Komatsu PC290LCi-11 Hydraulic Excavator Shop Manual SEN06726-09 PDF

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Komatsu PC290LCi-11 Hydraulic Excavator Shop Manual SEN06726-09 – PDF DOWNLOAD

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Komatsu PC290LCi-11 Hydraulic Excavator Shop Manual SEN06726-09 – PDF DOWNLOAD 

Language : English
Pages : 3758
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC290LCi-11 Hydraulic Excavator Shop Manual SEN06726-09 – PDF DOWNLOAD 

SERIAL NUMBERS 35039 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 23
Foreword, Safety, Basic Information 26
How to Read the Shop Manual 26
Safety Notice for Operation 28
Precautions to Prevent Fire 36
Procedures If Fire Occurs 38
Precautions When You Discard Waste Materials 39
Procedures for Exhaust Gas Regulations 40
Precautions for DEF 41
General Character and Precautions for Handling 41
Precautions When You Add 41
Precautions for Storage 41
Precautions for Fire Hazard and Leakage 41
Other Precautions 41
Store DEF 42
Precautions When You Handle Hydraulic Equipment 43
Precautions When You Disconnect and Connect Pipings 46
Precautions When You Handle Electrical Equipment 53
Precautions When You Handle Fuel System Equipment 55
Precautions When You Handle Intake System Equipment 56
Practical Use of KOMTRAX 57
Disconnect and Connect Push-Pull Type Coupler 58
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 59
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 60
Precautions for Disconnection and Connection of Connectors 62
Disconnect and Connect Deutsch Connector 66
How to Disconnect and Connect Slide Lock Type Connector 67
Disconnect and Connect Connector with Lock to Pull 69
Disconnect and Connect Connector with Lock to Push 70
Disconnect and Connect Connector with Housing to Rotate 72
How to Read the Codes for Electric Cable 73
Explanation of Terms for Maintenance Standard 77
Standard Tightening Torque Table 80
Conversion Table 87
01 Specification 93
Table of Contents 94
Specifications 95
Specification Drawing 95
Specification Drawing: PC290LCI-11 95
Working Range Drawings 97
Working Range: PC290LCI-11 97
Specifications 98
Specifications: PC290LCI-11 98
Weight Table 101
Weight Table: PC290LCI-11 101
Table of Fuel, Coolant, and Lubricants 103
10 Structure and Function 105
Table of Contents 106
Urea SCR System 110
Layout Drawing of Urea SCR System 111
Urea SCR System Diagram 116
Function of Urea SCR System 117
Function of DEF System 117
Inducement Strategy 119
Component Parts of Urea SCR System 133
DEF Mixing Tube 133
SCR Assembly 133
DEF Tank 136
DEF Pump 138
DEF Injector 139
DEF Hose 140
DEF Tank Heating Valve 141
Boot-up System 142
Layout Drawing of Boot-up System 142
System Operating Lamp System 144
System Diagram of System Operating Lamp System 144
Function of Operation Lamp System 144
Battery Disconnect Switch 146
Function of Battery Disconnect Switch 146
Engine System 147
Layout Drawing of Engine System 147
Specifications of Engine System 148
Function of Engine System 148
Engine Control System 149
System Diagram of Engine Control 149
Function of Engine Control System 150
Auto-Deceleration System 152
System Diagram of Auto-Deceleration System 152
Function of Auto-Deceleration System 152
Operation of Auto-Deceleration System 153
Engine Automatic Warm-up System 154
System Diagram of Engine Automatic Warm-up System 154
Function of Engine Automatic Warm-up System 155
Overheat Prevention System 156
Overheat Prevention System Diagram 156
Function of Overheat Prevention System 157
Turbocharger Protection System 159
System Diagram of Turbocharger Protection System 159
Function of Turbocharger Protection System 160
Automatic Idle Stop System 161
System Diagram of Automatic Idle Stop System 161
Function of Automatic Idle Stop System 161
Component Parts of Engine System 164
VGT 164
EGR System 168
EGR Valve 170
EGR Cooler 172
KCCV System 173
KCCV Ventilator 175
KDPF 177
Cooling System 182
Layout Drawing of Cooling System 182
Specifications of Cooling System 183
Control System 184
Layout Drawing of Control System 184
Machine Monitor System 186
System Diagram of Machine Monitor System 186
Function of Machine Monitor System 186
KomVision System 188
Layout Drawing of KomVision System 188
System Diagram of KomVision System 189
Function of KomVision System 190
KOMTRAX System 192
System Diagram of KOMTRAX System 192
Function of KOMTRAX System 192
Component Parts of Control System 193
Machine Monitor 193
KomVision Controller 207
KomVision Camera 211
KOMTRAX Terminal 212
Pump Controller 214
Resistor for PC-EPC Valve 219
CAN Terminating Resistor 220
Engine Controller 221
Fuel Control Dial 228
Fuel Feed Pump 230
Fuel Feed Pump Switch 231
Hydraulic System 232
Layout Drawing of Hydraulic System 232
CLSS 238
Structure of CLSS 238
Operation of Unload Valve and LS Pressure 240
Pump Swash Plate Angle (Oil Flow) Control 241
Pressure Compensation Control 257
Engine and Pump Combined Control System 258
Engine and Pump Combined Control System Diagram 258
Function of Engine and Pump Combined Control System 259
Pump and Valve Control System 264
Pump and Valve Control System Diagram 264
Function of Pump and Valve Control System 265
Component Parts of Hydraulic System 267
Hydraulic Tank 267
Main Pump 269
Control Valve 289
Work Equipment System 339
Layout Drawing of Work Equipment System 339
Structure of Valve Control 344
One-Touch Power Maximizing System 346
System Diagram of One-Touch Power Maximizing System 346
Function of One-Touch Power Maximizing System 347
PPC Lock System 348
System Diagram of PPC Lock 348
Function of PPC Lock System 348
Work Equipment and Travel Automatic Lock System 349
System Diagram of Lock Lever Automatic Lock System 349
Function of Work Equipment and Travel Automatic Lock System 349
Operation of Lock Lever Automatic Lock System 350
Attachment Oil Flow Adjuster System 351
Attachment Oil Flow Adjuster System Diagram 351
Function of Attachment Oil Flow Adjuster System 352
Component Parts of Work Equipment System 353
Work Equipment and Swing PPC Valve 353
1st-Line Attachment PPC Valve (with EPC Valve) 360
Solenoid Valve 366
Attachment Circuit Selector Valve (For High Pressure) 369
Attachment Circuit Selector Valve (For Low Pressure) 371
Pilot Circuit Accumulator 373
Attachment Circuit Accumulator 374
ICT System 375
Layout Drawing of ICT System 375
System Diagram of ICT Control System 377
Bucket Edge Position Detection System 378
Bucket Edge Position Detection System Diagram 378
Function of Bucket Edge Position Detection System 378
Operation of Bucket Edge Position Detection System 378
The Intelligent Machine Control System 380
Function of Intelligent Machine Control System 380
Auto Grade Assist Control 380
Auto Stop Control 387
Cushion System for Arm IN End 395
Cushion System for Arm IN End Diagram 395
Function of Cushion System for Arm IN End 395
Operation of Cushion System for Arm IN End 395
Boom Secondary Drive Switch 397
Control Function When Boom Secondary Drive Switch is Turned to ON Position 397
Component Parts of ICT System 398
ICT Sensor Controller 398
Work Equipment Controller 402
Control Box 406
GNSS Receiver 410
GNSS Antenna 414
IMU Sensor 415
Intelligent Machine Control EPC Valve 416
Stroke Sensor for Boom Cylinder 419
Stroke Sensor for Arm Cylinder 421
Stroke and Reset Sensor for Bucket Cylinder 423
Reset Sensor for Boom Cylinder 426
Reset Sensor for Arm Cylinder 427
Boom Spool Stroke Sensor 428
Arm Spool Stroke Sensor 430
Swing System 432
Layout Drawing of Swing System 432
Swing Control System Diagram 435
