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

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Komatsu PC290-11,PC290LC-11,PC290NLC-11 Hydraulic Excavator Shop Manual UENBM00352 – PDF DOWNLOAD

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Komatsu PC290-11,PC290LC-11,PC290NLC-11 Hydraulic Excavator Shop Manual UENBM00352 – PDF DOWNLOAD

Language : English
Pages : 2800
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC290-11,PC290LC-11,PC290NLC-11 Hydraulic Excavator Shop Manual UENBM00352 – PDF DOWNLOAD

• SERIAL NUMBERS K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC290LC-11, PC290NLC-11 101
WORKING RANGE DRAWINGS 103
WORKING RANGE: PC290LC-11, PC290NLC-11 103
SPECIFICATIONS 104
SPECIFICATIONS: PC290LC-11, PC290NLC-11 . 104
WEIGHT TABLE 107
WEIGHT TABLE: PC290LC-11, PC290NLC-11 . 107
TABLE OF FUEL, COOLANT, AND LUBRICANTS 109
10 STRUCTURE AND FUNCTION . 111
CONTENTS 112
ABBREVIATION LIST . 116
UREA SCR SYSTEM . 122
LAYOUT DRAWING OF UREA SCR SYSTEM . 123
UREA SCR SYSTEM DIAGRAM . 128
FUNCTION OF UREA SCR SYSTEM . 129
FUNCTION OF AdBlue/DEF SYSTEM . 129
INDUCEMENT STRATEGY . 131
COMPONENT PARTS OF UREA SCR SYSTEM 139
AdBlue/DEF MIXING TUBE 139
SCR ASSEMBLY 139
AdBlue/DEF TANK . 142
AdBlue/DEF PUMP . 144
AdBlue/DEF INJECTOR . 145
AdBlue/DEF HOSE . 146
AdBlue/DEF TANK HEATING VALVE . 147
BOOT-UP SYSTEM 148
LAYOUT DRAWING OF BOOT-UP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM 150
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 150
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 150
BATTERY DISCONNECT SWITCH . 152
FUNCTION OF BATTERY DISCONNECT SWITCH . 152
ENGINE SYSTEM . 153
LAYOUT DRAWING OF ENGINE SYSTEM . 153
SPECIFICATIONS OF ENGINE SYSTEM . 154
FUNCTION OF ENGINE SYSTEM . 154
ENGINE CONTROL SYSTEM . 155
ENGINE CONTROL SYSTEM DIAGRAM . 155
FUNCTION OF ENGINE CONTROL SYSTEM . 156
AUTO-DECELERATION SYSTEM 158
AUTO-DECELERATION SYSTEM DIAGRAM 158
FUNCTION OF AUTO-DECELERATION SYSTEM 158
OPERATION OF AUTO-DECELERATION SYSTEM . 159
ENGINE AUTOMATIC WARM-UP SYSTEM . 160
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 160
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 161
OVERHEAT PREVENTION SYSTEM 162
OVERHEAT PREVENTION SYSTEM DIAGRAM 162
FUNCTION OF OVERHEAT PREVENTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM 165
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 165
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 166
AUTOMATIC IDLE STOP SYSTEM 167
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 167
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 167
COMPONENT PARTS OF ENGINE SYSTEM 170
VGT . 170
EGR SYSTEM 174
EGR VALVE . 176
EGR COOLER 178
KCCV SYSTEM . 179
KCCV VENTILATOR . 181
KDPF 183
COOLING SYSTEM 188
LAYOUT DRAWING OF COOLING SYSTEM 188
SPECIFICATIONS OF COOLING SYSTEM 189
CONTROL SYSTEM 190
LAYOUT DRAWING OF CONTROL SYSTEM 190
MACHINE MONITOR SYSTEM 193
MACHINE MONITOR SYSTEM DIAGRAM 193
KomVision SYSTEM 194
LAYOUT DRAWING OF KOMVISION SYSTEM 194
KomVision SYSTEM DIAGRAM 196
FUNCTION OF KomVision SYSTEM 196
KOMTRAX SYSTEM 198
KOMTRAX SYSTEM DIAGRAM 198
FUNCTION OF KOMTRAX SYSTEM 198
PPC LEVERS 199
LH PPC LEVER 199
RH PPC LEVER 200
AUTOMATIC GREASE SYSTEM . 201
OUTLINE OF AUTO GREASE SYSTEM . 201
COMPONENT PARTS OF CONTROL SYSTEM . 216
MACHINE MONITOR . 216
KomVision CONTROLLER 229
KomVision CAMERA 233
KOMTRAX TERMINAL 233
PUMP CONTROLLER . 236
RESISTOR FOR PC-EPC VALVE . 240
CAN TERMINATING RESISTOR 240
PPC OIL PRESSURE SWITCH . 241
ENGINE CONTROLLER . 242
FUEL CONTROL DIAL . 248
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 249
FUNCTION OF ENGINE OIL PRESSURE SWITCH 250
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 250
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 251
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 251
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 251
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 251
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 251
STRUCTURE OF OVERLOAD CAUTION SENSOR 251
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 252
FUNCTION OF OVERLOAD CAUTION SENSOR . 252
HYDRAULIC SYSTEM 253
LAYOUT DRAWING OF HYDRAULIC SYSTEM 253
CLSS 259
STRUCTURE OF CLSS . 259
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 261
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 262
PRESSURE COMPENSATION CONTROL . 275
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 278
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 278
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 279
PUMP AND VALVE CONTROL SYSTEM . 284
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 284
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 285
COMPONENT PARTS OF HYDRAULIC SYSTEM . 287
HYDRAULIC TANK 287
MAIN PUMP . 289
PC-EPC VALVE 313
PILOT OIL FILTER 315
CONTROL VALVE . 315
WORK EQUIPMENT SYSTEM . 372
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 372
STRUCTURE OF VALVE CONTROL 377
ONE-TOUCH POWER MAXIMIZING SYSTEM . 379
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 379
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 380
PPC LOCK SYSTEM . 381
PPC LOCK SYSTEM DIAGRAM . 381
FUNCTION OF PPC LOCK SYSTEM . 381
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 382
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 382
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 382
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 383
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 384
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 384
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 386
TOOL CONTROL SYSTEM . 387
TOOL CONTROL SYSTEM DIAGRAM . 387
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 389
WORK EQUIPMENT AND SWING PPC VALVE 389
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 394
SOLENOID VALVE 400
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 403
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 405
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 408
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 410
ATTACHMENT BYPASS SOLENOID VALVE 413
ATT EPC VALVE ASSEMBLY 415
PILOT CIRCUIT ACCUMULATOR . 416
ATTACHMENT CIRCUIT ACCUMULATOR 417
SWING SYSTEM 418
LAYOUT DRAWING OF SWING SYSTEM 418
SWING CONTROL SYSTEM DIAGRAM 422
FUNCTION OF SWING CONTROL SYSTEM 422
COMPONENT PARTS OF SWING SYSTEM . 426
SWING MOTOR . 426
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 459
CENTER SWIVEL JOINT . 464
UNDERCARRIAGE AND FRAME . 466
LAYOUT DRAWING OF UNDERCARRIAGE . 466
SPECIFICATIONS OF UNDERCARRIAGE . 467
WORK EQUIPMENT 468
STRUCTURE OF WORK EQUIPMENT . 468
FUNCTION OF WORK EQUIPMENT 469
