Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06736-C7 PDF

Description

Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06736-C7  – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06736-C7  – PDF DOWNLOAD

Language : English
Pages : 2904
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06736-C7  – PDF DOWNLOAD

• SERIAL NUMBERS C60001 and up

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
PRECAUTIONS FOR DEF . 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING . 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 43
THE OTHER PRECAUTIONS . 43
STORE AdBlue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS . 95
CONTENTS 96
ABBREVIATION LIST . 97
SPECIFICATIONS 103
SPECIFICATION DRAWING . 103
SPECIFICATION DRAWING: PC290LC-11 . 103
WORKING RANGE DRAWINGS 105
WORKING RANGE: PC290LC-11 . 105
SPECIFICATIONS 106
SPECIFICATIONS: PC290LC-11 106
WEIGHT TABLE 109
WEIGHT TABLE: PC290LC-11 109
TABLE OF FUEL, COOLANT, AND LUBRICANTS 111
10 STRUCTURE AND FUNCTION . 113
CONTENTS 114
ABBREVIATION LIST . 117
UREA SCR SYSTEM . 123
LAYOUT DRAWING OF UREA SCR SYSTEM . 124
UREA SCR SYSTEM DIAGRAM . 129
FUNCTION OF UREA SCR SYSTEM . 130
FUNCTION OF AdBlue/DEF SYSTEM . 130
INDUCEMENT STRATEGY . 132
COMPONENT PARTS OF UREA SCR SYSTEM 146
AdBlue/DEF MIXING TUBE 146
SCR ASSEMBLY 146
AdBlue/DEF TANK . 149
AdBlue/DEF PUMP . 151
AdBlue/DEF INJECTOR . 152
AdBlue/DEF HOSE . 153
AdBlue/DEF TANK HEATING VALVE . 154
BOOT-UP SYSTEM 155
LAYOUT DRAWING OF BOOT-UP SYSTEM 155
SYSTEM OPERATING LAMP SYSTEM 157
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 157
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 157
OPERATION OF SYSTEM OPERATING LAMP SYSTEM . 157
BATTERY DISCONNECT SWITCH . 158
FUNCTION OF BATTERY DISCONNECT SWITCH . 158
ENGINE SYSTEM . 159
LAYOUT DRAWING OF ENGINE SYSTEM . 159
SPECIFICATIONS OF ENGINE SYSTEM . 160
FUNCTION OF ENGINE SYSTEM . 160
ENGINE CONTROL SYSTEM . 161
ENGINE CONTROL SYSTEM DIAGRAM . 161
OPERATION OF ENGINE CONTROL SYSTEM 162
AUTO-DECELERATION SYSTEM 164
AUTO-DECELERATION SYSTEM DIAGRAM 164
FUNCTION OF AUTO-DECELERATION SYSTEM 164
OPERATION OF AUTO-DECELERATION SYSTEM . 165
ENGINE AUTOMATIC WARM-UP SYSTEM . 166
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 166
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 167
OVERHEAT PREVENTION SYSTEM 168
OVERHEAT PREVENTION SYSTEM DIAGRAM 168
FUNCTION OF OVERHEAT PREVENTION SYSTEM 169
TURBOCHARGER PROTECTION SYSTEM 171
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 171
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 172
AUTOMATIC IDLE STOP SYSTEM 173
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 173
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 173
OPERATION OF AUTOMATIC IDLE STOP SYSTEM . 173
COMPONENT PARTS OF ENGINE SYSTEM 176
VGT . 176
EGR SYSTEM 180
EGR VALVE . 182
EGR COOLER 184
KCCV SYSTEM . 185
KCCV VENTILATOR . 187
KDPF 189
COOLING SYSTEM 194
LAYOUT DRAWING OF COOLING SYSTEM 194
SPECIFICATIONS OF COOLING SYSTEM 195
CONTROL SYSTEM 196
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 196
MACHINE MONITOR SYSTEM 199
MACHINE MONITOR SYSTEM DIAGRAM 199
FUNCTION OF MACHINE MONITOR SYSTEM 200
KomVision SYSTEM 201
LAYOUT DRAWING OF KOMVISION SYSTEM 201
KomVision SYSTEM DIAGRAM 203
FUNCTION OF KomVision SYSTEM 203
KOMTRAX SYSTEM 205
KOMTRAX SYSTEM DIAGRAM 205
FUNCTION OF KOMTRAX SYSTEM 205
COMPONENT PARTS OF CONTROL SYSTEM . 206
MACHINE MONITOR . 206
KomVision CONTROLLER 219
KomVision CAMERA 223
GATEWAY FUNCTION CONTROLLER . 224
COMMUNICATION TERMINAL 227
PUMP CONTROLLER . 229
RESISTOR FOR PC-EPC VALVE . 233
CAN TERMINATING RESISTOR 233
ENGINE CONTROLLER . 235
FUEL CONTROL DIAL . 241
HYDRAULIC SYSTEM 243
LAYOUT DRAWING OF HYDRAULIC SYSTEM 243
CLSS 249
STRUCTURE OF CLSS . 249
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 251
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 252
PRESSURE COMPENSATION CONTROL . 268
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 271
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 271
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 272
PUMP AND VALVE CONTROL SYSTEM . 277
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 277
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 278
COMPONENT PARTS OF HYDRAULIC SYSTEM . 280
HYDRAULIC TANK 280
MAIN PUMP . 282
CONTROL VALVE . 306
WORK EQUIPMENT SYSTEM . 369
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 369
STRUCTURE OF VALVE CONTROL 374
ONE-TOUCH POWER MAXIMIZING SYSTEM . 376
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 376
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 377
PPC LOCK SYSTEM . 378
PPC LOCK SYSTEM DIAGRAM . 378
FUNCTION OF PPC LOCK SYSTEM . 378
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 379
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 379
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 379
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 380
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 381
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 381
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 382
TOOL CONTROL SYSTEM . 383
TOOL CONTROL SYSTEM DIAGRAM . 383
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 385
WORK EQUIPMENT AND SWING PPC VALVE 385
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 391
2ND-LINE ATTACHMENT PPC VALVE . 397
SOLENOID VALVE 399
ANTI-DROP VALVE FOR BOOM 402
ANTI-DROP VALVE FOR ARM . 406
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 410
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 412
PILOT CIRCUIT ACCUMULATOR . 415
ATTACHMENT CIRCUIT ACCUMULATOR 416
SWING SYSTEM 417
LAYOUT DRAWING OF SWING SYSTEM 417
SWING CONTROL SYSTEM DIAGRAM 421
FUNCTION OF SWING CONTROL SYSTEM 421
COMPONENT PARTS OF SWING SYSTEM . 425
SWING MOTOR . 425
SWING MACHINERY . 437
SWING CIRCLE 438
TRAVEL SYSTEM . 440
LAYOUT DRAWING OF TRAVEL SYSTEM . 440
TRAVEL CONTROL SYSTEM DIAGRAM . 444
FUNCTION OF TRAVEL CONTROL SYSTEM . 444
COMPONENT PARTS OF TRAVEL SYSTEM 446
TRAVEL MOTOR 446
FINAL DRIVE . 458
TRAVEL PPC VALVE 460
CENTER SWIVEL JOINT . 465
UNDERCARRIAGE AND FRAME . 467
LAYOUT DRAWING OF UNDERCARRIAGE . 467
SPECIFICATIONS OF UNDERCARRIAGE . 468
WORK EQUIPMENT 469
STRUCTURE OF WORK EQUIPMENT . 469
FUNCTION OF WORK EQUIPMENT 470
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 471
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 471
BUCKET CLEARANCE ADJUSTMENT SHIM 472
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 472
CAB AND ITS ATTACHMENTS . 473
ROPS CAB 473
STRUCTURE OF ROPS CAB . 473
FUNCTION OF ROPS CAB 473
CAB MOUNT . 474
STRUCTURE OF CAB MOUNT 474
FUNCTION OF CAB MOUNT . 474
CAB TIPPING STOPPER . 475
STRUCTURE OF CAB TIPPING STOPPER 475