Function of Swing Control System 435
Component Parts of Swing System 439
Swing Motor 439
Swing Machinery 450
Swing Circle 451
Travel System 453
Layout Drawing of Travel System 453
System Diagram of Travel Control System 457
Function of Travel Control System 457
Component Parts of Travel System 459
Travel Motor 459
Final Drive 470
Travel PPC Valve 472
Center Swivel Joint 477
Undercarriage and Frame 479
Layout Drawing of Undercarriage 479
Specifications of Undercarriage 480
Work Equipment 481
Structure of Work Equipment 481
Function of Work Equipment 482
Work Equipment Clearance Adjustment Shim 483
Function of Work Equipment Clearance Adjustment Shim 483
Bucket Clearance Adjustment Shim 484
Function of Bucket Clearance Adjustment Shim 484
CAB Related Parts 485
ROPS CAB 485
Structure of ROPS CAB 485
Function of ROPS CAB 485
CAB Mount 486
Structure of CAB Mount 486
Function of CAB Mount 486
CAB Tipping Stopper 487
Structure of CAB Tipping Stopper 487
Function of CAB Tipping Stopper 487
20 Standard Value Table 489
Table of Contents 490
Standard Value Table for Engine 491
Standard Value Table for Engine: PC290LCI-11 491
Standard Value Table for Machine 495
Standard Value Table for Machine: PC290LCI-11 495
Machine Posture and Procedures to Measure Performance 517
Standard Value Table for Electricity 521
Standard Value Table for Electricity 521
30 Testing and Adjusting 531
Table of Contents 532
Precautions Before Work 536
Related Information on Testing and Adjusting 537
Tools for Testing and Adjusting 537
Sketch of Tools for Testing and Adjusting 547
Engine and Cooling System 549
Examine Engine Speed 549
How to Examine Engine Speed 549
Examine Boost Pressure 552
How to Examine Boost Pressure on Machine Monitor 552
How to Examine Boost Pressure by Testing Tool 553
Examine Exhaust Gas Color 554
How to Examine Exhaust Gas Color with the Handy Smoke Checker 554
How to Examine Exhaust Gas Color with Smoke Meter 555
Examine Mass Air Flow and Temperature Sensor 557
How to Examine Mass Air Flow and Temperature Sensor 557
Examine and Adjust Valve Clearance 559
Check Valve Clearance 559
Adjust Valve Clearance 560
Examine Compression Pressure 562
How to Examine Compression Pressure 562
Examine Blowby Pressure 567
How to Examine Blowby Pressure 567
Examine Engine Oil Pressure 569
How to Examine Engine Oil Pressure 569
Examine EGR Valve and VGT Oil Pressure 570
How to Examine EGR Valve and VGT Oil Pressure 570
Examine Fuel Pressure 572
How to Examine Fuel Pressure 573
Examine Fuel Discharge, Return and Leakage 578
How to Examine Fuel Discharge, Return, and Leakage 579
Bleed Air from Fuel System 585
How to Bleed Air from Fuel System 585
Examine Fuel Circuit for Leakage 586
How to Examine Fuel System for Leakage 586
Handle Cylinder Cut-out Mode Operation 588
Handle No-Injection Cranking Operation 589
Examine and Adjust Air Conditioner Compressor Belt Tension 590
How to Examine Air Conditioner Compressor Belt 590
How to Adjust Air Conditioner Compressor Belt 590
Examine Fan Belt and Alternator Belt 592
How to Examine Fan Belt and Alternator Belt 592
Examine Automatic Tensioner 593
How to Examine Automatic Tensioner 593
Write Correction for Ash in Soot Accumulation to Engine Controller 594
How to Write Correction for Ash in Soot Accumulation to Engine Controller 594
Examine SCR Related Functions 595
Examine DEF Pump Raised Pressure 599
Examine Injection Volume from DEF Injector 602
Examine DEF Line Heater Relay 1 607
Examine DEF Line Heater Relay 2 610
Examine DEF Pump Heater Relay 613
Examine DEF Tank Heater Valve 616
Examine SCR Denitration Efficiency 619
Clean DEF Tank 623
How to Clean DEF Tank 623
Bleed Air from Coolant Circuit of DEF Tank 627
How to Bleed Air from Coolant Circuit of DEF Tank 627
Clean DEF Pump 629
How to Clean DEF Pump 629
Power Train 635
Examine Swing Circle Bearing Clearance 635
How to Examine Swing Circle Bearing Clearance 635
Undercarriage and Frame 636
Examine and Adjust Track Tension 636
How to Examine Track Tension 636
How to Adjust Track Tension 636
Hydraulic System 638
Release Remained Pressure in Hydraulic Circuit 638
How to Release Remained Pressure in Hydraulic System 638
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 639
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 640
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 646
Examine Oil Pressure of Control Circuit 649
Examine Oil Pressure in Control Circuit 649
Examine and adjust oil pressure in pump PC control circuit 651
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 651
Examine PC-EPC Valve Outlet Pressure 652
How to Adjust Oil Pressure in Pump PC Control Circuit 653
Examine and Adjust Oil Pressure in Pump LS Control Circuit 655
Examine LS Differential Pressure with Machine Monitor 655
Examine LS Differential Pressure by Testing Tool 656
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 659
How to Examine LS-EPC Valve Outlet Pressure 660
Adjust LS Valve 661
Examine Outlet Pressure of Solenoid Valve 662
How to Examine Outlet Pressure of Solenoid Valve 662
Operating Condition of Solenoid Valve 663
Examine PPC Valve Outlet Pressure 666
Examine Outlet Pressure in PPC Valve 666
Adjust Play of Work Equipment and Swing PPC Valves 668
How to Adjust Play of Work Equipment and Swing PPC Valves 668
Examine Pump Swash Plate Sensor 669
How to Examine pump swash plate sensor 669
Examine Parts Which Cause Hydraulic Drift of Work Equipment 670
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 670
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 670
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 671
Examine Oil Leakage 672
How to Examine Oil Leakage from Boom Cylinder 672
How to Examine Oil Leakage from Arm Cylinder 672
How to Examine Oil Leakage from Bucket Cylinder 673
How to Examine Oil Leakage from Swing Motor 674
How to Examine Oil Leakage from Travel Motor 674
Bleed Air from Hydraulic System 675
How to Bleed Air from Hydraulic System 677
CAB Related Parts 679
Examine CAB Tipping Stopper 679
How to Examine Cab Tipping Stopper 679
How to Adjust Mirrors 680
Procedure to Adjust Machine Left Front Mirror (A) 680
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 681
Procedure to Adjust Machine Right Front Mirror (B) 682
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 683
Procedure to Adjust Machine Right Side Mirror (C) 684
Electrical System 686
Set and Operate Machine Monitor 686
Operator Mode 691
Function to Show Technician Identification Status Screen 691
Function to Show Operator Identification Input Screen 691
Examine Function by LCD (Liquid Crystal Display) 692
Examine Function of Service Meter 692
Usage Limitation and Maintenance Password Change Function 692
Service Mode 695
How to Operate Service Mode 695
How to See Pre-defined Monitoring Information 698
How to Examine Self-Define Monitor Information 704
Abnormality Record Menu 718
How to See Maintenance Record 722
Maintenance Mode Setting 723
Set Phone Number Entry 727
Default Menu 729
Diagnostic Tests Menu 737
Adjustment Menu 748
No-Injection Cranking Operation 780
KOMTRAX Settings Menu 782
Show Service Message 784
How to Start Up KOMTRAX Terminal 786
Adjust Rearview Camera Angle 791
How to Adjust Rearview Camera Angle 791
Adjust KomVision Camera Angle 794
How to Adjust KomVision Camera Angle 795
Adjust KomVision Related Function 799
Setting of KomVision (Main Setting) 799
Setting of KomVision (Camera Setting) 801
Setting of KomVision (Camera Calibration) 803
KomVision screen – Check 12 m visibility 816