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 470
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 470
BUCKET CLEARANCE ADJUSTMENT SHIM 471
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 471
CAB AND ITS ATTACHMENTS . 472
ROPS CAB 472
STRUCTURE OF ROPS CAB . 472
FUNCTION OF ROPS CAB 472
CAB MOUNT . 473
STRUCTURE OF CAB MOUNT 473
FUNCTION OF CAB MOUNT . 473
CAB TIPPING STOPPER . 474
STRUCTURE OF CAB TIPPING STOPPER 474
FUNCTION OF CAB TIPPING STOPPER . 474
20 STANDARD VALUE TABLE . 475
CONTENTS 476
ABBREVIATION LIST . 477
STANDARD VALUE TABLE FOR ENGINE . 483
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11, PC290NLC-11 483
STANDARD VALUE TABLE FOR MACHINE 487
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11, PC290NLC-11 . 487
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 500
STANDARD VALUE TABLE FOR ELECTRICAL . 504
STANDARD VALUE TABLE FOR ELECTRICAL . 504
30 TESTING AND ADJUSTING 515
CONTENTS 516
ABBREVIATION LIST . 519
RELATED INFORMATION ON TESTING AND ADJUSTING 525
TOOLS FOR TESTING AND ADJUSTING . 525
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 532
ENGINE AND COOLING SYSTEM . 534
TEST ENGINE SPEED . 534
METHOD FOR TESTING ENGINE SPEED . 534
TEST BOOST PRESSURE . 537
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 537
METHOD FOR TESTING BOOST PRESSURE . 538
TEST EXHAUST GAS COLOR 539
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 539
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 540
TEST AND ADJUST VALVE CLEARANCE . 542
METHOD FOR TESTING VALVE CLEARANCE 542
METHOD FOR ADJUSTING VALVE CLEARANCE 543
TEST COMPRESSION PRESSURE . 545
METHOD FOR TESTING COMPRESSION PRESSURE . 545
TEST BLOWBY PRESSURE 550
METHOD FOR TESTING BLOWBY PRESSURE 550
TEST ENGINE OIL PRESSURE 552
METHOD FOR TESTING ENGINE OIL PRESSURE 552
TEST EGR VALVE AND VGT OIL PRESSURE . 553
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 553
TEST FUEL PRESSURE 555
METHOD FOR TESTING FUEL PRESSURE 556
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 561
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 562
BLEEDING AIR FROM FUEL SYSTEM . 568
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 568
TEST FUEL CIRCUIT FOR LEAKAGE . 569
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 569
HANDLE CYLINDER CUT-OUT MODE OPERATION 571
HANDLE NO-INJECTION CRANKING OPERATION 572
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 573
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 573
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 573
REPLACING FAN BELT 575
METHOD FOR REPLACING FAN BELT . 575
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 576
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 576
TEST SCR RELATED FUNCTIONS 577
TEST AdBlue/DEF PUMP RAISED PRESSURE 580
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 583
TEST AdBlue/DEF LINE HEATER RELAY 1 . 587
TEST AdBlue/DEF LINE HEATER RELAY 2 . 590
TEST AdBlue/DEF PUMP HEATER RELAY . 592
TEST AdBlue/DEF TANK HEATER VALVE . 595
TEST DENITRATION EFFICIENCY OF SCR 598
CLEAN AdBlue/DEF TANK . 602
METHOD FOR CLEANING AdBlue/DEF TANK . 602
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 606
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 606
POWER TRAIN . 608
TEST SWING CIRCLE BEARING CLEARANCE . 608
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 608
UNDERCARRIAGE AND FRAME . 609
TEST AND ADJUST TRACK TENSION . 609
METHOD FOR TESTING TRACK TENSION 609
METHOD FOR ADJUSTING TRACK TENSION 609
HYDRAULIC SYSTEM 611
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 611
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 611
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 617
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 618
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 624
TEST OIL PRESSURE OF CONTROL CIRCUIT 627
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 627
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 629
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 629
TEST PC-EPC VALVE OUTLET PRESSURE . 630
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 631
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 633
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 633
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 634
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 637
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 638
METHOD FOR ADJUSTING LS VALVE . 639
TEST OUTLET PRESSURE OF SOLENOID VALVE 640
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 640
OPERATING CONDITION OF SOLENOID VALVE . 641
TEST PPC VALVE OUTLET PRESSURE 644
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 644
TEST ATTACHMENT CIRCUIT OIL PRESSURE 646
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 646
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 648
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 648
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 649
TEST PUMP SWASH PLATE SENSOR 651
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 651
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 652
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 652
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 652
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 653
TEST OIL LEAKAGE 654
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 654
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 654
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 655
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 656
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 656
BLEED AIR FROM HYDRAULIC CIRCUIT 657
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 659
CAB AND ITS ATTACHMENTS . 661
TEST CAB TIPPING STOPPER 661
METHOD FOR TESTING CAB TIPPING STOPPER 661
METHOD FOR ADJUSTING MIRRORS 662
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 662
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 663
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 664
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 665
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 666
ELECTRICAL SYSTEM . 668
ELECTRICAL SYSTEM . 669
SET AND OPERATE MACHINE MONITOR . 669
OPERATOR MODE . 672
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 673
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 673
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 674
CHECKING FUNCTION OF SERVICE METER 674
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 674
SERVICE MODE 677
SERVICE MODE 677
METHOD FOR OPERATING SERVICE MODE . 679
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 681
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 687
ABNORMALITY RECORD MENU . 698
