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

Description

Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Hydraulic Excavator Shop Manual UENBM00481 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Hydraulic Excavator Shop Manual UENBM00481 – PDF DOWNLOAD

Language : English
Pages : 2806
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Hydraulic Excavator Shop Manual UENBM00481 – PDF DOWNLOAD

• SERIAL NUMBERS K75001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC290LC-11E0, PC290NLC-11E0 101
WORKING RANGE DRAWINGS 103
WORKING RANGE: PC290LC-11E0, PC290NLC-11E0 103
SPECIFICATIONS 104
SPECIFICATIONS: PC290LC-11E0, PC290NLC-11E0 . 104
WEIGHT TABLE 107
WEIGHT TABLE: PC290LC-11E0, PC290NLC-11E0 . 107
TABLE OF FUEL, COOLANT, AND LUBRICANTS 109
10 STRUCTURE AND FUNCTION . 111
CONTENTS 112
ABBREVIATION LIST . 116
UREA SCR SYSTEM . 122
LAYOUT DRAWING OF UREA SCR SYSTEM . 123
UREA SCR SYSTEM DIAGRAM . 128
FUNCTION OF UREA SCR SYSTEM . 129
FUNCTION OF AdBlue/DEF SYSTEM . 129
INDUCEMENT STRATEGY . 131
COMPONENT PARTS OF UREA SCR SYSTEM 139
AdBlue/DEF MIXING TUBE 139
SCR ASSEMBLY 139
AdBlue/DEF TANK . 142
AdBlue/DEF PUMP . 144
AdBlue/DEF INJECTOR . 145
AdBlue/DEF HOSE . 146
AdBlue/DEF TANK HEATING VALVE . 147
BOOT-UP SYSTEM 148
LAYOUT DRAWING OF BOOT-UP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM 150
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 150
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 150
BATTERY DISCONNECT SWITCH . 152
FUNCTION OF BATTERY DISCONNECT SWITCH . 152
ENGINE SYSTEM . 153
LAYOUT DRAWING OF ENGINE SYSTEM . 153
SPECIFICATIONS OF ENGINE SYSTEM . 154
FUNCTION OF ENGINE SYSTEM . 154
ENGINE CONTROL SYSTEM . 155
ENGINE CONTROL SYSTEM DIAGRAM . 155
FUNCTION OF ENGINE CONTROL SYSTEM . 156
AUTO-DECELERATION SYSTEM 158
AUTO-DECELERATION SYSTEM DIAGRAM 158
FUNCTION OF AUTO-DECELERATION SYSTEM 158
OPERATION OF AUTO-DECELERATION SYSTEM . 159
ENGINE AUTOMATIC WARM-UP SYSTEM . 160
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 160
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 161
OVERHEAT PREVENTION SYSTEM 162
OVERHEAT PREVENTION SYSTEM DIAGRAM 162
FUNCTION OF OVERHEAT PREVENTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM 165
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 165
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 166
AUTOMATIC IDLE STOP SYSTEM 167
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 167
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 167
COMPONENT PARTS OF ENGINE SYSTEM 170
VGT . 170
EGR SYSTEM 174
EGR VALVE . 176
EGR COOLER 178
KCCV SYSTEM . 179
KCCV VENTILATOR . 181
KDPF 183
COOLING SYSTEM 188
LAYOUT DRAWING OF COOLING SYSTEM 188
SPECIFICATIONS OF COOLING SYSTEM 189
CONTROL SYSTEM 190
LAYOUT DRAWING OF CONTROL SYSTEM 190
MACHINE MONITOR SYSTEM 193
MACHINE MONITOR SYSTEM DIAGRAM 193
KomVision SYSTEM 194
LAYOUT DRAWING OF KOMVISION SYSTEM 194
KomVision SYSTEM DIAGRAM 196
FUNCTION OF KomVision SYSTEM 196
KOMTRAX SYSTEM 198
KOMTRAX SYSTEM DIAGRAM 198
FUNCTION OF KOMTRAX SYSTEM 198
PPC LEVERS 199
LH PPC LEVER 199
RH PPC LEVER 200
AUTOMATIC GREASE SYSTEM . 201
OUTLINE OF AUTO GREASE SYSTEM . 201
COMPONENT PARTS OF CONTROL SYSTEM . 216
MACHINE MONITOR . 216
KomVision CONTROLLER 234
KomVision CAMERA 238
KOMTRAX TERMINAL 238
PUMP CONTROLLER . 241
RESISTOR FOR PC-EPC VALVE . 245
CAN TERMINATING RESISTOR 245
PPC OIL PRESSURE SWITCH . 246
ENGINE CONTROLLER . 247
FUEL CONTROL DIAL . 253
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 254
FUNCTION OF ENGINE OIL PRESSURE SWITCH 255
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 255
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 256
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 256
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 256
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 256
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 256
STRUCTURE OF OVERLOAD CAUTION SENSOR 256
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 257
FUNCTION OF OVERLOAD CAUTION SENSOR . 257
HYDRAULIC SYSTEM 258
LAYOUT DRAWING OF HYDRAULIC SYSTEM 258
CLSS 264
STRUCTURE OF CLSS . 264
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 266
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 267
PRESSURE COMPENSATION CONTROL . 280
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 283
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 283
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 284
PUMP AND VALVE CONTROL SYSTEM . 289
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 289
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 290
COMPONENT PARTS OF HYDRAULIC SYSTEM . 292
HYDRAULIC TANK 292
MAIN PUMP . 294
PC-EPC VALVE 318
PILOT OIL FILTER 320
CONTROL VALVE . 320
WORK EQUIPMENT SYSTEM . 377
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 377
STRUCTURE OF VALVE CONTROL 382
ONE-TOUCH POWER MAXIMIZING SYSTEM . 384
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 384
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 385
PPC LOCK SYSTEM . 386
PPC LOCK SYSTEM DIAGRAM . 386
FUNCTION OF PPC LOCK SYSTEM . 386
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 387
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 387
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 387
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 388
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 389
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 389
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 391
TOOL CONTROL SYSTEM . 392
TOOL CONTROL SYSTEM DIAGRAM . 392
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 394
WORK EQUIPMENT AND SWING PPC VALVE 394
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 399
SOLENOID VALVE 405
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 408
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 410
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 413
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 415
ATTACHMENT BYPASS SOLENOID VALVE 418
ATT EPC VALVE ASSEMBLY 420
PILOT CIRCUIT ACCUMULATOR . 421
ATTACHMENT CIRCUIT ACCUMULATOR 422
SWING SYSTEM 423
LAYOUT DRAWING OF SWING SYSTEM 423
SWING CONTROL SYSTEM DIAGRAM 427
FUNCTION OF SWING CONTROL SYSTEM 427
COMPONENT PARTS OF SWING SYSTEM . 431
SWING MOTOR . 431
SWING MACHINERY . 442
SWING CIRCLE 443
TRAVEL SYSTEM . 445
LAYOUT DRAWING OF TRAVEL SYSTEM . 445
TRAVEL CONTROL SYSTEM DIAGRAM . 449
FUNCTION OF TRAVEL CONTROL SYSTEM . 449
COMPONENT PARTS OF TRAVEL SYSTEM 451
TRAVEL MOTOR 451
FINAL DRIVE . 463
TRAVEL PPC VALVE 464
CENTER SWIVEL JOINT . 469
UNDERCARRIAGE AND FRAME . 471
LAYOUT DRAWING OF UNDERCARRIAGE . 471
SPECIFICATIONS OF UNDERCARRIAGE . 472