Set Region of Bluetooth(R) Compatible Radio 819
Set Region of Bluetooth(R) Compatible Radio 819
Handle Voltage Circuit of Engine Controller 821
Handle Battery Disconnect Switch 822
Examine Diodes 823
Examine Diodes by Digital Tester 823
How to Examine Diodes by Analog Tester 823
ICT System 824
Set and Operate Control Box 824
How to Set the Starting Switch Interlock Function of the Control Box 826
How to Select Excavator Model in the Control Box 830
Switch Grade Transitions Fineness on Control Box 833
Monitoring and Logging Function on Control Box 836
Calibrate Intelligent Machine Control 842
PPC Pressure Sensor Calibration 845
Control Map Calibration 936
How to Examine the Intelligent Machine Control System 1099
Calibrate IMU Sensor for Yaw Angle 1104
Calibrate IMU Sensor 1112
Procedure to be Done If an Error Occurs During Calibration of IMU Sensor 1125
Work Equipment Cylinder Calibration 1126
If Error Occurs During Calibration of Work Equipment Cylinder 1139
General Calibration of Bucket Blade Edge Position, Boom Dimensions, Arm Dimensions, Bucket Link Dimensions, and GNSS Antenna Position with Total Station 1141
Calibration of Boom Dimensions and Arm Dimensions with Total Station 1193
Calibration of Bucket Link Dimensions with Total Station 1213
Calibration of GNSS Antenna with Total Station 1249
Input Range of the Measured Values in Calibration with Total Station 1274
Examine the Input Values in Calibration with Total Station 1275
Procedure to be Done If an Error Occurs During Calibration with Total Station 1276
Calibration of GNSS Antenna Without Total Station 1277
Calibration of Bucket Blade Edge Position Without Total Station 1281
Input Range of the Measured Values in Calibration Without Total Station 1291
Procedure to be Done If an Error Occurs During Calibration Without Total Station 1292
Pm Clinic 1293
Pm Clinic Service 1293
Pm Clinic Check Sheet: PC290LCI-11 1295
40 Troubleshooting 1307
Table of Contents 1308
Precautions Before Work 1321
Related Information to Troubleshooting 1322
General Troubleshooting Points 1322
Troubleshooting Points for Urea SCR System 1323
Sequence of Events in Troubleshooting 1337
Checks Before Troubleshooting 1339
Inspection Procedure Before Troubleshooting 1341
Walk-Around Check 1341
Test in Accordance with Testing Procedure 1343
Examine Fuel Level and Type 1343
Examine for Impure Ingredient in Fuel 1343
Examine Fuel Prefilter 1344
Examine Water Separator, Drain Water and Sediment 1344
How to Replace Fuel Prefilter Cartridge 1345
Examine Fuel Main Filter 1346
Examine Engine Oil Level (Oil Quantity in Oil Pan) 1348
Examine Coolant Level (Reservoir Tank) 1349
Examine Air Cleaner Clogging 1349
Clean Outer Element 1350
Replace Element 1352
Examine Hydraulic Oil Level 1353
Examine Hydraulic Oil Strainer 1354
Examine Hydraulic Oil Filter 1355
Examine Oil Level in Swing Machinery Case 1356
Examine Oil Level in Damper Case 1357
Examine Oil Level in Final Drive Case 1357
Bleed Air from Fuel System 1358
Bleed Air from Hydraulic System 1358
How to Examine Electric Equipment 1358
How to Examine Electric Equipment 1365
Preparation for Troubleshooting of Electrical System 1370
Preparation for Troubleshooting of Electrical System 1380
Preparation for Troubleshooting of Machine Monitor 1380
Preparation for Troubleshooting of Engine Controller 1380
Preparation for Troubleshooting of ICT Sensor Controller 1381
Preparation for Troubleshooting of Work Equipment Controller 1382
Preparation for Troubleshooting of KOMTRAX Terminal 1383
Preparation for Troubleshooting of KomVision Controller 1383
Preparation for Troubleshooting of Control Box 1384
Preparation for Troubleshooting of GNSS Receiver 1384
How to Disconnect and Connect Connector with a Special Lock 1384
Procedure for Troubleshooting 1389
Symptom and Troubleshooting Numbers 1392
Information Shown in Troubleshooting Table 1397
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 1399
Connectors List 1402
Connector Layout (1) 1411
Connector Layout (2) 1413
Connector Layout (3) 1415
Connector Layout (4) 1416
Connector Layout (5) 1417
Connector Layout (6) 1419
Connector Contact Connection Table 1421
T-Branch Box and T-Branch Adapter Table 1461
Fuse Location Table 1467
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 1470
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 1474
Failure Code Table 1476
Troubleshooting by Failure Code (Display of Code) 1498
Failure Code [879AKA] 1498
Failure Code [879AKB] 1499
Failure Code [879BKA] 1500
Failure Code [879BKB] 1502
Failure Code [879CKA] 1504
Failure Code [879CKB] 1505
Failure Code [879DKZ] 1506
Failure Code [879EMC] 1508
Failure Code [879FMC] 1509
Failure Code [879GKX] 1510
Failure Code [989L00] 1512
Failure Code [989M00] 1513
Failure Code [989N00] 1514
Failure Code [A1U0N3] 1515
Failure Code [A1U0N4] 1517
Failure Code [A900FR] 1519
Failure Code [A900N6] 1520
Failure Code [A900NY] 1521
Failure Code [AA10NX] 1522
Failure Code [AB00KE] 1524
Failure Code [AQ10N3] 1527
Failure Code [AS00N3] 1529
Failure Code [AS00R2] 1531
Failure Code [AS00R3] 1532
Failure Code [AS00R4] 1533
Failure Code [AS00R5] 1534
Failure Code [AS00R6] 1535
Failure Code [AS00ZK] 1536
Failure Code [AS10KM] 1537
Failure Code [AS10NR] 1538
Failure Code [AS10NT] 1539
Failure Code [B@BAZG] 1540
Failure Code [B@BAZK] 1541
Failure Code [B@BCNS] 1543
Failure Code [B@BCQA] 1544
Failure Code [B@BCZK] 1546
Failure Code [B@HANS] 1548
Failure Code [CA115] 1549
Failure Code [CA122] 1550
Failure Code [CA123] 1552
Failure Code [CA131] 1554
Failure Code [CA132] 1556
Failure Code [CA144] 1558
Failure Code [CA145] 1560
Failure Code [CA153] 1562
Failure Code [CA154] 1565
Failure Code [CA187] 1567
Failure Code [CA221] 1569
Failure Code [CA222] 1571
Failure Code [CA227] 1573
Failure Code [CA234] 1574
Failure Code [CA238] 1575
Failure Code [CA239] 1577
Failure Code [CA249] 1579
Failure Code [CA256] 1581
Failure Code [CA271] 1583
Failure Code [CA272] 1585
Failure Code [CA322] 1587
Failure Code [CA323] 1589
Failure Code [CA324] 1591
Failure Code [CA325] 1593
Failure Code [CA331] 1595
Failure Code [CA332] 1597
Failure Code [CA343] 1599
Failure Code [CA351] 1600
Failure Code [CA352] 1601
Failure Code [CA356] 1604
Failure Code [CA357] 1606
Failure Code [CA386] 1608
Failure Code [CA428] 1609
Failure Code [CA429] 1611
Failure Code [CA435] 1613
Failure Code [CA441] 1615
Failure Code [CA442] 1617
Failure Code [CA449] 1618
Failure Code [CA451] 1619
Failure Code [CA452] 1621
Failure Code [CA488] 1623
Failure Code [CA515] 1624
Failure Code [CA516] 1626
Failure Code [CA553] 1628
Failure Code [CA555] 1629
Failure Code [CA556] 1630
Failure Code [CA559] 1631
Failure Code [CA595] 1634
Failure Code [CA687] 1635
Failure Code [CA689] 1637
Failure Code [CA691] 1640
Failure Code [CA692] 1642
Failure Code [CA697] 1644
Failure Code [CA698] 1645
Failure Code [CA731] 1646
Failure Code [CA778] 1648
Failure Code [CA1117] 1653
Failure Code [CA1664] 1654
Failure Code [CA1669] 1656
Failure Code [CA1673] 1657
Failure Code [CA1677] 1658
Failure Code [CA1678] 1659
Failure Code [CA1682] 1660
Failure Code [CA1683] 1662
Failure Code [CA1684] 1664
Failure Code [CA1686] 1666
Failure Code [CA1691] 1667
Failure Code [CA1694] 1670
Failure Code [CA1695] 1673
Failure Code [CA1696] 1674
Failure Code [CA1712] 1676
Failure Code [CA1713] 1679
Failure Code [CA1714] 1681
Failure Code [CA1715] 1682
Failure Code [CA1776] 1683
Failure Code [CA1777] 1686
Failure Code [CA1843] 1689
Failure Code [CA1844] 1691
Failure Code [CA1879] 1694
Failure Code [CA1881] 1697
Failure Code [CA1883] 1699
Failure Code [CA1885] 1702