METHOD FOR CONFIRMING MAINTENANCE RECORD 703
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 704
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 708
DEFAULT MENU 709
DIAGNOSTIC TESTS MENU . 733
ADJUSTMENT MENU . 742
METHOD FOR PERFORMING NO-INJECTION CRANKING . 763
KOMTRAX SETTINGS MENU . 764
METHOD FOR DISPLAYING SERVICE MESSAGE . 767
METHOD FOR STARTING UP KOMTRAX TERMINAL . 769
ADJUST REARVIEW CAMERA ANGLE 774
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 774
ADJUST KomVision CAMERA ANGLE . 777
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 778
ADJUST KomVision RELATED ITEMS 782
SETTING OF KomVision (MAIN SETTING) . 782
SETTING OF KomVision (CAMERA SETTING) . 784
SETTING OF KomVision (CAMERA CALIBRATION) . 784
KomVision screen – Check 12 m visibility 798
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 801
HANDLE BATTERY DISCONNECT SWITCH 802
TEST DIODES . 803
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 803
METHOD FOR TESTING DIODE USING ANALOG TESTER 803
Pm CLINIC . 804
Pm CLINIC SERVICE . 804
Pm CLINIC CHECK SHEET . 808
40 TROUBLESHOOTING 819
CONTENTS 820
ABBREVIATION LIST . 831
RELATED INFORMATION ON TROUBLESHOOTING 837
GENERAL TROUBLESHOOTING POINTS 837
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 838
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 850
CHECKS BEFORE TROUBLESHOOTING . 852
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 854
WALK-AROUND CHECK . 854
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 856
CHECK FUEL LEVEL AND TYPE . 856
CHECK IMPURE INGREDIENT IN FUEL . 856
CHECK FUEL PREFILTER 857
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 857
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 858
CHECK MAIN FILTER . 859
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 861
CHECK COOLANT LEVEL (RESERVOIR TANK) 862
CHECK CLOGGING OF AIR CLEANER . 862
OUTER ELEMENT – CLEAN . 863
ELEMENTS – REPLACE 865
CHECK HYDRAULIC OIL LEVEL . 866
CHECK HYDRAULIC OIL STRAINER 867
CHECK HYDRAULIC FILTER 868
CHECK OIL LEVEL IN SWING MACHINERY CASE . 869
CHECK OIL LEVEL IN DAMPER CASE 870
CHECK OIL LEVEL IN FINAL DRIVE CASE . 870
BLEED AIR FROM FUEL SYSTEM 871
BLEED AIR FROM HYDRAULIC SYSTEM . 871
ELECTRICAL EQUIPMENT – CHECK METHOD . 871
AUTOMATIC GREASE SYSTEM . 879
FINDING MALFUNCTIONS 879
MALFUNCTION FINDING PROCEDURES 881
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 883
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 893
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 896
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 900
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 902
CONNECTOR LIST AND LAYOUT . 905
CONNECTOR CONTACT IDENTIFICATION 918
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 958
FUSE LOCATION TABLE . 964
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 966
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 970
FAILURE CODE TABLE 972
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 990
FAILURE CODE [879AKA] . 990
FAILURE CODE [879AKB] . 991
FAILURE CODE [879BKA] . 992
FAILURE CODE [879BKB] . 994
FAILURE CODE [879CKA] . 996
FAILURE CODE [879CKB] . 997
FAILURE CODE [879DKZ] . 998
FAILURE CODE [879EMC] .1000
FAILURE CODE [879FMC] .1001
FAILURE CODE [879GKX] .1002
FAILURE CODE [989L00] .1004
FAILURE CODE [989M00] .1005
FAILURE CODE [989N00] .1006
FAILURE CODE [A1U0N3] .1007
FAILURE CODE [A1U0N4] .1009
FAILURE CODE [A900FR] .1011
FAILURE CODE [A900N6] .1012
FAILURE CODE [A900NY] .1013
FAILURE CODE [AA10NX] .1014
FAILURE CODE [AB00KE] .1016
FAILURE CODE [AQ10N3] .1019
FAILURE CODE [AS00N3] .1021
FAILURE CODE [AS00R2] .1023
FAILURE CODE [AS00R3] .1024
FAILURE CODE [AS00R4] .1025
FAILURE CODE [AS00R5] .1026
FAILURE CODE [AS00R6] .1027
FAILURE CODE [AS00ZK] .1028
FAILURE CODE [AS10KM] .1029
FAILURE CODE [AS10NR] .1030
FAILURE CODE [AS10NT] .1031
FAILURE CODE [B@BAZG] .1032
FAILURE CODE [B@BAZK] .1033
FAILURE CODE [B@BCNS] .1035
FAILURE CODE [B@BCQA] .1036
FAILURE CODE [B@BCZK] .1038
FAILURE CODE [B@HANS] .1040
FAILURE CODE [CA115] 1041
FAILURE CODE [CA122] 1042
FAILURE CODE [CA123] 1044
FAILURE CODE [CA131] 1046
FAILURE CODE [CA132] 1048
FAILURE CODE [CA144] 1050
FAILURE CODE [CA145] 1052
FAILURE CODE [CA153] 1054
FAILURE CODE [CA154] 1057
FAILURE CODE [CA187] 1059
FAILURE CODE [CA221] 1061
FAILURE CODE [CA222] 1063
FAILURE CODE [CA227] 1065
FAILURE CODE [CA234] 1066
FAILURE CODE [CA238] 1067
FAILURE CODE [CA239] 1069
FAILURE CODE [CA249] 1071
FAILURE CODE [CA256] 1073
FAILURE CODE [CA271] 1075
FAILURE CODE [CA272] 1077
FAILURE CODE [CA322] 1079
FAILURE CODE [CA323] 1081
FAILURE CODE [CA324] 1083
FAILURE CODE [CA325] 1085
FAILURE CODE [CA331] 1087
FAILURE CODE [CA332] 1089
FAILURE CODE [CA343] 1091
FAILURE CODE [CA351] 1092
FAILURE CODE [CA352] 1093
FAILURE CODE [CA356] 1096
FAILURE CODE [CA357] 1098
FAILURE CODE [CA386] 1100
FAILURE CODE [CA428] 1101
FAILURE CODE [CA429] 1103
FAILURE CODE [CA435] 1105
FAILURE CODE [CA441] 1107
FAILURE CODE [CA442] 1109
FAILURE CODE [CA449] 1110
FAILURE CODE [CA451] 1111
FAILURE CODE [CA452] 1113
FAILURE CODE [CA488] 1115
FAILURE CODE [CA515] 1116
FAILURE CODE [CA516] 1118
FAILURE CODE [CA553] 1120
FAILURE CODE [CA555] 1121
FAILURE CODE [CA556] 1122
FAILURE CODE [CA559] 1123
FAILURE CODE [CA595] 1126
FAILURE CODE [CA687] 1127
FAILURE CODE [CA689] 1129
FAILURE CODE [CA691] 1132
FAILURE CODE [CA692] 1134
FAILURE CODE [CA697] 1136
FAILURE CODE [CA698] 1137
FAILURE CODE [CA731] 1138
FAILURE CODE [CA778] 1140
FAILURE CODE [CA1117] .1145
FAILURE CODE [CA1664] .1146
FAILURE CODE [CA1669] .1148
FAILURE CODE [CA1673] .1149
FAILURE CODE [CA1677] .1150
FAILURE CODE [CA1678] .1151
FAILURE CODE [CA1682] .1152
FAILURE CODE [CA1683] .1154
FAILURE CODE [CA1684] .1156
FAILURE CODE [CA1686] .1158
FAILURE CODE [CA1691] .1159
FAILURE CODE [CA1694] .1162
FAILURE CODE [CA1695] .1165
FAILURE CODE [CA1696] .1166
FAILURE CODE [CA1712] .1168
FAILURE CODE [CA1713] .1171
FAILURE CODE [CA1714] .1173
FAILURE CODE [CA1715] .1174
FAILURE CODE [CA1776] .1175
FAILURE CODE [CA1777] .1178
FAILURE CODE [CA1843] .1181
FAILURE CODE [CA1844] .1183
FAILURE CODE [CA1879] .1186
FAILURE CODE [CA1881] .1188
FAILURE CODE [CA1883] .1190
FAILURE CODE [CA1885] .1193
FAILURE CODE [CA1887] .1195
FAILURE CODE [CA1921] .1197
FAILURE CODE [CA1922] .1200
FAILURE CODE [CA1942] .1205
FAILURE CODE [CA1993] .1206
FAILURE CODE [CA2185] .1209
FAILURE CODE [CA2186] .1210
FAILURE CODE [CA2249] .1212
FAILURE CODE [CA2271] .1213
FAILURE CODE [CA2272] .1216
FAILURE CODE [CA2288] .1219
FAILURE CODE [CA2311] .1220
FAILURE CODE [CA2349] .1221
FAILURE CODE [CA2353] .1224
FAILURE CODE [CA2357] .1226
FAILURE CODE [CA2381] .1227