WORK EQUIPMENT 473
STRUCTURE OF WORK EQUIPMENT . 473
FUNCTION OF WORK EQUIPMENT 474
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 475
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 475
BUCKET CLEARANCE ADJUSTMENT SHIM 476
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 476
CAB AND ITS ATTACHMENTS . 477
ROPS CAB 477
STRUCTURE OF ROPS CAB . 477
FUNCTION OF ROPS CAB 477
CAB MOUNT . 478
STRUCTURE OF CAB MOUNT 478
FUNCTION OF CAB MOUNT . 478
CAB TIPPING STOPPER . 479
STRUCTURE OF CAB TIPPING STOPPER 479
FUNCTION OF CAB TIPPING STOPPER . 479
20 STANDARD VALUE TABLE . 481
CONTENTS 482
ABBREVIATION LIST . 483
STANDARD VALUE TABLE FOR ENGINE . 489
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11E0, PC290NLC-11E0 489
STANDARD VALUE TABLE FOR MACHINE 493
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11E0, PC290NLC-11E0 . 493
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 506
STANDARD VALUE TABLE FOR ELECTRICAL . 510
STANDARD VALUE TABLE FOR ELECTRICAL . 510
30 TESTING AND ADJUSTING 521
CONTENTS 522
ABBREVIATION LIST . 525
RELATED INFORMATION ON TESTING AND ADJUSTING 531
TOOLS FOR TESTING AND ADJUSTING . 531
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 538
ENGINE AND COOLING SYSTEM . 540
TEST ENGINE SPEED . 540
METHOD FOR TESTING ENGINE SPEED . 540
TEST BOOST PRESSURE . 543
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 543
METHOD FOR TESTING BOOST PRESSURE . 544
TEST EXHAUST GAS COLOR 545
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 545
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 546
TEST AND ADJUST VALVE CLEARANCE . 548
METHOD FOR TESTING VALVE CLEARANCE 548
METHOD FOR ADJUSTING VALVE CLEARANCE 549
TEST COMPRESSION PRESSURE . 551
METHOD FOR TESTING COMPRESSION PRESSURE . 551
TEST BLOWBY PRESSURE 556
METHOD FOR TESTING BLOWBY PRESSURE 556
TEST ENGINE OIL PRESSURE 558
METHOD FOR TESTING ENGINE OIL PRESSURE 558
TEST EGR VALVE AND VGT OIL PRESSURE . 559
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 559
TEST FUEL PRESSURE 561
METHOD FOR TESTING FUEL PRESSURE 562
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 567
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 568
BLEEDING AIR FROM FUEL SYSTEM . 574
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 574
TEST FUEL CIRCUIT FOR LEAKAGE . 575
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 575
HANDLE CYLINDER CUT-OUT MODE OPERATION 577
HANDLE NO-INJECTION CRANKING OPERATION 578
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 579
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 579
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 579
REPLACING FAN BELT 581
METHOD FOR REPLACING FAN BELT . 581
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 582
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 582
TEST SCR RELATED FUNCTIONS 583
TEST AdBlue/DEF PUMP RAISED PRESSURE 586
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 589
TEST AdBlue/DEF LINE HEATER RELAY 1 . 593
TEST AdBlue/DEF LINE HEATER RELAY 2 . 596
TEST AdBlue/DEF PUMP HEATER RELAY . 598
TEST AdBlue/DEF TANK HEATER VALVE . 601
TEST DENITRATION EFFICIENCY OF SCR 604
CLEAN AdBlue/DEF TANK . 608
METHOD FOR CLEANING AdBlue/DEF TANK . 608
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 612
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 612
POWER TRAIN . 614
TEST SWING CIRCLE BEARING CLEARANCE . 614
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 614
UNDERCARRIAGE AND FRAME . 615
TEST AND ADJUST TRACK TENSION . 615
METHOD FOR TESTING TRACK TENSION 615
METHOD FOR ADJUSTING TRACK TENSION 615
HYDRAULIC SYSTEM 617
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 617
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 617
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 623
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 624
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 630
TEST OIL PRESSURE OF CONTROL CIRCUIT 633
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 633
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 635
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 635
TEST PC-EPC VALVE OUTLET PRESSURE . 636
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 637
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 639
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 639
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 640
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 643
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 644
METHOD FOR ADJUSTING LS VALVE . 645
TEST OUTLET PRESSURE OF SOLENOID VALVE 646
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 646
OPERATING CONDITION OF SOLENOID VALVE . 647
TEST PPC VALVE OUTLET PRESSURE 650
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 650
TEST ATTACHMENT CIRCUIT OIL PRESSURE 652
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 652
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 654
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 654
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 655
TEST PUMP SWASH PLATE SENSOR 657
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 657
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 658
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 658
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 658
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 659
TEST OIL LEAKAGE 660
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 660
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 660
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 661
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 662
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 662
BLEED AIR FROM HYDRAULIC CIRCUIT 663
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 665
CAB AND ITS ATTACHMENTS . 667
TEST CAB TIPPING STOPPER 667
METHOD FOR TESTING CAB TIPPING STOPPER 667
METHOD FOR ADJUSTING MIRRORS 668
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 668
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 669
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 670
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 671
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 672
ELECTRICAL SYSTEM . 674
ELECTRICAL SYSTEM . 675
SET AND OPERATE MACHINE MONITOR . 675
OPERATOR MODE . 678
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 679
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 679
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 680
CHECKING FUNCTION OF SERVICE METER 680
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 680
SERVICE MODE 683
METHOD FOR OPERATING SERVICE MODE . 684
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 687
