Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU PC290LC-10 PC290NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05644-02 – PDF
$40.95
KOMATSU PC290LC-10 PC290NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05644-02 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU PC290LC-10 PC290NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05644-02 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC290LC-10 PC290NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05644-02 – PDF DOWNLOAD
Language : English
Pages : 1660
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC290LC-10 PC290NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05644-02 – PDF DOWNLOAD
UEN05644-02_MA4.pdf............................................................................................................................ 0 00 Index and foreword ..................................................................................................................... 3 Index ................................................................................................................................. 4 Foreword, safety and general information .............................................................................................. 16 Important safety notice ........................................................................................................... 16 How to read the shop manual ....................................................................................................... 21 Explanation of terms for maintenance standard ..................................................................................... 23 Handling of fuel system devices ................................................................................................... 25 Handling of intake system parts ................................................................................................... 26 Handling of hydraulic equipment ................................................................................................... 27 Method of disconnecting and connecting push-pull type coupler ..................................................................... 29 Handling of electrical equipment .................................................................................................. 32 How to read electric wire code .................................................................................................... 40 Precautions when performing operation ............................................................................................. 43 Standard tightening torque table .................................................................................................. 46 List of abbreviation .............................................................................................................. 50 Conversion table .................................................................................................................. 54 01 Specification .......................................................................................................................... 59 Table of contents ..................................................................................................................... 60 Specifications ........................................................................................................................ 61 Specification drawings ............................................................................................................ 61 Working range drawings ............................................................................................................ 62 Specifications .................................................................................................................... 63 Weight table ...................................................................................................................... 66 Table of fuel, coolant and lubricants ............................................................................................. 67 10 Structure and function ................................................................................................................. 69 Table of contents ..................................................................................................................... 70 Engine and cooling system ............................................................................................................. 71 Engine related parts .............................................................................................................. 71 Cooling system .................................................................................................................... 73 Power train system .................................................................................................................... 75 Power train ....................................................................................................................... 75 Swing circle ...................................................................................................................... 77 Swing machinery ................................................................................................................... 78 Final drive ....................................................................................................................... 80 Undercarriage and frame ............................................................................................................... 82 Track frame and idler cushion ..................................................................................................... 82 Hydraulic system ...................................................................................................................... 84 Hydraulic equipment layout drawing ................................................................................................ 84 Valve control ..................................................................................................................... 86 Hydraulic tank .................................................................................................................... 87 CLSS .............................................................................................................................. 89 Main pump ......................................................................................................................... 94 Control valve ..................................................................................................................... 118 Swing motor ....................................................................................................................... 170 Travel motor ...................................................................................................................... 181 PPC valve ......................................................................................................................... 195 Solenoid valve .................................................................................................................... 216 Attachment circuit selector valve (for low pressure circuit) ...................................................................... 219 Center swivel joint ............................................................................................................... 222 Accumulator ....................................................................................................................... 224 ATT EPC valve assembly ............................................................................................................ 225 Return oil filter ................................................................................................................. 227 Quick coupler control valve ....................................................................................................... 228 Work equipment ........................................................................................................................ 231 Work equipment .................................................................................................................... 231 Work equipment shim ............................................................................................................... 232 Bucket play adjustment shim ....................................................................................................... 233 Cab and its attachments ............................................................................................................... 234 Cab mount and cab tipping stopper ................................................................................................. 234 ROPS cab .......................................................................................................................... 235 Electrical system ..................................................................................................................... 236 Electrical control system ......................................................................................................... 236 Machine monitor system ............................................................................................................ 280 KOMTRAX system .................................................................................................................... 300 Sensors ........................................................................................................................... 302 PPC levers ........................................................................................................................ 321 Auto grease system ................................................................................................................ 323 20 Standard value table ................................................................................................................... 335 Table of contents ..................................................................................................................... 336 Standard service value table .......................................................................................................... 337 Standard value table for engine related parts ..................................................................................... 337 Standard value table for chassis related parts .................................................................................... 339 30 Testing and adjusting .................................................................................................................. 353 Table of contents ..................................................................................................................... 354 General information on testing and adjusting .......................................................................................... 