Failure Code [CA1887] 1704
Failure Code [CA1921] 1706
Failure Code [CA1922] 1709
Failure Code [CA1942] 1714
Failure Code [CA1993] 1715
Failure Code [CA2185] 1718
Failure Code [CA2186] 1719
Failure Code [CA2249] 1721
Failure Code [CA2271] 1722
Failure Code [CA2272] 1724
Failure Code [CA2288] 1727
Failure Code [CA2311] 1728
Failure Code [CA2349] 1729
Failure Code [CA2353] 1732
Failure Code [CA2357] 1734
Failure Code [CA2381] 1735
Failure Code [CA2382] 1737
Failure Code [CA2383] 1740
Failure Code [CA2386] 1743
Failure Code [CA2387] 1745
Troubleshooting Flowchart 1749
Failure Code [CA2555] 1750
Failure Code [CA2556] 1753
Failure Code [CA2637] 1756
Failure Code [CA2639] 1758
Failure Code [CA2771] 1761
Failure Code [CA2777] 1767
Failure Code [CA2976] 1770
Failure Code [CA3133] 1772
Failure Code [CA3134] 1774
Failure Code [CA3135] 1776
Failure Code [CA3142] 1779
Failure Code [CA3143] 1780
Failure Code [CA3144] 1781
Failure Code [CA3146] 1783
Failure Code [CA3147] 1784
Failure Code [CA3148] 1785
Failure Code [CA3151] 1787
Failure Code [CA3165] 1793
Failure Code [CA3229] 1795
Failure Code [CA3231] 1797
Failure Code [CA3232] 1799
Failure Code [CA3235] 1803
Failure Code [CA3239] 1805
Failure Code [CA3241] 1808
Failure Code [CA3242] 1811
Failure Code [CA3251] 1814
Failure Code [CA3253] 1816
Failure Code [CA3254] 1819
Failure Code [CA3255] 1822
Failure Code [CA3256] 1826
Failure Code [CA3311] 1828
Failure Code [CA3312] 1830
Failure Code [CA3313] 1833
Failure Code [CA3314] 1834
Failure Code [CA3315] 1835
Failure Code [CA3316] 1837
Failure Code [CA3317] 1838
Failure Code [CA3318] 1839
Failure Code [CA3319] 1841
Failure Code [CA3321] 1842
Failure Code [CA3322] 1844
Failure Code [CA3419] 1846
Failure Code [CA3421] 1848
Failure Code [CA3497] 1850
Failure Code [CA3498] 1851
Failure Code [CA3543] 1852
Failure Code [CA3545] 1859
Failure Code [CA3547] 1861
Failure Code [CA3558] 1862
Failure Code [CA3559] 1864
Failure Code [CA3562] 1866
Failure Code [CA3563] 1868
Failure Code [CA3567] 1871
Failure Code [CA3568] 1874
Failure Code [CA3571] 1878
Failure Code [CA3572] 1880
Failure Code [CA3574] 1882
Failure Code [CA3575] 1884
Failure Code [CA3577] 1885
Failure Code [CA3578] 1887
Failure Code [CA3582] 1889
Failure Code [CA3583] 1895
Failure Code [CA3596] 1897
Failure Code [CA3649] 1899
Failure Code [CA3681] 1901
Failure Code [CA3682] 1906
Failure Code [CA3713] 1912
Failure Code [CA3717] 1915
Failure Code [CA3718] 1916
Failure Code [CA3725] 1917
Failure Code [CA3741] 1920
Failure Code [CA3748] 1921
Failure Code [CA3751] 1923
Failure Code [CA3755] 1925
Failure Code [CA3866] 1927
Failure Code [CA3867] 1931
Failure Code [CA3868] 1934
Failure Code [CA3899] 1938
Failure Code [CA3911] 1940
Failure Code [CA3912] 1944
Failure Code [CA3932] 1946
Failure Code [CA3933] 1948
Failure Code [CA3934] 1950
Failure Code [CA3935] 1953
Failure Code [CA3936] 1955
Failure Code [CA4151] 1957
Failure Code [CA4152] 1961
Failure Code [CA4155] 1965
Failure Code [CA4156] 1967
Failure Code [CA4157] 1970
Failure Code [CA4158] 1972
Failure Code [CA4159] 1973
Failure Code [CA4161] 1974
Failure Code [CA4162] 1977
Failure Code [CA4163] 1980
Failure Code [CA4164] 1981
Failure Code [CA4165] 1983
Failure Code [CA4166] 1985
Failure Code [CA4168] 1986
Failure Code [CA4169] 1989
Failure Code [CA4171] 1991
Failure Code [CA4249] 1994
Failure Code [CA4251] 1996
Failure Code [CA4259] 1998
Failure Code [CA4261] 2001
Failure Code [CA4277] 2004
Failure Code [CA4281] 2008
Failure Code [CA4459] 2011
Failure Code [CA4461] 2013
Failure Code [CA4658] 2016
Failure Code [CA4731] 2020
Failure Code [CA4732] 2021
Failure Code [CA4739] 2022
Failure Code [CA4768] 2023
Failure Code [CA4769] 2025
Failure Code [CA4842] 2028
Failure Code [CA4952] 2032
Failure Code [CA5115] 2034
Failure Code [CA5179] 2037
Failure Code [CA5181] 2039
Failure Code [CA5383] 2041
Failure Code [D110KB] 2043
Failure Code [D19JKZ] 2045
Failure Code [D811MC] 2048
Failure Code [D862KA] 2049
Failure Code [D8ALKA] 2050
Failure Code [D8ALKB] 2052
Failure Code [D8AQKR] 2054
Failure Code [DA20MC] 2062
Failure Code [DA22KK] 2063
Failure Code [DA25KP] 2066
Failure Code [DA26KP] 2068
Failure Code [DA29KQ] 2071
Failure Code [DA2LKA] 2074
Failure Code [DA2LKB] 2076
Failure Code [DA2QKR] 2078
Failure Code [DA2RKR] 2087
Failure Code [DAF0MB] 2096
Failure Code [DAF0MC] 2097
Failure Code [DAF8KB] 2098
Failure Code [DAF9KQ] 2100
Failure Code [DAFGMC] 2101
Failure Code [DAFLKA] 2102
Failure Code [DAFLKB] 2104
Failure Code [DAFQKR] 2106
Failure Code [DAZ9KQ] 2114
Failure Code [DAZQKR] 2115
Failure Code [DB2QKR] 2123
Failure Code [DB2RKR] 2131
Failure Code [DB90MC] 2139
Failure Code [DB92KK] 2140
Failure Code [DB95KP] 2142
Failure Code [DB96KP] 2146
Failure Code [DB99KQ] 2150
Failure Code [DB9LKA] 2153
Failure Code [DB9LKB] 2155
Failure Code [DB9QKR] 2157
Failure Code [DB9RKR] 2166
Failure Code [DBP0KM] 2175
Failure Code [DBP0KT] 2176
Failure Code [DBPQKR] 2177
Failure Code [DBR0MC] 2187
Failure Code [DBR2KK] 2188
Failure Code [DBR5KP] 2191
Failure Code [DBR6KP] 2193
Failure Code [DBR9KQ] 2195
Failure Code [DBRLKA] 2198
Failure Code [DBRLKB] 2200
Failure Code [DBRQKR] 2202
Failure Code [DBRRKR] 2211
Failure Code [DBRSKB] 2220
Failure Code [DBRTKB] 2222
Failure Code [DBUSKR] 2224
Failure Code [DD20MA] 2228
Failure Code [DDNRKA] 2231
Failure Code [DDNRKY] 2233
Failure Code [DDNS00] 2235
Failure Code [DFB1KZ] 2237
Failure Code [DFB2KZ] 2239
Failure Code [DFB3L8] 2241
Failure Code [DFB4L8] 2243
Failure Code [DFB5KZ] 2245
Failure Code [DFB6KZ] 2247
Failure Code [DGH2KA] 2249
Failure Code [DGH2KB] 2251
Failure Code [DHA4KA] 2253
Failure Code [DHAAMA] 2255
Failure Code [DHACMA] 2257
Failure Code [DHPAMA] 2259
Failure Code [DHPBMA] 2262
Failure Code [DHS3MA] 2265
Failure Code [DHS4MA] 2268
Failure Code [DHS8MA] 2271
Failure Code [DHS9MA] 2274
Failure Code [DHSAMA] 2277
Failure Code [DHSBMA] 2280
Failure Code [DHSCMA] 2283
Failure Code [DHSDMA] 2286
Failure Code [DHSFMA] 2289
Failure Code [DHSGMA] 2292
Failure Code [DHSHMA] 2295
Failure Code [DHSJMA] 2298
Failure Code [DK80KM] 2301
Failure Code [DK80KR] 2302
Failure Code [DK80KT] 2308
Failure Code [DKG1KM] 2309
Failure Code [DKG1L8] 2310
Failure Code [DKG1MB] 2311
Failure Code [DKR0MA] 2312
Failure Code [DKR1MA] 2315
Failure Code [DKT0KM] 2318
Failure Code [DKT0L8] 2319
Failure Code [DKT0MB] 2320
Failure Code [DKT1KA] 2321
Failure Code [DKT1KB] 2323
Failure Code [DKT2KA] 2325
Failure Code [DKT2KB] 2327
Failure Code [DKT4KM] 2329
Failure Code [DKT4L8] 2330
Failure Code [DKT4MB] 2331
Failure Code [DKT5KA] 2332
Failure Code [DKT5KB] 2334
Failure Code [DKT6KA] 2336
Failure Code [DKT6KB] 2338
Failure Code [DKT8KA] 2340
Failure Code [DKT8KB] 2342
Failure Code [DKT9KA] 2344
Failure Code [DKT9KB] 2346
Failure Code [DKTAKA] 2348
Failure Code [DKTAKB] 2350
Failure Code [DKTAMB] 2352
Failure Code [DKTBKX] 2353
Failure Code [DKTBMC] 2355
Failure Code [DKTEMB] 2356
Failure Code [DKTFKX] 2358
Failure Code [DKTFMC] 2360
Failure Code [DKTJMB] 2361
Failure Code [DKTUMB] 2363
Failure Code [DKU1MA] 2364
Failure Code [DKU2MA] 2365
Failure Code [DKUGKA] 2366
Failure Code [DKUGKB] 2368
Failure Code [DKUGKY] 2370
Failure Code [DKUHKA] 2372
Failure Code [DKUHKB] 2374
Failure Code [DKUHKY] 2376
Failure Code [DKULKA] 2378
Failure Code [DKULKB] 2380
Failure Code [DKULKY] 2382
Failure Code [DKV0KA] 2384
Failure Code [DKV0KY] 2387
Failure Code [DKV1KA] 2389
Failure Code [DKV1KY] 2391
Failure Code [DKV2KA] 2393
Failure Code [DKV2KY] 2395
Failure Code [DKV3KA] 2397
Failure Code [DKV3KY] 2399
Failure Code [DKV4MA] 2401