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 693
ABNORMALITY RECORD MENU . 703
METHOD FOR CONFIRMING MAINTENANCE RECORD 708
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 709
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 713
DEFAULT MENU 714
DIAGNOSTIC TESTS MENU . 725
ADJUSTMENT MENU . 735
METHOD FOR PERFORMING NO-INJECTION CRANKING . 769
KOMTRAX SETTINGS MENU . 770
METHOD FOR DISPLAYING SERVICE MESSAGE . 772
METHOD FOR STARTING UP KOMTRAX TERMINAL . 774
ADJUST REARVIEW CAMERA ANGLE 779
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 779
ADJUST KomVision CAMERA ANGLE . 782
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 783
ADJUST KomVision RELATED ITEMS 787
SETTING OF KomVision (MAIN SETTING) . 787
SETTING OF KomVision (CAMERA SETTING) . 789
SETTING OF KomVision (CAMERA CALIBRATION) . 789
KomVision screen – Check 12 m visibility 803
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 806
HANDLE BATTERY DISCONNECT SWITCH 807
TEST DIODES . 808
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 808
METHOD FOR TESTING DIODE USING ANALOG TESTER 808
Pm CLINIC . 809
Pm CLINIC SERVICE . 809
Pm CLINIC CHECK SHEET . 813
40 TROUBLESHOOTING 825
CONTENTS 826
ABBREVIATION LIST . 837
RELATED INFORMATION ON TROUBLESHOOTING 843
GENERAL TROUBLESHOOTING POINTS 843
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 844
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 856
CHECKS BEFORE TROUBLESHOOTING . 858
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 860
WALK-AROUND CHECK . 860
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 862
CHECK FUEL LEVEL AND TYPE . 862
CHECK IMPURE INGREDIENT IN FUEL . 862
CHECK FUEL PREFILTER 863
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 863
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 864
CHECK MAIN FILTER . 865
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 867
CHECK COOLANT LEVEL (RESERVOIR TANK) 868
CHECK CLOGGING OF AIR CLEANER . 868
OUTER ELEMENT – CLEAN . 869
ELEMENTS – REPLACE 871
CHECK HYDRAULIC OIL LEVEL . 872
CHECK HYDRAULIC OIL STRAINER 873
CHECK HYDRAULIC FILTER 874
CHECK OIL LEVEL IN SWING MACHINERY CASE . 875
CHECK OIL LEVEL IN DAMPER CASE 876
CHECK OIL LEVEL IN FINAL DRIVE CASE . 876
BLEED AIR FROM FUEL SYSTEM 877
BLEED AIR FROM HYDRAULIC SYSTEM . 877
ELECTRICAL EQUIPMENT – CHECK METHOD . 877
AUTOMATIC GREASE SYSTEM . 885
FINDING MALFUNCTIONS 885
MALFUNCTION FINDING PROCEDURES 887
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 889
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 899
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 902
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 906
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 908
CONNECTOR LIST AND LAYOUT . 911
CONNECTOR CONTACT IDENTIFICATION 924
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 964
FUSE LOCATION TABLE . 970
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 972
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 976
FAILURE CODE TABLE 978
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 996
FAILURE CODE [879AKA] . 996
FAILURE CODE [879AKB] . 997
FAILURE CODE [879BKA] . 998
FAILURE CODE [879BKB] .1000
FAILURE CODE [879CKA] .1002
FAILURE CODE [879CKB] .1003
FAILURE CODE [879DKZ] .1004
FAILURE CODE [879EMC] .1006
FAILURE CODE [879FMC] .1007
FAILURE CODE [879GKX] .1008
FAILURE CODE [989L00] .1010
FAILURE CODE [989M00] .1011
FAILURE CODE [989N00] .1012
FAILURE CODE [A1U0N3] .1013
FAILURE CODE [A1U0N4] .1015
FAILURE CODE [A900FR] .1017
FAILURE CODE [A900N6] .1018
FAILURE CODE [A900NY] .1019
FAILURE CODE [AA10NX] .1020
FAILURE CODE [AB00KE] .1022
FAILURE CODE [AQ10N3] .1025
FAILURE CODE [AS00N3] .1027
FAILURE CODE [AS00R2] .1029
FAILURE CODE [AS00R3] .1030
FAILURE CODE [AS00R4] .1031
FAILURE CODE [AS00R5] .1032
FAILURE CODE [AS00R6] .1033
FAILURE CODE [AS00ZK] .1034
FAILURE CODE [AS10KM] .1035
FAILURE CODE [AS10NR] .1036
FAILURE CODE [AS10NT] .1037
FAILURE CODE [B@BAZG] .1038
FAILURE CODE [B@BAZK] .1039
FAILURE CODE [B@BCNS] .1041
FAILURE CODE [B@BCQA] .1042
FAILURE CODE [B@BCZK] .1044
FAILURE CODE [B@HANS] .1046
FAILURE CODE [CA115] 1047
FAILURE CODE [CA122] 1048
FAILURE CODE [CA123] 1050
FAILURE CODE [CA131] 1052
FAILURE CODE [CA132] 1054
FAILURE CODE [CA144] 1056
FAILURE CODE [CA145] 1058
FAILURE CODE [CA153] 1060
FAILURE CODE [CA154] 1063
FAILURE CODE [CA187] 1065
FAILURE CODE [CA221] 1067
FAILURE CODE [CA222] 1069
FAILURE CODE [CA227] 1071
FAILURE CODE [CA234] 1072
FAILURE CODE [CA238] 1073
FAILURE CODE [CA239] 1075
FAILURE CODE [CA249] 1077
FAILURE CODE [CA256] 1079
FAILURE CODE [CA271] 1081
FAILURE CODE [CA272] 1083
FAILURE CODE [CA322] 1085
FAILURE CODE [CA323] 1087
FAILURE CODE [CA324] 1089
FAILURE CODE [CA325] 1091
FAILURE CODE [CA331] 1093
FAILURE CODE [CA332] 1095
FAILURE CODE [CA343] 1097
FAILURE CODE [CA351] 1098
FAILURE CODE [CA352] 1099
FAILURE CODE [CA356] 1102
FAILURE CODE [CA357] 1104
FAILURE CODE [CA386] 1106
FAILURE CODE [CA428] 1107
FAILURE CODE [CA429] 1109
FAILURE CODE [CA435] 1111
FAILURE CODE [CA441] 1113
FAILURE CODE [CA442] 1115
FAILURE CODE [CA449] 1116
FAILURE CODE [CA451] 1117
FAILURE CODE [CA452] 1119
FAILURE CODE [CA488] 1121
FAILURE CODE [CA515] 1122
FAILURE CODE [CA516] 1124
FAILURE CODE [CA553] 1126
FAILURE CODE [CA555] 1127
FAILURE CODE [CA556] 1128
FAILURE CODE [CA559] 1129
FAILURE CODE [CA595] 1132
FAILURE CODE [CA687] 1133
FAILURE CODE [CA689] 1135
FAILURE CODE [CA691] 1138
FAILURE CODE [CA692] 1140
FAILURE CODE [CA697] 1142
FAILURE CODE [CA698] 1143
FAILURE CODE [CA731] 1144
FAILURE CODE [CA778] 1146
FAILURE CODE [CA1117] .1151
FAILURE CODE [CA1664] .1152
FAILURE CODE [CA1669] .1154
FAILURE CODE [CA1673] .1155
FAILURE CODE [CA1677] .1156
FAILURE CODE [CA1678] .1157
FAILURE CODE [CA1682] .1158
FAILURE CODE [CA1683] .1160
FAILURE CODE [CA1684] .1162
FAILURE CODE [CA1686] .1164
FAILURE CODE [CA1691] .1165
FAILURE CODE [CA1694] .1168
FAILURE CODE [CA1695] .1171
FAILURE CODE [CA1696] .1172
FAILURE CODE [CA1712] .1174
FAILURE CODE [CA1713] .1177
FAILURE CODE [CA1714] .1179
FAILURE CODE [CA1715] .1180
FAILURE CODE [CA1776] .1181
FAILURE CODE [CA1777] .1184
FAILURE CODE [CA1843] .1187
FAILURE CODE [CA1844] .1189
FAILURE CODE [CA1879] .1192
FAILURE CODE [CA1881] .1194
FAILURE CODE [CA1883] .1196
FAILURE CODE [CA1885] .1199
FAILURE CODE [CA1887] .1201
FAILURE CODE [CA1921] .1203
FAILURE CODE [CA1922] .1206
FAILURE CODE [CA1942] .1211
FAILURE CODE [CA1993] .1212
FAILURE CODE [CA2185] .1215
FAILURE CODE [CA2186] .1216
FAILURE CODE [CA2249] .1218
FAILURE CODE [CA2271] .1219
FAILURE CODE [CA2272] .1222
FAILURE CODE [CA2288] .1225
FAILURE CODE [CA2311] .1226
FAILURE CODE [CA2349] .1227
FAILURE CODE [CA2353] .1230
