ 40-181 Phase Error .............................................. 40-230
Failure code [CA324] Inj #3(L#3) Open/Short Failure code [CA778] Eng Bkup Speed Sensor
Error ........................................................ 40-183 Error ........................................................ 40-231
Failure code [CA325] Inj #6(L#6) Open/Short Failure code [D110KB] Battery Relay Drive S/C...40-
Error ........................................................ 40-185 403
Failure code [CA3254] KDOC Outlet Temp Failure code [D19JKZ] Personal Code Relay
High Error 1 .............................................. 40-347 Abnormality .............................................. 40-405
Failure code [D811MC] KOMTRAX Error ...... 40-408
4 PC490LC-10
INDEX
Failure code [D862KA] GPS Antenna Open Failure code [DHS8MA] Boom RAISE PPC
Circuit ...................................................... 40-409 Press Sensor Abnormality ......................... 40-472
Failure code [D8ALKA] Operating Lamp Open Failure code [DHS9MA] Boom LOWER Press
Circuit (KOMTRAX)................................... 40-410 Sensor Abnormality................................... 40-475
Failure code [D8ALKB] Operating Lamp Short Failure code [DHSAMA] Swing RH PPC Press
Circuit (KOMTRAX)................................... 40-412 Sensor Abnomality .................................... 40-478
Failure code [D8AQKR] CAN2 Discon Failure code [DHSBMA] Swing LH PPC Press
(KOMTRAX) ............................................. 40-413 Sensor Abnomality .................................... 40-481
Failure code [DA20MC] Pump Controller Failure code [DHSCMA] Arm OUT PPC Press
Malfunction............................................... 40-414 Sensor Abnormality................................... 40-484
Failure code [DA22KK] Pump Solenoid Power Failure code [DHSDMA] Bucket Dump PPC
Low Error ................................................. 40-415 Press Sensor Abnormality ......................... 40-487
Failure code [DA25KP] 5V Sensor1 Power Failure code [DHSFMA] Travel FW L PPC
Abnormality .............................................. 40-417 Press Sensor Abnormality ......................... 40-490
Failure code [DA29KQ] Model Selection Failure code [DHSGMA] Travel FW R PPC
Abnormality .............................................. 40-419 Press Sensor Abnormality ......................... 40-493
Failure code [DA2LKA] Operating Lamp Open Failure code [DHSHMA] Travel BW L PPC
Circuit (Pump Con).................................... 40-422 Press Sensor Abnormality ......................... 40-496
Failure code [DA2LKB] Operating Lamp Short Failure code [DHSJMA] Travel BW R PPC
Circuit (Pump Con).................................... 40-424 Press Sensor Abnormality ......................... 40-499
Failure code [DA2QKR] CAN2 Discon (Pump Failure code [DKR0MA] F pump S/P sensor
Con) ........................................................ 40-425 Abnormality .............................................. 40-502
Failure code [DA2RKR] CAN1 Discon ( Pump Failure code [DKR1MA] R pump S/P sensor
Con) ........................................................ 40-428 Abnormality .............................................. 40-504
Failure code [DAF0MB] Monitor ROM Failure code [DLM3KA] Fan speed sensor:
Abnormality .............................................. 40-429 Open circuit .............................................. 40-506
Failure code [DAF0MC] Monitor Error ........... 40-430 Failure code [DLM3KB] Fan Speed Sensor
Failure code [DAF8KB] Camera Power Supply Short Circuit ............................................. 40-507
Short Circuit ............................................. 40-431 Failure code [DLM3MB] Fan Control Mismatch....40-
Failure code [DAF9KQ] Model Selection 508
Abnormality .............................................. 40-433 Failure code [DR21KX] Camera 2 Picture Rev.
Failure code [DAFGMC] GPS Module Error .. 40-434 Drive Abnormality...................................... 40-509
Failure code [DAFLKA] Operating Lamp Open Failure code [DR31KX] Camera 3 Picture Rev.
Circuit (Monitor) ........................................ 40-435 Drive Abnormality...................................... 40-511
Failure code [DAFLKB] Operating Lamp Short Failure code [DV20KB] Travel Alarm Short
Circuit (Monitor) ........................................ 40-437 Circuit ...................................................... 40-513
Failure code [DAFQKR] CAN2 Discon Failure code [DW43KA] Travel Speed Sol
(Monitor) .................................................. 40-438 Open Circuit ............................................. 40-515
Failure code [DAZ9KQ] AC Model Selection Failure code [DW43KB] Travel Speed Sol
Abnormality .............................................. 40-439 Short Circuit ............................................. 40-517
Failure code [DAZQKR] CAN2 Discon (AC) .. 40-440 Failure code [DW45KA] Swing Brake Sol Open
Failure code [DB2QKR] CAN2 Discon (Engine Circuit ...................................................... 40-519
Con) ........................................................ 40-445 Failure code [DW45KB] Swing Brake Sol Short
Failure code [DB2RKR] CAN1 Discon (Engine Circuit ...................................................... 40-522
Con) ........................................................ 40-450 Failure code [DW7BKA] Fan Reverse Sol
Failure code [DGH2KA] Hyd Oil Temp Sensor Open Circuit ............................................. 40-524
Open ....................................................... 40-455 Failure code [DW7BKB] Fan Reverse Sol
Failure code [DGH2KB] Hyd Oil Sensor Short Short Circuit ............................................. 40-526
Circuit ...................................................... 40-457 Failure code [DWA2KB] Attachment Sol Short
Failure code [DHA4KA] Air Cleaner Clogging Circuit ...................................................... 40-534
Sensor Open Circuit .................................. 40-459 Failure code [DWK0KA] 2-stage Relief Sol
Failure code [DHPAMA] Pump Press Sensor Open Circuit ............................................. 40-536
Abnormality .............................................. 40-461 Failure code [DWK2KB] Variable Back
Failure code [DHPBMA] R Pump Press Sensor Pressure Sol Short Circuit.......................... 40-542
Abnormality .............................................. 40-464 Failure code [DWK8KA] Swing C/O Solenoid