355 Tools for testing and adjusting ................................................................................................... 355 Sketch of tools for testing and adjusting ......................................................................................... 359 Engine and cooling system ............................................................................................................. 361 Checking engine speed ............................................................................................................. 361 Measuring boost pressure .......................................................................................................... 362 Measuring exhaust gas color ....................................................................................................... 363 Measuring and adjusting valve clearance ........................................................................................... 365 Measuring compression pressure .................................................................................................... 368 Measuring blowby pressure ......................................................................................................... 372 Measuring engine oil pressure ..................................................................................................... 373 Measuring EGR valve and KVGT oil pressure ......................................................................................... 374 Measuring fuel pressure ........................................................................................................... 375 Measuring fuel delivery, return and leakage ....................................................................................... 381 Bleeding air from fuel system ..................................................................................................... 386 Checking fuel circuit for leakage ................................................................................................. 388 Handling cylinder cutout mode operation ........................................................................................... 389 Handling no injection cranking operation .......................................................................................... 390 Checking and adjusting air conditioner compressor belt tension .................................................................... 391 Replacing fan belt ................................................................................................................ 392 Power train ........................................................................................................................... 393 Testing swing circle bearing clearance ............................................................................................ 393 Undercarriage and frame ............................................................................................................... 394 Testing and adjusting track shoe tension .......................................................................................... 394 Hydraulic system ...................................................................................................................... 395 Releasing remaining pressure from hydraulic circuit ............................................................................... 395 Measuring and adjusting of oil pressure in work equipment, swing, and travel circuits ............................................. 396 Measuring oil pressure in control circuit ......................................................................................... 400 Measuring and adjusting oil pressure in pump PC control circuit ................................................................... 401 Measuring and adjusting oil pressure in pump LS control circuit ................................................................... 404 Measuring solenoid valve output pressure .......................................................................................... 409 Measuring PPC valve output pressure ............................................................................................... 412 Adjusting play of work equipment and swing PPC valves ............................................................................. 414 Measuring and adjusting quick coupler control valve output pressure ............................................................... 415 Testing pump swash plate sensor ................................................................................................... 416 Isolating the parts causing hydraulic drift in work equipment ..................................................................... 417 Measuring oil leakage ............................................................................................................. 418 Bleeding air from hydraulic circuit ............................................................................................... 421 Cab and its attachments ............................................................................................................... 423 Checking cab tipping stopper ...................................................................................................... 423 Adjusting mirrors ................................................................................................................. 424 Electrical system ..................................................................................................................... 426 Special functions of machine monitor .............................................................................................. 426 Angle adjustment of rear view camera .............................................................................................. 495 Handling voltage circuit of engine controller ..................................................................................... 497 Handling battery disconnect switch ................................................................................................ 498 Testing diodes .................................................................................................................... 499 Pm clinic ............................................................................................................................. 500 Pm clinic service ................................................................................................................. 500 40 Troubleshooting ........................................................................................................................ 511 Table of contents ..................................................................................................................... 512 General information on troubleshooting ................................................................................................ 519 Instruction on troubleshooting .................................................................................................... 519 How to proceed troubleshooting .................................................................................................... 521 Testing before troubleshooting .................................................................................................... 522 Testing procedure before troubleshooting .......................................................................................... 524 Preparation work for troubleshooting of electrical system ......................................................................... 552 Classification and procedure for troubleshooting .................................................................................. 556 Symptom of probable failure and troubleshooting No. ............................................................................... 559 Information mentioned in troubleshooting table .................................................................................... 562 Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................................................... 565 Connector list and layout ......................................................................................................... 568 Connector contact identification .................................................................................................. 579 T-branch box and T-branch adapter table ........................................................................................... 615 Fuse list and location ............................................................................................................ 621 Precautions for cleaning and replacing KDPF (KCSF, KDOC) .......................................................................... 623 Failure codes table ............................................................................................................... 625 Troubleshooting by failure code (Display of code) ..................................................................................... 634 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................... 634 Failure code [879AKB] A/C Inner Sensor Short Circuit .............................................................................. 635 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................... 636 Failure code [879BKB] A/C Outer Sensor Short Circuit .............................................................................. 637 Failure code [879CKA] Ventilating Sensor Open Circuit ............................................................................. 638 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................ 639 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....................................................................... 640 Failure code [879EMC] Ventilation Damper Abnormality .............................................................................. 641 Failure code [879FMC] Air Mix Damper Abnormality .................................................................................. 642 Failure code [879GKX] Refrigerant Abnormality ..................................................................................... 643 Failure code [989L00] Engine Controller Lock Caution1 ............................................................................. 644 Failure code [989M00] Engine Controller Lock Caution2 ............................................................................. 645 Failure code [989N00] Engine Controller Lock Caution3 ............................................................................. 646 Failure code [A1U0N3] HC desorb request1 .......................................................................................... 647 Failure code [A1U0N4] HC desorb request2 .......................................................................................... 649 Failure code [AA10NX] Air Cleaner Clogging ........................................................................................ 651 Failure code [AB00KE] Charge Voltage Low .......................................................................................... 