FAILURE CODE [CA2357] .1232
FAILURE CODE [CA2381] .1233
FAILURE CODE [CA2382] .1236
FAILURE CODE [CA2383] .1239
FAILURE CODE [CA2386] .1242
FAILURE CODE [CA2387] .1244
FAILURE CODE [CA2555] .1245
FAILURE CODE [CA2556] .1248
FAILURE CODE [CA2637] .1251
FAILURE CODE [CA2639] .1253
FAILURE CODE [CA2771] .1256
FAILURE CODE [CA2777] .1262
FAILURE CODE [CA2976] .1265
FAILURE CODE [CA3133] .1267
FAILURE CODE [CA3134] .1270
FAILURE CODE [CA3135] .1272
FAILURE CODE [CA3142] .1275
FAILURE CODE [CA3143] .1276
FAILURE CODE [CA3144] .1277
FAILURE CODE [CA3146] .1279
FAILURE CODE [CA3147] .1280
FAILURE CODE [CA3148] .1281
FAILURE CODE [CA3151] .1283
FAILURE CODE [CA3165] .1289
FAILURE CODE [CA3229] .1291
FAILURE CODE [CA3231] .1293
FAILURE CODE [CA3232] .1295
FAILURE CODE [CA3235] .1299
FAILURE CODE [CA3239] .1301
FAILURE CODE [CA3241] .1304
FAILURE CODE [CA3242] .1307
FAILURE CODE [CA3251] .1310
FAILURE CODE [CA3253] .1312
FAILURE CODE [CA3254] .1315
FAILURE CODE [CA3255] .1318
FAILURE CODE [CA3256] .1322
FAILURE CODE [CA3311] .1324
FAILURE CODE [CA3312] .1326
FAILURE CODE [CA3313] .1329
FAILURE CODE [CA3314] .1330
FAILURE CODE [CA3315] .1331
FAILURE CODE [CA3316] .1333
FAILURE CODE [CA3317] .1334
FAILURE CODE [CA3318] .1335
FAILURE CODE [CA3319] .1337
FAILURE CODE [CA3321] .1338
FAILURE CODE [CA3322] .1340
FAILURE CODE [CA3419] .1342
FAILURE CODE [CA3421] .1344
FAILURE CODE [CA3497] .1346
FAILURE CODE [CA3498] .1347
FAILURE CODE [CA3543] .1348
FAILURE CODE [CA3545] .1355
FAILURE CODE [CA3547] .1357
FAILURE CODE [CA3558] .1358
FAILURE CODE [CA3559] .1360
FAILURE CODE [CA3562] .1362
FAILURE CODE [CA3563] .1364
FAILURE CODE [CA3567] .1367
FAILURE CODE [CA3568] .1370
FAILURE CODE [CA3571] .1374
FAILURE CODE [CA3572] .1376
FAILURE CODE [CA3574] .1378
FAILURE CODE [CA3575] .1380
FAILURE CODE [CA3577] .1382
FAILURE CODE [CA3578] .1384
FAILURE CODE [CA3582] .1386
FAILURE CODE [CA3583] .1392
FAILURE CODE [CA3596] .1394
FAILURE CODE [CA3649] .1396
FAILURE CODE [CA3681] .1398
FAILURE CODE [CA3682] .1403
FAILURE CODE [CA3713] .1409
FAILURE CODE [CA3717] .1412
FAILURE CODE [CA3718] .1413
FAILURE CODE [CA3725] .1414
FAILURE CODE [CA3741] .1417
FAILURE CODE [CA3748] .1418
FAILURE CODE [CA3751] .1420
FAILURE CODE [CA3755] .1422
FAILURE CODE [CA3866] .1424
FAILURE CODE [CA3867] .1428
FAILURE CODE [CA3868] .1431
FAILURE CODE [CA3899] .1435
FAILURE CODE [CA3911] .1437
FAILURE CODE [CA3912] .1441
FAILURE CODE [CA3932] .1443
FAILURE CODE [CA3933] .1445
FAILURE CODE [CA3934] .1447
FAILURE CODE [CA3935] .1450
FAILURE CODE [CA3936] .1452
FAILURE CODE [CA4151] .1454
FAILURE CODE [CA4152] .1458
FAILURE CODE [CA4155] .1462
FAILURE CODE [CA4156] .1464
FAILURE CODE [CA4157] .1467
FAILURE CODE [CA4158] .1469
FAILURE CODE [CA4159] .1470
FAILURE CODE [CA4161] .1471
FAILURE CODE [CA4162] .1474
FAILURE CODE [CA4163] .1477
FAILURE CODE [CA4164] .1478
FAILURE CODE [CA4165] .1480
FAILURE CODE [CA4166] .1482
FAILURE CODE [CA4168] .1483
FAILURE CODE [CA4169] .1486
FAILURE CODE [CA4171] .1488
FAILURE CODE [CA4249] .1491
FAILURE CODE [CA4251] .1493
FAILURE CODE [CA4259] .1495
FAILURE CODE [CA4261] .1498
FAILURE CODE [CA4277] .1501
FAILURE CODE [CA4281] .1505
FAILURE CODE [CA4459] .1508
FAILURE CODE [CA4461] .1511
FAILURE CODE [CA4658] .1514
FAILURE CODE [CA4731] .1518
FAILURE CODE [CA4732] .1519
FAILURE CODE [CA4739] .1520
FAILURE CODE [CA4768] .1521
FAILURE CODE [CA4769] .1523
FAILURE CODE [CA4842] .1526
FAILURE CODE [CA4952] .1530
FAILURE CODE [CA5115] .1532
FAILURE CODE [CA5179] .1535
FAILURE CODE [CA5181] .1537
FAILURE CODE [CA5383] .1539
FAILURE CODE [D110KB] .1541
FAILURE CODE [D19JKZ] .1543
FAILURE CODE [D811MC] .1546
FAILURE CODE [D862KA] .1547
FAILURE CODE [D8ALKA] .1548
FAILURE CODE [D8ALKB] .1550
FAILURE CODE [D8AQKR] .1552
FAILURE CODE [DA20MC] .1554
FAILURE CODE [DA22KK] .1555
FAILURE CODE [DA25KP] .1558
FAILURE CODE [DA26KP] .1561
FAILURE CODE [DA29KQ] .1564
FAILURE CODE [DA2LKA] .1566
FAILURE CODE [DA2LKB] .1568
FAILURE CODE [DA2QKR] .1570
FAILURE CODE [DA2RKR] .1573
FAILURE CODE [DAF0KM] .1574
FAILURE CODE [DAF0MB] .1575
FAILURE CODE [DAF0MC] .1576
FAILURE CODE [DAF8KB] .1577
FAILURE CODE [DAF9KQ] .1579
FAILURE CODE [DAFGMC] .1580
FAILURE CODE [DAFLKA] .1581
FAILURE CODE [DAFLKB] .1583
FAILURE CODE [DAFQKR] .1585
FAILURE CODE [DAZ9KQ] .1586
FAILURE CODE [DAZQKR] .1587
FAILURE CODE [DB2QKR] .1592
FAILURE CODE [DB2RKR] .1597
FAILURE CODE [DBP0KM] .1602
FAILURE CODE [DBP0KT] .1603
FAILURE CODE [DBP5KB] .1604
FAILURE CODE [DBP5KY] .1607
FAILURE CODE [DBPQKR] .1610
FAILURE CODE [DDNRKA] .1615
FAILURE CODE [DDNRKY] .1617
FAILURE CODE [DDNS00] .1619
FAILURE CODE [DFB1KZ] .1621
FAILURE CODE [DFB2KZ] .1624
FAILURE CODE [DFB3L8] .1627
FAILURE CODE [DFB4L8] .1629
FAILURE CODE [DFB5KZ] .1631
FAILURE CODE [DFB6KZ] .1634
FAILURE CODE [DGH2KA] .1637
FAILURE CODE [DGH2KB] .1639
FAILURE CODE [DHA4KA] .1641
FAILURE CODE [DHAAMA] .1643
FAILURE CODE [DHACMA] .1645
FAILURE CODE [DHPAMA] .1647
FAILURE CODE [DHPBMA] .1650
FAILURE CODE [DHS3MA] .1653
FAILURE CODE [DHS4MA] .1656
FAILURE CODE [DHS8MA] .1659
FAILURE CODE [DHS9MA] .1662
FAILURE CODE [DHSAMA] .1665
FAILURE CODE [DHSBMA] .1668
FAILURE CODE [DHSCMA] .1671
FAILURE CODE [DHSDMA] .1674
FAILURE CODE [DHSFMA] .1677
FAILURE CODE [DHSGMA] .1680
FAILURE CODE [DHSHMA] .1683
FAILURE CODE [DHSJMA] .1686
FAILURE CODE [DHX1MA] .1689
FAILURE CODE [DKR0MA] .1692
FAILURE CODE [DKR1MA] .1695
FAILURE CODE [DKULKA] .1698
FAILURE CODE [DKULKB] .1700
FAILURE CODE [DKULKY] .1702
FAILURE CODE [DR10KA] .1704
FAILURE CODE [DR12KA] .1707
FAILURE CODE [DR20KA] .1709
FAILURE CODE [DR21KX] .1711
FAILURE CODE [DR30KA] .1713
FAILURE CODE [DR31KX] .1715
FAILURE CODE [DR40KA] .1717
FAILURE CODE [DUMBKA] .1719
FAILURE CODE [DUMBKB] .1721
FAILURE CODE [DV20KB] .1723
FAILURE CODE [DW43KA] .1725
FAILURE CODE [DW43KB] .1727
FAILURE CODE [DW43KY] .1729
FAILURE CODE [DW45KA] .1731
FAILURE CODE [DW45KB] .1734
FAILURE CODE [DW45KY] .1737
FAILURE CODE [DW4CKY] .1739
FAILURE CODE [DW91KA] .1741
FAILURE CODE [DW91KB] .1743
FAILURE CODE [DW91KY] .1745
FAILURE CODE [DWA2KA] .1747
FAILURE CODE [DWA2KB] .1749
FAILURE CODE [DWA2KY] .1751
FAILURE CODE [DWK0KA] .1753
FAILURE CODE [DWK0KB] .1755
FAILURE CODE [DWK0KY] .1757
FAILURE CODE [DWK2KA] .1759
FAILURE CODE [DWK2KB] .1761
FAILURE CODE [DWK2KY] .1763
FAILURE CODE [DWK8KA] .1765
FAILURE CODE [DWK8KB] .1767
FAILURE CODE [DWK8KY] .1769
FAILURE CODE [DXA8KA] .1771
FAILURE CODE [DXA8KB] .1773
FAILURE CODE [DXA9KA] .1775
FAILURE CODE [DXA9KB] .1777
FAILURE CODE [DXE0KA] .1779
FAILURE CODE [DXE0KB] .1780
FAILURE CODE [DXE4KA] .1782
FAILURE CODE [DXE4KB] .1784
FAILURE CODE [DXE4KY] .1786
FAILURE CODE [DXE5KA] .1788
FAILURE CODE [DXE5KB] .1790
FAILURE CODE [DXE6KA] .1792