Failure Code [DKV5MA] 2404
Failure Code [DKV6MA] 2407
Failure Code [DKV7MA] 2410
Failure Code [DKV8MA] 2413
Failure Code [DKV9MA] 2416
Failure Code [DKVAMA] 2419
Failure Code [DKVBKA] 2422
Failure Code [DKVBKB] 2424
Failure Code [DKVBKY] 2426
Failure Code [DKVCKA] 2428
Failure Code [DKVCKB] 2430
Failure Code [DKVCKY] 2432
Failure Code [DKVDKA] 2434
Failure Code [DKVDKB] 2436
Failure Code [DKVDKY] 2438
Failure Code [DKVDMA] 2440
Failure Code [DLM5KA] 2442
Failure Code [DLM5MB] 2444
Failure Code [DR10KA] 2446
Failure Code [DR21KX] 2450
Failure Code [DR31KX] 2452
Failure Code [DUMBKA] 2454
Failure Code [DUMBKB] 2456
Failure Code [DV20KB] 2458
Failure Code [DW43KA] 2460
Failure Code [DW43KB] 2462
Failure Code [DW43KY] 2464
Failure Code [DW45KA] 2466
Failure Code [DW45KB] 2469
Failure Code [DW45KY] 2472
Failure Code [DW4CKY] 2474
Failure Code [DW4FKA] 2476
Failure Code [DW4FKB] 2479
Failure Code [DW4FKY] 2481
Failure Code [DW4GKA] 2484
Failure Code [DW4GKB] 2487
Failure Code [DW4GKY] 2489
Failure Code [DW4SKA] 2491
Failure Code [DW4SKB] 2493
Failure Code [DW4SKY] 2495
Failure Code [DW91KA] 2497
Failure Code [DW91KB] 2499
Failure Code [DW91KY] 2501
Failure Code [DWA2KA] 2503
Failure Code [DWA2KB] 2505
Failure Code [DWA2KY] 2507
Failure Code [DWK0KA] 2509
Failure Code [DWK0KB] 2511
Failure Code [DWK0KY] 2513
Failure Code [DWK2KA] 2515
Failure Code [DWK2KB] 2517
Failure Code [DWK2KY] 2519
Failure Code [DWK8KA] 2521
Failure Code [DWK8KB] 2523
Failure Code [DWK8KY] 2525
Failure Code [DXA8KA] 2527
Failure Code [DXA8KB] 2529
Failure Code [DXA9KA] 2531
Failure Code [DXA9KB] 2533
Failure Code [DXE0KA] 2535
Failure Code [DXE0KB] 2536
Failure Code [DXE4KA] 2538
Failure Code [DXE4KB] 2540
Failure Code [DXE4KY] 2542
Failure Code [DXE5KA] 2544
Failure Code [DXE5KB] 2546
Failure Code [DXE6KA] 2548
Failure Code [DXE6KB] 2550
Failure Code [DXE7KA] 2552
Failure Code [DXE7KB] 2554
Failure Code [DXE7KY] 2556
Failure Code [DXE8KA] 2558
Failure Code [DXE8KB] 2560
Failure Code [DXE8KY] 2562
Failure Code [DXE9KA] 2564
Failure Code [DXE9KB] 2566
Failure Code [DXE9KY] 2568
Failure Code [DXEAKA] 2570
Failure Code [DXEAKB] 2572
Failure Code [DXEAKY] 2574
Failure Code [DY20KA] 2576
Failure Code [DY20MA] 2578
Failure Code [DY2CKB] 2580
Failure Code [DY2DKB] 2583
Failure Code [DY2EKB] 2585
Troubleshooting of Electrical System (E-Mode) 2587
E-1 Engine Does Not Start (Engine Does Not Crank) 2587
E-2 Manual Preheating System Does Not Operate 2593
E-3 Automatic Preheating System Does Not Operate 2596
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 2598
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2600
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 2603
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 2604
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 2605
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 2606
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 2607
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 2608
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 2609
E-13 Water Separator Monitor Comes On in Red While Engine Runs 2610
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 2611
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 2612
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 2613
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 2614
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 2616
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 2617
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 2618
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 2619
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 2621
E-23 Some Areas of Machine Monitor Screen are Not Shown 2622
E-24 Function Switch Does Not Operate 2623
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 2624
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 2625
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 2626
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 2627
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 2628
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 2629
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 2630
E-32 Alarm Buzzer Cannot be Canceled 2632
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 2633
E-34 Service Mode Cannot be Selected 2634
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 2635
E-36 All Work Equipment, Swing and Travel Do Not Lock 2638
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 2640
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 2643
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 2645
E-40 One-Touch Power Maximizing Function is Not Cancelled 2648
E-41 Alarm Does Not Sound During Travel 2649
E-42 Alarm Does Not Stop When Machine Stops 2651
E-43 Horn Does Not Sound 2652
E-44 Horn Does Not Stop 2655
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 2657
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 2658
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 2660
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 2661
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 2662
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function 2663
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 2664
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 2665
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function 2666
E-54 “Swing” is Not Shown Correctly with Monitoring Function 2667
E-55 “Travel” is Not Shown Correctly with Monitoring Function 2668
E-56 Service is Not Shown Correctly with Monitoring Function 2669
E-57 Attachment Hydraulic Circuit Cannot be Changed 2671
E-58 KOMTRAX System Does Not Operate Correctly 2672
E-59 Control Box Shows Message [GPS Receiver Not Connected !] and [Slope Sensor Not Connected !], and Then Shuts Down 2673
E-60 Control Box Shows Message [GPS receiver not connected!] 2678
E-61 Control Box Shows Message [Waiting for Radio Link] 2682
E-62 Control Box Shows Message [Tilt Bucket Sensor Offline!] 2683
E-63 Control Box Shows Message [Waiting for satellites ] 2684
E-64 Control Box Shows Message [Komatsu controller not connected!] Show Production 2685
E-65 Control Box Shows Message [Sensors are invalid] 2688
E-66 Control Box Shows Message [Waiting to Initialize ] 2691
E-67 Control Box Shows Message [Waiting to Initialize ] 2692
E-68 Control Box Shows Message [No GPS Localization] 2693
E-69 Control Box Shows Message [Low Precisions ] 2694
E-70 Control Box Shows Message [Out of Design Area] 2695
E-71 Control Box Shows Message [Avoidance Area Breach!] 2696
E-72 Control Box Cannot be Turned on 2697
E-73 Control Box Does Not Show Intelligent Machine Control Screen 2698
E-74 Control Box Does Not Display Hydraulic Excavator Image 2699
E-75 Control Box Does Not Show Design Surface 2700
E-76 Control Box Touch Panel Does Not Respond 2701
E-77 Control Box Touch Panel is Inaccurate 2702
E-78 When You Examine and Adjust the Bucket Edge Position, the Value is Different from Actual Machine 2703
E-79 Semi-Auto Mode is Not Shown When Auto/Manual Switch is Pushed 2705
E-80 Auto Grade Assist Control Does Not Operate While Semi-Auto Mode is Shown 2706
E-81 Auto Stop Control Does Not Operate While Semi-Auto Mode is Shown 2707
E-82 Blade Edge Position on Design Surface is Not Accurate When Auto Grade Assist Function is on 2708
E-83 Blade Edge Stop Position is Not Accurate for Design Surface When Auto Stop Control Function is on 2710
E-84 Facing Angle Compass Does Not Become Perpendicular to Target 2712
E-85 NG Occurs Frequently in IMU Calibration Diagnosis 2713
