Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Excavator Shop Manual PDF

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Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Hydraulic Excavator Shop Manual UENBM00483 – PDF DOWNLOAD

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Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Hydraulic Excavator Shop Manual UENBM00483 – PDF DOWNLOAD

Language : English
Pages : 2864
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Hydraulic Excavator Shop Manual UENBM00483 – PDF DOWNLOAD

SERIAL NUMBERS

• PC290LC-11E0 – K75001 ~ K75244
• PC290NLC-11E0 – K75001 ~ K75245

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 22
FOREWORD, SAFETY, BASIC INFORMATION . 28
HOW TO READ THE SHOP MANUAL . 28
SAFETY NOTICE FOR OPERATION . 30
PRECAUTIONS TO PREVENT FIRE . 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 42
METHOD FOR CHECKING ENGINE TYPE . 43
PRECAUTIONS FOR DEF . 45
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 45
PRECAUTIONS FOR ADDING 45
PRECAUTIONS FOR STORING . 45
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 45
THE OTHER PRECAUTIONS . 45
STORE AdBlue/DEF 46
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 50
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 57
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 59
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 60
PRACTICAL USE OF KOMTRAX 61
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 64
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 66
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 70
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 76
HOW TO READ ELECTRICAL WIRE CODE 77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 81
STANDARD TIGHTENING TORQUE TABLE 84
CONVERSION TABLE 91
01 SPECIFICATIONS . 97
CONTENTS 98
ABBREVIATION LIST . 99
SPECIFICATIONS 105
SPECIFICATION DRAWING . 105
SPECIFICATION DRAWING: PC290LC-11E0, PC290NLC-11E0 105
WORKING RANGE DRAWINGS 107
WORKING RANGE: PC290LC-11E0, PC290NLC-11E0 107
SPECIFICATIONS 108
SPECIFICATIONS: PC290LC-11E0, PC290NLC-11E0 . 108
WEIGHT TABLE 111
WEIGHT TABLE: PC290LC-11E0, PC290NLC-11E0 . 111
TABLE OF FUEL, COOLANT, AND LUBRICANTS 113
10 STRUCTURE AND FUNCTION . 115
CONTENTS 116
ABBREVIATION LIST . 120
UREA SCR SYSTEM . 126
LAYOUT DRAWING OF UREA SCR SYSTEM . 127
UREA SCR SYSTEM DIAGRAM . 132
FUNCTION OF UREA SCR SYSTEM . 133
FUNCTION OF AdBlue/DEF SYSTEM . 133
INDUCEMENT STRATEGY . 137
COMPONENT PARTS OF UREA SCR SYSTEM 156
AdBlue/DEF MIXING TUBE 156
SCR ASSEMBLY 156
AdBlue/DEF TANK . 159
AdBlue/DEF PUMP . 161
AdBlue/DEF INJECTOR . 162
AdBlue/DEF HOSE . 163
AdBlue/DEF TANK HEATING VALVE . 164
BOOT-UP SYSTEM 165
LAYOUT DRAWING OF BOOT-UP SYSTEM 165
SYSTEM OPERATING LAMP SYSTEM 167
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 167
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 167
BATTERY DISCONNECT SWITCH . 169
FUNCTION OF BATTERY DISCONNECT SWITCH . 169
ENGINE SYSTEM . 170
LAYOUT DRAWING OF ENGINE SYSTEM . 170
SPECIFICATIONS OF ENGINE SYSTEM . 171
FUNCTION OF ENGINE SYSTEM . 171
ENGINE CONTROL SYSTEM . 172
ENGINE CONTROL SYSTEM DIAGRAM . 172
FUNCTION OF ENGINE CONTROL SYSTEM . 173
AUTO-DECELERATION SYSTEM 175
AUTO-DECELERATION SYSTEM DIAGRAM 175
FUNCTION OF AUTO-DECELERATION SYSTEM 175
OPERATION OF AUTO-DECELERATION SYSTEM . 176
ENGINE AUTOMATIC WARM-UP SYSTEM . 177
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 177
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 178
OVERHEAT PREVENTION SYSTEM 179
OVERHEAT PREVENTION SYSTEM DIAGRAM 179
FUNCTION OF OVERHEAT PREVENTION SYSTEM 180
TURBOCHARGER PROTECTION SYSTEM 182
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 182
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 183
AUTOMATIC IDLE STOP SYSTEM 184
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 184
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 184
COMPONENT PARTS OF ENGINE SYSTEM 187
VGT . 187
EGR SYSTEM 191
EGR VALVE . 193
EGR COOLER 195
KCCV SYSTEM . 196
KCCV VENTILATOR . 198
KDPF 200
COOLING SYSTEM 205
LAYOUT DRAWING OF COOLING SYSTEM 205
SPECIFICATIONS OF COOLING SYSTEM 206
CONTROL SYSTEM 207
LAYOUT DRAWING OF CONTROL SYSTEM 207
MACHINE MONITOR SYSTEM 210
MACHINE MONITOR SYSTEM DIAGRAM 210
KomVision SYSTEM 211
LAYOUT DRAWING OF KOMVISION SYSTEM 211
KomVision SYSTEM DIAGRAM 213
FUNCTION OF KomVision SYSTEM 213
KOMTRAX SYSTEM 215
KOMTRAX SYSTEM DIAGRAM 215
FUNCTION OF KOMTRAX SYSTEM 215
PPC LEVERS 216
LH PPC LEVER 216
RH PPC LEVER 217
AUTOMATIC GREASE SYSTEM . 218
OUTLINE OF AUTO GREASE SYSTEM . 218
COMPONENT PARTS OF CONTROL SYSTEM . 233
MACHINE MONITOR . 233
KomVision CONTROLLER 251
KomVision CAMERA 255
KOMTRAX TERMINAL 255
PUMP CONTROLLER . 258
RESISTOR FOR PC-EPC VALVE . 262
CAN TERMINATING RESISTOR 262
PPC OIL PRESSURE SWITCH . 263
ENGINE CONTROLLER . 264
FUEL CONTROL DIAL . 270
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 271
FUNCTION OF ENGINE OIL PRESSURE SWITCH 272
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 272
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 273
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 273
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 273
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 273
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 273
STRUCTURE OF OVERLOAD CAUTION SENSOR 273
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 274
FUNCTION OF OVERLOAD CAUTION SENSOR . 274
HYDRAULIC SYSTEM 275
LAYOUT DRAWING OF HYDRAULIC SYSTEM 275
CLSS 281
STRUCTURE OF CLSS . 281
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 283
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 284
PRESSURE COMPENSATION CONTROL . 297
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 300
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 300
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 301
PUMP AND VALVE CONTROL SYSTEM . 306
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 306
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 307
COMPONENT PARTS OF HYDRAULIC SYSTEM . 309
HYDRAULIC TANK 309
MAIN PUMP . 311
PC-EPC VALVE 335
PILOT OIL FILTER 337
CONTROL VALVE . 337
WORK EQUIPMENT SYSTEM . 394
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 394
STRUCTURE OF VALVE CONTROL 399
ONE-TOUCH POWER MAXIMIZING SYSTEM . 401
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 401
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 402
PPC LOCK SYSTEM . 403
PPC LOCK SYSTEM DIAGRAM . 403
FUNCTION OF PPC LOCK SYSTEM . 403
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 404
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 404
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 404
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 405
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 406
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 406
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 408