FUNCTION OF CAB TIPPING STOPPER . 475
20 STANDARD VALUE TABLE . 477
CONTENTS 478
ABBREVIATION LIST . 479
STANDARD VALUE TABLE FOR ENGINE . 485
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11 . 485
STANDARD VALUE TABLE FOR MACHINE 489
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11 489
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 502
STANDARD VALUE TABLE FOR ELECTRICAL . 506
STANDARD VALUE TABLE FOR ELECTRICAL . 506
30 TESTING AND ADJUSTING 517
CONTENTS 518
ABBREVIATION LIST . 521
RELATED INFORMATION ON TESTING AND ADJUSTING 527
TOOLS FOR TESTING AND ADJUSTING . 527
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 534
ENGINE AND COOLING SYSTEM . 536
TEST ENGINE SPEED . 536
METHOD FOR TESTING ENGINE SPEED . 536
TEST BOOST PRESSURE . 539
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 539
METHOD FOR TESTING BOOST PRESSURE . 540
TEST EXHAUST GAS COLOR 541
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 541
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 542
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 544
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 544
TEST AND ADJUST VALVE CLEARANCE . 546
METHOD FOR TESTING VALVE CLEARANCE 546
METHOD FOR ADJUSTING VALVE CLEARANCE 547
TEST COMPRESSION PRESSURE . 549
METHOD FOR TESTING COMPRESSION PRESSURE . 549
TEST BLOWBY PRESSURE 554
METHOD FOR TESTING BLOWBY PRESSURE 554
TEST ENGINE OIL PRESSURE 556
METHOD FOR TESTING ENGINE OIL PRESSURE 556
TEST EGR VALVE AND VGT OIL PRESSURE . 557
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 557
TEST FUEL PRESSURE 559
METHOD FOR TESTING FUEL PRESSURE 560
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 565
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 566
BLEEDING AIR FROM FUEL SYSTEM . 572
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 572
TEST FUEL CIRCUIT FOR LEAKAGE . 573
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 573
HANDLE CYLINDER CUT-OUT MODE OPERATION 575
HANDLE NO-INJECTION CRANKING OPERATION 576
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 577
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 577
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 577
TEST FAN BELT AND ALTERNATOR BELT . 579
METHOD FOR TESTING FAN BELT AND ALTERNATOR BELT . 579
TEST AUTO-TENSIONER . 580
METHOD FOR TESTING AUTO-TENSIONER . 580
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 581
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 581
TEST SCR RELATED FUNCTIONS 582
TEST AdBlue/DEF PUMP RAISED PRESSURE 585
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 588
TEST AdBlue/DEF LINE HEATER RELAY 1 . 592
TEST AdBlue/DEF LINE HEATER RELAY 2 . 595
TEST AdBlue/DEF PUMP HEATER RELAY . 597
TEST AdBlue/DEF TANK HEATER VALVE . 600
TEST DENITRATION EFFICIENCY OF SCR 603
CLEAN AdBlue/DEF TANK . 607
METHOD FOR CLEANING AdBlue/DEF TANK . 607
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 611
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 611
CLEAN AdBlue/DEF PUMP . 613
CLEAN AdBlue/DEF PUMP . 613
POWER TRAIN . 619
TEST SWING CIRCLE BEARING CLEARANCE . 619
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 619
UNDERCARRIAGE AND FRAME . 620
TEST AND ADJUST TRACK TENSION . 620
METHOD FOR TESTING TRACK TENSION 620
METHOD FOR ADJUSTING TRACK TENSION 620
HYDRAULIC SYSTEM 622
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 622
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 622
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
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 652
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 652
TEST PUMP SWASH PLATE SENSOR 653
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 653
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 654
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 654
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 654
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 655
TEST OIL LEAKAGE 656
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 656
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 656
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 657
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 658
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 658
BLEED AIR FROM HYDRAULIC CIRCUIT 659
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 661
CAB AND ITS ATTACHMENTS . 663
TEST CAB TIPPING STOPPER 663
METHOD FOR TESTING CAB TIPPING STOPPER 663
METHOD FOR ADJUSTING MIRRORS 664
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 664
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 665
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 666
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 667
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 668
ELECTRICAL SYSTEM . 670
SET AND OPERATE MACHINE MONITOR . 670
OPERATOR MODE . 673
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 674
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 674
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 675
CHECKING FUNCTION OF SERVICE METER 675
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 675
SERVICE MODE 678
SERVICE MODE 678
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 680
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 686
ABNORMALITY RECORD MENU . 697
METHOD FOR CONFIRMING MAINTENANCE RECORD 701
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 702
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 706
DEFAULT MENU 707
DIAGNOSTIC TESTS MENU . 719
ADJUSTMENT MENU . 728
METHOD FOR PERFORMING NO-INJECTION CRANKING . 745
KOMTRAX SETTINGS MENU . 746
METHOD FOR DISPLAYING SERVICE MESSAGE . 749
METHOD FOR STARTING UP KOMTRAX SYSTEM . 751
ADJUST REARVIEW CAMERA ANGLE 756
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 756
ADJUST KomVision CAMERA ANGLE . 759
ADJUST KomVision RELATED ITEMS 761
SETTING OF KomVision (MAIN SETTING) . 761
SETTING OF KomVision (CAMERA SETTING) . 763
SETTING OF KomVision (CAMERA CALIBRATION) . 765
KomVision screen – Check 12 m visibility 778
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 781
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 781
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 783
HANDLE BATTERY DISCONNECT SWITCH 784
TEST DIODES . 785
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 785
METHOD FOR TESTING DIODE USING ANALOG TESTER 785
Pm CLINIC . 786
Pm CLINIC SERVICE . 786
Pm CLINIC CHECK SHEET . 787
40 TROUBLESHOOTING 799
CONTENTS 800
ABBREVIATION LIST . 811
RELATED INFORMATION ON TROUBLESHOOTING 817
GENERAL TROUBLESHOOTING POINTS 817
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 818
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 833