E-86 Cushion for Boom Raise End Does Not Work or is Weak 2714
E-87 Cushion for Arm IN End Does Not Work or is Weak 2715
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2718
Information Shown in Troubleshooting Table (H-Mode) 2718
System Chart of Hydraulic and Mechanical Systems 2719
Failure Mode and Cause Table 2721
H-1 All Work Equipment, Swing and Travel Do Not Work 2730
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2731
H-3 Fine Control Performance or Response is Unsatisfactory 2734
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2735
H-5 Engine Speed Drops Largely or Engine Stops 2736
H-6 Speed or Power of Boom is Low 2738
H-7 Arm Speed or Power is Low 2742
H-8 Bucket Speed or Power is Low 2747
H-9 Work Equipment Does Not Move in Single Operation 2750
H-10 Hydraulic Drift of Boom is Large 2751
H-11 Hydraulic Drift of Arm is Large 2753
H-12 Hydraulic Drift of Bucket is Large 2755
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2756
H-14 Time Lag of Work Equipment is Large 2757
H-15 One-Touch Power Maximizing Function Does Not Operate 2758
H-16 Attachment Circuit Cannot be Changed 2759
H-17 Oil Flow in Attachment Circuit Cannot be Changed 2760
H-18 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 2761
H-19 In Mixed Operation of Swing and Travel, Travel Speed Decreases Largely 2762
H-20 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low 2763
H-21 Machine Does Not Travel Straight 2764
H-22 Machine is Not Steered Correctly or Steering Power is Low 2766
H-23 Travel Speed is Low 2769
H-24 One of Tracks Does Not Run 2771
H-25 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 2772
H-26 Upper Structure Does Not Swing to Right and Left 2773
H-27 Upper Structure Swings Only to Right or Left 2774
H-28 Swing Acceleration or Swing Speed is Low in Right and Left Directions 2775
H-29 Swing Acceleration or Swing Speed is Low in Only One Direction 2776
H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2777
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2778
H-32 Shock is Large When Upper Structure Stops Swing Operation 2779
H-33 There is Large Unusual Noise When It Stops Swing Operation 2780
H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2781
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 2782
H-36 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2783
H-37 Unusual Noise is Heard from Around Fan 2784
Troubleshooting of Engine (S-Mode) 2785
Information Shown in Troubleshooting Table (S-Mode) 2785
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2786
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2787
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2788
S-4 Engine Startability is Unsatisfactory 2790
S-5 Engine Does Not Pick Up Smoothly 2792
S-6 Engine Stops During Operation 2794
S-7 Engine Runs Rough or is Not Stable 2796
S-8 Engine Lacks Power 2797
S-9 KDPF Becomes Clogged in a Short Time 2799
S-10 Engine Oil Consumption is Excessive 2801
S-11 Oil Becomes Dirty Quickly 2802
S-12 Fuel Consumption is Excessive 2803
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2804
S-14 Oil Pressure Drops 2805
S-15 Fuel Mixes Into Engine Oil 2807
S-16 Water Mixes Into Engine Oil (Milky) 2808
S-17 Coolant Temperature Increases Too High (Overheating) 2809
S-18 Unusual Noise is Heard 2810
S-19 Vibration is Excessive 2811
S-20 Air Cannot be Bled from Fuel Circuit 2812
S-21 Active Regeneration is Done Frequently 2813
S-22 Active Regeneration Continues Long 2815
S-23 White Smoke is Exhausted During Active Regeneration 2816
S-24 DEF Consumption is Excessive 2817
S-25 There is Unusual Smell (Irritating Odor) 2819
S-26 Foreign Materials Enter DEF (DEF Increases) 2820
50 Disassembly and Assembly 2821
Table of Contents 2822
Precautions Before Work 2828
Related Information on Disassembly and Assembly 2829
How to Read This Manual 2829
Coating Materials List 2830
Special Tool List 2835
Sketches of Special Tools 2847
Engine and Cooling System 2853
Remove and Install Supply Pump Assembly 2853
Remove Supply Pump Assembly 2853
Install Supply Pump Assembly 2856
Remove and Install Injector Assembly 2860
How to Remove Injector Assembly 2860
How to Install Injector Assembly 2865
Remove and Install Cylinder Head Assembly 2873
How to Remove Cylinder Head Assembly 2874
How to Install Cylinder Head Assembly 2883
Remove and Install EGR Valve Assembly 2899
Remove EGR Valve Assembly 2899
Install EGR Valve Assembly 2900
Remove and Install EGR Cooler Assembly 2903
How to Remove EGR Cooler Assembly 2903
How to Install EGR Cooler Assembly 2906
Remove and Install Starter Assembly 2911
Remove Starting Motor Assembly 2911
Install Starting Motor Assembly 2913
Remove and Install Alternator Belt 2915
Remove Alternator Belt 2915
Install Alternator Belt 2918
Remove and Install Radiator Assembly 2920
How to Remove Radiator Assembly 2920
How to Install Radiator Assembly 2924
Remove and Install Hydraulic Oil Cooler Assembly 2928
How to Remove Hydraulic Oil Cooler Assembly 2929
How to Install Hydraulic Oil Cooler Assembly 2934
Remove and Install Aftercooler Assembly 2939
Remove Aftercooler Assembly 2939
Install Aftercooler Assembly 2941
Remove and Install Engine and Main Pump Assembly 2943
Remove Engine and Main Pump Assembly 2945
Install Engine and Main Pump Assembly 2955
Remove and Install Engine Front Oil Seal 2968
How to Remove Engine Front Oil Seal 2968
How to Install Engine Front Oil Seal 2972
Remove and Install Engine Rear Oil Seal 2977
How to Remove Engine Rear Oil Seal 2977
How to Install Engine Rear Oil Seal 2978
Remove and Install Fuel Cooler Assembly 2981
Remove Fuel Cooler Assembly 2981
Install Fuel Cooler Assembly 2982
Remove and Install Engine Hood Assembly 2983
How to Remove Engine Hood Assembly 2983
How to Install Engine Hood Assembly 2985
Remove and Install Fuel Tank Assembly 2991
Remove Fuel Tank Assembly 2992
Install Fuel Tank Assembly 2996
Remove and Install DEF Tank Assembly 3002
How to Remove DEF Tank Assembly 3002
How to Install DEF Tank Assembly 3007
Remove and Install DEF Tank Sensor Flange Assembly 3013
How to Remove DEF Tank Sensor Flange Assembly 3013
How to Install DEF Tank Sensor Flange Assembly 3018
Remove and Install DEF Tank Sensor 3024
Remove DEF Tank Sensor 3024
Install DEF Tank Sensor 3024
Remove and Install DEF Tank Strainer 3031
Remove DEF Tank Strainer 3031
Install DEF Tank Strainer 3031
Remove and Install DEF Tank Filler Port Filter 3032
Remove DEF Tank Filler Port Filter 3032
Install DEF Tank Filler Port Filter 3034
Remove and Install KDPF Assembly 3037
How to Remove KDPF Assembly 3037
How to Install KDPF Assembly 3039
Disassemble and Assemble KDPF Assembly 3041
Disassemble KDPF Assembly 3042
Assemble KDPF Assembly 3045
Remove and Install SCR Assembly 3050
How to Remove SCR Assembly 3050
How to Install SCR Assembly 3052
Remove and Install KDPF and SCR Assembly 3054
How to Remove KDPF and SCR Assembly 3054
Install KDPF and SCR Assembly 3060
Remove and Install KDPF and SCR Assembly Bracket 3066
Remove KDPF and SCR Assembly Bracket 3066
Install KDPF and SCR Assembly Bracket 3073
Remove and Install Bellows Pipe Assembly 3081
How to Remove Bellows Pipe Assembly 3081
How to Install Bellows Pipe Assembly 3083
Remove and Install KCCV Assembly 3087
Remove KCCV Assembly 3087
Install KCCV Assembly 3089
Remove and Install DEF Mixing Tube 3094
Remove DEF Mixing Tube 3094
Install DEF Mixing Tube 3099
Remove and Install DEF Injector 3104
Remove DEF Injector 3104
Install DEF Injector 3106
Remove and Install DEF Pump 3108
Remove DEF Pump 3108
Install DEF Pump 3110