FAILURE CODE [DXE6KB] .1794
FAILURE CODE [DXE7KA] .1796
FAILURE CODE [DXE7KB] .1798
FAILURE CODE [DXE7KY] .1800
FAILURE CODE [DXE8KA] .1802
FAILURE CODE [DXE8KB] .1804
FAILURE CODE [DXE8KY] .1806
FAILURE CODE [DXE9KA] .1808
FAILURE CODE [DXE9KB] .1810
FAILURE CODE [DXE9KY] .1812
FAILURE CODE [DXEAKA] .1814
FAILURE CODE [DXEAKB] .1816
FAILURE CODE [DXEAKY] .1818
FAILURE CODE [DY20KA] .1820
FAILURE CODE [DY20MA] .1822
FAILURE CODE [DY2CKB] .1824
FAILURE CODE [DY2DKB] .1827
FAILURE CODE [DY2EKB] .1829
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1831
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1831
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1837
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1840
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1842
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1844
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1847
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1848
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1849
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1850
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1851
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1852
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1853
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1854
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1855
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1856
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1857
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1858
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1860
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1861
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1862
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1863
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1865
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1866
E-24 FUNCTION SWITCH DOES NOT OPERATE .1867
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1868
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1869
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1870
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1871
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1872
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1873
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1874
E-32 ALARM BUZZER CANNOT BE CANCELED 1876
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1877
E-34 SERVICE MODE CANNOT BE SELECTED 1878
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1879
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1882
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1884
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1887
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1889
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1892
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1893
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1895
E-43 HORN DOES NOT SOUND 1896
E-44 HORN DOES NOT STOP SOUNDING 1899
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1901
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1902
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1904
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1905
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1906
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1907
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1908
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1909
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1910
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1911
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1912
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1913
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1915
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1916
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1917
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1917
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1918
FAILURE MODE AND CAUSE TABLE 1920
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1929
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1930
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1933
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1934
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1935
H-6 SPEED OR POWER OF BOOM IS LOW .1937
H-7 ARM SPEED OR POWER IS LOW .1941
H-8 BUCKET SPEED OR POWER IS LOW 1946
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1949
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1950
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1952
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1954
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1955
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1956
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1957
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1958
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1959
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1960
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1961
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1962
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1963
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1965
H-23 TRAVEL SPEED IS LOW 1968
H-24 ONE OF TRACKS DOES NOT RUN .1970
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1971
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1972
H-27 SWINGS ONLY IN ONE DIRECTION .1973
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1974
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1975
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1976
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1977
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1978
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1979
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1980
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1981
H-36 Quick coupler cylinder will not extend .1982
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .1984
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .1986
H-39 Quick coupler cylinder extends and retracts slowly .1988
TROUBLESHOOTING OF ENGINE (S-MODE) 1989
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1989
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1990
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1991
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1992
S-4 ENGINE STARTABILITY IS POOR .1994
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1996
S-6 ENGINE STOPS DURING OPERATION .1998
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2000
S-8 ENGINE LACKS POWER 2001