CHECKS BEFORE TROUBLESHOOTING . 835
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 837
WALK-AROUND CHECK . 837
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 839
CHECK FUEL LEVEL AND TYPE . 839
CHECK IMPURE INGREDIENT IN FUEL . 839
CHECK FUEL PREFILTER 840
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 840
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 841
CHECK MAIN FILTER . 842
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 844
CHECK COOLANT LEVEL (RESERVOIR TANK) 845
CHECK CLOGGING OF AIR CLEANER . 845
OUTER ELEMENT – CLEAN . 846
ELEMENTS – REPLACE 848
CHECK HYDRAULIC OIL LEVEL . 849
CHECK HYDRAULIC OIL STRAINER 850
CHECK HYDRAULIC FILTER 851
CHECK OIL LEVEL IN SWING MACHINERY CASE . 852
CHECK OIL LEVEL IN DAMPER CASE 853
CHECK OIL LEVEL IN FINAL DRIVE CASE . 853
BLEED AIR FROM FUEL SYSTEM 854
BLEED AIR FROM HYDRAULIC SYSTEM . 854
ELECTRICAL EQUIPMENT – CHECK METHOD . 854
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 862
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 872
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 875
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 879
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 881
CONNECTOR LIST AND LAYOUT . 884
CONNECTOR CONTACT IDENTIFICATION 897
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 937
FUSE LOCATION TABLE . 943
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 946
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 950
FAILURE CODE TABLE 952
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 971
FAILURE CODE [879AKA] . 971
FAILURE CODE [879AKB] . 972
FAILURE CODE [879BKA] . 973
FAILURE CODE [879BKB] . 975
FAILURE CODE [879CKA] . 977
FAILURE CODE [879CKB] . 978
FAILURE CODE [879DKZ] . 979
FAILURE CODE [879EMC] . 981
FAILURE CODE [879FMC] . 982
FAILURE CODE [879GKX] . 983
FAILURE CODE [989L00] . 985
FAILURE CODE [989M00] . 986
FAILURE CODE [989N00] . 987
FAILURE CODE [A1U0N3] . 988
FAILURE CODE [A1U0N4] . 990
FAILURE CODE [A900FR] . 992
FAILURE CODE [A900N6] . 993
FAILURE CODE [A900NY] . 994
FAILURE CODE [AA10NX] . 995
FAILURE CODE [AB00KE] . 997
FAILURE CODE [AQ10N3] .1000
FAILURE CODE [AS00N3] .1002
FAILURE CODE [AS00R2] .1004
FAILURE CODE [AS00R3] .1005
FAILURE CODE [AS00R4] .1006
FAILURE CODE [AS00R5] .1007
FAILURE CODE [AS00R6] .1008
FAILURE CODE [AS00ZK] .1009
FAILURE CODE [AS10KM] .1010
FAILURE CODE [AS10NR] .1011
FAILURE CODE [AS10NT] .1012
FAILURE CODE [B@BAZG] .1013
FAILURE CODE [B@BAZK] .1014
FAILURE CODE [B@BCNS] .1016
FAILURE CODE [B@BCQA] .1017
FAILURE CODE [B@BCZK] .1019
FAILURE CODE [B@HANS] .1021
FAILURE CODE [CA115] 1022
FAILURE CODE [CA122] 1023
FAILURE CODE [CA123] 1025
FAILURE CODE [CA131] 1027
FAILURE CODE [CA132] 1029
FAILURE CODE [CA144] 1031
FAILURE CODE [CA145] 1033
FAILURE CODE [CA153] 1035
FAILURE CODE [CA154] 1038
FAILURE CODE [CA187] 1040
FAILURE CODE [CA221] 1042
FAILURE CODE [CA222] 1044
FAILURE CODE [CA227] 1046
FAILURE CODE [CA234] 1047
FAILURE CODE [CA238] 1048
FAILURE CODE [CA239] 1050
FAILURE CODE [CA249] 1052
FAILURE CODE [CA256] 1054
FAILURE CODE [CA271] 1056
FAILURE CODE [CA272] 1058
FAILURE CODE [CA322] 1060
FAILURE CODE [CA323] 1062
FAILURE CODE [CA324] 1064
FAILURE CODE [CA325] 1066
FAILURE CODE [CA331] 1068
FAILURE CODE [CA332] 1070
FAILURE CODE [CA343] 1072
FAILURE CODE [CA351] 1073
FAILURE CODE [CA352] 1074
FAILURE CODE [CA356] 1077
FAILURE CODE [CA357] 1079
FAILURE CODE [CA386] 1081
FAILURE CODE [CA428] 1082
FAILURE CODE [CA429] 1084
FAILURE CODE [CA435] 1086
FAILURE CODE [CA441] 1088
FAILURE CODE [CA442] 1090
FAILURE CODE [CA449] 1091
FAILURE CODE [CA451] 1092
FAILURE CODE [CA452] 1094
FAILURE CODE [CA488] 1096
FAILURE CODE [CA515] 1097
FAILURE CODE [CA516] 1099
FAILURE CODE [CA553] 1101
FAILURE CODE [CA555] 1102
FAILURE CODE [CA556] 1103
FAILURE CODE [CA559] 1104
FAILURE CODE [CA595] 1107
FAILURE CODE [CA687] 1108
FAILURE CODE [CA689] 1110
FAILURE CODE [CA691] 1113
FAILURE CODE [CA692] 1115
FAILURE CODE [CA697] 1117
FAILURE CODE [CA698] 1118
FAILURE CODE [CA731] 1119
FAILURE CODE [CA778] 1121
FAILURE CODE [CA1117] .1126
FAILURE CODE [CA1664] .1127
FAILURE CODE [CA1669] .1129
FAILURE CODE [CA1673] .1130
FAILURE CODE [CA1677] .1131
FAILURE CODE [CA1678] .1132
FAILURE CODE [CA1682] .1133
FAILURE CODE [CA1683] .1135
FAILURE CODE [CA1684] .1137
FAILURE CODE [CA1686] .1139
FAILURE CODE [CA1691] .1140
FAILURE CODE [CA1694] .1143
FAILURE CODE [CA1695] .1146
FAILURE CODE [CA1696] .1147
FAILURE CODE [CA1712] .1149
FAILURE CODE [CA1713] .1152
FAILURE CODE [CA1714] .1154
FAILURE CODE [CA1715] .1155
FAILURE CODE [CA1776] .1156
FAILURE CODE [CA1777] .1159
FAILURE CODE [CA1843] .1162
FAILURE CODE [CA1844] .1164
FAILURE CODE [CA1879] .1167
FAILURE CODE [CA1881] .1169
FAILURE CODE [CA1883] .1171
FAILURE CODE [CA1885] .1174
FAILURE CODE [CA1887] .1176
FAILURE CODE [CA1921] .1178
FAILURE CODE [CA1922] .1181
FAILURE CODE [CA1942] .1186
FAILURE CODE [CA1993] .1187
FAILURE CODE [CA2185] .1190
FAILURE CODE [CA2186] .1191
FAILURE CODE [CA2249] .1193
FAILURE CODE [CA2271] .1194
FAILURE CODE [CA2272] .1197
FAILURE CODE [CA2288] .1200
FAILURE CODE [CA2311] .1201
FAILURE CODE [CA2349] .1202
FAILURE CODE [CA2353] .1205
FAILURE CODE [CA2357] .1207
FAILURE CODE [CA2381] .1208
FAILURE CODE [CA2382] .1211
FAILURE CODE [CA2383] .1214
FAILURE CODE [CA2386] .1217
FAILURE CODE [CA2387] .1219
TROUBLESHOOTING FLOWCHART .1223
FAILURE CODE [CA2555] .1224
FAILURE CODE [CA2556] .1227
FAILURE CODE [CA2637] .1230
FAILURE CODE [CA2639] .1232
FAILURE CODE [CA2771] .1235
FAILURE CODE [CA2777] .1241
FAILURE CODE [CA2976] .1244
FAILURE CODE [CA3133] .1246
FAILURE CODE [CA3134] .1249
FAILURE CODE [CA3135] .1251
FAILURE CODE [CA3142] .1254
FAILURE CODE [CA3143] .1255
FAILURE CODE [CA3144] .1256
FAILURE CODE [CA3146] .1258
FAILURE CODE [CA3147] .1259
FAILURE CODE [CA3148] .1260
FAILURE CODE [CA3151] .1262
FAILURE CODE [CA3165] .1268
FAILURE CODE [CA3229] .1270
FAILURE CODE [CA3231] .1272
FAILURE CODE [CA3232] .1274
FAILURE CODE [CA3235] .1278
FAILURE CODE [CA3239] .1280
FAILURE CODE [CA3241] .1283
FAILURE CODE [CA3242] .1286
FAILURE CODE [CA3251] .1289
FAILURE CODE [CA3253] .1291
FAILURE CODE [CA3254] .1294
FAILURE CODE [CA3255] .1297
FAILURE CODE [CA3256] .1301
FAILURE CODE [CA3311] .1303
FAILURE CODE [CA3312] .1305
FAILURE CODE [CA3313] .1308
FAILURE CODE [CA3314] .1309
FAILURE CODE [CA3315] .1310
FAILURE CODE [CA3316] .1312
FAILURE CODE [CA3317] .1313
FAILURE CODE [CA3318] .1314
FAILURE CODE [CA3319] .1316
FAILURE CODE [CA3321] .1317
FAILURE CODE [CA3322] .1319
FAILURE CODE [CA3419] .1321
FAILURE CODE [CA3421] .1323
FAILURE CODE [CA3497] .1325
FAILURE CODE [CA3498] .1326
FAILURE CODE [CA3543] .1327
FAILURE CODE [CA3545] .1334
FAILURE CODE [CA3547] .1336
