Komatsu PC290LC-11E0 Hydraulic Excavator Shop Manual SEN06950-00 PDF

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Komatsu PC290LC-11E0 Hydraulic Excavator Shop Manual SEN06950-00 –  PDF DOWNLOAD

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Komatsu PC290LC-11E0 Hydraulic Excavator Shop Manual SEN06950-00 –  PDF DOWNLOAD

Language : English
Pages : 2916
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC290LC-11E0 Hydraulic Excavator Shop Manual SEN06950-00 –  PDF DOWNLOAD

• SERIAL NUMBERS 35268 and up

COVER 1
00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 22
FOREWORD, SAFETY, BASIC INFORMATION . 28
HOW TO READ THE SHOP MANUAL . 28
SAFETY NOTICE FOR OPERATION . 30
PRECAUTIONS TO PREVENT FIRE . 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 42
METHOD FOR CHECKING ENGINE TYPE . 43
PRECAUTIONS FOR DEF . 44
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 44
PRECAUTIONS FOR ADDING 44
PRECAUTIONS FOR STORING . 44
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 44
THE OTHER PRECAUTIONS . 44
STORE AdBlue/DEF 45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 46
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 49
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 56
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 58
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 59
PRACTICAL USE OF KOMTRAX 60
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 62
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 65
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 69
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 73
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 75
HOW TO READ ELECTRICAL WIRE CODE 76
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 80
STANDARD TIGHTENING TORQUE TABLE 83
CONVERSION TABLE 90
01 SPECIFICATIONS . 95
CONTENTS 96
ABBREVIATION LIST . 97
SPECIFICATIONS 103
SPECIFICATION DRAWING . 103
SPECIFICATION DRAWING: PC290LC-11E0 . 103
WORKING RANGE DRAWINGS 105
WORKING RANGE: PC290LC-11E0 . 105
SPECIFICATIONS 106
SPECIFICATIONS: PC290LC-11E0 106
WEIGHT TABLE 109
WEIGHT TABLE: PC290LC-11E0 109
TABLE OF FUEL, COOLANT, AND LUBRICANTS 111
10 STRUCTURE AND FUNCTION . 113
CONTENTS 114
ABBREVIATION LIST . 118
UREA SCR SYSTEM . 124
LAYOUT DRAWING OF UREA SCR SYSTEM . 125
UREA SCR SYSTEM DIAGRAM . 130
FUNCTION OF UREA SCR SYSTEM . 131
FUNCTION OF AdBlue/DEF SYSTEM . 131
INDUCEMENT STRATEGY . 135
COMPONENT PARTS OF UREA SCR SYSTEM 143
AdBlue/DEF MIXING TUBE 143
SCR ASSEMBLY 143
AdBlue/DEF TANK . 146
AdBlue/DEF PUMP . 148
AdBlue/DEF INJECTOR . 149
AdBlue/DEF HOSE . 150
AdBlue/DEF TANK HEATING VALVE . 151
BOOT-UP SYSTEM 152
LAYOUT DRAWING OF BOOT-UP SYSTEM 152
SYSTEM OPERATING LAMP SYSTEM 154
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 154
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 154
BATTERY DISCONNECT SWITCH . 155
FUNCTION OF BATTERY DISCONNECT SWITCH . 155
ENGINE SYSTEM . 156
LAYOUT DRAWING OF ENGINE SYSTEM . 156
SPECIFICATIONS OF ENGINE SYSTEM . 157
FUNCTION OF ENGINE SYSTEM . 157
ENGINE CONTROL SYSTEM . 158
ENGINE CONTROL SYSTEM DIAGRAM . 158
FUNCTION OF ENGINE CONTROL SYSTEM . 159
AUTO-DECELERATION SYSTEM 161
AUTO-DECELERATION SYSTEM DIAGRAM 161
FUNCTION OF AUTO-DECELERATION SYSTEM 161
OPERATION OF AUTO-DECELERATION SYSTEM . 162
ENGINE AUTOMATIC WARM-UP SYSTEM . 163
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 163
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 164
OVERHEAT PREVENTION SYSTEM 165
OVERHEAT PREVENTION SYSTEM DIAGRAM 165