TOOL CONTROL SYSTEM . 409
TOOL CONTROL SYSTEM DIAGRAM . 409
FUNCTION OF TOOL CONTROL SYSTEM . 410
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 411
WORK EQUIPMENT AND SWING PPC VALVE 411
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 416
SOLENOID VALVE 422
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 425
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 427
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 430
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 432
ATTACHMENT BYPASS SOLENOID VALVE 435
ATT EPC VALVE ASSEMBLY 437
PILOT CIRCUIT ACCUMULATOR . 438
ATTACHMENT CIRCUIT ACCUMULATOR 439
SWING SYSTEM 440
LAYOUT DRAWING OF SWING SYSTEM 440
SWING CONTROL SYSTEM DIAGRAM 444
FUNCTION OF SWING CONTROL SYSTEM 444
COMPONENT PARTS OF SWING SYSTEM . 448
SWING MOTOR . 448
SWING MACHINERY . 460
SWING CIRCLE 461
TRAVEL SYSTEM . 463
LAYOUT DRAWING OF TRAVEL SYSTEM . 463
TRAVEL CONTROL SYSTEM DIAGRAM . 467
FUNCTION OF TRAVEL CONTROL SYSTEM . 467
COMPONENT PARTS OF TRAVEL SYSTEM 469
TRAVEL MOTOR 469
FINAL DRIVE . 481
TRAVEL PPC VALVE 483
CENTER SWIVEL JOINT . 488
UNDERCARRIAGE AND FRAME . 490
LAYOUT DRAWING OF UNDERCARRIAGE . 490
SPECIFICATIONS OF UNDERCARRIAGE . 491
WORK EQUIPMENT 492
STRUCTURE OF WORK EQUIPMENT . 492
FUNCTION OF WORK EQUIPMENT 493
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 494
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 494
BUCKET CLEARANCE ADJUSTMENT SHIM 495
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 495
CAB AND ITS ATTACHMENTS . 496
ROPS CAB 496
STRUCTURE OF ROPS CAB . 496
FUNCTION OF ROPS CAB 496
CAB MOUNT . 497
STRUCTURE OF CAB MOUNT 497
FUNCTION OF CAB MOUNT . 497
CAB TIPPING STOPPER . 498
STRUCTURE OF CAB TIPPING STOPPER 498
FUNCTION OF CAB TIPPING STOPPER . 498
20 STANDARD VALUE TABLE . 499
CONTENTS 500
ABBREVIATION LIST . 501
STANDARD VALUE TABLE FOR ENGINE . 507
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11E0, PC290NLC-11E0 507
STANDARD VALUE TABLE FOR MACHINE 511
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11E0, PC290NLC-11E0 . 511
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 524
STANDARD VALUE TABLE FOR ELECTRICAL . 528
STANDARD VALUE TABLE FOR ELECTRICAL . 528
30 TESTING AND ADJUSTING 539
CONTENTS 540
ABBREVIATION LIST . 543
RELATED INFORMATION ON TESTING AND ADJUSTING 549
TOOLS FOR TESTING AND ADJUSTING . 549
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 556
ENGINE AND COOLING SYSTEM . 558
TEST ENGINE SPEED . 558
METHOD FOR TESTING ENGINE SPEED . 558
TEST BOOST PRESSURE . 561
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 561
METHOD FOR TESTING BOOST PRESSURE . 562
TEST EXHAUST GAS COLOR 563
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 563
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 564
TEST AND ADJUST VALVE CLEARANCE . 566
METHOD FOR TESTING VALVE CLEARANCE 566
METHOD FOR ADJUSTING VALVE CLEARANCE 567
TEST COMPRESSION PRESSURE . 569
METHOD FOR TESTING COMPRESSION PRESSURE . 569
TEST BLOWBY PRESSURE 574
METHOD FOR TESTING BLOWBY PRESSURE 574
TEST ENGINE OIL PRESSURE 576
METHOD FOR TESTING ENGINE OIL PRESSURE 576
TEST EGR VALVE AND VGT OIL PRESSURE . 577
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 577
TEST FUEL PRESSURE 579
METHOD FOR TESTING FUEL PRESSURE 580
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 585
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 586
BLEEDING AIR FROM FUEL SYSTEM . 592
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 592
TEST FUEL CIRCUIT FOR LEAKAGE . 593
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 593
HANDLE CYLINDER CUT-OUT MODE OPERATION 595
HANDLE NO-INJECTION CRANKING OPERATION 596
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 597
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 597
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 597
REPLACING FAN BELT 599
METHOD FOR REPLACING FAN BELT . 599
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 600
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 600
TEST SCR RELATED FUNCTIONS 601
TEST AdBlue/DEF PUMP RAISED PRESSURE 604
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 607
TEST AdBlue/DEF LINE HEATER RELAY 1 . 611
TEST AdBlue/DEF LINE HEATER RELAY 2 . 614
TEST AdBlue/DEF PUMP HEATER RELAY . 616
TEST AdBlue/DEF TANK HEATER VALVE . 619
TEST DENITRATION EFFICIENCY OF SCR 622
CLEAN AdBlue/DEF TANK . 626
METHOD FOR CLEANING AdBlue/DEF TANK . 626
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 630
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 630
POWER TRAIN . 632
TEST SWING CIRCLE BEARING CLEARANCE . 632
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 632
UNDERCARRIAGE AND FRAME . 633
TEST AND ADJUST TRACK TENSION . 633
METHOD FOR TESTING TRACK TENSION 633
METHOD FOR ADJUSTING TRACK TENSION 633
HYDRAULIC SYSTEM 635
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 635
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 635
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 635
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 641
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 642
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 648
TEST OIL PRESSURE OF CONTROL CIRCUIT 651
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 651
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 653
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 653
TEST PC-EPC VALVE OUTLET PRESSURE . 654
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 655
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 657
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 657
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 658
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 661
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 662
METHOD FOR ADJUSTING LS VALVE . 663
TEST OUTLET PRESSURE OF SOLENOID VALVE 664
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 664
OPERATING CONDITION OF SOLENOID VALVE . 665
TEST PPC VALVE OUTLET PRESSURE 668
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 668
TEST ATTACHMENT CIRCUIT OIL PRESSURE 670
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 670
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 672
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 672
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 673
TEST PUMP SWASH PLATE SENSOR 675
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 675
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 676
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 676
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 676
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 677
TEST OIL LEAKAGE 678
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 678
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 678
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 679
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 680