Failure code [DHS3MA] Arm IN PPC Sen. Open Circuit ............................................. 40-544
Abnormality .............................................. 40-467 Failure code [DWK8KB] Swing C/O Solenoid
Failure code [DHS4MA] Bucket CURL PPC Short Circuit ............................................. 40-546
Press Sensor Abnormality ......................... 40-469
PC490LC-10 5
INDEX
Failure code [DXA8KA] PC-EPC (F) Sol Open Failure code [DW91KA] Travel Junction Sol
Circuit ...................................................... 40-552 Open Circuit ............................................. 40-528
Failure code [DXA8KB] PC-EPC (F) Sol Short Failure code [DW91KB] Travel Junction Sol
Circuit ...................................................... 40-554 Short Circuit ............................................. 40-530
Failure code [DXE0KA] LS-EPC Sol Open Failure code [DWA2KA] Attachment Sol Open
Circuit ...................................................... 40-560 Circuit ...................................................... 40-532
Failure code [DXE4KA] Service Current EPC Failure code [DWK0KB] 2-stage Relief Sol
Disc. ........................................................ 40-564 Short Circuit ............................................. 40-538
Failure code [DXE4KB] Service Current EPC Failure code [DWK2KA] Variable Back
S/C .......................................................... 40-565 Pressure Sol Open Circuit.......................... 40-540
Failure code [DY2CKB] Washer Drive Short Failure code [DX16KA] Fan Pump EPC Sol
Circuit ...................................................... 40-578 Open Circuit ............................................. 40-548
Failure code [879BKA] A/C Outer sensor Open Failure code [DX16KB] Fan Pump EPC Sol
Circuit ........................................................ 80-56 Short Circuit ............................................. 40-550
Failure code [879BKB] A/C Outer sensor Short Failure code [DXA9KA] PC-EPC (R) Sol Open
Circuit ........................................................ 80-58 Circuit ...................................................... 40-556
Failure code [879DKZ] Sunlight sensor Open Failure code [DXA9KB] PC-EPC (R) Sol Short
or Short Circuit............................................ 80-62 Circuit ...................................................... 40-558
Failure code [879GKX] Refrigerant Failure code [DXE0KB] LS-EPC Sol Short
Abnormality ................................................ 80-66 Circuit ...................................................... 40-562
Failure mode and cause table ...................... 40-668 Failure code [DXE5KA] Merge-divider Main Sol
Failure code [CA3134] KDPF Outlet Pressure Open Circuit ............................................. 40-566
Sensor Low Error ...................................... 40-332 Failure code [DXE5KB] Merge-divider Main Sol
Failure code [CA3135] KDPF Outlet Pressure Short Circuit ............................................. 40-568
Sensor In Range Error............................... 40-334 Failure code [DXE6KA] Merge-divider LS Sol
Failure code [CA3251] KDOC Inlet Open Circuit ............................................. 40-570
Temperature High Error ............................. 40-341 Failure code [DXE6KB] Merge-divider LS Sol
Failure code [CA3253] KDOC Temp Error - Short Circuit ............................................. 40-572
Non Regeneration ..................................... 40-344 Failure code [DY20KA] Wiper Working
Failure code [CA3255] KDPF Temp Error - Non Abnormality .............................................. 40-574
Regeneration............................................ 40-350 Failure code [DY20MA] Wiper Parking
Failure code [CA3256] KDPF Outlet Temp Abnormality .............................................. 40-576
High Error 1 .............................................. 40-354 Failure code [DY2DKB] Wiper Drive (For)
Failure code [CA3311] KDOC Outlet Temp Short........................................................ 40-580
High Error 2 .............................................. 40-357 Failure code [DY2EKB] Wiper Drive (Rev)
Failure code [CA3312] KDPF Outlet Temp Short........................................................ 40-582
High Error 2 .............................................. 40-360 Failure code list related to air conditioner ........ 80-53
Failure code [CA3313] KDOC Inlet Failure codes table ..................................... 40-108
Temperature Sensor Low Error................... 40-363 Final drive .......................................... 10-52, 60-11
Failure code [CA3314] KDOC Inlet Fuel doser cleaning procedure....................... 30-33
Temperature Sensor High Error .................. 40-366
Failure code [CA3315] KDOC Intlet
Temperature Sensor In Range Error ........... 40-370
H
Failure code [CA3316] KDOC Outlet H-1 Speed or power of all work equipment,
Temperature Sensor Low Error................... 40-375 swing, and travel is low. ............................. 40-674
Failure code [CA3317] KDOC Outlet H-2 Engine speed lowers significantly or
Temperature Sensor High Error .................. 40-378 engine stalls ............................................. 40-676
Failure code [CA3318] KDOC Outlet Temp H-3 Any of work equipment, swing and travel
Sensor In Range Error............................... 40-382 does not work ........................................... 40-678
Failure code [CA3319] KDPF Outlet H-4 Unusual sound is heard from around
Temperature Sensor High Error .................. 40-387 hydraulic pump ......................................... 40-679
Failure code [CA3321] KDPF Outlet H-5 Fine control performance or response is
Temperature Sensor Low Error................... 40-391 poor ......................................................... 40-680
Failure code [CA3322] KDPF Outlet Temp H-6 Speed or power of boom is low .............. 40-681
Sensor In Range Error............................... 40-394 H-7 Speed or power of arm is low................. 40-685
Failure code [CA3419] Mass Air Flow Sensor H-8 Speed or power of bucket is low............. 40-689
Power Supply High Error ........................... 40-399 H-9 Work equipment does not move in single
Failure code [CA3421] Mass Air Flow Sensor operation.................................................. 40-692
Power Supply Low Error ............................ 40-401
6 PC490LC-10
INDEX
H-10 Hydraulic drift of work equipment is large ....40- I