FUNCTION OF OVERHEAT PREVENTION SYSTEM 166
TURBOCHARGER PROTECTION SYSTEM 168
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 168
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 169
AUTOMATIC IDLE STOP SYSTEM 170
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 170
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 170
COMPONENT PARTS OF ENGINE SYSTEM 173
VGT . 173
EGR SYSTEM 177
EGR VALVE . 179
EGR COOLER 181
KCCV SYSTEM . 182
KCCV VENTILATOR . 184
KDPF 186
COOLING SYSTEM 191
LAYOUT DRAWING OF COOLING SYSTEM 191
SPECIFICATIONS OF COOLING SYSTEM 192
CONTROL SYSTEM 193
LAYOUT DRAWING OF CONTROL SYSTEM 193
MACHINE MONITOR SYSTEM 196
MACHINE MONITOR SYSTEM DIAGRAM 196
FUNCTION OF MACHINE MONITOR SYSTEM 196
KomVision SYSTEM 197
LAYOUT DRAWING OF KOMVISION SYSTEM 197
KomVision SYSTEM DIAGRAM 199
FUNCTION OF KomVision SYSTEM 199
KOMTRAX SYSTEM 201
KOMTRAX SYSTEM DIAGRAM 201
FUNCTION OF KOMTRAX SYSTEM 201
COMPONENT PARTS OF CONTROL SYSTEM . 202
MACHINE MONITOR . 202
KomVision CONTROLLER 220
KomVision CAMERA 224
GATEWAY FUNCTION CONTROLLER . 225
COMMUNICATION TERMINAL 228
PUMP CONTROLLER . 230
RESISTOR FOR PC-EPC VALVE . 234
CAN TERMINATING RESISTOR 234
PPC OIL PRESSURE SWITCH . 235
ENGINE CONTROLLER . 236
FUEL CONTROL DIAL . 242
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 243
FUNCTION OF ENGINE OIL PRESSURE SWITCH 244
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 244
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 245
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 245
STRUCTURE OF OVERLOAD CAUTION SENSOR 245
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 245
FUNCTION OF OVERLOAD CAUTION SENSOR . 245
HYDRAULIC SYSTEM 246
LAYOUT DRAWING OF HYDRAULIC SYSTEM 246
CLSS 252
STRUCTURE OF CLSS . 252
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 254
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 255
PRESSURE COMPENSATION CONTROL . 268
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 271
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 271
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 272
PUMP AND VALVE CONTROL SYSTEM . 277
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 277
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 278
COMPONENT PARTS OF HYDRAULIC SYSTEM . 280
HYDRAULIC TANK 280
MAIN PUMP . 282
PC-EPC VALVE 306
PILOT OIL FILTER 308
CONTROL VALVE . 308
WORK EQUIPMENT SYSTEM . 364
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 364
STRUCTURE OF VALVE CONTROL 369
ONE-TOUCH POWER MAXIMIZING SYSTEM . 371
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 371
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 372
PPC LOCK SYSTEM . 373
PPC LOCK SYSTEM DIAGRAM . 373
FUNCTION OF PPC LOCK SYSTEM . 373
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 374
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 374
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 374
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 375
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 376
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 376
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 377
TOOL CONTROL SYSTEM . 378
TOOL CONTROL SYSTEM DIAGRAM . 378
FUNCTION OF TOOL CONTROL SYSTEM . 379
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 380
WORK EQUIPMENT AND SWING PPC VALVE 380
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 385
SOLENOID VALVE 391
ANTI-DROP VALVE FOR BOOM 395
ANTI-DROP VALVE FOR ARM . 400