FAILURE CODE [CA3558] .1337
FAILURE CODE [CA3559] .1339
FAILURE CODE [CA3562] .1341
FAILURE CODE [CA3563] .1343
FAILURE CODE [CA3567] .1346
FAILURE CODE [CA3568] .1349
FAILURE CODE [CA3571] .1353
FAILURE CODE [CA3572] .1355
FAILURE CODE [CA3574] .1357
FAILURE CODE [CA3575] .1359
FAILURE CODE [CA3577] .1361
FAILURE CODE [CA3578] .1363
FAILURE CODE [CA3582] .1365
FAILURE CODE [CA3583] .1371
FAILURE CODE [CA3596] .1373
FAILURE CODE [CA3649] .1375
FAILURE CODE [CA3681] .1377
FAILURE CODE [CA3682] .1382
FAILURE CODE [CA3713] .1388
FAILURE CODE [CA3717] .1391
FAILURE CODE [CA3718] .1392
FAILURE CODE [CA3725] .1393
FAILURE CODE [CA3741] .1396
FAILURE CODE [CA3748] .1397
FAILURE CODE [CA3751] .1399
FAILURE CODE [CA3755] .1401
FAILURE CODE [CA3866] .1403
FAILURE CODE [CA3867] .1407
FAILURE CODE [CA3868] .1410
FAILURE CODE [CA3899] .1414
FAILURE CODE [CA3911] .1416
FAILURE CODE [CA3912] .1420
FAILURE CODE [CA3932] .1422
FAILURE CODE [CA3933] .1424
FAILURE CODE [CA3934] .1426
FAILURE CODE [CA3935] .1429
FAILURE CODE [CA3936] .1431
FAILURE CODE [CA4151] .1433
FAILURE CODE [CA4152] .1437
FAILURE CODE [CA4155] .1441
FAILURE CODE [CA4156] .1443
FAILURE CODE [CA4157] .1446
FAILURE CODE [CA4158] .1448
FAILURE CODE [CA4159] .1449
FAILURE CODE [CA4161] .1450
FAILURE CODE [CA4162] .1453
FAILURE CODE [CA4163] .1456
FAILURE CODE [CA4164] .1457
FAILURE CODE [CA4165] .1459
FAILURE CODE [CA4166] .1461
FAILURE CODE [CA4168] .1462
FAILURE CODE [CA4169] .1465
FAILURE CODE [CA4171] .1467
FAILURE CODE [CA4249] .1470
FAILURE CODE [CA4251] .1472
FAILURE CODE [CA4259] .1474
FAILURE CODE [CA4261] .1477
FAILURE CODE [CA4277] .1480
FAILURE CODE [CA4281] .1484
FAILURE CODE [CA4459] .1487
FAILURE CODE [CA4461] .1490
FAILURE CODE [CA4658] .1493
FAILURE CODE [CA4731] .1497
FAILURE CODE [CA4732] .1498
FAILURE CODE [CA4739] .1499
FAILURE CODE [CA4768] .1500
FAILURE CODE [CA4769] .1502
FAILURE CODE [CA4842] .1505
FAILURE CODE [CA4952] .1509
FAILURE CODE [CA5115] .1511
FAILURE CODE [CA5179] .1514
FAILURE CODE [CA5181] .1516
FAILURE CODE [CA5383] .1518
FAILURE CODE [D110KB] .1520
FAILURE CODE [D19JKZ] .1522
FAILURE CODE [D811MC] .1525
FAILURE CODE [D862KA] .1526
FAILURE CODE [D8ALKA] .1528
FAILURE CODE [D8ALKB] .1531
FAILURE CODE [D8AQKR] .1533
FAILURE CODE [D8G1KT] .1535
FAILURE CODE [D8G6KT] .1536
FAILURE CODE [DA20MC] .1537
FAILURE CODE [DA22KK] .1538
FAILURE CODE [DA25KP] .1541
FAILURE CODE [DA26KP] .1544
FAILURE CODE [DA29KQ] .1547
FAILURE CODE [DA2LKA] .1549
FAILURE CODE [DA2LKB] .1552
FAILURE CODE [DA2QKR] .1554
FAILURE CODE [DA2RKR] .1563
FAILURE CODE [DAF0MB] .1564
FAILURE CODE [DAF0MC] .1565
FAILURE CODE [DAF8KB] .1566
FAILURE CODE [DAF9KQ] .1568
FAILURE CODE [DAFGMC] .1569
FAILURE CODE [DAFLKA] .1570
FAILURE CODE [DAFLKB] .1573
FAILURE CODE [DAFQKR] .1575
FAILURE CODE [DAZ9KQ] .1583
FAILURE CODE [DB2QKR] .1584
FAILURE CODE [DB2RKR] .1592
FAILURE CODE [DBP0KM] .1597
FAILURE CODE [DBP0KT] .1598
FAILURE CODE [DBP5KB] .1599
FAILURE CODE [DBP5KY] .1602
FAILURE CODE [DBPQKR] .1605
FAILURE CODE [DDNRKA] .1613
FAILURE CODE [DDNRKY] .1615
FAILURE CODE [DDNS00] .1617
FAILURE CODE [DGH2KA] .1619
FAILURE CODE [DGH2KB] .1621
FAILURE CODE [DHA4KA] .1623
FAILURE CODE [DHAAMA] .1625
FAILURE CODE [DHACMA] .1627
FAILURE CODE [DHPAMA] .1629
FAILURE CODE [DHPBMA] .1632
FAILURE CODE [DHS3MA] .1635
FAILURE CODE [DHS4MA] .1638
FAILURE CODE [DHS8MA] .1641
FAILURE CODE [DHS9MA] .1644
FAILURE CODE [DHSAMA] .1647
FAILURE CODE [DHSBMA] .1650
FAILURE CODE [DHSCMA] .1653
FAILURE CODE [DHSDMA] .1656
FAILURE CODE [DHSFMA] .1659
FAILURE CODE [DHSGMA] .1662
FAILURE CODE [DHSHMA] .1665
FAILURE CODE [DHSJMA] .1668
FAILURE CODE [DHZAMA] .1671
FAILURE CODE [DHZCL8] .1675
FAILURE CODE [DKR0MA] .1676
FAILURE CODE [DKR1MA] .1679
FAILURE CODE [DKULKA] .1682
FAILURE CODE [DKULKB] .1684
FAILURE CODE [DKULKY] .1686
FAILURE CODE [DR10KA] .1688
FAILURE CODE [DR12KA] .1691
FAILURE CODE [DR20KA] .1693
FAILURE CODE [DR21KX] .1695
FAILURE CODE [DR30KA] .1697
FAILURE CODE [DR31KX] .1699
FAILURE CODE [DR40KA] .1701
FAILURE CODE [DUMBKA] .1703
FAILURE CODE [DUMBKB] .1706
FAILURE CODE [DV20KB] .1708
FAILURE CODE [DW43KA] .1710
FAILURE CODE [DW43KB] .1712
FAILURE CODE [DW43KY] .1714
FAILURE CODE [DW45KA] .1716
FAILURE CODE [DW45KB] .1719
FAILURE CODE [DW45KY] .1722
FAILURE CODE [DW4CKY] .1724
FAILURE CODE [DW91KA] .1726
FAILURE CODE [DW91KB] .1728
FAILURE CODE [DW91KY] .1730
FAILURE CODE [DWA2KA] .1732
FAILURE CODE [DWA2KB] .1734
FAILURE CODE [DWA2KY] .1736
FAILURE CODE [DWK0KA] .1738
FAILURE CODE [DWK0KB] .1740
FAILURE CODE [DWK0KY] .1742
FAILURE CODE [DWK2KA] .1744
FAILURE CODE [DWK2KB] .1746
FAILURE CODE [DWK2KY] .1748
FAILURE CODE [DWK8KA] .1750
FAILURE CODE [DWK8KB] .1752
FAILURE CODE [DWK8KY] .1754
FAILURE CODE [DXA8KA] .1756
FAILURE CODE [DXA8KB] .1758
FAILURE CODE [DXA9KA] .1760
FAILURE CODE [DXA9KB] .1762
FAILURE CODE [DXE0KA] .1764
FAILURE CODE [DXE0KB] .1765
FAILURE CODE [DXE4KA] .1767
FAILURE CODE [DXE4KB] .1769
FAILURE CODE [DXE4KY] .1771
FAILURE CODE [DXE5KA] .1773
FAILURE CODE [DXE5KB] .1775
FAILURE CODE [DXE6KA] .1777
FAILURE CODE [DXE6KB] .1779
FAILURE CODE [DXE7KA] .1781
FAILURE CODE [DXE7KB] .1783
FAILURE CODE [DXE7KY] .1785
FAILURE CODE [DXE8KA] .1787
FAILURE CODE [DXE8KB] .1789
FAILURE CODE [DXE8KY] .1791
FAILURE CODE [DXE9KA] .1793
FAILURE CODE [DXE9KB] .1795
FAILURE CODE [DXE9KY] .1797
FAILURE CODE [DXEAKA] .1799
FAILURE CODE [DXEAKB] .1801
FAILURE CODE [DXEAKY] .1803
FAILURE CODE [DXEKKA] .1805
FAILURE CODE [DXEKKB] .1807
FAILURE CODE [DXEKKY] .1809
FAILURE CODE [DXELKA] .1811
FAILURE CODE [DXELKB] .1813
FAILURE CODE [DXELKY] .1815
FAILURE CODE [DY20KA] .1817
FAILURE CODE [DY20MA] .1819
FAILURE CODE [DY2CKB] .1821
FAILURE CODE [DY2DKB] .1824
FAILURE CODE [DY2EKB] .1826
FAILURE CODE [F311KA] .1828
FAILURE CODE [F311KB] .1830
FAILURE CODE [F312KA] .1832
FAILURE CODE [F312KB] .1834
FAILURE CODE [F313KA] .1836
FAILURE CODE [F313KB] .1838
FAILURE CODE [F314KA] .1841
FAILURE CODE [F314KB] .1843
FAILURE CODE [F315KB] .1845
FAILURE CODE [F315KY] .1847
FAILURE CODE [F316KB] .1849
FAILURE CODE [F316KY] .1851
FAILURE CODE [F318KB] .1853
FAILURE CODE [F318KY] .1856
FAILURE CODE [F31AKB] .1858
FAILURE CODE [F31AKY] .1860
FAILURE CODE [F31BKB] .1862
FAILURE CODE [F31BKY] .1864
FAILURE CODE [F31CKB] .1866
FAILURE CODE [F31CKY] .1868
FAILURE CODE [F31DKB] .1870
FAILURE CODE [F31DKY] .1872
FAILURE CODE [F31EKB] .1874
FAILURE CODE [F31EKY] .1876
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1878
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1878
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1884
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1887
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1889
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1891