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2003
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2005
S-11 OIL BECOMES CONTAMINATED QUICKLY .2006
S-12 FUEL CONSUMPTION IS EXCESSIVE 2007
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2008
S-14 OIL PRESSURE DROPS .2009
S-15 FUEL MIXES INTO ENGINE OIL .2011
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2012
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2013
S-18 UNUSUAL NOISE IS HEARD .2014
S-19 VIBRATION IS EXCESSIVE .2015
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2016
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2017
S-22 ACTIVE REGENERATION TAKES TIME .2019
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2020
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2021
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2023
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2024
50 DISASSEMBLY AND ASSEMBLY .2025
CONTENTS 2026
ABBREVIATION LIST .2031
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2037
HOW TO READ THIS MANUAL .2037
COATING MATERIALS LIST 2039
SPECIAL TOOLS LIST 2043
SKETCHES OF SPECIAL TOOLS .2055
ENGINE AND COOLING SYSTEM .2061
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2061
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2061
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2064
REMOVE AND INSTALL INJECTOR ASSEMBLY 2068
METHOD FOR REMOVING INJECTOR ASSEMBLY .2068
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2073
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2081
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2082
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2091
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2107
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2107
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2108
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2111
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2111
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2114
REMOVE AND INSTALL STARTER ASSEMBLY .2119
METHOD FOR REMOVING STARTER ASSEMBLY 2119
METHOD FOR INSTALLING STARTER ASSEMBLY 2121
REMOVE AND INSTALL ALTERNATOR BELT 2123
METHOD FOR REMOVING ALTERNATOR BELT .2123
METHOD FOR INSTALLING ALTERNATOR BELT .2125
REMOVE AND INSTALL RADIATOR ASSEMBLY 2127
METHOD FOR REMOVING RADIATOR ASSEMBLY .2127
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2129
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2131
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2131
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2134
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2137
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2137
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2138
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2140
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2141
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2149
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2160
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2160
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2163
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2167
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2167
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2168
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2171
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2171
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2172
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2173
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2173
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2175
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2181
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2181
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2185
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2191
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2191
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2196
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2202
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2202
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2207
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2213
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2213
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2213
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2215
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2215
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2215
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2216
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2216
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2218
REMOVE AND INSTALL KDPF ASSEMBLY 2221
METHOD FOR REMOVING KDPF ASSEMBLY .2221
METHOD FOR INSTALLING KDPF ASSEMBLY .2223
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2225
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2226
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2229
REMOVE AND INSTALL SCR ASSEMBLY .2234
METHOD FOR REMOVING SCR ASSEMBLY 2234
METHOD FOR INSTALLING SCR ASSEMBLY 2236
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2238
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2238
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2244
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2250
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2250
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2258
REMOVE AND INSTALL KCCV ASSEMBLY 2267
METHOD FOR REMOVING KCCV ASSEMBLY .2267
METHOD FOR INSTALLING KCCV ASSEMBLY .2269
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2274
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2274
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2279
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2284
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2284
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2286
REMOVE AND INSTALL AdBlue/DEF PUMP 2288
METHOD FOR REMOVING AdBlue/DEF PUMP .2288
METHOD FOR INSTALLING AdBlue/DEF PUMP .2290
REMOVE AND INSTALL AdBlue/DEF HOSE 2293
METHOD FOR REMOVING AdBlue/DEF HOSE .2293
METHOD FOR INSTALLING AdBlue/DEF HOSE .2301
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2307
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2307
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2308
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2310
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2310
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2312
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2315
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2315
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2316
POWER TRAIN .2317