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 404
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 406
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 409
ATTACHMENT BYPASS SOLENOID VALVE 411
PILOT CIRCUIT ACCUMULATOR . 413
ATTACHMENT CIRCUIT ACCUMULATOR 414
SWING SYSTEM 415
LAYOUT DRAWING OF SWING SYSTEM 415
SWING CONTROL SYSTEM DIAGRAM 419
FUNCTION OF SWING CONTROL SYSTEM 419
COMPONENT PARTS OF SWING SYSTEM . 423
SWING MOTOR . 423
SWING MACHINERY . 435
SWING CIRCLE 436
TRAVEL SYSTEM . 438
LAYOUT DRAWING OF TRAVEL SYSTEM . 438
TRAVEL CONTROL SYSTEM DIAGRAM . 442
FUNCTION OF TRAVEL CONTROL SYSTEM . 442
COMPONENT PARTS OF TRAVEL SYSTEM 444
TRAVEL MOTOR 444
FINAL DRIVE . 456
TRAVEL PPC VALVE 458
CENTER SWIVEL JOINT . 463
UNDERCARRIAGE AND FRAME . 465
LAYOUT DRAWING OF UNDERCARRIAGE . 465
SPECIFICATIONS OF UNDERCARRIAGE . 466
WORK EQUIPMENT 467
STRUCTURE OF WORK EQUIPMENT . 467
FUNCTION OF WORK EQUIPMENT 468
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 469
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 469
BUCKET CLEARANCE ADJUSTMENT SHIM 470
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 470
CAB AND ITS ATTACHMENTS . 471
ROPS CAB 471
STRUCTURE OF ROPS CAB . 471
FUNCTION OF ROPS CAB 471
CAB MOUNT . 472
STRUCTURE OF CAB MOUNT 472
FUNCTION OF CAB MOUNT . 472
CAB TIPPING STOPPER . 473
STRUCTURE OF CAB TIPPING STOPPER 473
FUNCTION OF CAB TIPPING STOPPER . 473
20 STANDARD VALUE TABLE . 475
CONTENTS 476
ABBREVIATION LIST . 477
STANDARD VALUE TABLE FOR ENGINE . 483
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11E0 . 483
STANDARD VALUE TABLE FOR MACHINE 487
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11E0 487
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 500
STANDARD VALUE TABLE FOR ELECTRICAL . 504
STANDARD VALUE TABLE FOR ELECTRICAL . 504
30 TESTING AND ADJUSTING 515
CONTENTS 516
ABBREVIATION LIST . 519
RELATED INFORMATION ON TESTING AND ADJUSTING 525
TOOLS FOR TESTING AND ADJUSTING . 525
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 532
ENGINE AND COOLING SYSTEM . 534
TEST ENGINE SPEED . 534
METHOD FOR TESTING ENGINE SPEED . 534
TEST BOOST PRESSURE . 537
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 537
METHOD FOR TESTING BOOST PRESSURE . 538
TEST EXHAUST GAS COLOR 539
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 539
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 540
TEST AND ADJUST VALVE CLEARANCE . 542
METHOD FOR TESTING VALVE CLEARANCE 542
METHOD FOR ADJUSTING VALVE CLEARANCE 543
TEST COMPRESSION PRESSURE . 545
METHOD FOR TESTING COMPRESSION PRESSURE . 545
TEST BLOWBY PRESSURE 550
METHOD FOR TESTING BLOWBY PRESSURE 550
TEST ENGINE OIL PRESSURE 552
METHOD FOR TESTING ENGINE OIL PRESSURE 552
TEST EGR VALVE AND VGT OIL PRESSURE . 553
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 553
TEST FUEL PRESSURE 555
METHOD FOR TESTING FUEL PRESSURE 556
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 561
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 562
BLEEDING AIR FROM FUEL SYSTEM . 568
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 568
TEST FUEL CIRCUIT FOR LEAKAGE . 569
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 569
HANDLE CYLINDER CUT-OUT MODE OPERATION 571
HANDLE NO-INJECTION CRANKING OPERATION 572
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 573
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 573
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 573
REPLACING FAN BELT 575
METHOD FOR REPLACING FAN BELT . 575