Remove and Install DEF Hose 3113
Remove DEF Hose 3113
Install DEF Hose 3121
Remove and Install Air Cleaner Assembly 3127
Remove Air Cleaner Assembly 3127
Install Air Cleaner Assembly 3128
Remove and Install Air Conditioner Compressor Assembly 3130
Remove Air Conditioner Compressor Assembly 3130
How to Install Air Conditioner Compressor Assembly 3132
Remove and Install Air Conditioner Condenser Assembly 3136
How to Remove Air Conditioner Condenser Assembly 3136
How to Install Air Conditioner Condenser Assembly 3137
Power Train 3138
Remove and Install Travel Motor and Final Drive Assembly 3138
Remove Travel Motor and Final Drive Assembly 3138
Install Travel Motor and Final Drive Assembly 3139
Disassemble and Assemble Final Drive Assembly 3140
Disassemble Final Drive Assembly 3140
Assemble Final Drive Assembly 3144
Remove and Install Swing Motor and Swing Machinery Assembly 3153
Remove Swing Motor and Swing Machinery Assembly 3153
Install Swing Motor and Swing Machinery Assembly 3155
Disassemble and Assemble Swing Machinery Assembly 3159
Disassemble Swing Machinery Assembly 3159
Assemble Swing Machinery Assembly 3163
Remove and Install Swing Circle Assembly 3170
Remove Swing Circle Assembly 3170
Install Swing Circle Assembly 3170
Undercarriage and Frame 3172
Separate and Connect Track Assembly 3172
Separate Track Assembly 3172
Install Track Assembly 3174
Remove and Install Sprocket 3177
Remove Sprocket 3177
Install Sprocket 3177
Remove and Install Idler and Idler Cushion Assembly 3179
Remove Idler and Idler Cushion Assembly 3179
Install Idler and Idler Cushion Assembly 3180
Disassemble and Assemble Idler Assembly 3181
Disassemble Idler Assembly 3181
Assemble Idler Assembly 3182
Disassemble and Assemble Idler Cushion Assembly 3186
Disassemble Idler Cushion Assembly 3187
Assemble Idler Cushion Assembly 3188
Disassemble and Assemble Track Roller Assembly 3189
Disassemble Track Roller Assembly 3190
Assemble Track Roller Assembly 3191
Disassemble and Assemble Carrier Roller Assembly 3193
Disassemble Carrier Roller Assembly 3193
Assemble Carrier Roller Assembly 3194
Remove and Install Revolving Frame Assembly 3197
Remove Revolving Frame Assembly 3197
Install Revolving Frame Assembly 3199
Remove and Install Counterweight Assembly 3201
Remove Counterweight Assembly 3201
Install Counterweight Assembly 3204
Hydraulic System 3208
Remove and Install Center Swivel Joint Assembly 3208
Remove Center Swivel Joint Assembly 3208
Install Center Swivel Joint Assembly 3210
Disassemble and Assemble Center Swivel Joint Assembly 3213
Disassemble Center Swivel Joint Assembly 3214
Assemble Center Swivel Joint Assembly 3215
Remove and Install Hydraulic Tank Assembly 3216
Remove Hydraulic Tank Assembly 3217
How to Install Hydraulic Tank Assembly 3219
Remove and Install Main Pump Assembly 3223
Remove Main Pump Assembly 3223
Install Main Pump Assembly 3226
Remove and Install Junction Block Assembly for Intelligent Machine Control 3230
Remove Junction Block Assembly for Intelligent Machine Control 3231
Install Junction Block Assembly for Intelligent Machine Control 3234
Remove and Install Pressure Sensor for Intelligent Machine Control 3238
How to Remove Pressure Sensor for Intelligent Machine Control 3238
How to Install Pressure Sensor for Intelligent Machine Control 3240
Remove and Install Boom Spool Stroke Sensor 3242
How to Remove Boom Spool Stroke Sensor 3242
How to Install Boom Spool Stroke Sensor 3243
Remove and Install Arm Spool Stroke Sensor 3244
How to Remove Arm Spool Stroke Sensor 3244
How to Install Arm Spool Stroke Sensor 3245
Remove and Install Junction Block Bypass Adapter for Intelligent Machine Control 3246
How to Remove Junction Block Bypass Adapter for Intelligent Machine Control 3247
How to Remove Junction Block Bypass Adapter for Intelligent Machine Control 3248
Remove and Install Control Valve Assembly 3250
How to Remove Control Valve Assembly 3252
How to Install Control Valve Assembly 3260
Disassemble and Assemble Control Valve Assembly 3270
Replace Pressure Compensation Valve Seal Ring 3270
Assemble Control Valve Assembly 3271
Disassemble and Assemble Work Equipment PPC Valve Assembly 3275
Disassemble Work Equipment PPC Valve Assembly 3275
How to Assemble Work Equipment PPC Valve Assembly 3275
Disassemble and Assemble Travel PPC Valve Assembly 3277
Disassemble Travel PPC Valve Assembly 3277
How to Assemble Travel PPC Valve Assembly 3278
Work Equipment 3280
Remove and Install Work Equipment Assembly 3280
Remove Work Equipment Assembly 3281
Install Work Equipment Assembly 3286
Disassemble and Assemble Stroke Sensing Boom Cylinder Assembly 3292
How to Disassemble Stroke Sensing Boom Cylinder Assembly 3293
How to Assemble Stroke Sensing Boom Cylinder Assembly 3299
Disassemble and Assemble Stroke Sensing Arm Cylinder Assembly 3307
How to Disassemble Stroke Sensing Arm Cylinder Assembly 3308
How to Assemble Stroke Sensing Arm Cylinder Assembly 3314
Disassemble and Assemble Stroke Sensing Bucket Cylinder Assembly 3324
How to Disassemble Stroke and Reset Sensing Bucket Cylinder Assembly 3325
How to Assemble Stroke and Reset Sensing Bucket Cylinder Assembly 3331
CAB Related Parts 3341
Remove and Install Operator Cab Assembly 3341
How to Remove Operator Cab Assembly 3342
Install Operator CAB Assembly 3351
Remove and Install Operator Cab Glass (Adhered Glass) 3361
Remove Operator CAB Glass (Adhered Glass) 3363
Install Operator CAB Glass (Adhered Glass) 3363
Remove and Install Front Window Assembly 3373
Remove Front Window Assembly 3373
Install Front Window Assembly 3376
Remove and Install Floor Frame Assembly 3382
How to Remove Floor Frame Assembly 3383
How to Install Floor Frame Assembly 3391
Remove and Install Air Conditioner Unit Assembly 3399
Remove Air Conditioner Unit Assembly 3399
Install Air Conditioner Unit Assembly 3406
Remove and Install Operator Seat 3414
Remove Operator’s Seat 3414
Install Operator’s Seat 3416
How to Remove and Install Seat Belt 3420
How to Remove Seat Belt 3420
How to Install Seatbelt 3420
Remove and Install Work Equipment Control Lever Assembly 3422
How to Remove Work Equipment Control Lever Assembly 3422
How to Install Work Equipment Control Lever Assembly 3428
Remove and Install Front Wiper Assembly 3437
Remove Front Wiper Assembly 3437
Install Front Wiper Assembly 3443
Electrical System 3452
Remove and Install Engine Controller Assembly 3452
Remove Engine Controller Assembly 3452
Install Engine Controller Assembly 3453
Remove and Install Pump Controller Assembly 3455
Remove Pump Controller Assembly 3455
Install Pump Controller Assembly 3459
Remove and Install Work Equipment Controller Assembly 3465
Remove Work Equipment Controller Assembly 3465
Install Work Equipment Controller Assembly 3467
Remove and Install KomVision Controller Assembly 3470
Remove KomVision Controller Assembly 3470
Install KomVision Controller Assembly 3471
Remove and Install Machine Monitor Assembly 3473
Remove Machine Monitor Assembly 3473
Install Machine Monitor Assembly 3476
Remove and Install Pump Swash Plate Sensor 3480
Remove Pump Swash Plate Sensor 3480
Install Pump Swash Plate Sensor 3481
Remove and Install Mass Air Flow and Temperature Sensor 3482
How to Remove Mass Air Flow and Temperature Sensor 3482
How to Install Mass Air Flow and Temperature Sensor 3482
Remove and Install KCCV Crankcase Pressure Sensor 3484
How to Remove KCCV Crankcase Pressure Sensor 3484
How to Install KCCV Crankcase Pressure Sensor 3485
Remove and Install SCR Temperature Sensor 3487
Remove SCR Temperature Sensor 3487