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1894
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1895
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1896
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1897
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1898
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1899
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1900
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1901
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1902
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1903
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1904
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1905
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1907
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1908
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1909
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1910
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1912
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1913
E-24 FUNCTION SWITCH DOES NOT OPERATE .1914
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1915
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1916
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1917
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1918
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1919
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1920
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1921
E-32 ALARM BUZZER CANNOT BE CANCELED 1923
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1924
E-34 SERVICE MODE CANNOT BE SELECTED 1925
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1926
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1929
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1931
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1934
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1936
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1939
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1940
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1942
E-43 HORN DOES NOT SOUND 1943
E-44 HORN DOES NOT STOP SOUNDING 1946
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1948
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1949
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1951
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1952
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1953
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1954
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1955
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1956
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1957
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1958
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1959
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1960
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1962
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1963
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1964
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1964
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1965
FAILURE MODE AND CAUSE TABLE 1967
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1976
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1977
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1980
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1981
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1982
H-6 SPEED OR POWER OF BOOM IS LOW .1984
H-7 ARM SPEED OR POWER IS LOW .1988
H-8 BUCKET SPEED OR POWER IS LOW 1993
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1996
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1997
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1999
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2001
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2002
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2003
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2004
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2005
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2006
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2007
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2008
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2009
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .2010
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2012
H-23 TRAVEL SPEED IS LOW 2015
H-24 ONE OF TRACKS DOES NOT RUN .2017
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2018
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2019
H-27 SWINGS ONLY IN ONE DIRECTION .2020
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2021
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2022
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2023
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2024
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2025
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2026
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2027
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2028
TROUBLESHOOTING OF ENGINE (S-MODE) 2029
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2029
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2030
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2031
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2032
S-4 ENGINE STARTABILITY IS POOR .2034
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2036
S-6 ENGINE STOPS DURING OPERATION .2038
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2040
S-8 ENGINE LACKS POWER 2041
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2043
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2045
S-11 OIL BECOMES CONTAMINATED QUICKLY .2046
S-12 FUEL CONSUMPTION IS EXCESSIVE 2047
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2048
S-14 OIL PRESSURE DROPS .2049
S-15 FUEL MIXES INTO ENGINE OIL .2051
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2052
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2053
S-18 UNUSUAL NOISE IS HEARD .2054
S-19 VIBRATION IS EXCESSIVE .2055
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2056
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2057
S-22 ACTIVE REGENERATION TAKES TIME .2059
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2060
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2061
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2063
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2064
50 DISASSEMBLY AND ASSEMBLY .2065
CONTENTS 2066
ABBREVIATION LIST .2071
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2077
HOW TO READ THIS MANUAL .2077
COATING MATERIALS LIST 2079