FAILURE CODE [CA2382] .1230
FAILURE CODE [CA2383] .1233
FAILURE CODE [CA2386] .1236
FAILURE CODE [CA2387] .1238
FAILURE CODE [CA2555] .1239
FAILURE CODE [CA2556] .1242
FAILURE CODE [CA2637] .1245
FAILURE CODE [CA2639] .1247
FAILURE CODE [CA2771] .1250
FAILURE CODE [CA2777] .1256
FAILURE CODE [CA2976] .1259
FAILURE CODE [CA3133] .1261
FAILURE CODE [CA3134] .1264
FAILURE CODE [CA3135] .1266
FAILURE CODE [CA3142] .1269
FAILURE CODE [CA3143] .1270
FAILURE CODE [CA3144] .1271
FAILURE CODE [CA3146] .1273
FAILURE CODE [CA3147] .1274
FAILURE CODE [CA3148] .1275
FAILURE CODE [CA3151] .1277
FAILURE CODE [CA3165] .1283
FAILURE CODE [CA3229] .1285
FAILURE CODE [CA3231] .1287
FAILURE CODE [CA3232] .1289
FAILURE CODE [CA3235] .1293
FAILURE CODE [CA3239] .1295
FAILURE CODE [CA3241] .1298
FAILURE CODE [CA3242] .1301
FAILURE CODE [CA3251] .1304
FAILURE CODE [CA3253] .1306
FAILURE CODE [CA3254] .1309
FAILURE CODE [CA3255] .1312
FAILURE CODE [CA3256] .1316
FAILURE CODE [CA3311] .1318
FAILURE CODE [CA3312] .1320
FAILURE CODE [CA3313] .1323
FAILURE CODE [CA3314] .1324
FAILURE CODE [CA3315] .1325
FAILURE CODE [CA3316] .1327
FAILURE CODE [CA3317] .1328
FAILURE CODE [CA3318] .1329
FAILURE CODE [CA3319] .1331
FAILURE CODE [CA3321] .1332
FAILURE CODE [CA3322] .1334
FAILURE CODE [CA3419] .1336
FAILURE CODE [CA3421] .1338
FAILURE CODE [CA3497] .1340
FAILURE CODE [CA3498] .1341
FAILURE CODE [CA3543] .1342
FAILURE CODE [CA3545] .1349
FAILURE CODE [CA3547] .1351
FAILURE CODE [CA3558] .1352
FAILURE CODE [CA3559] .1354
FAILURE CODE [CA3562] .1356
FAILURE CODE [CA3563] .1358
FAILURE CODE [CA3567] .1361
FAILURE CODE [CA3568] .1364
FAILURE CODE [CA3571] .1368
FAILURE CODE [CA3572] .1370
FAILURE CODE [CA3574] .1372
FAILURE CODE [CA3575] .1374
FAILURE CODE [CA3577] .1376
FAILURE CODE [CA3578] .1378
FAILURE CODE [CA3582] .1380
FAILURE CODE [CA3583] .1386
FAILURE CODE [CA3596] .1388
FAILURE CODE [CA3649] .1390
FAILURE CODE [CA3681] .1392
FAILURE CODE [CA3682] .1397
FAILURE CODE [CA3713] .1403
FAILURE CODE [CA3717] .1406
FAILURE CODE [CA3718] .1407
FAILURE CODE [CA3725] .1408
FAILURE CODE [CA3741] .1411
FAILURE CODE [CA3748] .1412
FAILURE CODE [CA3751] .1414
FAILURE CODE [CA3755] .1416
FAILURE CODE [CA3866] .1418
FAILURE CODE [CA3867] .1422
FAILURE CODE [CA3868] .1425
FAILURE CODE [CA3899] .1429
FAILURE CODE [CA3911] .1431
FAILURE CODE [CA3912] .1435
FAILURE CODE [CA3932] .1437
FAILURE CODE [CA3933] .1439
FAILURE CODE [CA3934] .1441
FAILURE CODE [CA3935] .1444
FAILURE CODE [CA3936] .1446
FAILURE CODE [CA4151] .1448
FAILURE CODE [CA4152] .1452
FAILURE CODE [CA4155] .1456
FAILURE CODE [CA4156] .1458
FAILURE CODE [CA4157] .1461
FAILURE CODE [CA4158] .1463
FAILURE CODE [CA4159] .1464
FAILURE CODE [CA4161] .1465
FAILURE CODE [CA4162] .1468
FAILURE CODE [CA4163] .1471
FAILURE CODE [CA4164] .1472
FAILURE CODE [CA4165] .1474
FAILURE CODE [CA4166] .1476
FAILURE CODE [CA4168] .1477
FAILURE CODE [CA4169] .1480
FAILURE CODE [CA4171] .1482
FAILURE CODE [CA4249] .1485
FAILURE CODE [CA4251] .1487
FAILURE CODE [CA4259] .1489
FAILURE CODE [CA4261] .1492
FAILURE CODE [CA4277] .1495
FAILURE CODE [CA4281] .1499
FAILURE CODE [CA4459] .1502
FAILURE CODE [CA4461] .1505
FAILURE CODE [CA4658] .1508
FAILURE CODE [CA4731] .1512
FAILURE CODE [CA4732] .1513
FAILURE CODE [CA4739] .1514
FAILURE CODE [CA4768] .1515
FAILURE CODE [CA4769] .1517
FAILURE CODE [CA4842] .1520
FAILURE CODE [CA4952] .1524
FAILURE CODE [CA5115] .1526
FAILURE CODE [CA5179] .1529
FAILURE CODE [CA5181] .1531
FAILURE CODE [CA5383] .1533
FAILURE CODE [D110KB] .1535
FAILURE CODE [D19JKZ] .1537
FAILURE CODE [D811MC] .1540
FAILURE CODE [D862KA] .1541
FAILURE CODE [D8ALKA] .1542
FAILURE CODE [D8ALKB] .1544
FAILURE CODE [D8AQKR] .1546
FAILURE CODE [DA20MC] .1548
FAILURE CODE [DA22KK] .1549
FAILURE CODE [DA25KP] .1552
FAILURE CODE [DA26KP] .1555
FAILURE CODE [DA29KQ] .1558
FAILURE CODE [DA2LKA] .1560
FAILURE CODE [DA2LKB] .1562
FAILURE CODE [DA2QKR] .1564
FAILURE CODE [DA2RKR] .1567
FAILURE CODE [DAF0KM] .1568
FAILURE CODE [DAF0MB] .1569
FAILURE CODE [DAF0MC] .1570
FAILURE CODE [DAF8KB] .1571
FAILURE CODE [DAF9KQ] .1573
FAILURE CODE [DAFGMC] .1574
FAILURE CODE [DAFLKA] .1575
FAILURE CODE [DAFLKB] .1577
FAILURE CODE [DAFQKR] .1579
FAILURE CODE [DAZ9KQ] .1580
FAILURE CODE [DAZQKR] .1581
FAILURE CODE [DB2QKR] .1586
FAILURE CODE [DBP0KM] .1591
FAILURE CODE [DBP0KT] .1592
FAILURE CODE [DB2RKR] .1593
FAILURE CODE [DBP5KB] .1598
FAILURE CODE [DBP5KY] .1601
FAILURE CODE [DBPQKR] .1604
FAILURE CODE [DDNRKA] .1609
FAILURE CODE [DDNRKY] .1611
FAILURE CODE [DDNS00] .1613
FAILURE CODE [DFB1KZ] .1615
FAILURE CODE [DFB2KZ] .1618
FAILURE CODE [DFB3L8] .1621
FAILURE CODE [DFB4L8] .1623
FAILURE CODE [DFB5KZ] .1625
FAILURE CODE [DFB6KZ] .1628
FAILURE CODE [DGH2KA] .1631
FAILURE CODE [DGH2KB] .1633
FAILURE CODE [DHA4KA] .1635
FAILURE CODE [DHAAMA] .1637
FAILURE CODE [DHACMA] .1639
FAILURE CODE [DHPAMA] .1641
FAILURE CODE [DHPBMA] .1644
FAILURE CODE [DHS3MA] .1647
FAILURE CODE [DHS4MA] .1650
FAILURE CODE [DHS8MA] .1653
FAILURE CODE [DHS9MA] .1656
FAILURE CODE [DHSAMA] .1659
FAILURE CODE [DHSBMA] .1662
FAILURE CODE [DHSCMA] .1665
FAILURE CODE [DHSDMA] .1668
FAILURE CODE [DHSFMA] .1671
FAILURE CODE [DHSGMA] .1674
FAILURE CODE [DHSHMA] .1677
FAILURE CODE [DHSJMA] .1680
FAILURE CODE [DHX1MA] .1683
FAILURE CODE [DKR0MA] .1686
FAILURE CODE [DKR1MA] .1689
FAILURE CODE [DKULKA] .1692
FAILURE CODE [DKULKB] .1694
FAILURE CODE [DKULKY] .1696
FAILURE CODE [DR10KA] .1698
FAILURE CODE [DR12KA] .1701
FAILURE CODE [DR20KA] .1703
FAILURE CODE [DR21KX] .1705
FAILURE CODE [DR30KA] .1707
FAILURE CODE [DR31KX] .1709
FAILURE CODE [DR40KA] .1711
FAILURE CODE [DUMBKA] .1713
FAILURE CODE [DUMBKB] .1715
FAILURE CODE [DV20KB] .1717
FAILURE CODE [DW43KA] .1719
FAILURE CODE [DW43KB] .1721
FAILURE CODE [DW43KY] .1723
FAILURE CODE [DW45KA] .1725
FAILURE CODE [DW45KB] .1728
FAILURE CODE [DW45KY] .1731
FAILURE CODE [DW4CKY] .1733
FAILURE CODE [DW91KA] .1735
FAILURE CODE [DW91KB] .1737
FAILURE CODE [DW91KY] .1739
FAILURE CODE [DWA2KA] .1741
FAILURE CODE [DWA2KB] .1743
FAILURE CODE [DWA2KY] .1745
FAILURE CODE [DWK0KA] .1747
FAILURE CODE [DWK0KB] .1749
FAILURE CODE [DWK0KY] .1751
FAILURE CODE [DWK2KA] .1753
FAILURE CODE [DWK2KB] .1755
FAILURE CODE [DWK2KY] .1757
FAILURE CODE [DWK8KA] .1759
FAILURE CODE [DWK8KB] .1761
FAILURE CODE [DWK8KY] .1763
FAILURE CODE [DXA8KA] .1765
FAILURE CODE [DXA8KB] .1767
FAILURE CODE [DXA9KA] .1769
FAILURE CODE [DXA9KB] .1771
FAILURE CODE [DXE0KA] .1773
FAILURE CODE [DXE0KB] .1774
FAILURE CODE [DXE4KA] .1776
FAILURE CODE [DXE4KB] .1778
FAILURE CODE [DXE4KY] .1780
FAILURE CODE [DXE5KA] .1782
FAILURE CODE [DXE5KB] .1784
FAILURE CODE [DXE6KA] .1786
FAILURE CODE [DXE6KB] .1788