693
Idler ............................................................. 60-16
H-11 Time lag of work equipment is large ...... 40-697
Important safety notice .................................. 00-14
H-12 Other work equipment moves when one
Information described in troubleshooting table
of work equipment is relieved ..................... 40-698
(H-mode).................................................. 40-665
H-13 One-touch power maximizing function
Information in troubleshooting table ...... 40-44, 80-52
does not work ........................................... 40-699
Information mentioned in troubleshooting table
H-14 Machine push-up function does not work ....40-
(S mode) .................................................. 40-726
700
Inspection procedure before troubleshooting... 40-15
H-15 In combined operation of work equipment
Isolating the parts causing hydraulic drift in
, equipment having heavier load moves
work equipment .......................................... 30-69
slower. ..................................................... 40-701
H-16 In combined operation of swing and
boom RAISE, boom rising speed is low....... 40-702 K
H-17 Travel speed drops largely in combined
KCCV layout drawing .................................... 10-18
operation of swing and trave ...................... 40-703
KCCV ventilator............................................ 10-20
H-18 Machine does not travel straight........... 40-704
KDPF .......................................................... 10-22
H-19 Travel speed is low ............................. 40-706
KOMTRAX Settings (GPS & Communication
H-20 Machine is hard to steer or travel power
Status) ..................................................... 30-147
is low ....................................................... 40-708
KOMTRAX Settings (terminal setting status) . 30-146
H-21 Travel speed does not change, or travel
KOMTRAX Settings screen (Modem Status) . 30-148
speed is too low or high ............................. 40-710
KOMTRAX system ..................................... 10-272
H-22 One of tracks does not run................... 40-711
KVGT ............................................................ 10-5
H-23 Upper structure does not swing............ 40-712
H-24 Swing acceleration is poor or swing
speed is low ............................................. 40-714 L
H-25 Upper structure overruns excessively
Layout of air conditioner related parts and
when it stops swinging............................... 40-716
connectors ................................................. 80-32
H-26 Shock is large when upper structure
List of abbreviation........................................ 00-55
stops swinging .......................................... 40-718
LS bypass plug........................................... 10-108
H-27 Large unusual noise is heard when upper
structure stops swinging ............................ 40-719
H-28 Swing drift on a slope is large............... 40-720 M
H-29 Attachment circuit cannot be changed .. 40-722
Machine monitor system.............................. 10-254
H-30 Oil flow in attachment circuit cannot be
Main pump ......................................... 10-68, 60-23
controlled ................................................. 40-723
Main relief valve.......................................... 10-143
H-31 Fan speed is abnormal (high, low, or 0
Measuring boost pressure ............................... 30-9
rpm) ......................................................... 40-724
Measuring exhaust gas color ......................... 30-11
H-32 Unusual noise is heard from around fan......40-
Method of disconnecting and connecting of
725
push-pull type coupler ................................. 00-29
Handling battery disconnect switch .............. 30-153
Handling cylinder cutout mode operation ........ 30-29
Handling equipment of fuel system devices..... 00-25 N
Handling no injection cranking operation......... 30-30
No-Injection................................................ 30-145
Handling of compressor oil ............................ 80-83
Handling of electrical equipment .................... 00-32
Handling of hydraulic equipment .................... 00-27 O
Handling of intake system parts ..................... 00-26
Outer temperature sensor.............................. 80-23
Handling voltage circuit of engine controller .. 30-152
Outline of refrigeration cycle ............................ 80-8
How to open the electrical system abnormality
record screen in service mode of the machine
monitor....................................................... 80-39 P
How to read electric wire code ....................... 00-40
How to read the shop manual ........................ 00-21 Parts and connectors layout .......................... 80-31
How to read this manual .................................. 50-4 Pm clinic .................................................... 30-155
Power train................................................... 10-47
Hydraulic circuit diagram ................................. 90-7
PPC valve........................................ 10-172, 60-41
Hydraulic circuit diagram and valve names ... 10-104
Practical use of KOMTRAX............................ 00-48
Hydraulic component layout........................... 10-56
Hydraulic tank .............................................. 10-60
PC490LC-10 7
INDEX
Precautions for disconnecting and connecting Removal and installation of KCCV assembly ... 50-74
air conditioner piping ................................... 80-81 Removal and installation of KDPF assembly ... 50-72
Precautions for KDPF (KCSF and KDOC) Removal and installation of KOMTRAX
Cleaning and Replacement........................ 40-103 terminal assembly ..................................... 50-201