SPECIAL TOOLS LIST 2084
SKETCHES OF SPECIAL TOOLS .2096
ENGINE AND COOLING SYSTEM .2102
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2102
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2102
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2105
REMOVE AND INSTALL INJECTOR ASSEMBLY 2109
METHOD FOR REMOVING INJECTOR ASSEMBLY .2109
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2114
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2122
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2123
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2132
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2148
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2148
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2149
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2152
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2152
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2155
REMOVE AND INSTALL STARTER ASSEMBLY .2160
METHOD FOR REMOVING STARTER ASSEMBLY 2160
METHOD FOR INSTALLING STARTER ASSEMBLY 2162
REMOVE AND INSTALL ALTERNATOR BELT 2164
METHOD FOR REMOVING ALTERNATOR BELT .2164
METHOD FOR INSTALLING ALTERNATOR BELT .2166
REMOVE AND INSTALL RADIATOR ASSEMBLY 2168
METHOD FOR REMOVING RADIATOR ASSEMBLY .2168
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2170
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2172
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2172
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2175
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2178
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2178
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2179
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2181
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2182
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2190
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2201
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2201
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2204
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2208
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2208
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2209
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2212
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2212
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2213
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2214
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2214
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2216
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2222
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2222
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2226
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2232
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2232
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2237
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2243
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2243
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2248
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2254
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2254
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2254
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2261
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2261
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2261
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2262
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2262
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2264
REMOVE AND INSTALL KDPF ASSEMBLY 2267
METHOD FOR REMOVING KDPF ASSEMBLY .2267
METHOD FOR INSTALLING KDPF ASSEMBLY .2269
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2271
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2272
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2275
REMOVE AND INSTALL SCR ASSEMBLY .2280
METHOD FOR REMOVING SCR ASSEMBLY 2280
METHOD FOR INSTALLING SCR ASSEMBLY 2282
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2284
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2284
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2290
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2296
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2296
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2303
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2311
REMOVE BELLOWS PIPE ASSEMBLY 2311
INSTALL BELLOWS PIPE ASSEMBLY .2313
REMOVE AND INSTALL KCCV ASSEMBLY 2317
METHOD FOR REMOVING KCCV ASSEMBLY .2317
METHOD FOR INSTALLING KCCV ASSEMBLY .2319
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2324
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2324
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2329
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2334
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2334
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2336
REMOVE AND INSTALL AdBlue/DEF PUMP 2338
METHOD FOR REMOVING AdBlue/DEF PUMP .2338
METHOD FOR INSTALLING AdBlue/DEF PUMP .2340
REMOVE AND INSTALL AdBlue/DEF HOSE 2343
METHOD FOR REMOVING AdBlue/DEF HOSE .2343
METHOD FOR INSTALLING AdBlue/DEF HOSE .2351
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2357
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2357
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2358
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2360
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2360
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2362
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2365
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2365
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2366
POWER TRAIN .2367
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2367
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2367
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2368
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2369
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2369
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2373
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2382
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2382
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2384
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2388
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2388
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2392
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2399
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2399
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2399
UNDERCARRIAGE AND FRAME .2401
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2401
METHOD FOR SEPARATING TRACK ASSEMBLY 2401