Install SCR Temperature Sensor 3489
Remove and Install KomVision Camera 3492
Remove KomVision Camera 3492
Install KomVision Camera 3495
Remove and Install KOMTRAX Terminal Assembly 3498
Remove KOMTRAX Terminal Assembly 3498
Install KOMTRAX Terminal Assembly 3501
Remove and Install ICT Sensor Controller Assembly 3504
Remove ICT Sensor Controller Assembly 3504
Install ICT Sensor Controller Assembly 3507
Remove and Install Junction Harness of Control Box 3511
How to Remove Junction Harness of Control Box 3511
How to Install Junction Harness of Control Box 3515
Remove and Install Control Box Harness 3519
Remove Control Box Harness 3519
Install Control Box Harness 3520
Remove and Install GNSS Receiver 3522
Remove GNSS Receiver 3522
Install GNSS Receiver 3523
Remove and Install Network Modem 3525
How to Remove Network Modem 3525
How to Install Network Modem 3525
Remove and Install GNSS Receiver Antenna 3526
How to Remove GNSS Receiver Antenna 3526
How to Install GNSS Receiver Antenna 3527
Remove and Install Network Modem Antenna 3529
Remove Network Modem Antenna 3529
Install Network Modem Antenna 3530
Remove and Install GNSS Antenna 3532
Remove GNSS Antenna 3532
Install GNSS Antenna 3533
Remove and Install IMU Sensor 3534
Remove IMU Sensor 3534
Install IMU Sensor 3535
60 Maintenance Standard 3537
Table of Contents 3538
Engine and Cooling System 3539
Maintenance Standard for Engine Mount 3539
Maintenance Standard for Cooling System 3540
Power Train 3541
Maintenance Standard for Swing Circle 3541
Maintenance Standard for Swing Machinery 3542
Maintenance Standard for Final Drive 3544
Maintenance Standard for Sprocket 3546
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 3547
Undercarriage and Frame 3548
Maintenance Standard for Track Frame and Idler Cushion 3548
Maintenance Standard for Idler 3550
Maintenance Standard for Track Roller 3552
Maintenance Standard for Carrier Roller 3554
Maintenance Standard for Track Shoes 3555
Maintenance Standard for Triple Shoes 3558
Hydraulic System 3559
Maintenance Standard for Hydraulic Tank 3559
Maintenance Standard for Main Pump 3560
Maintenance Standard for LS-EPC Valve 3561
Maintenance Standard for PC-EPC Valve 3562
Maintenance Standard for Swing Motor 3563
Maintenance Standard for Travel Motor 3566
Maintenance Standard for Control Valve 3569
Maintenance Standard for Work Equipment and Swing PPC Valve 3580
Maintenance Standard for Travel PPC Valve 3583
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 3586
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 3587
Maintenance Standard for 2nd-Line Attachment PPC Valve 3589
Maintenance Standard for Solenoid Valve 3591
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 3592
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 3593
Maintenance Standard for Center Swivel Joint 3594
Work Equipment 3595
Maintenance Standard for Work Equipment Linkage 3595
Dimensions of Arm 3600
Dimensions of Bucket 3602
Maintenance Standard for Boom Cylinder 3604
Maintenance Standard for Stroke Sensing Boom Cylinder 3605
Maintenance Standard for Stroke Sensing Arm Cylinder 3607
Maintenance Standard for Stroke and Reset Sensing Bucket Cylinder 3609
Maintenance Standard for Stroke Sensor for Boom Cylinder 3611
Maintenance Standard for Stroke Sensor for Arm Cylinder 3612
Maintenance Standard for Stroke and Reset Sensor for Bucket Cylinder 3613
80 Appendix 3615
Table of Contents 3616
Precautions Before Work 3618
Air Conditioner System 3619
Precautions for Refrigerant 3619
Air Conditioner Component 3620
Specifications of Air Conditioner 3622
Structure and Function of Refrigeration Cycle 3623
Outline of Refrigeration Cycle 3624
Component Parts of Air Conditioner System 3626
Air Conditioner Unit 3626
Configuration Diagram of Air Conditioner Unit 3626
Function of Air Conditioner Unit 3628
Component Parts of Air Conditioner Unit 3630
Function of Evaporator as Air Conditioner Unit Component 3631
Function of Heater Core as Air Conditioner Unit Component 3631
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3631
Function of Servo Motor as Air Conditioner Unit Component 3631
Structure of Expansion Valve as Air Conditioner Unit Component 3632
Function of Expansion Valve as Air Conditioner Unit Component 3632
Operate Expansion Valve as Air Conditioner Unit Component 3632
Function of Dual Pressure Switch 3633
Air Conditioner Controller 3634
Structure of Air Conditioner Controller 3634
Compressor 3635
Structure of Compressor 3635
Specifications of Compressor 3635
Function of Compressor 3635
Condenser 3636
Structure of Condenser 3636
Specifications of Condenser 3636
Function of Condenser 3636
Air Conditioner Related Sensors 3638
Structure of Sunlight Sensor 3638
Function of Sunlight Sensor 3638
Structure of Outside Temperature Sensor 3638
Function of Outside Air Temperature Sensor 3638
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3640
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3642
System Diagram of Air Conditioner 3644
Input and Output Signals of Air Conditioner Controller 3645
Function of Air Conditioner Controller 3646
Examine Air Leakage (Duct) 3647
How to Examine Air Leakage (Duct) 3647
Examine Air Conditioner with Self-Diagnosis Function 3649
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3650
Examine Vent (Mode) Changeover 3651
How to Examine Vent (Mode) Changeover 3651
Examine Fresh/Recirc Air Changeover 3653
How to Examine Fresh/Recirc Air Changeover 3653
Examine Sunlight Sensor 3654
How to Examine Sunlight Sensor 3654
Examine Refrigerant (Dual) Pressure Switch 3655
How to Examine Refrigerant (Dual) Pressure Switch 3655
Examine Relay 3656
How to Examine Relay 3656
Air Conditioner Troubleshooting Chart 1 3657
Air Conditioner Troubleshooting Chart 2 3658
Information Shown in Troubleshooting Table 3661
Failure Code [879AKA] 3662
Failure Code [879AKB] 3663
Failure Code [879BKA] 3664
Failure Code [879BKB] 3666
Failure Code [879CKA] 3668
Failure Code [879CKB] 3669
Failure Code [879DKZ] 3670
Failure Code [879EMC] 3672
Failure Code [879FMC] 3673
Failure Code [879GKX] 3674
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3676
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3678
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3681
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3683
Troubleshooting by Gauge Pressure 3685
Connect Service Tool 3688
How to Connect Service Tool 3688
Precautions for Disconnection and Connection of Air Conditioner Piping 3690
Handle Compressor Oil 3692
Replace Desiccant 3694
90 Circuit Diagrams 3697
Table of Contents 3698
Hydraulic Circuit Diagram 3699
Symbols Used in Hydraulic Circuit Diagram 3699
Hydraulic Circuit Diagram (1/2) 3703
Hydraulic Circuit Diagram (2/2) 3705
Electrical Circuit Diagram 3707
Symbols Used in Electric Circuit Diagram 3707
Electrical Circuit Diagram (1/12) 3711
Electrical Circuit Diagram (2/12) 3713
Electrical Circuit Diagram (3/12) 3715
Electrical Circuit Diagram (4/12) 3717
Electrical Circuit Diagram (5/12) 3719
Electrical Circuit Diagram (6/12) 3721
Electrical Circuit Diagram (7/12) 3723
Electrical Circuit Diagram (8/12) 3725
Electrical Circuit Diagram (9/12) 3727
Electrical Circuit Diagram (10/12) 3729
Electrical Circuit Diagram (11/12) 3731
Electrical Circuit Diagram (12/12) 3733
Index 3735

DESCRIPTION:

Komatsu PC290LCi-11 Hydraulic Excavator Shop Manual SEN06726-09 – PDF DOWNLOAD 

SERIAL NUMBERS 35039 and up

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 Specification
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.

S.V 30/12/24