Precautions for refrigerant ............................... 80-3 Removal and installation of machine monitor
Precautions when performing operation.......... 00-43 assembly.................................................. 50-196
Preparation for troubleshooting of electrical Removal and installation of main pump
system ....................................................... 40-32 assembly.................................................. 50-120
Preparation of dummy temperature sensor (for Removal and installation of mass air flow and
KDOC and KDPF temperature sensors)...... 40-106 temperature sensor ................................... 50-199
Preparation of short circuit electrical connector Removal and installation of operator's cab
(for failure codes [CA1883] and [CA3135]) .. 40-107 assembly.................................................. 50-145
Procedure for testing and troubleshooting ....... 80-24 Removal and installation of operator's cab
glass (adhered window glass) .................... 50-150
Removal and installation of operator’s seat ... 50-176
R Removal and installation of pump controller
Receiver drier............................................... 80-21 assembly.................................................. 50-193
Releasing remaining pressure from hydraulic Removal and installation of radiator assembly . 50-41
circuit ......................................................... 30-42 Removal and installation of revolving frame
Removal .................................................... 50-109 assembly.................................................. 50-109
Removal and installation of aftercooler Removal and installation of seat belt............. 50-178
assembly.................................................... 50-46 Removal and installation of supply pump
Removal and installation of air cleaner assembly.................................................... 50-19
assembly.................................................... 50-76 Removal and installation of travel motor and
Removal and installation of air conditioner final drive assembly..................................... 50-78
compressor assembly ............................... 50-186 Removal and installation of work equipment
Removal and installation of air conditioner assembly.................................................. 50-137
condenser assembly ................................. 50-189 Replacing alternator belt................................ 30-32
Removal and installation of air conditioner unit ROPS cab.................................................. 10-204
assembly.................................................. 50-172
Removal and installation of center swivel joint
assembly.................................................. 50-113
S
Removal and installation of control valve S-1 When starting switch is turned to START
assembly.................................................. 50-124 position, engine is not cranked ................... 40-727
Removal and installation of cooling fan and fan S-2 The engine cranks but exhaust smoke
motor assembly .......................................... 50-48 does not come out..................................... 40-728
Removal and installation of counterweight S-3 Fuel is injected but engine does not start
assembly...................................................50-111 (incomplete combustion, engine seems to
Removal and installation of cylinder head start but does not) ..................................... 40-729
assembly.................................................... 50-33 S-4 Engine startability is poor....................... 40-730
Removal and installation of engine and main S-5 Engine does not pick-up smoothly .......... 40-732
pump assembly .......................................... 50-52 S-6 Engine stops during operation................ 40-734
Removal and installation of engine controller S-7 Engine runs rough or is unstable ............ 40-736
assembly.................................................. 50-191 S-8 Engine lacks power............................... 40-737
Removal and installation of engine front seal... 50-62 S-9 KDPF gets clogged in a short time.......... 40-739
Removal and installation of engine hood S-10 Engine oil consumption is excessive..... 40-741
assembly.................................................... 50-71 S-11 Engine oil becomes contaminated early 40-742
Removal and installation of engine rear seal ... 50-66 S-12 Fuel consumption is excessive............. 40-743
Removal and installation of floor frame S-13 Oil is in coolant (or coolant spurts or
assembly.................................................. 50-166 coolant level goes down) ........................... 40-744
Removal and installation of front window S-14 Oil pressure drops............................... 40-745
assembly.................................................. 50-160 S-15 Fuel mixes into engine oil .................... 40-746
Removal and installation of front wiper S-16 Water mixes into engine oil (milky)........ 40-747
assembly.................................................. 50-179 S-17 Coolant temperature rises too high
Removal and installation of hydraulic oil cooler (overheating) ............................................ 40-748
assembly.................................................... 50-44 S-18 Unusual noise is heard ........................ 40-749
Removal and installation of idler and idler S-19 Vibration is excessive.......................... 40-750
cushion assembly ..................................... 50-100 S-20 Air cannot be bled from fuel circuit ........ 40-751
Removal and installation of injector assembly . 50-26
8 PC490LC-10
INDEX
S-21 Active regeneration is executed Testing fan speed ......................................... 30-65