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 680
BLEED AIR FROM HYDRAULIC CIRCUIT 681
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 683
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 685
CAB AND ITS ATTACHMENTS . 690
TEST CAB TIPPING STOPPER 690
METHOD FOR TESTING CAB TIPPING STOPPER 690
METHOD FOR ADJUSTING MIRRORS 691
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 691
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 692
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 693
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 694
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 695
ELECTRICAL SYSTEM . 697
SET AND OPERATE MACHINE MONITOR . 697
OPERATOR MODE . 700
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 701
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 701
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 702
CHECKING FUNCTION OF SERVICE METER 702
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 702
SERVICE MODE 705
METHOD FOR OPERATING SERVICE MODE . 706
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 709
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 715
ABNORMALITY RECORD MENU . 725
METHOD FOR CONFIRMING MAINTENANCE RECORD 730
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 731
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 735
DEFAULT MENU 736
DIAGNOSTIC TESTS MENU . 747
ADJUSTMENT MENU . 757
METHOD FOR PERFORMING NO-INJECTION CRANKING . 791
KOMTRAX SETTINGS MENU . 792
METHOD FOR DISPLAYING SERVICE MESSAGE . 794
METHOD FOR STARTING UP KOMTRAX TERMINAL . 796
ADJUST REARVIEW CAMERA ANGLE 801
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 801
ADJUST KomVision CAMERA ANGLE . 804
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 805
ADJUST KomVision RELATED ITEMS 809
SETTING OF KomVision (MAIN SETTING) . 809
SETTING OF KomVision (CAMERA SETTING) . 811
SETTING OF KomVision (CAMERA CALIBRATION) . 813
KomVision screen – Check 12 m visibility 826
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 829
HANDLE BATTERY DISCONNECT SWITCH 830
TEST DIODES . 831
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 831
METHOD FOR TESTING DIODE USING ANALOG TESTER 831
Pm CLINIC . 832
Pm CLINIC SERVICE . 832
Pm CLINIC CHECK SHEET . 836
40 TROUBLESHOOTING 847
CONTENTS 848
ABBREVIATION LIST . 859
RELATED INFORMATION ON TROUBLESHOOTING 865
GENERAL TROUBLESHOOTING POINTS 865
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 866
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 878
CHECKS BEFORE TROUBLESHOOTING . 880
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 882
WALK-AROUND CHECK . 882
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 884
CHECK FUEL LEVEL AND TYPE . 884
CHECK IMPURE INGREDIENT IN FUEL . 884
CHECK FUEL PREFILTER 885
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 885
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 886
CHECK MAIN FILTER . 887
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 889
CHECK COOLANT LEVEL (RESERVOIR TANK) 890
CHECK CLOGGING OF AIR CLEANER . 890
OUTER ELEMENT – CLEAN . 891
ELEMENTS – REPLACE 893
CHECK HYDRAULIC OIL LEVEL . 894
CHECK HYDRAULIC OIL STRAINER 895
CHECK HYDRAULIC FILTER 896
CHECK OIL LEVEL IN SWING MACHINERY CASE . 897
CHECK OIL LEVEL IN DAMPER CASE 898
CHECK OIL LEVEL IN FINAL DRIVE CASE . 898
BLEED AIR FROM FUEL SYSTEM 899
BLEED AIR FROM HYDRAULIC SYSTEM . 899
ELECTRICAL EQUIPMENT – CHECK METHOD . 899
AUTOMATIC GREASE SYSTEM . 907
FINDING MALFUNCTIONS 907
MALFUNCTION FINDING PROCEDURES 909
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 911
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 921
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 924
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 928
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 930
CONNECTOR LIST AND LAYOUT . 933
CONNECTOR CONTACT IDENTIFICATION 946
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 986
FUSE LOCATION TABLE . 992
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 994
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 998
FAILURE CODE TABLE 1000
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1018
FAILURE CODE [879AKA] .1018
FAILURE CODE [879AKB] .1019
FAILURE CODE [879BKA] .1020
FAILURE CODE [879BKB] .1022
FAILURE CODE [879CKA] .1024
FAILURE CODE [879CKB] .1025
FAILURE CODE [879DKZ] .1026
FAILURE CODE [879EMC] .1028
FAILURE CODE [879FMC] .1029
FAILURE CODE [879GKX] .1030
FAILURE CODE [989L00] .1032
FAILURE CODE [989M00] .1033
FAILURE CODE [989N00] .1034
FAILURE CODE [A1U0N3] .1035
FAILURE CODE [A1U0N4] .1037
FAILURE CODE [A900FR] .1039
FAILURE CODE [A900N6] .1040
FAILURE CODE [A900NY] .1041
FAILURE CODE [AA10NX] .1042
FAILURE CODE [AB00KE] .1044
FAILURE CODE [AQ10N3] .1047
FAILURE CODE [AS00N3] .1049
FAILURE CODE [AS00R2] .1051
FAILURE CODE [AS00R3] .1052
FAILURE CODE [AS00R4] .1053
FAILURE CODE [AS00R5] .1054
FAILURE CODE [AS00R6] .1055
FAILURE CODE [AS00ZK] .1056
FAILURE CODE [AS10KM] .1057
FAILURE CODE [AS10NR] .1058
FAILURE CODE [AS10NT] .1059
FAILURE CODE [B@BAZG] .1060
FAILURE CODE [B@BAZK] .1061
FAILURE CODE [B@BCNS] .1063
FAILURE CODE [B@BCQA] .1064
FAILURE CODE [B@BCZK] .1066
FAILURE CODE [B@HANS] .1068
FAILURE CODE [CA115] 1069
FAILURE CODE [CA122] 1070
FAILURE CODE [CA123] 1072
FAILURE CODE [CA131] 1074
FAILURE CODE [CA132] 1076
FAILURE CODE [CA144] 1078
FAILURE CODE [CA145] 1080
FAILURE CODE [CA153] 1082
FAILURE CODE [CA154] 1085
FAILURE CODE [CA187] 1087
FAILURE CODE [CA221] 1089
FAILURE CODE [CA222] 1091
FAILURE CODE [CA227] 1093
FAILURE CODE [CA234] 1094
FAILURE CODE [CA238] 1095
FAILURE CODE [CA239] 1097
FAILURE CODE [CA249] 1099
FAILURE CODE [CA256] 1101
FAILURE CODE [CA271] 1103
FAILURE CODE [CA272] 1105
FAILURE CODE [CA322] 1107
FAILURE CODE [CA323] 1109
FAILURE CODE [CA324] 1111
FAILURE CODE [CA325] 1113
FAILURE CODE [CA331] 1115
FAILURE CODE [CA332] 1117
FAILURE CODE [CA343] 1119
FAILURE CODE [CA351] 1120
FAILURE CODE [CA352] 1121
FAILURE CODE [CA356] 1124
FAILURE CODE [CA357] 1126
FAILURE CODE [CA386] 1128
FAILURE CODE [CA428] 1129
FAILURE CODE [CA429] 1131
FAILURE CODE [CA435] 1133
FAILURE CODE [CA441] 1135
FAILURE CODE [CA442] 1137
FAILURE CODE [CA449] 1138
FAILURE CODE [CA451] 1139
FAILURE CODE [CA452] 1141
FAILURE CODE [CA488] 1143
FAILURE CODE [CA515] 1144
FAILURE CODE [CA516] 1146
FAILURE CODE [CA553] 1148
FAILURE CODE [CA555] 1149
FAILURE CODE [CA556] 1150
FAILURE CODE [CA559] 1151
FAILURE CODE [CA595] 1154
FAILURE CODE [CA687] 1155
FAILURE CODE [CA689] 1157
FAILURE CODE [CA691] 1160
FAILURE CODE [CA692] 1162
FAILURE CODE [CA697] 1164
FAILURE CODE [CA698] 1165
FAILURE CODE [CA731] 1166
FAILURE CODE [CA778] 1168
FAILURE CODE [CA1117] .1173
FAILURE CODE [CA1664] .1174
FAILURE CODE [CA1669] .1176
FAILURE CODE [CA1673] .1177
FAILURE CODE [CA1677] .1178
FAILURE CODE [CA1678] .1179
FAILURE CODE [CA1682] .1180
FAILURE CODE [CA1683] .1182
FAILURE CODE [CA1684] .1184
FAILURE CODE [CA1686] .1186