FAILURE CODE [DXE7KA] .1790
FAILURE CODE [DXE7KB] .1792
FAILURE CODE [DXE7KY] .1794
FAILURE CODE [DXE8KA] .1796
FAILURE CODE [DXE8KB] .1798
FAILURE CODE [DXE8KY] .1800
FAILURE CODE [DXE9KA] .1802
FAILURE CODE [DXE9KB] .1804
FAILURE CODE [DXE9KY] .1806
FAILURE CODE [DXEAKA] .1808
FAILURE CODE [DXEAKB] .1810
FAILURE CODE [DXEAKY] .1812
FAILURE CODE [DY20KA] .1814
FAILURE CODE [DY20MA] .1816
FAILURE CODE [DY2CKB] .1818
FAILURE CODE [DY2DKB] .1821
FAILURE CODE [DY2EKB] .1823
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1825
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1825
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1831
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1834
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1836
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1838
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1841
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1842
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1843
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1844
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1845
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1846
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1847
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1848
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1849
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1850
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1851
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1852
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1854
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1855
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1856
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1857
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1859
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1860
E-24 FUNCTION SWITCH DOES NOT OPERATE .1861
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1862
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1863
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1864
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1865
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1866
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1867
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1868
E-32 ALARM BUZZER CANNOT BE CANCELED 1870
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1871
E-34 SERVICE MODE CANNOT BE SELECTED 1872
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1873
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1876
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1878
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1881
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1883
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1886
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1887
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1889
E-43 HORN DOES NOT SOUND 1890
E-44 HORN DOES NOT STOP SOUNDING 1893
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1895
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1896
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1898
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1899
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1900
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1901
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1902
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1903
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1904
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1905
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1906
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1907
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1909
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1910
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1911
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1911
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1912
FAILURE MODE AND CAUSE TABLE 1914
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1923
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1924
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1927
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1928
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1929
H-6 SPEED OR POWER OF BOOM IS LOW .1931
H-7 ARM SPEED OR POWER IS LOW .1935
H-8 BUCKET SPEED OR POWER IS LOW 1940
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1943
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1944
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1946
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1948
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1949
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1950
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1951
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1952
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1953
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1954
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1955
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1956
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1957
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1959
H-23 TRAVEL SPEED IS LOW 1962
H-24 ONE OF TRACKS DOES NOT RUN .1964
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1965
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1966
H-27 SWINGS ONLY IN ONE DIRECTION .1967
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1968
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1969
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1970
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1971
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1972
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1973
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1974
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1975
H-36 Quick coupler cylinder will not extend .1976
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .1978
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .1980
H-39 Quick coupler cylinder extends and retracts slowly .1982
TROUBLESHOOTING OF ENGINE (S-MODE) 1983
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1983
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1984
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1985
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1986
S-4 ENGINE STARTABILITY IS POOR .1988
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1990
S-6 ENGINE STOPS DURING OPERATION .1992
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1994
S-8 ENGINE LACKS POWER 1995
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1997