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 576
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 576
TEST SCR RELATED FUNCTIONS 577
TEST AdBlue/DEF PUMP RAISED PRESSURE 580
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 583
TEST AdBlue/DEF LINE HEATER RELAY 1 . 587
TEST AdBlue/DEF LINE HEATER RELAY 2 . 590
TEST AdBlue/DEF PUMP HEATER RELAY . 592
TEST AdBlue/DEF TANK HEATER VALVE . 595
TEST DENITRATION EFFICIENCY OF SCR 598
CLEAN AdBlue/DEF TANK . 602
METHOD FOR CLEANING AdBlue/DEF TANK . 602
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 606
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 606
POWER TRAIN . 608
TEST SWING CIRCLE BEARING CLEARANCE . 608
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 608
UNDERCARRIAGE AND FRAME . 609
TEST AND ADJUST TRACK TENSION . 609
METHOD FOR TESTING TRACK TENSION 609
METHOD FOR ADJUSTING TRACK TENSION 609
HYDRAULIC SYSTEM 611
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 611
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 611
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 611
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 617
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 618
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 624
TEST OIL PRESSURE OF CONTROL CIRCUIT 627
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 627
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 629
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 629
TEST PC-EPC VALVE OUTLET PRESSURE . 630
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 631
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 633
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 633
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 634
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 637
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 638
METHOD FOR ADJUSTING LS VALVE . 639
TEST OUTLET PRESSURE OF SOLENOID VALVE 640
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 640
OPERATING CONDITION OF SOLENOID VALVE . 641
TEST PPC VALVE OUTLET PRESSURE 644
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 644
TEST ATTACHMENT CIRCUIT OIL PRESSURE 646
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 646
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 647
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 647
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 648
TEST PUMP SWASH PLATE SENSOR 649
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 649
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 650
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 650
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 650
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 651
TEST OIL LEAKAGE 652
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 652
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 652
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 653
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 654
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 654
BLEED AIR FROM HYDRAULIC CIRCUIT 655
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 657
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 659
CAB AND ITS ATTACHMENTS . 664
TEST CAB TIPPING STOPPER 664
METHOD FOR TESTING CAB TIPPING STOPPER 664
METHOD FOR ADJUSTING MIRRORS 665
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 665
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 666
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 667