FAILURE CODE [CA1691] .1187
FAILURE CODE [CA1694] .1190
FAILURE CODE [CA1695] .1193
FAILURE CODE [CA1696] .1194
FAILURE CODE [CA1712] .1196
FAILURE CODE [CA1713] .1199
FAILURE CODE [CA1714] .1201
FAILURE CODE [CA1715] .1202
FAILURE CODE [CA1776] .1203
FAILURE CODE [CA1777] .1206
FAILURE CODE [CA1843] .1209
FAILURE CODE [CA1844] .1211
FAILURE CODE [CA1879] .1214
FAILURE CODE [CA1881] .1216
FAILURE CODE [CA1883] .1218
FAILURE CODE [CA1885] .1221
FAILURE CODE [CA1887] .1223
FAILURE CODE [CA1921] .1225
FAILURE CODE [CA1922] .1228
FAILURE CODE [CA1942] .1233
FAILURE CODE [CA1993] .1234
FAILURE CODE [CA2185] .1237
FAILURE CODE [CA2186] .1238
FAILURE CODE [CA2249] .1240
FAILURE CODE [CA2271] .1241
FAILURE CODE [CA2272] .1244
FAILURE CODE [CA2288] .1247
FAILURE CODE [CA2311] .1248
FAILURE CODE [CA2349] .1249
FAILURE CODE [CA2353] .1252
FAILURE CODE [CA2357] .1254
FAILURE CODE [CA2381] .1255
FAILURE CODE [CA2382] .1258
FAILURE CODE [CA2383] .1261
FAILURE CODE [CA2386] .1264
FAILURE CODE [CA2387] .1266
FAILURE CODE [CA2555] .1267
FAILURE CODE [CA2556] .1270
FAILURE CODE [CA2637] .1273
FAILURE CODE [CA2639] .1275
FAILURE CODE [CA2771] .1278
FAILURE CODE [CA2777] .1284
FAILURE CODE [CA2976] .1287
FAILURE CODE [CA3133] .1289
FAILURE CODE [CA3134] .1292
FAILURE CODE [CA3135] .1294
FAILURE CODE [CA3142] .1297
FAILURE CODE [CA3143] .1298
FAILURE CODE [CA3144] .1299
FAILURE CODE [CA3146] .1301
FAILURE CODE [CA3147] .1302
FAILURE CODE [CA3148] .1303
FAILURE CODE [CA3151] .1305
FAILURE CODE [CA3165] .1311
FAILURE CODE [CA3229] .1313
FAILURE CODE [CA3231] .1315
FAILURE CODE [CA3232] .1317
FAILURE CODE [CA3235] .1321
FAILURE CODE [CA3239] .1323
FAILURE CODE [CA3241] .1326
FAILURE CODE [CA3242] .1329
FAILURE CODE [CA3251] .1332
FAILURE CODE [CA3253] .1334
FAILURE CODE [CA3254] .1337
FAILURE CODE [CA3255] .1340
FAILURE CODE [CA3256] .1344
FAILURE CODE [CA3311] .1346
FAILURE CODE [CA3312] .1348
FAILURE CODE [CA3313] .1351
FAILURE CODE [CA3314] .1352
FAILURE CODE [CA3315] .1353
FAILURE CODE [CA3316] .1355
FAILURE CODE [CA3317] .1356
FAILURE CODE [CA3318] .1357
FAILURE CODE [CA3319] .1359
FAILURE CODE [CA3321] .1360
FAILURE CODE [CA3322] .1362
FAILURE CODE [CA3419] .1364
FAILURE CODE [CA3421] .1366
FAILURE CODE [CA3497] .1368
FAILURE CODE [CA3498] .1369
FAILURE CODE [CA3543] .1370
FAILURE CODE [CA3545] .1377
FAILURE CODE [CA3547] .1379
FAILURE CODE [CA3558] .1380
FAILURE CODE [CA3559] .1382
FAILURE CODE [CA3562] .1384
FAILURE CODE [CA3563] .1386
FAILURE CODE [CA3567] .1389
FAILURE CODE [CA3568] .1392
FAILURE CODE [CA3571] .1396
FAILURE CODE [CA3572] .1398
FAILURE CODE [CA3574] .1400
FAILURE CODE [CA3575] .1402
FAILURE CODE [CA3577] .1404
FAILURE CODE [CA3578] .1406
FAILURE CODE [CA3582] .1408
FAILURE CODE [CA3583] .1414
FAILURE CODE [CA3596] .1416
FAILURE CODE [CA3649] .1418
FAILURE CODE [CA3681] .1420
FAILURE CODE [CA3682] .1425
FAILURE CODE [CA3713] .1431
FAILURE CODE [CA3717] .1434
FAILURE CODE [CA3718] .1435
FAILURE CODE [CA3725] .1436
FAILURE CODE [CA3741] .1439
FAILURE CODE [CA3748] .1440
FAILURE CODE [CA3751] .1442
FAILURE CODE [CA3755] .1444
FAILURE CODE [CA3866] .1446
FAILURE CODE [CA3867] .1450
FAILURE CODE [CA3868] .1453
FAILURE CODE [CA3899] .1457
FAILURE CODE [CA3911] .1459
FAILURE CODE [CA3912] .1463
FAILURE CODE [CA3932] .1465
FAILURE CODE [CA3933] .1467
FAILURE CODE [CA3934] .1469
FAILURE CODE [CA3935] .1472
FAILURE CODE [CA3936] .1474
FAILURE CODE [CA4151] .1476
FAILURE CODE [CA4152] .1480
FAILURE CODE [CA4155] .1484
FAILURE CODE [CA4156] .1486
FAILURE CODE [CA4157] .1489
FAILURE CODE [CA4158] .1491
FAILURE CODE [CA4159] .1492
FAILURE CODE [CA4161] .1493
FAILURE CODE [CA4162] .1496
FAILURE CODE [CA4163] .1499
FAILURE CODE [CA4164] .1500
FAILURE CODE [CA4165] .1502
FAILURE CODE [CA4166] .1504
FAILURE CODE [CA4168] .1505
FAILURE CODE [CA4169] .1508
FAILURE CODE [CA4171] .1510
FAILURE CODE [CA4249] .1513
FAILURE CODE [CA4251] .1515
FAILURE CODE [CA4259] .1517
FAILURE CODE [CA4261] .1520
FAILURE CODE [CA4277] .1523
FAILURE CODE [CA4281] .1527
FAILURE CODE [CA4459] .1530
FAILURE CODE [CA4461] .1533
FAILURE CODE [CA4658] .1536
FAILURE CODE [CA4731] .1540
FAILURE CODE [CA4732] .1541
FAILURE CODE [CA4739] .1542
FAILURE CODE [CA4768] .1543
FAILURE CODE [CA4769] .1545
FAILURE CODE [CA4842] .1548
FAILURE CODE [CA4952] .1552
FAILURE CODE [CA5115] .1554
FAILURE CODE [CA5179] .1557
FAILURE CODE [CA5181] .1559
FAILURE CODE [CA5383] .1561
FAILURE CODE [D110KB] .1563
FAILURE CODE [D19JKZ] .1565
FAILURE CODE [D811MC] .1568
FAILURE CODE [D862KA] .1569
FAILURE CODE [D8ALKA] .1570
FAILURE CODE [D8ALKB] .1572
FAILURE CODE [D8AQKR] .1574
FAILURE CODE [DA20MC] .1576
FAILURE CODE [DA22KK] .1577
FAILURE CODE [DA25KP] .1580
FAILURE CODE [DA26KP] .1583
FAILURE CODE [DA29KQ] .1586
FAILURE CODE [DA2LKA] .1588
FAILURE CODE [DA2LKB] .1590
FAILURE CODE [DA2QKR] .1592
FAILURE CODE [DA2RKR] .1601
FAILURE CODE [DAF0KM] .1602
FAILURE CODE [DAF0MB] .1603
FAILURE CODE [DAF0MC] .1604
FAILURE CODE [DAF8KB] .1605
FAILURE CODE [DAF9KQ] .1607
FAILURE CODE [DAFGMC] .1608
FAILURE CODE [DAFLKA] .1609
FAILURE CODE [DAFLKB] .1611
FAILURE CODE [DAFQKR] .1613
FAILURE CODE [DAZ9KQ] .1614
FAILURE CODE [DAZQKR] .1615
FAILURE CODE [DB2QKR] .1620
FAILURE CODE [DB2RKR] .1625
FAILURE CODE [DBP0KM] .1630
FAILURE CODE [DBP0KT] .1631
FAILURE CODE [DBP5KB] .1632
FAILURE CODE [DBP5KY] .1635
FAILURE CODE [DBPQKR] .1638
FAILURE CODE [DDNRKA] .1643
FAILURE CODE [DDNRKY] .1645
FAILURE CODE [DDNS00] .1647
FAILURE CODE [DFB1KZ] .1649
FAILURE CODE [DFB2KZ] .1651
FAILURE CODE [DFB3L8] .1653
FAILURE CODE [DFB4L8] .1655
FAILURE CODE [DFB5KZ] .1657
FAILURE CODE [DFB6KZ] .1659
FAILURE CODE [DGH2KA] .1661
FAILURE CODE [DGH2KB] .1663
FAILURE CODE [DHA4KA] .1665
FAILURE CODE [DHAAMA] .1667
FAILURE CODE [DHACMA] .1669
FAILURE CODE [DHPAMA] .1671
FAILURE CODE [DHPBMA] .1674
FAILURE CODE [DHS3MA] .1677
FAILURE CODE [DHS4MA] .1680
FAILURE CODE [DHS8MA] .1683
FAILURE CODE [DHS9MA] .1686
FAILURE CODE [DHSAMA] .1689
FAILURE CODE [DHSBMA] .1692
FAILURE CODE [DHSCMA] .1695
FAILURE CODE [DHSDMA] .1698
FAILURE CODE [DHSFMA] .1701
FAILURE CODE [DHSGMA] .1704
FAILURE CODE [DHSHMA] .1707
FAILURE CODE [DHSJMA] .1710
FAILURE CODE [DHX1MA] .1713
FAILURE CODE [DHZAMA] .1716
FAILURE CODE [DHZCL8] .1720
FAILURE CODE [DKR0MA] .1721
FAILURE CODE [DKR1MA] .1724
FAILURE CODE [DKULKA] .1727
FAILURE CODE [DKULKB] .1729
FAILURE CODE [DKULKY] .1731
FAILURE CODE [DR10KA] .1733
FAILURE CODE [DR12KA] .1736
FAILURE CODE [DR20KA] .1738
FAILURE CODE [DR21KX] .1740
FAILURE CODE [DR30KA] .1742
FAILURE CODE [DR31KX] .1744
FAILURE CODE [DR40KA] .1746
FAILURE CODE [DUMBKA] .1748
FAILURE CODE [DUMBKB] .1750
FAILURE CODE [DV00KA] .1752
FAILURE CODE [DV00KB] .1753
FAILURE CODE [DV20KB] .1754
FAILURE CODE [DW43KA] .1756
FAILURE CODE [DW43KB] .1758
FAILURE CODE [DW43KY] .1760
FAILURE CODE [DW45KA] .1762
FAILURE CODE [DW45KB] .1765
FAILURE CODE [DW45KY] .1768
FAILURE CODE [DW4CKY] .1770
FAILURE CODE [DW91KA] .1772