frequently ................................................. 40-752 Testing FRESH/RECIRC air changeover ........ 80-43
S-22 Active regeneration takes a long time ... 40-753 Testing fuel circuit for leakage ........................ 30-28
S-23 White smoke is exhausted during active Testing fuel leakage and return ...................... 30-23
regeneration ............................................. 40-754 Testing fuel pressure ..................................... 30-21
Sensor....................................................... 10-274 Testing oil leakage ........................................ 30-71
Separation and connection of track shoe Testing oil pressure in control circuit ............... 30-48
assembly.................................................... 50-97 Testing output pressure of solenoid valve........ 30-57
Sequence of events in troubleshooting ........... 40-11 Testing PPC valve output pressure................. 30-61
Service Message ........................................ 30-148 Testing pump swash plate sensor................... 30-64
Sketch of tools for testing and adjusting ............ 30-6 Testing relays ............................................... 80-47
Sketches of special tools ............................... 50-14 Testing sunlight sensor.................................. 80-44
Solenoid valve.............................................. 60-48 Testing swing circle bearing clearance............ 30-40
Special functions of machine monitor.............. 30-81 Testing vent (mode) changeover .................... 80-41
Special tools list............................................ 50-10 Testing with self-diagnosis function................. 80-38
Specification .................................................. 01-5 Tools for testing and adjusting.......................... 30-3
Specification drawing ...................................... 01-3 Track frame and idler cushion .............. 10-54, 60-15
Specifications ................................................. 01-3 Track roller ................................................... 60-18
Sprocket ...................................................... 60-13 Track shoe ................................................... 60-20
Standard tightening torque table .................... 00-49 Travel junction valve ................................... 10-126
Standard value table for engine........................ 20-3 Travel motor ..................................... 10-157, 60-38
Standard value table for machine ..................... 20-5 Travel PPC valve ........................................ 10-178
Sunlight sensor............................................. 80-22 Troubleshooting chart 1................................. 80-48
Swing circle..........................................10-49, 60-8 Troubleshooting chart 2................................. 80-49
Swing machinery ..................................10-50, 60-9 Troubleshooting points .................................... 40-9
Swing motor ..................................... 10-146, 60-36 Troubleshooting with gauge pressure ............. 80-76
Symbols in electric circuit diagram.................. 90-11
Symbols in hydraulic circuit diagram................. 90-3
Symptom and troubleshooting numbers.......... 40-41
V
System component parts............................. 10-243 Valve control ................................................ 10-58
System diagram ........................................... 80-28
System diagram of hydraulic equipment
system ..................................................... 40-666
W
Work equipment ............................... 10-200, 60-51
Work equipment and swing PPC valve ......... 10-172
T Work equipment cylinder ............................... 60-60
T-boxes and T-adapters list............................ 40-96 Work equipment shims................................ 10-201
Table of fuel, coolant and lubricants .................. 01-9 Working range drawing ................................... 01-4
Table of weight ............................................... 01-8 Writing compensation values at replacement of
Testing air leakage (duct)............................... 80-35 injector and engine controller ....................... 30-36
Testing and adjusting air conditioner
compressor belt tension............................... 30-31
Testing and adjusting oil pressure in pump LS
control circuit .............................................. 30-52
Testing and adjusting oil pressure in pump PC
control circuit .............................................. 30-49
Testing and adjusting oil pressure in work
equipment, swing and travel circuits.............. 30-43
Testing and adjusting track tension................. 30-41
Testing and adjusting valve clearance ............ 30-13
Testing blowby pressure ................................ 30-18
Testing compression pressure ....................... 30-16
Testing diodes ............................................ 30-154
Testing (dual) pressure switch for refrigerant ... 80-45
Testing EGR valve and KVGT oil pressure ...... 30-20
Testing engine oil pressure ............................ 30-19
Testing fan pump circuit oil pressure ............... 30-66
Testing fan pump EPC solenoid valve output
pressure..................................................... 30-68
PC490LC-10 9
PC490LC-10 HYDRAULIC EXCAVATOR
Form No. SEN05622-05
© 2016 KOMATSU
All Rights Reserved
Printed in Japan 10-16