METHOD FOR INSTALLING TRACK ASSEMBLY 2403
REMOVE AND INSTALL SPROCKET .2406
METHOD FOR REMOVING SPROCKET 2406
METHOD FOR INSTALLING SPROCKET 2406
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2408
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2408
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2409
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2410
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2410
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2411
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2415
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2416
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2417
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2418
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2419
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2420
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2422
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2422
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2423
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2426
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2426
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2428
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2430
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2430
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2433
HYDRAULIC SYSTEM 2437
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2437
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2437
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2439
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2442
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2443
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2444
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2445
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2445
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2448
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2452
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2452
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2455
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2459
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2459
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2464
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2471
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2471
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2473
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2477
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2477
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2477
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2479
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2479
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2480
WORK EQUIPMENT 2482
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2482
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2482
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2486
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2492
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2492
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2494
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM .2495
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2495
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2497
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .2498
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY .2498
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2498
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2499
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2499
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2502
CAB AND ITS ATTACHMENTS .2508
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2508
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2508
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2514
REMOVE AND INSTALL OPERATOR’S CAB GLASS (ADHERED GLASS) .2521
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2523
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2523
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2533
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2533
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2536
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2542
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2542
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2549
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2556
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2556
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2562
REMOVE AND INSTALL OPERATOR’S SEAT 2569
METHOD FOR REMOVING OPERATOR’S SEAT .2569
METHOD FOR INSTALLING OPERATOR’S SEAT .2571
REMOVE AND INSTALL SEAT BELT 2574
METHOD FOR REMOVING SEAT BELT .2574
METHOD FOR INSTALLING SEAT BELT .2575
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY 2576
REMOVE WORK EQUIPMENT CONTROL LEVER ASSEMBLY 2576
INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY .2582
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2591
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2591
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2596
ELECTRICAL SYSTEM .2605
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2605
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2605
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2606
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2608
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2608
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2612
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2617
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2617
METHOD FOR INSTALLING KomVision CONTROLLER 2618
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2619
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2619
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2622
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2626
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2626
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2627
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2628
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2628
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2628
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2630
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2630
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2631
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2633
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2633
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2635
REMOVE AND INSTALL KomVision CAMERA .2638
METHOD FOR REMOVING KomVision CAMERA 2638
METHOD FOR INSTALLING KomVision CAMERA 2639