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2317
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2317
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2318
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2319
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2319
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2323
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2332
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2332
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2334
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2338
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2338
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2342
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2349
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2349
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2349
UNDERCARRIAGE AND FRAME .2351
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2351
METHOD FOR SEPARATING TRACK ASSEMBLY 2351
METHOD FOR INSTALLING TRACK ASSEMBLY 2353
REMOVE AND INSTALL SPROCKET .2356
METHOD FOR REMOVING SPROCKET 2356
METHOD FOR INSTALLING SPROCKET 2356
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2358
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2358
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2359
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2360
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2360
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2361
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2365
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2366
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2367
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2368
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2369
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2370
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2372
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2372
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2373
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2376
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2376
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2378
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2380
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2380
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2383
HYDRAULIC SYSTEM 2387
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2387
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2387
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2389
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2392
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2393
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2394
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2395
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2395
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2398
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2401
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2401
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2404
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2407
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2407
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2414
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2422
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2422
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2424
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2428
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2428
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2428
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2430
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2430
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2431
REMOVE AND INSTALL QUICK COUPLER VALVE 2433
WORK EQUIPMENT 2435
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2435
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2435
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2439
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2445
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2445
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2448
CAB AND ITS ATTACHMENTS .2454
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2454
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2454
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2460
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2467
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2469
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2469
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2479
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2479
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2482
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2488
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2488
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2495
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2502
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2502
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2508
REMOVE AND INSTALL OPERATOR’S SEAT 2515
METHOD FOR REMOVING OPERATOR’S SEAT .2515
METHOD FOR INSTALLING OPERATOR’S SEAT .2517
REMOVE AND INSTALL SEAT BELT 2520
METHOD FOR REMOVING SEAT BELT .2520
METHOD FOR INSTALLING SEAT BELT .2521
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2522
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2522
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2527
ELECTRICAL SYSTEM .2536
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2536
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2536
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2537
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2539
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2539
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2543
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2548
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2548
METHOD FOR INSTALLING KomVision CONTROLLER 2549
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2551
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2551
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2554
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2558
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2558
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2559
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2560
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2560
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2560
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2562
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2562
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2563