653 Failure code [B@BAZG] Engine Oil Pressure Low ..................................................................................... 655 Failure code [B@BAZK] Eng Oil Level Low ........................................................................................... 656 Failure code [B@BCNS] Engine Coolant Overheat ..................................................................................... 657 Failure code [B@BCZK] Radiator Coolant Level Low .................................................................................. 658 Failure code [B@HANS] Hyd Oil Overheat ............................................................................................ 660 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................................. 661 Failure code [CA122] Chg Air Press Sensor High Error .............................................................................. 662 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................... 664 Failure code [CA131] Throttle Sensor High Error ................................................................................... 666 Failure code [CA132] Throttle Sensor Low Error .................................................................................... 668 Failure code [CA144] Coolant Temp Sens High Error ................................................................................. 670 Failure code [CA145] Coolant Temp Sens Low Error .................................................................................. 672 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 674 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 676 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................... 678 Failure code [CA221] Ambient Press Sensor High Error .............................................................................. 680 Failure code [CA222] Ambient Press Sensor Low Error ............................................................................... 682 Failure code [CA227] Sensor 2 Supply Volt High Error .............................................................................. 684 Failure code [CA234] Eng Overspeed ................................................................................................ 685 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................................ 686 Failure code [CA239] Ne Speed Sens Supply Volt High Error ......................................................................... 687 Failure code [CA271] IMV/PCV1 Short Error ......................................................................................... 688 Failure code [CA272] IMV/PCV1 Open Error .......................................................................................... 690 Failure code [CA295] Ambient Press Sens In Range Error ............................................................................ 691 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................................. 692 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................................. 694 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................................. 696 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................................. 698 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................................. 700 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................................. 702 Failure code [CA343] ECM Critical Internal Failure ................................................................................ 704 Failure code [CA351] Injectors Drive Circuit Error ................................................................................ 705 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................... 706 Failure code [CA356] Mass Air Flow Sensor High Error .............................................................................. 708 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................... 710 Failure code [CA386] Sensor 1 Supply Volt High Error .............................................................................. 712 Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 713 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................... 715 Failure code [CA435] Eng Oil Press Sw Error ....................................................................................... 717 Failure code [CA441] Battery Voltage Low Error .................................................................................... 718 Failure code [CA442] Battery Voltage High Error ................................................................................... 720 Failure code [CA449] Rail Press Very High Error ................................................................................... 721 Failure code [CA451] Rail Press Sensor High Error ................................................................................. 722 Failure code [CA452] Rail Press Sensor Low Error .................................................................................. 724 Failure code [CA488] Chg Air Temp High Torque Derate .............................................................................. 725 Failure code [CA515] Rail Press Sens Sup Volt High Error .......................................................................... 726 Failure code [CA516] Rail Press Sens Sup Volt Low Error ........................................................................... 728 Failure code [CA553] Rail Press High Error ........................................................................................ 730 Failure code [CA555] Crankcase Press High Error 1 ................................................................................. 731 Failure code [CA556] Crankcase Press High Error 2 ................................................................................. 732 Failure code [CA559] Rail Press Low Error ......................................................................................... 733 Failure code [CA595] Turbo Speed High Error 2 ..................................................................................... 735 Failure code [CA687] Turbo Speed Low Error ........................................................................................ 736 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................... 738 Failure code [CA691] Intake Air Temp Sens High Error .............................................................................. 740 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................... 742 Failure code [CA697] ECM Int Temp Sensor High Error ............................................................................... 744 Failure code [CA698] ECM Int Temp Sensor Low Error ................................................................................ 745 Failure code [CA731] Eng Bkup Speed Sens Phase Error .............................................................................. 746 Failure code [CA778] Eng Bkup Speed Sensor Error .................................................................................. 747 Failure code [CA1117] Persistent Data Lost Error .................................................................................. 751 Failure code [CA1664] KDOC Malfunction ............................................................................................ 752 Failure code [CA1691] Regeneration Ineffective .................................................................................... 754 Failure code [CA1695] Sensor 5 Supply Volt Low Error .............................................................................. 756 Failure code [CA1696] Sensor 5 Supply Volt High Error ............................................................................. 758 Failure code [CA1843] Crankcase Press Sens High Error ............................................................................. 760 Failure code [CA1844] Crankcase Press Sens Low Error .............................................................................. 762 Failure code [CA1879] KDPF Delta P Sensor High Error .............................................................................. 764 Failure code [CA1881] KDPF Delta P Sensor Low Error ............................................................................... 766 Failure code [CA1883] KDPF Delta P Sens In Range Error ............................................................................ 768 Failure code [CA1921] KDPF Soot Load High Error 1 ................................................................................. 771 Failure code [CA1922] KDPF Soot Load High Error 2 ................................................................................. 773 Failure code [CA1942] Crankcase Press Sens In Range Error ......................................................................... 777 Failure code [CA1993] KDPF Delta Pressure Low Error ............................................................................... 778 Failure code [CA2185] Throt Sensor Sup Volt High Error ............................................................................ 779 Failure code [CA2186] Throt Sensor Sup Volt Low Error ............................................................................. 780 Failure code [CA2249] Rail Press Very Low Error ................................................................................... 781 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................... 782 Failure code [CA2272] EGR Valve Pos Sens Low Error ................................................................................ 784 Failure code [CA2288] Turbo Speed High Error 1 .................................................................................... 787 Failure code [CA2311] IMV Solenoid Error .......................................................................................... 788 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................... 789 Failure code [CA2353] EGR Valve Solenoid Short Error .............................................................................. 791 Failure code [CA2357] EGR Differential Pressure ................................................................................... 793 Failure code [CA2373] Exh Manifold Press. Sens Volt ............................................................................... 794 Failure code [CA2374] Exhaust Manifold Press Sens Low Error ....................................................................... 796 Failure code [CA2375] EGR Orifice Temp Sens High Error ............................................................................ 798 Failure code [CA2376] EGR Orifice Temp Sens Low Error ............................................................................. 800 Failure code [CA2381] KVGT Pos Sens High Error .................................................................................... 802 Failure code [CA2382] KVGT Pos Sens Low Error ..................................................................................... 