FAILURE CODE [DW91KB] .1774
FAILURE CODE [DW91KY] .1776
FAILURE CODE [DWA2KA] .1778
FAILURE CODE [DWA2KB] .1780
FAILURE CODE [DWA2KY] .1782
FAILURE CODE [DWK0KA] .1784
FAILURE CODE [DWK0KB] .1786
FAILURE CODE [DWK0KY] .1788
FAILURE CODE [DWK2KA] .1790
FAILURE CODE [DWK2KB] .1792
FAILURE CODE [DWK2KY] .1794
FAILURE CODE [DWK8KA] .1796
FAILURE CODE [DWK8KB] .1798
FAILURE CODE [DWK8KY] .1800
FAILURE CODE [DWPUKA] .1802
FAILURE CODE [DWPUKB] .1804
FAILURE CODE [DWPUKY] .1806
FAILURE CODE [DXA8KA] .1808
FAILURE CODE [DXA8KB] .1810
FAILURE CODE [DXA9KA] .1812
FAILURE CODE [DXA9KB] .1814
FAILURE CODE [DXE0KA] .1816
FAILURE CODE [DXE0KB] .1817
FAILURE CODE [DXE4KA] .1819
FAILURE CODE [DXE4KB] .1821
FAILURE CODE [DXE4KY] .1823
FAILURE CODE [DXE5KA] .1825
FAILURE CODE [DXE5KB] .1827
FAILURE CODE [DXE6KA] .1829
FAILURE CODE [DXE6KB] .1831
FAILURE CODE [DXE7KA] .1833
FAILURE CODE [DXE7KB] .1835
FAILURE CODE [DXE7KY] .1837
FAILURE CODE [DXE8KA] .1839
FAILURE CODE [DXE8KB] .1841
FAILURE CODE [DXE8KY] .1843
FAILURE CODE [DXE9KA] .1845
FAILURE CODE [DXE9KB] .1847
FAILURE CODE [DXE9KY] .1849
FAILURE CODE [DXEAKA] .1851
FAILURE CODE [DXEAKB] .1853
FAILURE CODE [DXEAKY] .1855
FAILURE CODE [DXEKKA] .1857
FAILURE CODE [DXEKKB] .1859
FAILURE CODE [DXEKKY] .1861
FAILURE CODE [DXELKA] .1863
FAILURE CODE [DXELKB] .1865
FAILURE CODE [DXELKY] .1867
FAILURE CODE [DY20KA] .1869
FAILURE CODE [DY20MA] .1871
FAILURE CODE [DY2CKB] .1873
FAILURE CODE [DY2DKB] .1876
FAILURE CODE [DY2EKB] .1878
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1880
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1880
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1886
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1889
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1891
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1893
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1896
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1897
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1898
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1899
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1900
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1901
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1902
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1903
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1904
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1905
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1906
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1907
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1909
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1910
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1911
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1912
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1914
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1915
E-24 FUNCTION SWITCH DOES NOT OPERATE .1916
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1917
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1918
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1919
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1920
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1921
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1922
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1923
E-32 ALARM BUZZER CANNOT BE CANCELED 1925
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1926
E-34 SERVICE MODE CANNOT BE SELECTED 1927
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1928
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1931
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1933
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1936
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1938
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1941
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1942
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1944
E-43 HORN DOES NOT SOUND 1945
E-44 HORN DOES NOT STOP SOUNDING 1948
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1950
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1951
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1953
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1954
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1955
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1956
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1957
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1958
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1959
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1960
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1961
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1962
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1964
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1965
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1966
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1966
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1967
FAILURE MODE AND CAUSE TABLE 1969
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1978
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1979
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1982
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1983
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1984
H-6 SPEED OR POWER OF BOOM IS LOW .1986
H-7 ARM SPEED OR POWER IS LOW .1990
H-8 BUCKET SPEED OR POWER IS LOW 1995
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1998
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1999
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2001
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2003
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2004
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2005
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2006
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2007
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2008
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2009
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2010
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2011
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .2012
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2014
H-23 TRAVEL SPEED IS LOW 2017
H-24 ONE OF TRACKS DOES NOT RUN .2019
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2020
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2021
H-27 SWINGS ONLY IN ONE DIRECTION .2022
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2023
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2024
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2025
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2026
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2027
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2028
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2029
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2030