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 668
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 669
ELECTRICAL SYSTEM . 671
SET AND OPERATE MACHINE MONITOR . 671
OPERATOR MODE . 674
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 675
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 675
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 676
CHECKING FUNCTION OF SERVICE METER 676
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 676
SERVICE MODE 679
METHOD FOR OPERATING SERVICE MODE . 680
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 682
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 689
ABNORMALITY RECORD MENU . 699
METHOD FOR CONFIRMING MAINTENANCE RECORD 704
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 705
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 709
DEFAULT MENU 710
DIAGNOSTIC TESTS MENU . 718
ADJUSTMENT MENU . 727
METHOD FOR PERFORMING NO-INJECTION CRANKING . 746
KOMTRAX SETTINGS MENU . 747
METHOD FOR DISPLAYING SERVICE MESSAGE . 749
METHOD FOR STARTING UP KOMTRAX SYSTEM . 751
ADJUST REARVIEW CAMERA ANGLE 756
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 756
ADJUST KomVision CAMERA ANGLE . 759
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 760
ADJUST KomVision RELATED ITEMS 764
SETTING OF KomVision (MAIN SETTING) . 764
SETTING OF KomVision (CAMERA SETTING) . 766
SETTING OF KomVision (CAMERA CALIBRATION) . 766
KomVision screen – Check 12 m visibility 780
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 783
HANDLE BATTERY DISCONNECT SWITCH 784
TEST DIODES . 785
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 785
METHOD FOR TESTING DIODE USING ANALOG TESTER 785
Pm CLINIC . 786
Pm CLINIC SERVICE . 786
Pm CLINIC CHECK SHEET . 790
40 TROUBLESHOOTING 801
CONTENTS 802
ABBREVIATION LIST . 813
RELATED INFORMATION ON TROUBLESHOOTING 819
GENERAL TROUBLESHOOTING POINTS 819
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 820
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 832
CHECKS BEFORE TROUBLESHOOTING . 834
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 836
WALK-AROUND CHECK . 836
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 838
CHECK FUEL LEVEL AND TYPE . 838
CHECK IMPURE INGREDIENT IN FUEL . 838
CHECK FUEL PREFILTER 839
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 839
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 840
CHECK MAIN FILTER . 841
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 843
CHECK COOLANT LEVEL (RESERVOIR TANK) 844
CHECK CLOGGING OF AIR CLEANER . 844
OUTER ELEMENT – CLEAN . 845
ELEMENTS – REPLACE 847
CHECK HYDRAULIC OIL LEVEL . 848
CHECK HYDRAULIC OIL STRAINER 849
CHECK HYDRAULIC FILTER 850
CHECK OIL LEVEL IN SWING MACHINERY CASE . 851
CHECK OIL LEVEL IN DAMPER CASE 852
CHECK OIL LEVEL IN FINAL DRIVE CASE . 852
BLEED AIR FROM FUEL SYSTEM 853
BLEED AIR FROM HYDRAULIC SYSTEM . 853
ELECTRICAL EQUIPMENT – CHECK METHOD . 853
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 861
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 871
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 874
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 878
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 880
CONNECTOR LIST AND LAYOUT . 883
CONNECTOR CONTACT IDENTIFICATION 896
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 936
FUSE LOCATION TABLE . 942
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 945
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 949
FAILURE CODE TABLE 951