804 Failure code [CA2383] KVGT Solenoid Open Error .................................................................................... 806 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................... 808 Failure code [CA2387] KVGT Servo Error ............................................................................................ 810 Failure code [CA2554] Exh Manifold Press Sens In Range Error ...................................................................... 811 Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................................... 812 Failure code [CA2556] Grid Htr Relay Volt High Error .............................................................................. 814 Failure code [CA2637] KDOC Face Plugging .......................................................................................... 816 Failure code [CA2639] Manual Stationary Regeneration Request ...................................................................... 818 Failure code [CA2961] EGR Orifice Temp High Error 1 ............................................................................... 820 Failure code [CA2973] Chg Air Press Sensor In Range Error ......................................................................... 821 Failure code [CA3133] KDPF Outlet Press Sens High Error ........................................................................... 822 Failure code [CA3134] KDPF Outlet Press Sens Low Error ............................................................................ 824 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ....................................................................... 826 Failure code [CA3251] DOC Inlet Temp High Error ................................................................................... 829 Failure code [CA3253] KDOC Temp Error - Non Regeneration .......................................................................... 832 Failure code [CA3254] KDOC Outlet Temp High Error 1 ............................................................................... 833 Failure code [CA3255] KDPF Temp Error - Non Regeneration .......................................................................... 836 Failure code [CA3256] KDPF Outlet Temp High Error 1 ............................................................................... 837 Failure code [CA3311] KDOC Outlet Temp High Error 2 ............................................................................... 838 Failure code [CA3312] KDPF Outlet Temp High Error 2 ............................................................................... 839 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ............................................................................ 841 Failure code [CA3314] KDOC Inlet Temp Sens High Error ............................................................................. 844 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ......................................................................... 848 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ............................................................................. 852 Failure code [CA3317] KDOC Outlet Temp Sens High Error ............................................................................ 855 Failure code [CA3318] KDOC Inlet Temp Sens In Range Error ......................................................................... 859 Failure code [CA3319] KDPF Outlet Temp Sens High Error ............................................................................ 863 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ............................................................................. 867 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ........................................................................ 870 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .................................................................... 874 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ..................................................................... 875 Failure code [CA3741] Rail Press Valve Trip Error ................................................................................. 877 Failure code [D110KB] Battery Relay Output Voltage ................................................................................ 878 Failure code [D19JKZ] Personal Code Relay Abnormality ............................................................................. 880 Failure code [D811MC] KOMTRAX Error ............................................................................................... 883 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................... 884 Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX) ........................................................................ 885 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................................................... 887 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....................................................................................... 888 Failure code [DA20MC] Pump Controller ............................................................................................. 889 Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................................... 890 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ............................................................................... 892 Failure code [DA29KQ] Model Selection Abnormality ................................................................................. 895 Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con) ....................................................................... 897 Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con) ...................................................................... 899 Failure code [DA2QKR] CAN2 Discon (Pump Con) ...................................................................................... 900 Failure code [DA2QKR] CAN1 Discon (Pump Con) ...................................................................................... 902 Failure code [DAF0MB] Monitor ROM Abnormality ..................................................................................... 903 Failure code [DAF0MC] Monitor Error ............................................................................................... 904 Failure code [DAF8KB] Camera Power Supply Short Circuit ........................................................................... 905 Failure code [DAF9KQ] Model Selection Abnormality ................................................................................. 907 Failure code [DAFGMC] GPS Module Error ............................................................................................ 908 Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ........................................................................ 909 Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) ....................................................................... 911 Failure code [DAFQKR] CAN2 Discon (Monitor) ....................................................................................... 912 Failure code [DAZ9KQ] A/C Model Selection Abnormality ............................................................................. 913 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .................................................................................... 914 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................................... 918 Failure code [DB2RKR] CAN1 Discon (Engine Con) .................................................................................... 923 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ................................................................................ 927 Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality ........................................................................ 929 Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality ........................................................................ 931 Failure code [DFB3L8] Service Lever 1 Potentio Error .............................................................................. 933 Failure code [DFB4L8] Service Lever 2 Potentio Error .............................................................................. 934 Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality .................................................................... 935 Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality .................................................................... 937 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ........................................................................ 939 Failure code [DHPAMA] F Pump Press Sensor Abnormality ............................................................................. 940 Failure code [DHPBMA] R Pump Press Sensor Abnormality ............................................................................. 943 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ....................................................................... 946 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................................................... 948 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ..................................................................... 951 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ..................................................................... 954 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ....................................................................... 957 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................................................... 960 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ....................................................................... 963 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................................................... 966 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality .................................................................. 969 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .................................................................. 972 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality .................................................................. 975 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality .................................................................. 978 Failure code [DHX1MA] Overload Sensor Abnormality (Analog) ........................................................................ 981 Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality ....................................................................... 983 Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ....................................................................... 986 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ..................................................................... 989 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ..................................................................... 