H-36 Quick coupler cylinder will not extend .2031
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2033
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .2035
H-39 Quick coupler cylinder extends and retracts slowly .2037
TROUBLESHOOTING OF ENGINE (S-MODE) 2038
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2038
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2039
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2040
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2041
S-4 ENGINE STARTABILITY IS POOR .2043
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2045
S-6 ENGINE STOPS DURING OPERATION .2047
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2049
S-8 ENGINE LACKS POWER 2050
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2052
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2054
S-11 OIL BECOMES CONTAMINATED QUICKLY .2055
S-12 FUEL CONSUMPTION IS EXCESSIVE 2056
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2057
S-14 OIL PRESSURE DROPS .2058
S-15 FUEL MIXES INTO ENGINE OIL .2060
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2061
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2062
S-18 UNUSUAL NOISE IS HEARD .2063
S-19 VIBRATION IS EXCESSIVE .2064
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2065
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2066
S-22 ACTIVE REGENERATION TAKES TIME .2068
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2069
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2070
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2072
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2073
50 DISASSEMBLY AND ASSEMBLY .2075
CONTENTS 2076
ABBREVIATION LIST .2081
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2087
HOW TO READ THIS MANUAL .2087
COATING MATERIALS LIST 2089
SPECIAL TOOLS LIST 2093
SKETCHES OF SPECIAL TOOLS .2105
ENGINE AND COOLING SYSTEM .2111
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2111
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2111
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2114
REMOVE AND INSTALL INJECTOR ASSEMBLY 2118
METHOD FOR REMOVING INJECTOR ASSEMBLY .2118
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2123
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2131
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2132
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2141
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2157
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2157
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2158
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2161
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2161
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2164
REMOVE AND INSTALL STARTER ASSEMBLY .2169
METHOD FOR REMOVING STARTER ASSEMBLY 2169
METHOD FOR INSTALLING STARTER ASSEMBLY 2171
REMOVE AND INSTALL ALTERNATOR BELT 2173
METHOD FOR REMOVING ALTERNATOR BELT .2173
METHOD FOR INSTALLING ALTERNATOR BELT .2175
REMOVE AND INSTALL RADIATOR ASSEMBLY 2177
METHOD FOR REMOVING RADIATOR ASSEMBLY .2177
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2179
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2181
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2181
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2184
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2187
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2187
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2188
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2190
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2191
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2199
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2210
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2210
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2213
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2217
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2217
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2218
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2221
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2221
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2222
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2223
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2223
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2225
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2231
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2231
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2235
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2241
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2241
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2246
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2252
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2252
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2257
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2263
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2263
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2263
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2270
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2270
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2270
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2271
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2271
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2273
REMOVE AND INSTALL KDPF ASSEMBLY 2276
METHOD FOR REMOVING KDPF ASSEMBLY .2276
METHOD FOR INSTALLING KDPF ASSEMBLY .2278
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2280
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2281
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2284
REMOVE AND INSTALL SCR ASSEMBLY .2289
METHOD FOR REMOVING SCR ASSEMBLY 2289
METHOD FOR INSTALLING SCR ASSEMBLY 2291
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2293
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2293
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2299
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2305
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2305
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2313
REMOVE AND INSTALL KCCV ASSEMBLY 2322
METHOD FOR REMOVING KCCV ASSEMBLY .2322
METHOD FOR INSTALLING KCCV ASSEMBLY .2324
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2329
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2329
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2334
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2339
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2339
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2341
REMOVE AND INSTALL AdBlue/DEF PUMP 2343
METHOD FOR REMOVING AdBlue/DEF PUMP .2343
METHOD FOR INSTALLING AdBlue/DEF PUMP .2345
REMOVE AND INSTALL AdBlue/DEF HOSE 2348
METHOD FOR REMOVING AdBlue/DEF HOSE .2348
METHOD FOR INSTALLING AdBlue/DEF HOSE .2356
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2362