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HYDRAULIC PC490LC -10

00 Index and foreword

Attachment circuit selector valve ....................................................................................... 10-194

Testing fan pump circuit oil pressure .................................................................................... 30-66

Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-141

H-9 Work equipment does not move in single operation....................................................... 40-692

Removal and installation of supply pump assembly............................................................... 50-19

Removal and installation of KOMTRAX terminal assembly .................................................. 50-201

Testing (dual) pressure switch for refrigerant......................................................................... 80-45

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

Safety points before starting. While working, always keep

k Slinging with one rope may cause turning

Precautions for using mobile crane

Precautions for using overhead traveling crane

• When tightening nuts of the air conditioner

For tightening torques, see "Others",

Precautions to prevent fire (ALL-0000-17B-K-03-A)

Actions if fire occurs (ALL-0000-17A-K-01-A)

• Turn the starting switch to OFF position to stop

To prevent pollution, pay full attention to the way to

Some kinds of rubber and plastics may produce

How to read the shop manual (ALL-0320-010-A-01-A)

Composition of shop manual

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

the parts can not be used any longer. This value

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

Use care for working environment

How to clean parts when dirt is stuck

Precautions for replacing fuel filter cartridge

Handling of intake system parts (PC220-A900-2A4-K-00-A)

Be careful of working environment

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

Be careful of working environment

Disassembly and maintenance work in the field

Plugging of opening (prevention of flowing out

Method of disconnecting and connecting of push-pull type coupler (ALL-

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

blow it with compressed air and spray it with

High-pressure water entering connector

Entry of water, mud or dirt when disconnecting a

• Check that there is no oil, dirt or water stick

3. Action to take after removing connectors

• If the connector clamp is removed, be sure to Drying wiring harness

2. Dry the inside of the connector with a dryer.

3. Perform a continuity test on the connector.

2. While pressing lock (L2), pull out connector (1).

Slide, lock type

a If the lock is located on the underside, use

temperature even for a short period of time.

• Precautions when performing arc welding

Precautions for troubleshooting electrical

How to read electric wire code (ALL-E500-030-P-00-A)

Type, symbol, and material

Nominal No. 8 15 20 30 40 50 60 85 100