991 Failure code [DV20KB] Travel Alarm Short Circuit .................................................................................. 993 Failure code [DW43KA] Travel Speed Sol Open Circuit ............................................................................... 995 Failure code [DW43KB] Travel Speed Sol Short Circuit .............................................................................. 997 Failure code [DW45KA] Swing Brake Sol Open Circuit ................................................................................ 999 Failure code [DW45KB] Swing Brake Sol Short Circuit ...............................................................................1001 Failure code [DW91KA] Travel Junction Sol Open Circuit ............................................................................1004 Failure code [DW91KB] Travel Junction Sol Short Circuit ...........................................................................1006 Failure code [DWA2KA] Attachment Sol Open Circuit .................................................................................1008 Failure code [DWA2KB] Attachment Sol Short Circuit ................................................................................1010 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .............................................................................1012 Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit ............................................................................1014 Failure code [DWK2KA] Variable Back Press Sol Open Circuit ........................................................................1016 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .......................................................................1018 Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ............................................................................1020 Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ...........................................................................1022 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .................................................................................1024 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ................................................................................1026 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .................................................................................1028 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ................................................................................1030 Failure code [DXE0KA] LS-EPC Sol Open Circuit .....................................................................................1032 Failure code [DXE0KB] LS-EPC Sol Short Circuit ....................................................................................1034 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ............................................................................1036 Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...........................................................................1038 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..........................................................................1040 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .........................................................................1042 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ............................................................................1044 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ...........................................................................1046 Failure code [DXEAKA] Service Current EPC1 Discon .................................................................................1048 Failure code [DXEAKB] Service Current EPC1 Short ..................................................................................1050 Failure code [DXE7KA] Service Current EPC2 Discon .................................................................................1052 Failure code [DXE7KB] Service Current EPC2 Short ..................................................................................1054 Failure code [DXE8KA] Service Current EPC3 Discon .................................................................................1056 Failure code [DXE8KB] Service Current EPC3 Short ..................................................................................1058 Failure code [DXE9KA] Service Current EPC4 Discon .................................................................................1060 Failure code [DXE9KB] Service Current EPC4 Short ..................................................................................1062 Failure code [DY20KA] Wiper Working Abnormality ...................................................................................1064 Failure code [DY20MA] Wiper Parking Abnormality ...................................................................................1066 Failure code [DY2CKB] Washer Drive Short Circuit ..................................................................................1068 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .............................................................................1070 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .............................................................................1072 Troubleshooting of electrical system (E-mode) .........................................................................................1074 E-1 Engine does not start (Engine does not rotate) ................................................................................1074 E-2 Manual preheating system does not work ........................................................................................1080 E-3 Automatic preheating system does not work .....................................................................................1083 E-4 Preheating monitor does not light up when preheater is operated ...............................................................1085 E-5 When starting switch is turned to ON position, machine monitor displays nothing ...............................................1087 E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow ..........1090 E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow ....1091 E-8 Coolant temperature monitor lights up in white while engine is running ........................................................1092 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................................................1093 E-10 Charge level monitor lights up while engine is running .......................................................................1094 E-11 Fuel level monitor lights up in red while engine is running ..................................................................1095 E-12 Air cleaner clogging monitor lights up in yellow while engine is running .....................................................1096 E-13 Water separator monitor lights up while engine is running ....................................................................1097 E-14 Coolant temperature monitor lights up in red while engine is running .........................................................1098 E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................................................1099 E-16 Engine oil pressure monitor lights up in red while engine is running .........................................................1100 E-17 Fuel gauge indicate either full or empty and does not move ...................................................................1101 E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .....................................................1102 E-19 Coolant temperature gauge indicate either Min or Max and does not move .......................................................1103 E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max) ....................................1104 E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move .................................................1105 E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max) ..............................1107 E-23 Content of display on machine monitor is different from that of actual machine ...............................................1108 E-24 Machine monitor does not display some items ..................................................................................1109 E-25 Function switch does not work ................................................................................................1110 E-26 Automatic preheating system does not work (In cold season) ...................................................................1111 E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated .....................1112 E-28 Auto-deceleration is not actuated or canceled when lever is operated .........................................................1113 E-29 Working mode selector screen selection screen is not diplayed when working mode switch is operated ...........................1115 E-30 Engine or hydraulic pump setting does not change when working mode is changed ................................................1116 E-31 Travel speed monitor does not change when travel speed switch is operated ....................................................1117 E-32 Travel speed does not change when travel speed is shifted ....................................................................1118 E-33 Alarm buzzer does not stop sounding ..........................................................................................1119 E-34 When starting switch is turned to OFF position, service meter is not displayed ...............................................1120 E-35 Service mode cannot be selected ..............................................................................................1121 E-36 Any of work equipment, swing and travel does not work ........................................................................1122 E-37 Any of work equipment, swing and travel can not be locked ....................................................................1124 E-38 Machine can not swing while swing brake cancel switch is canceled ............................................................1125 E-39 Swing brake does not operate while swing brake cancel switch is locked .......................................................1127 E-40 One-touch power maximizing function does not work or monitor is not displayed ................................................1129 E-41 One-touch power maximizing function cannot be released .......................................................................1131 E-42 Travel alarm does not sound when machine travels .............................................................................1132 E-43 Travel alarm does not stop sounding when machine stops .......................................................................1133 E-44 Horn does not sound ..........................................................................................................1134 E-45 Horn does not stop sounding ..................................................................................................1136 E-46 Wiper monitor does not light up or go out when wipper switch is operated .....................................................1137 E-47 Wiper does not operate when wipper switch is operated ........................................................................1138 E-48 Window washer does not operate when window washer switch is operated .........................................................1140 E-49 BOOM LOWER indication is not displayed properly with monitoring function .....................................................1141 E-50 ARM DUMP indication is not displayed properly with monitoring function .......................................................1142 E-51 ARM IN indication is not displayed properly with monitoring function .........................................................1143 E-52 BOOM RAISE indication is not displayed properly with monitoring function .....................................................1144 E-53 BUCKET CURL indication is not displayed properly with monitoring function ....................................................1145 E-54 BUCKET DUMP indication is not displayed properly with monitoring function ....................................................1146 E-55 SWING indication is not displayed properly with monitoring function ..........................................................1147 E-56 TRAVEL indication is not displayed properly with monitoring function .........................................................1148 E-57 Service is not displayed properly with monitoring function ...................................................................1149 E-58 Attachment hydraulic circuit cannot be changed ...............................................................................1152 E-59 KOMTRAX system does not work properly ........................................................................................1153 Troubleshooting of hydraulic and mechanical system (H-mode) ...........................................................................1154 Information mentioned in troubleshooting table (H mode) ...........................................................................1154 System chart for hydraulic system .................................................................................................1155 Failure mode and cause table ......................................................................................................1157 H-1 All of work equipment, swing and travel operation lacks speed or power ........................................................1165 H-2 Engine speed lowers significantly or engine stalls ............................................................................1168 H-3 Any of work equipment, swing and travel does not work .........................................................................1170 H-4 Unusual sound is heard from around hydraulic pump .............................................................................1171 H-5 Fine control performance or response is poor ..................................................................................1172 H-6 Boom operation lacks speed or power ...........................................................................................1173 H-7 Arm operation lacks speed or power ............................................................................................1175 H-8 Bucket operation lacks speed or power .........................................................................................1177 H-9 Work equipment does not move in single operation ..............................................................................1178 H-10 Hydraulic drift of boom is large .............................................................................................1179 H-11 Hydraulic drift of arm is large ..............................................................................................1180 H-12 Hydraulic drift of bucket is large ...........................................................................................1181 H-13 Time lag of work equipment is large ..........................................................................................1182 H-14 When part of work equipment is relieved singly, other parts of work equipment move ...........................................1184 H-15 One-touch power maximizing function does not work ............................................................................1185 H-16 In combined operation of work equipment, equipment having heavier load moves slower ..........................................1186 H-17 In combined operations of swing and boom RAISE, boom rising speed is low .....................................................1187 H-18 In combined operations of swing and travel, travel speed drops largely .......................................................1188 H-19 Machine does not travel straight .............................................................................................1189 H-20 Travel speed is too low ......................................................................................................1190 H-21 Machine is hard to steer or travel power is low ..............................................................................1192 H-22 Travel speed does not change, or travel speed is too low or high .............................................................1194 H-23 One of tracks dose not run ...................................................................................................1195 H-24 Upper structure does not swing to the right or left ..........................................................................1196 H-25 Upper structure swing only to the right or left ..............................................................................1197 H-26 Swing acceleration is poor or swing speed is low (both right and left) .......................................................1198 H-27 Swing acceleration is poor or swing speed is low (either right or left) ......................................................1199 H-28 Upper structure overruns excessively when it stops swinging (both right and left) ............................................1200 H-29 Upper structure overruns excessively when it stops swinging (either right or left) ...........................................1201 H-30 Shock is large when upper structure stops swinging ...........................................................................1202 H-31 Large unusual noise is heard when upper structure stops swinging .............................................................1203 H-32 Swing drift on a slope is large while swing holding brake is applied .........................................................1204 H-33 Swing drift on a slope is large while swing holding brake is released ........................................................1205 H-34 Attachment circuit cannot be changed while attachment is installed ...........................................................1206 H-35 Oil flow in attachment circuit cannot be controlled ..........................................................................1207 H-36 Quick coupler cylinder will not extend .......................................................................................1208 H-37 Quick coupler cylinder will not extend (but buzzer does not sound) ...........................................................1210 H-38 Buzzer does not sound (but quick coupler cylinder does retract) ..............................................................1212 H-39 Quick coupler cylinder extends and retracts slowly ...........................................................................1214 Troubleshooting of engine (S-mode) ....................................................................................................1215 Information mentioned in troubleshooting table (S mode) ...........................................................................1215 S-1 When starting switch is turned to START position, engine does not crank .......................................................1216 S-2 When engine cranks, smoke does not come out ...................................................................................1217 S-3 Engine does not start while fuel is injected (Incomplete combustion) ..........................................................1218 S-4 Startability is poor ..........................................................................................................1219 S-5 Engine does not pick up smoothly ..............................................................................................1221 S-6 Engine stops during operation .................................................................................................1222 S-7 Engine runs rough or is unstable ..............................................................................................1224 S-8 Engine lacks power ............................................................................................................1225 S-9 Exhaust smoke is black (KDPF clogs up early) ..................................................................................1227 S-10 Engine oil consumption is too much ...........................................................................................1229 S-11 Oil becomes contaminated early ...............................................................................................1230 S-12 Fuel consumption is excessive ................................................................................................1231 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .............................................................1232 S-14 Engine oil pressure drops ....................................................................................................1233 S-15 Fuel is contaminated in engine oil ...........................................................................................1234 S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) .............................................................1235 S-17 Coolant temperature rises too high (Overheating) .............................................................................1236 S-18 Unusual noise is heard .......................................................................................................1237 S-19 Vibration is excessive .......................................................................................................1238 S-20 Automatic regeneration is operated frequently ................................................................................1239 S-21 Active regeneration is operated for long .....................................................................................1240 S-22 White smoke comes out in the process of active regeneration ..................................................................1241 Auto grease system ....................................................................................................................1242 Finding malfunctions ..............................................................................................................1242 Malfunction finding procedures ....................................................................................................1245 50 Disassembly and assembly ...............................................................................................................1247 Table of contents .....................................................................................................................1248 General information on disassembly and assembly .......................................................................................1250 How to read this manual ...........................................................................................................1250 Coating materials list ............................................................................................................1252 Special tools list ................................................................................................................1256 Sketches of special tools .........................................................................................................1260 Engine and cooling system .............................................................................................................1263 Removal and installation of supply pump assembly ..................................................................................1263 Removal and installation of injector assembly .....................................................................................1268 Removal and installation of cylinder head assembly ................................................................................1277 Removal and installation of radiator assembly .....................................................................................1297 Removal and installation of hydraulic oil cooler assembly .........................................................................1299 Removal and installation of aftercooler assembly ..................................................................................1302 Removal and installation of engine and main pump assembly .........................................................................1304 Removal and installation of engine front oil seal .................................................................................1316 Removal and installation of engine rear oil seal ..................................................................................1320 Removal and installation of fuel cooler assembly ..................................................................................1323 Removal and installation of fuel tank assembly ....................................................................................1324 Removal and installation of engine hood assembly ..................................................................................1327 Removal and installation of KDPF assembly .........................................................................................1330 Disassembly and assembly of KDPF ..................................................................................................1338 Removal and installation of KCCV assembly .........................................................................................1346 Removal and installation of air cleaner assembly ..................................................................................1348 Power train system ....................................................................................................................1351 Removal and installation of travel motor and final drive assembly .................................................................1351 Disassembly and assembly of final drive ...........................................................................................1352 Removal and installation of swing motor and swing machinery assembly ..............................................................1360 Disassembly and assembly of swing machinery .......................................................................................1363 Removal and installation of swing circle assembly .................................................................................1371 Undercarriage and frame ...............................................................................................................1372 Separation and connection of track shoe assembly ..................................................................................1372 Removal and installation of sprocket ..............................................................................................1374 Removal and installation of idler and idler cushion assembly ......................................................................1375 Disassembly and assembly of idler .................................................................................................1376 Disassembly and assembly of idler cushion .........................................................................................1379 Disassembly and assembly of track roller ..........................................................................................1381 Disassembly and assembly of carrier roller ........................................................................................1383 Removal and installation of revolving frame assembly ..............................................................................1386 Removal and installation of counterweight assembly ................................................................................1388 Hydraulic system ......................................................................................................................1391 Removal and installation of center swivel joint assembly ..........................................................................1391 Disassembly and assembly of center swivel joint ...................................................................................1393 Removal and installation of hydraulic tank assembly ...............................................................................1394 Removal and installation of main pump assembly ....................................................................................1398 Removal and installation of control valve assembly ................................................................................1402 Disassembly and assembly of control valve .........................................................................................1409 Disassembly and assembly of work equipment PPC valve ..............................................................................1413 Disassembly and assembly of travel PPC valve ......................................................................................1415 Removal and installation of quick coupler valve ...................................................................................1418 Work equipment ........................................................................................................................1419 Removal and installation of work equipment assembly ...............................................................................1419 Disassembly and assembly of work equipment cylinder ...............................................................................1422 Cab and its attachments ...............................................................................................................1428 Removal and installation of operator's cab assembly ...............................................................................1428 Removal and installation of operator cab glass (adhered glass) ....................................................................1433 Removal and installation of front window assembly .................................................................................1441 Removal and installation of floor frame assembly ..................................................................................1447 Removal and installation of air conditioner unit assembly .........................................................................1453 Removal and installation of operator's seat .......................................................................................1457 Removal and installation of seat belt .............................................................................................1459 Removal and installation of front wiper assembly ..................................................................................1461 Electric system .......................................................................................................................1467 Removal and installation of air conditioner compressor assembly ...................................................................1467 Removal and installation of air conditioner condenser assembly ....................................................................1470 Removal and installation of engine controller assembly ............................................................................1472 Removal and installation of pump controller assembly ..............................................................................1474 Removal and installation of machine monitor assembly ..............................................................................1477 Removal and installation of pump swash plate sensor ...............................................................................1479 Removal and installation of Mass air flow and temperature sensor ..................................................................1480 Removal and installation of KOMTRAX terminal assembly .............................................................................1481 60 Maintenance standard ...................................................................................................................1483 Table of contents .....................................................................................................................1484 Engine and cooling system .............................................................................................................1485 Engine mount ......................................................................................................................1485 Cooling system ....................................................................................................................1486 Power train system ....................................................................................................................1487 Swing circle ......................................................................................................................1487 Swing machinery ...................................................................................................................1488 Final drive .......................................................................................................................1490 Sprocket ..........................................................................................................................1492 Undercarriage and frame ...............................................................................................................1494 Truck frame and idler cushion .....................................................................................................1494 Idler .............................................................................................................................1496 Track roller ......................................................................................................................1498 Carrier roller ....................................................................................................................1500 Track shoe ........................................................................................................................1501 Hydraulic system ......................................................................................................................1504 Hydraulic tank ....................................................................................................................1504 Main pump .........................................................................................................................1505 Control valve .....................................................................................................................1506 Swing motor .......................................................................................................................1514 Travel motor ......................................................................................................................1516 PPC valve .........................................................................................................................1519 Solenoid valve ....................................................................................................................1528 Hydraulic drift prevention valve ..................................................................................................1529 Attachment circuit selector valve (for low-pressure circuit) ......................................................................1531 Center swivel joint ...............................................................................................................1532 Work equipment ....................................................................................................................1533 80 Appendix ...............................................................................................................................1545 Table of contents .....................................................................................................................1546 Air conditioner .......................................................................................................................1547 Precautions for refrigerant .......................................................................................................1547 Air conditioner component .........................................................................................................1548 Configuration and function of refrigeration cycle .................................................................................1550 Outline of refrigeration cycle ....................................................................................................1551 Air conditioner unit ..............................................................................................................1553 Dual pressure switch ..............................................................................................................1559 Air conditioner controller ........................................................................................................1560 Air conditioner compressor ........................................................................................................1561 Air conditioner condenser .........................................................................................................1562 Sunlight sensor ...................................................................................................................1564 Outside air temperature sensor ....................................................................................................1565 Procedure for testing and troubleshooting .........................................................................................1566 Circuit diagram and arrangement of connector pins .................................................................................1568 System diagram ....................................................................................................................1570 Input and output signals of the air conditioner controller ........................................................................1571 Parts and connectors layout .......................................................................................................1573 Layout of air conditioner related parts and connectors ............................................................................1574 Testing air leakage (duct) ........................................................................................................1577 Testing with self-diagnosis function ..............................................................................................1580 How to enter air conditioner "Electrical Systems" screen in service mode of the machine monitor. ..................................1581 Testing vent (mode) changeover ....................................................................................................1583 Testing FRESH/RECIRC air changeover ...............................................................................................1585 Testing sunlight sensor ...........................................................................................................1586 Testing (dual) pressure switch for refrigerant ....................................................................................1587 Testing relays ....................................................................................................................1589 Troubleshooting chart 1 ...........................................................................................................1590 Troubleshooting chart 2 ...........................................................................................................1591 Information mentioned in troubleshooting table ....................................................................................1594 Failure code list related to air conditioner ......................................................................................1595 Failure code [879AKA] A/C Inner sensor Open Circuit ...............................................................................1596 Failure code [879AKB] A/C Inner sensor Short Circuit ..............................................................................1597 Failure code [879BKA] A/C Outer sensor Open Circuit ...............................................................................1598 Failure code [879BKB] A/C Outer sensor Short Circuit ..............................................................................1600 Failure code [879CKA] Ventilating sensor Open Circuit .............................................................................1602 Failure code [879CKB] Ventilating sensor Short Circuit ............................................................................1603 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .......................................................................1604 Failure code [879EMC] Ventilating Damper Abnormality ..............................................................................1606 Failure code [879FMC] Air Mix Damper Abnormality ..................................................................................1607 Failure code [879GKX] Refrigerant Abnormality .....................................................................................1608 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ....................................................1609 A-2 Troubleshooting of compressor system (Air is not cooled) ......................................................................1611 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ............................................1614 A-4 Troubleshooting for FRESH/RECIRC air changeover ...............................................................................1616 Troubleshooting with gauge pressure ...............................................................................................1618 Testing refrigerant pressure ......................................................................................................1621 Precautions for disconnecting and connecting air conditioner piping ...............................................................1624 Handling of compressor oil ........................................................................................................1626 Desiccant replacement .............................................................................................................1628 90 Diagrams and drawings ..................................................................................................................1631 Table of contents .....................................................................................................................1632 Hydraulic circuit diagram .............................................................................................................1633 Symbols in hydraulic circuit diagram ..............................................................................................1633 Electric circuit diagram ..............................................................................................................1637 Symbols in electric circuit diagram ...............................................................................................1637
DESCRIPTION:
KOMATSU PC290LC-10 PC290NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05644-02 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
• Locate a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the work. During the work, hang UNDER REPAIR warning tag in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep all tools in good condition. Learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift truck, service car, etc.
• If welding repairs are needed, always have a trained and experienced welder perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 24/12/24