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2362
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2363
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2365
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2365
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2367
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2370
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2370
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2371
POWER TRAIN .2372
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2372
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2372
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2373
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2374
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2374
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2378
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2387
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2387
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2389
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2393
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2393
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2397
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2404
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2404
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2404
UNDERCARRIAGE AND FRAME .2406
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2406
METHOD FOR SEPARATING TRACK ASSEMBLY 2406
METHOD FOR INSTALLING TRACK ASSEMBLY 2408
REMOVE AND INSTALL SPROCKET .2411
METHOD FOR REMOVING SPROCKET 2411
METHOD FOR INSTALLING SPROCKET 2411
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2413
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2413
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2414
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2415
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2415
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2416
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2420
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2421
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2422
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2423
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2424
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2425
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2427
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2427
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2428
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2431
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2431
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2433
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2435
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2435
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2438
HYDRAULIC SYSTEM 2442
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2442
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2442
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2444
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2447
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2448
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2449
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2450
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2450
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2453
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2456
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2456
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2459
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2463
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2463
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2470
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2478
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2478
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2480
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2484
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2484
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2484
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2486
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2486
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2487
REMOVE AND INSTALL QUICK COUPLER VALVE 2489
WORK EQUIPMENT 2491
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2491
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2491
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2495
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2501
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2501
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2504
CAB AND ITS ATTACHMENTS .2510
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2510
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2510
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2516
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2523
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2525
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2525
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2535
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2535
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2538
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2544
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2544
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2551
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2558
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2558
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2564
REMOVE AND INSTALL OPERATOR’S SEAT 2571
METHOD FOR REMOVING OPERATOR’S SEAT .2571
METHOD FOR INSTALLING OPERATOR’S SEAT .2573
REMOVE AND INSTALL SEAT BELT 2576
METHOD FOR REMOVING SEAT BELT .2576
METHOD FOR INSTALLING SEAT BELT .2577
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2578
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2578
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2583
ELECTRICAL SYSTEM .2592
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2592
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2592
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2593
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2595
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2595
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2599
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2604
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2604
METHOD FOR INSTALLING KomVision CONTROLLER 2605
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2607
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2607
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2610
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2614
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2614
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2615
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2616