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2641
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2641
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2646
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2651
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS .2651
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS .2659
REMOVE AND INSTALL COMMUNICATION TERMINAL .2668
METHOD FOR REMOVING COMMUNICATION TERMINAL 2668
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2670
60 MAINTENANCE STANDARD .2673
CONTENTS 2674
ABBREVIATION LIST .2675
ENGINE AND COOLING SYSTEM .2681
MAINTENANCE STANDARD OF ENGINE MOUNT 2681
MAINTENANCE STANDARD OF COOLING SYSTEM 2682
POWER TRAIN .2683
MAINTENANCE STANDARD OF SWING CIRCLE 2683
MAINTENANCE STANDARD OF SWING MACHINERY .2684
MAINTENANCE STANDARD OF FINAL DRIVE .2686
MAINTENANCE STANDARD OF SPROCKET 2688
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2689
UNDERCARRIAGE AND FRAME .2691
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2691
MAINTENANCE STANDARD OF IDLER .2693
MAINTENANCE STANDARD OF TRACK ROLLER 2695
MAINTENANCE STANDARD OF CARRIER ROLLER 2697
MAINTENANCE STANDARD OF TRACK SHOE 2698
MAINTENANCE STANDARD OF TRIPLE SHOE .2701
HYDRAULIC SYSTEM 2702
MAINTENANCE STANDARD OF HYDRAULIC TANK 2702
MAINTENANCE STANDARD OF MAIN PUMP .2703
MAINTENANCE STANDARD OF LS-EPC VALVE 2704
MAINTENANCE STANDARD OF PC-EPC VALVE 2705
MAINTENANCE STANDARD OF SWING MOTOR .2706
MAINTENANCE STANDARD OF TRAVEL MOTOR 2709
MAINTENANCE STANDARD OF CONTROL VALVE .2712
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2722
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2724
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2726
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2729
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2732
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2734
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .2735
MAINTENANCE STANDARD OF SOLENOID VALVE 2737
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2738
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2739
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2740
WORK EQUIPMENT 2741
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2741
DIMENSION OF ARM 2746
DIMENSIONS OF BUCKET 2748
MAINTENANCE STANDARD OF BOOM CYLINDER .2750
MAINTENANCE STANDARD OF ARM CYLINDER 2751
MAINTENANCE STANDARD OF BUCKET CYLINDER .2752
80 APPENDIX .2753
CONTENTS 2754
ABBREVIATION LIST .2756
AIR CONDITIONER SYSTEM 2762
PRECAUTIONS FOR REFRIGERANT .2762
AIR CONDITIONER COMPONENT .2763
SPECIFICATIONS OF AIR CONDITIONER .2765
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2766
OUTLINE OF REFRIGERATION CYCLE 2767
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2769
AIR CONDITIONER UNIT 2769
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2769
FUNCTION OF AIR CONDITIONER UNIT 2771
COMPONENT PARTS OF AIR CONDITIONER UNIT .2773
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2774
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2774
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2774
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2774
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2775
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2775
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2775
FUNCTION OF DUAL PRESSURE SWITCH 2776
AIR CONDITIONER CONTROLLER 2777
STRUCTURE OF AIR CONDITIONER CONTROLLER .2777
COMPRESSOR 2778
STRUCTURE OF COMPRESSOR .2778
SPECIFICATIONS OF COMPRESSOR 2778
FUNCTION OF COMPRESSOR 2778
CONDENSER .2779
STRUCTURE OF CONDENSER 2779
SPECIFICATIONS OF CONDENSER .2779
FUNCTION OF CONDENSER .2779
SENSORS FOR AIR CONDITIONER SYSTEM 2781
STRUCTURE OF SUNLIGHT SENSOR 2781
FUNCTION OF SUNLIGHT SENSOR .2781
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2781
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2781
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2783
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2785
AIR CONDITIONER SYSTEM DIAGRAM 2787
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2788
FUNCTION OF AIR CONDITIONER CONTROLLER 2789
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2790
TESTING AIR LEAKAGE (DUCT) 2794
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2794
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2796
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2797
TEST VENT (MODE) CHANGEOVER .2798
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2798
TESTING FRESH/RECIRC AIR CHANGEOVER .2800
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2800
TEST SUNLIGHT SENSOR 2801
METHOD FOR TESTING SUNLIGHT SENSOR 2801
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2802
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2802
TEST RELAYS .2803
METHOD FOR TESTING RELAYS .2803
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2804
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2805
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2808
FAILURE CODE [879AKA] .2810
FAILURE CODE [879AKB] .2811
FAILURE CODE [879BKA] .2812
FAILURE CODE [879BKB] .2814
FAILURE CODE [879CKA] .2816
FAILURE CODE [879CKB] .2817
FAILURE CODE [879DKZ] .2818
FAILURE CODE [879EMC] .2820
FAILURE CODE [879FMC] .2821
FAILURE CODE [879GKX] .2822
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2824
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2826
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2829
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2831
TROUBLESHOOTING USING GAUGE PRESSURE 2833
CONNECTION OF SERVICE TOOL 2836
METHOD FOR CONNECTING SERVICE TOOL 2836
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2838
HANDLE COMPRESSOR OIL .2840
METHOD FOR REPLACING DESICCANT 2842
90 CIRCUIT DIAGRAMS .2845
CONTENTS 2846
ABBREVIATION LIST .2847
HYDRAULIC CIRCUIT DIAGRAM .2853
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2853
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2857
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2859
ELECTRICAL CIRCUIT DIAGRAM 2861
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2861
ELECTRICAL CIRCUIT DIAGRAM (1/10) .2865
ELECTRICAL CIRCUIT DIAGRAM (2/10) .2867
ELECTRICAL CIRCUIT DIAGRAM (3/10) .2869
ELECTRICAL CIRCUIT DIAGRAM (4/10) .2871
ELECTRICAL CIRCUIT DIAGRAM (5/10) .2873
ELECTRICAL CIRCUIT DIAGRAM (6/10) .2875
ELECTRICAL CIRCUIT DIAGRAM (7/10) .2877
ELECTRICAL CIRCUIT DIAGRAM (8/10) .2879
ELECTRICAL CIRCUIT DIAGRAM (9/10) .2881
ELECTRICAL CIRCUIT DIAGRAM (10/10) 2883
INDEX 2885

DESCRIPTION:

Komatsu PC290LC-11 Hydraulic Excavator Shop Manual SEN06736-C7  – PDF DOWNLOAD

• SERIAL NUMBERS C60001 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