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1999
S-11 OIL BECOMES CONTAMINATED QUICKLY .2000
S-12 FUEL CONSUMPTION IS EXCESSIVE 2001
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2002
S-14 OIL PRESSURE DROPS .2003
S-15 FUEL MIXES INTO ENGINE OIL .2005
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2006
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2007
S-18 UNUSUAL NOISE IS HEARD .2008
S-19 VIBRATION IS EXCESSIVE .2009
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2010
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2011
S-22 ACTIVE REGENERATION TAKES TIME .2013
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2014
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2015
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2017
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2018
50 DISASSEMBLY AND ASSEMBLY .2019
CONTENTS 2020
ABBREVIATION LIST .2025
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2031
HOW TO READ THIS MANUAL .2031
COATING MATERIALS LIST 2033
SPECIAL TOOLS LIST 2037
SKETCHES OF SPECIAL TOOLS .2049
ENGINE AND COOLING SYSTEM .2055
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2055
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2055
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2058
REMOVE AND INSTALL INJECTOR ASSEMBLY 2062
METHOD FOR REMOVING INJECTOR ASSEMBLY .2062
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2067
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2075
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2076
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2085
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2101
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2101
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2102
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2105
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2105
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2108
REMOVE AND INSTALL STARTER ASSEMBLY .2113
METHOD FOR REMOVING STARTER ASSEMBLY 2113
METHOD FOR INSTALLING STARTER ASSEMBLY 2115
REMOVE AND INSTALL ALTERNATOR BELT 2117
METHOD FOR REMOVING ALTERNATOR BELT .2117
METHOD FOR INSTALLING ALTERNATOR BELT .2119
REMOVE AND INSTALL RADIATOR ASSEMBLY 2121
METHOD FOR REMOVING RADIATOR ASSEMBLY .2121
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2123
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2125
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2125
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2128
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2131
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2131
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2132
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2134
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2135
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2143
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2154
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2154
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2157
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2161
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2161
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2162
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2165
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2165
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2166
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2167
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2167
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2169
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2175
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2175
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2179
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2185
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2185
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2190
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2196
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2196
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2201
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2207
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2207
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2207
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2209
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2209
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2209
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2210
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2210
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2212
REMOVE AND INSTALL KDPF ASSEMBLY 2215
METHOD FOR REMOVING KDPF ASSEMBLY .2215
METHOD FOR INSTALLING KDPF ASSEMBLY .2217
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2219
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2220
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2223
REMOVE AND INSTALL SCR ASSEMBLY .2228
METHOD FOR REMOVING SCR ASSEMBLY 2228
METHOD FOR INSTALLING SCR ASSEMBLY 2230
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2232
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2232
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2238
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2244
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2244
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2252
REMOVE AND INSTALL KCCV ASSEMBLY 2261
METHOD FOR REMOVING KCCV ASSEMBLY .2261
METHOD FOR INSTALLING KCCV ASSEMBLY .2263
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2268
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2268
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2273
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2278
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2278
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2280
REMOVE AND INSTALL AdBlue/DEF PUMP 2282
METHOD FOR REMOVING AdBlue/DEF PUMP .2282
METHOD FOR INSTALLING AdBlue/DEF PUMP .2284
REMOVE AND INSTALL AdBlue/DEF HOSE 2287
METHOD FOR REMOVING AdBlue/DEF HOSE .2287
METHOD FOR INSTALLING AdBlue/DEF HOSE .2295
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2301
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2301
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2302
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2304
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2304
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2306
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2309
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2309
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2310
POWER TRAIN .2311