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2616
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2616
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2618
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2618
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2619
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2621
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2621
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2623
REMOVE AND INSTALL KomVision CAMERA .2626
METHOD FOR REMOVING KomVision CAMERA 2626
METHOD FOR INSTALLING KomVision CAMERA 2629
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2632
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2632
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2635
60 MAINTENANCE STANDARD .2639
CONTENTS 2640
ABBREVIATION LIST .2641
ENGINE AND COOLING SYSTEM .2647
MAINTENANCE STANDARD OF ENGINE MOUNT 2647
MAINTENANCE STANDARD OF COOLING SYSTEM 2648
POWER TRAIN .2649
MAINTENANCE STANDARD OF SWING CIRCLE 2649
MAINTENANCE STANDARD OF SWING MACHINERY .2650
MAINTENANCE STANDARD OF FINAL DRIVE .2652
MAINTENANCE STANDARD OF SPROCKET 2654
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2655
UNDERCARRIAGE AND FRAME .2657
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2657
MAINTENANCE STANDARD OF IDLER .2659
MAINTENANCE STANDARD OF TRACK ROLLER 2661
MAINTENANCE STANDARD OF CARRIER ROLLER 2663
MAINTENANCE STANDARD OF TRACK SHOE 2664
MAINTENANCE STANDARD OF TRIPLE SHOE .2667
HYDRAULIC SYSTEM 2668
MAINTENANCE STANDARD OF HYDRAULIC TANK 2668
MAINTENANCE STANDARD OF MAIN PUMP .2669
MAINTENANCE STANDARD OF LS-EPC VALVE 2670
MAINTENANCE STANDARD OF PC-EPC VALVE 2671
MAINTENANCE STANDARD OF SWING MOTOR .2672
MAINTENANCE STANDARD OF TRAVEL MOTOR 2675
MAINTENANCE STANDARD OF CONTROL VALVE .2678
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2688
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2691
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2694
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2696
MAINTENANCE STANDARD OF SOLENOID VALVE 2697
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2698
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2699
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2700
WORK EQUIPMENT 2701
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2701
DIMENSION OF ARM 2706
DIMENSIONS OF BUCKET 2708
MAINTENANCE STANDARD OF BOOM CYLINDER .2710
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2711
MAINTENANCE STANDARD OF ARM CYLINDER 2712
MAINTENANCE STANDARD OF BUCKET CYLINDER .2713
80 APPENDIX .2715
CONTENTS 2716
ABBREVIATION LIST .2718
AIR CONDITIONER SYSTEM 2724
PRECAUTIONS FOR REFRIGERANT .2724
AIR CONDITIONER COMPONENT .2725
SPECIFICATIONS OF AIR CONDITIONER .2727
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2728
OUTLINE OF REFRIGERATION CYCLE 2729
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2731
AIR CONDITIONER UNIT 2731
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2731
FUNCTION OF AIR CONDITIONER UNIT 2733
COMPONENT PARTS OF AIR CONDITIONER UNIT .2735
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2736
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2736
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2736
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2736
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2737
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2737
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2737
FUNCTION OF DUAL PRESSURE SWITCH 2738
AIR CONDITIONER CONTROLLER 2739
STRUCTURE OF AIR CONDITIONER CONTROLLER .2739
COMPRESSOR 2740
STRUCTURE OF COMPRESSOR .2740
SPECIFICATIONS OF COMPRESSOR 2740
FUNCTION OF COMPRESSOR 2740
CONDENSER .2741
STRUCTURE OF CONDENSER 2741
SPECIFICATIONS OF CONDENSER .2741
FUNCTION OF CONDENSER .2741
SENSORS FOR AIR CONDITIONER SYSTEM 2743
STRUCTURE OF SUNLIGHT SENSOR 2743
FUNCTION OF SUNLIGHT SENSOR .2743
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2743
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2743
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2745
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2747
AIR CONDITIONER SYSTEM DIAGRAM 2749
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2750
FUNCTION OF AIR CONDITIONER CONTROLLER 2751
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2752
TESTING AIR LEAKAGE (DUCT) 2756
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2756
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2758
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2759
TEST VENT (MODE) CHANGEOVER .2760
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2760
TESTING FRESH/RECIRC AIR CHANGEOVER .2762
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2762
TEST SUNLIGHT SENSOR 2763
METHOD FOR TESTING SUNLIGHT SENSOR 2763
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2764
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2764
TEST RELAYS .2765
METHOD FOR TESTING RELAYS .2765
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2766
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2767
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2770
FAILURE CODE [879AKA] .2772
FAILURE CODE [879AKB] .2773
FAILURE CODE [879BKA] .2774
FAILURE CODE [879BKB] .2776
FAILURE CODE [879CKA] .2778
FAILURE CODE [879CKB] .2779
FAILURE CODE [879DKZ] .2780
FAILURE CODE [879EMC] .2782
FAILURE CODE [879FMC] .2783
FAILURE CODE [879GKX] .2784
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2786
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2788
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2791
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2793
TROUBLESHOOTING USING GAUGE PRESSURE 2795
CONNECTION OF SERVICE TOOL 2798
METHOD FOR CONNECTING SERVICE TOOL 2798
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2800
HANDLE COMPRESSOR OIL .2802
METHOD FOR REPLACING DESICCANT 2804
90 CIRCUIT DIAGRAMS .2807
CONTENTS 2808
ABBREVIATION LIST .2809
HYDRAULIC CIRCUIT DIAGRAM .2815
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2815
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2819
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2821
ELECTRICAL CIRCUIT DIAGRAM 2823
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2823
ELECTRICAL CIRCUIT DIAGRAM (1/9) 2827
ELECTRICAL CIRCUIT DIAGRAM (2/9) 2829
ELECTRICAL CIRCUIT DIAGRAM (3/9) 2831
ELECTRICAL CIRCUIT DIAGRAM (4/9) 2833
ELECTRICAL CIRCUIT DIAGRAM (5/9) 2835
ELECTRICAL CIRCUIT DIAGRAM (6/9) 2837
ELECTRICAL CIRCUIT DIAGRAM (7/9) 2839
ELECTRICAL CIRCUIT DIAGRAM (8/9) 2841
ELECTRICAL CIRCUIT DIAGRAM (9/9) 2843
INDEX 2845

DESCRIPTION:

Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Hydraulic Excavator Shop Manual UENBM00483 – PDF DOWNLOAD

SERIAL NUMBERS

• PC290LC-11E0 – K75001 ~ K75244
• PC290NLC-11E0 – K75001 ~ K75245

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

G.B 31/12/24