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2565
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2565
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2567
REMOVE AND INSTALL KomVision CAMERA .2570
METHOD FOR REMOVING KomVision CAMERA 2570
METHOD FOR INSTALLING KomVision CAMERA 2573
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2576
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2576
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2579
60 MAINTENANCE STANDARD .2583
CONTENTS 2584
ABBREVIATION LIST .2585
ENGINE AND COOLING SYSTEM .2591
MAINTENANCE STANDARD OF ENGINE MOUNT 2591
MAINTENANCE STANDARD OF COOLING SYSTEM 2592
POWER TRAIN .2593
MAINTENANCE STANDARD OF SWING CIRCLE 2593
MAINTENANCE STANDARD OF SWING MACHINERY .2594
MAINTENANCE STANDARD OF FINAL DRIVE .2596
MAINTENANCE STANDARD OF SPROCKET 2598
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2599
UNDERCARRIAGE AND FRAME .2601
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2601
MAINTENANCE STANDARD OF IDLER .2603
MAINTENANCE STANDARD OF TRACK ROLLER 2605
MAINTENANCE STANDARD OF CARRIER ROLLER 2607
MAINTENANCE STANDARD OF TRACK SHOE 2608
MAINTENANCE STANDARD OF TRIPLE SHOE .2611
HYDRAULIC SYSTEM 2612
MAINTENANCE STANDARD OF HYDRAULIC TANK 2612
MAINTENANCE STANDARD OF MAIN PUMP .2613
MAINTENANCE STANDARD OF LS-EPC VALVE 2614
MAINTENANCE STANDARD OF PC-EPC VALVE 2615
MAINTENANCE STANDARD OF SWING MOTOR .2616
MAINTENANCE STANDARD OF TRAVEL MOTOR 2619
MAINTENANCE STANDARD OF CONTROL VALVE .2622
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2632
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2635
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2638
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2640
MAINTENANCE STANDARD OF SOLENOID VALVE 2641
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2642
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2643
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2644
WORK EQUIPMENT 2645
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2645
DIMENSION OF ARM 2650
DIMENSIONS OF BUCKET 2652
MAINTENANCE STANDARD OF BOOM CYLINDER .2654
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2655
MAINTENANCE STANDARD OF ARM CYLINDER 2656
MAINTENANCE STANDARD OF BUCKET CYLINDER .2657
80 APPENDIX .2659
CONTENTS 2660
ABBREVIATION LIST .2662
AIR CONDITIONER SYSTEM 2668
PRECAUTIONS FOR REFRIGERANT .2668
AIR CONDITIONER COMPONENT .2669
SPECIFICATIONS OF AIR CONDITIONER .2671
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2672
OUTLINE OF REFRIGERATION CYCLE 2673
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2675
AIR CONDITIONER UNIT 2675
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2675
FUNCTION OF AIR CONDITIONER UNIT 2677
COMPONENT PARTS OF AIR CONDITIONER UNIT .2679
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2680
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2680
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2680
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2680
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2681
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2681
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2681
FUNCTION OF DUAL PRESSURE SWITCH 2682
AIR CONDITIONER CONTROLLER 2683
STRUCTURE OF AIR CONDITIONER CONTROLLER .2683
COMPRESSOR 2684
STRUCTURE OF COMPRESSOR .2684
SPECIFICATIONS OF COMPRESSOR 2684
FUNCTION OF COMPRESSOR 2684
CONDENSER .2685
STRUCTURE OF CONDENSER 2685
SPECIFICATIONS OF CONDENSER .2685
FUNCTION OF CONDENSER .2685
SENSORS FOR AIR CONDITIONER SYSTEM 2687
STRUCTURE OF SUNLIGHT SENSOR 2687
FUNCTION OF SUNLIGHT SENSOR .2687
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2687
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2687
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2689
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2691
AIR CONDITIONER SYSTEM DIAGRAM 2693
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2694
FUNCTION OF AIR CONDITIONER CONTROLLER 2695
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2696
TESTING AIR LEAKAGE (DUCT) 2700
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2700
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2702
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2703
TEST VENT (MODE) CHANGEOVER .2704
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2704
TESTING FRESH/RECIRC AIR CHANGEOVER .2706
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2706
TEST SUNLIGHT SENSOR 2707
METHOD FOR TESTING SUNLIGHT SENSOR 2707
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2708
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2708
TEST RELAYS .2709
METHOD FOR TESTING RELAYS .2709
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2710
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2711
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2714
FAILURE CODE [879AKA] .2716
FAILURE CODE [879AKB] .2717
FAILURE CODE [879BKA] .2718
FAILURE CODE [879BKB] .2720
FAILURE CODE [879CKA] .2722
FAILURE CODE [879CKB] .2723
FAILURE CODE [879DKZ] .2724
FAILURE CODE [879EMC] .2726
FAILURE CODE [879FMC] .2727
FAILURE CODE [879GKX] .2728
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2730
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2732
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2735
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2737
TROUBLESHOOTING USING GAUGE PRESSURE 2739
CONNECTION OF SERVICE TOOL 2742
METHOD FOR CONNECTING SERVICE TOOL 2742
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2744
HANDLE COMPRESSOR OIL .2746
METHOD FOR REPLACING DESICCANT 2748
90 CIRCUIT DIAGRAMS .2751
CONTENTS 2752
ABBREVIATION LIST .2753
HYDRAULIC CIRCUIT DIAGRAM .2759
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2759
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2763
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2765
ELECTRICAL CIRCUIT DIAGRAM 2767
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2767
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2771
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2773
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2775
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2777
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2779
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2781
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2783
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2785
INDEX 2787

DESCRIPTION:

Komatsu PC290-11E0,PC290LC-11E0,PC290NLC-11E0 Hydraulic Excavator Shop Manual UENBM00481 – PDF DOWNLOAD

• SERIAL NUMBERS K75001 and up

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

G.B 29/12/24