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2311
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2311
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2312
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2313
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2313
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2317
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2326
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2326
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2328
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2332
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2332
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2336
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2343
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2343
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2343
UNDERCARRIAGE AND FRAME .2345
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2345
METHOD FOR SEPARATING TRACK ASSEMBLY 2345
METHOD FOR INSTALLING TRACK ASSEMBLY 2347
REMOVE AND INSTALL SPROCKET .2350
METHOD FOR REMOVING SPROCKET 2350
METHOD FOR INSTALLING SPROCKET 2350
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2352
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2352
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2353
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2354
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2354
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2355
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2359
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2360
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2361
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2362
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2363
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2364
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2366
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2366
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2367
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2370
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2370
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2372
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2374
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2374
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2377
HYDRAULIC SYSTEM 2381
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2381
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2381
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2383
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2386
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2387
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2388
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2389
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2389
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2392
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2395
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2395
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2398
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2401
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2401
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2408
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2416
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2416
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2418
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2422
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2422
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2422
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2424
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2424
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2425
REMOVE AND INSTALL QUICK COUPLER VALVE 2427
WORK EQUIPMENT 2429
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2429
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2429
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2433
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2439
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2439
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2442
CAB AND ITS ATTACHMENTS .2448
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2448
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2448
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2454
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2461
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2463
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2463
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2473
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2473
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2476
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2482
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2482
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2489
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2496
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2496
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2502
REMOVE AND INSTALL OPERATOR’S SEAT 2509
METHOD FOR REMOVING OPERATOR’S SEAT .2509
METHOD FOR INSTALLING OPERATOR’S SEAT .2511
REMOVE AND INSTALL SEAT BELT 2514
METHOD FOR REMOVING SEAT BELT .2514
METHOD FOR INSTALLING SEAT BELT .2515
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2516
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2516
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2521
ELECTRICAL SYSTEM .2530
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2530
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2530
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2531
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2533
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2533
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2537
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2542
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2542
METHOD FOR INSTALLING KomVision CONTROLLER 2543
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2545
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2545
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2548
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2552
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2552
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2553
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2554
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2554
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2554
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2556
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2556
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2557
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2559
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2559
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2561
REMOVE AND INSTALL KomVision CAMERA .2564
METHOD FOR REMOVING KomVision CAMERA 2564
METHOD FOR INSTALLING KomVision CAMERA 2567
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2570
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2570
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2573
60 MAINTENANCE STANDARD .2577
CONTENTS 2578
ABBREVIATION LIST .2579
ENGINE AND COOLING SYSTEM .2585
MAINTENANCE STANDARD OF ENGINE MOUNT 2585
MAINTENANCE STANDARD OF COOLING SYSTEM 2586
POWER TRAIN .2587
MAINTENANCE STANDARD OF SWING CIRCLE 2587
MAINTENANCE STANDARD OF SWING MACHINERY .2588
MAINTENANCE STANDARD OF FINAL DRIVE .2590
MAINTENANCE STANDARD OF SPROCKET 2592
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2593
UNDERCARRIAGE AND FRAME .2595
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2595
MAINTENANCE STANDARD OF IDLER .2597
MAINTENANCE STANDARD OF TRACK ROLLER 2599
MAINTENANCE STANDARD OF CARRIER ROLLER 2601
MAINTENANCE STANDARD OF TRACK SHOE 2602
MAINTENANCE STANDARD OF TRIPLE SHOE .2605
HYDRAULIC SYSTEM 2606
MAINTENANCE STANDARD OF HYDRAULIC TANK 2606
MAINTENANCE STANDARD OF MAIN PUMP .2607
MAINTENANCE STANDARD OF LS-EPC VALVE 2608
MAINTENANCE STANDARD OF PC-EPC VALVE 2609
MAINTENANCE STANDARD OF SWING MOTOR .2610
MAINTENANCE STANDARD OF TRAVEL MOTOR 2613
MAINTENANCE STANDARD OF CONTROL VALVE .2616
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2626
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2629
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2632
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2634
MAINTENANCE STANDARD OF SOLENOID VALVE 2635
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2636
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2637
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2638
WORK EQUIPMENT 2639
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2639
DIMENSION OF ARM 2644
DIMENSIONS OF BUCKET 2646
MAINTENANCE STANDARD OF BOOM CYLINDER .2648
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2649
MAINTENANCE STANDARD OF ARM CYLINDER 2650
MAINTENANCE STANDARD OF BUCKET CYLINDER .2651
80 APPENDIX .2653
CONTENTS 2654
ABBREVIATION LIST .2656
AIR CONDITIONER SYSTEM 2662
PRECAUTIONS FOR REFRIGERANT .2662
AIR CONDITIONER COMPONENT .2663
SPECIFICATIONS OF AIR CONDITIONER .2665
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2666
OUTLINE OF REFRIGERATION CYCLE 2667
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2669
AIR CONDITIONER UNIT 2669
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2669
FUNCTION OF AIR CONDITIONER UNIT 2671
COMPONENT PARTS OF AIR CONDITIONER UNIT .2673
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2674
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2674
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2674
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2674
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2675
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2675
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2675
FUNCTION OF DUAL PRESSURE SWITCH 2676
AIR CONDITIONER CONTROLLER 2677
STRUCTURE OF AIR CONDITIONER CONTROLLER .2677
COMPRESSOR 2678
STRUCTURE OF COMPRESSOR .2678
SPECIFICATIONS OF COMPRESSOR 2678
FUNCTION OF COMPRESSOR 2678
CONDENSER .2679
STRUCTURE OF CONDENSER 2679
SPECIFICATIONS OF CONDENSER .2679
FUNCTION OF CONDENSER .2679
SENSORS FOR AIR CONDITIONER SYSTEM 2681
STRUCTURE OF SUNLIGHT SENSOR 2681
FUNCTION OF SUNLIGHT SENSOR .2681
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2681
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2681
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2683
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2685
AIR CONDITIONER SYSTEM DIAGRAM 2687
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2688
FUNCTION OF AIR CONDITIONER CONTROLLER 2689
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2690
TESTING AIR LEAKAGE (DUCT) 2694
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2694
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2696
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2697
TEST VENT (MODE) CHANGEOVER .2698
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2698
TESTING FRESH/RECIRC AIR CHANGEOVER .2700
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2700
TEST SUNLIGHT SENSOR 2701
METHOD FOR TESTING SUNLIGHT SENSOR 2701
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2702
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2702
TEST RELAYS .2703
METHOD FOR TESTING RELAYS .2703
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2704
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2705
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2708
FAILURE CODE [879AKA] .2710
FAILURE CODE [879AKB] .2711
FAILURE CODE [879BKA] .2712
FAILURE CODE [879BKB] .2714
FAILURE CODE [879CKA] .2716
FAILURE CODE [879CKB] .2717
FAILURE CODE [879DKZ] .2718
FAILURE CODE [879EMC] .2720
FAILURE CODE [879FMC] .2721
FAILURE CODE [879GKX] .2722
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2724
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2726
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2729
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2731
TROUBLESHOOTING USING GAUGE PRESSURE 2733
CONNECTION OF SERVICE TOOL 2736
METHOD FOR CONNECTING SERVICE TOOL 2736
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2738
HANDLE COMPRESSOR OIL .2740
METHOD FOR REPLACING DESICCANT 2742
90 CIRCUIT DIAGRAMS .2745
CONTENTS 2746
ABBREVIATION LIST .2747
HYDRAULIC CIRCUIT DIAGRAM .2753
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2753
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2757
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2759
ELECTRICAL CIRCUIT DIAGRAM 2761
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2761
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2765
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2767
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2769
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2771
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2773
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2775
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2777
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2779
INDEX 2781

DESCRIPTION:

Komatsu PC290-11,PC290LC-11,PC290NLC-11 Hydraulic Excavator Shop Manual UENBM00352 – PDF DOWNLOAD

• SERIAL NUMBERS K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 31/12/24