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 970
FAILURE CODE [879AKA] . 970
FAILURE CODE [879AKB] . 971
FAILURE CODE [879BKA] . 972
FAILURE CODE [879BKB] . 974
FAILURE CODE [879CKA] . 976
FAILURE CODE [879CKB] . 977
FAILURE CODE [879DKZ] . 978
FAILURE CODE [879EMC] . 980
FAILURE CODE [879FMC] . 981
FAILURE CODE [879GKX] . 982
FAILURE CODE [989L00] . 984
FAILURE CODE [989M00] . 985
FAILURE CODE [989N00] . 986
FAILURE CODE [A1U0N3] . 987
FAILURE CODE [A1U0N4] . 989
FAILURE CODE [A900FR] . 991
FAILURE CODE [A900N6] . 992
FAILURE CODE [A900NY] . 993
FAILURE CODE [AA10NX] . 994
FAILURE CODE [AB00KE] . 996
FAILURE CODE [AQ10N3] . 999
FAILURE CODE [AS00N3] .1001
FAILURE CODE [AS00R2] .1003
FAILURE CODE [AS00R3] .1004
FAILURE CODE [AS00R4] .1005
FAILURE CODE [AS00R5] .1006
FAILURE CODE [AS00R6] .1007
FAILURE CODE [AS00ZK] .1008
FAILURE CODE [AS10KM] .1009
FAILURE CODE [AS10NR] .1010
FAILURE CODE [AS10NT] .1011
FAILURE CODE [B@BAZG] .1012
FAILURE CODE [B@BAZK] .1013
FAILURE CODE [B@BCNS] .1015
FAILURE CODE [B@BCQA] .1016
FAILURE CODE [B@BCZK] .1018
FAILURE CODE [B@HANS] .1020
FAILURE CODE [CA115] 1021
FAILURE CODE [CA122] 1022
FAILURE CODE [CA123] 1024
FAILURE CODE [CA131] 1026
FAILURE CODE [CA132] 1028
FAILURE CODE [CA144] 1030
FAILURE CODE [CA145] 1032
FAILURE CODE [CA153] 1034
FAILURE CODE [CA154] 1037
FAILURE CODE [CA187] 1039
FAILURE CODE [CA221] 1041
FAILURE CODE [CA222] 1043
FAILURE CODE [CA227] 1045
FAILURE CODE [CA234] 1046
FAILURE CODE [CA238] 1047
FAILURE CODE [CA239] 1049
FAILURE CODE [CA249] 1051
FAILURE CODE [CA256] 1053
FAILURE CODE [CA271] 1055
FAILURE CODE [CA272] 1057
FAILURE CODE [CA322] 1059
FAILURE CODE [CA323] 1061
FAILURE CODE [CA324] 1063
FAILURE CODE [CA325] 1065
FAILURE CODE [CA331] 1067
FAILURE CODE [CA332] 1069
FAILURE CODE [CA343] 1071
FAILURE CODE [CA351] 1072
FAILURE CODE [CA352] 1073
FAILURE CODE [CA356] 1076
FAILURE CODE [CA357] 1078
FAILURE CODE [CA386] 1080
FAILURE CODE [CA428] 1081
FAILURE CODE [CA429] 1083
FAILURE CODE [CA435] 1085
FAILURE CODE [CA441] 1087
FAILURE CODE [CA442] 1089
FAILURE CODE [CA449] 1090
FAILURE CODE [CA451] 1091
FAILURE CODE [CA452] 1093
FAILURE CODE [CA488] 1095
FAILURE CODE [CA515] 1096
FAILURE CODE [CA516] 1098
FAILURE CODE [CA553] 1100
FAILURE CODE [CA555] 1101
FAILURE CODE [CA556] 1102
FAILURE CODE [CA559] 1103
FAILURE CODE [CA595] 1106
FAILURE CODE [CA687] 1107
FAILURE CODE [CA689] 1109
FAILURE CODE [CA691] 1112
FAILURE CODE [CA692] 1114
FAILURE CODE [CA697] 1116
FAILURE CODE [CA698] 1117
FAILURE CODE [CA731] 1118
FAILURE CODE [CA778] 1119
FAILURE CODE [CA1117] .1124
FAILURE CODE [CA1664] .1125
FAILURE CODE [CA1669] .1127
FAILURE CODE [CA1673] .1128
FAILURE CODE [CA1677] .1129
FAILURE CODE [CA1678] .1130
FAILURE CODE [CA1682] .1131
FAILURE CODE [CA1683] .1133
FAILURE CODE [CA1684] .1135
FAILURE CODE [CA1686] .1137
FAILURE CODE [CA1691] .1138
FAILURE CODE [CA1694] .1141
FAILURE CODE [CA1695] .1144
FAILURE CODE [CA1696] .1145
FAILURE CODE [CA1712] .1147
FAILURE CODE [CA1713] .1150
FAILURE CODE [CA1714] .1152
FAILURE CODE [CA1715] .1153
FAILURE CODE [CA1776] .1154
FAILURE CODE [CA1777] .1157
FAILURE CODE [CA1843] .1160
FAILURE CODE [CA1844] .1162
FAILURE CODE [CA1879] .1165
FAILURE CODE [CA1881] .1167
FAILURE CODE [CA1883] .1169
FAILURE CODE [CA1885] .1172
FAILURE CODE [CA1887] .1174
FAILURE CODE [CA1921] .1176
FAILURE CODE [CA1922] .1179
FAILURE CODE [CA1942] .1184
FAILURE CODE [CA1993] .1185
FAILURE CODE [CA2185] .1188
FAILURE CODE [CA2186] .1189
FAILURE CODE [CA2249] .1191
FAILURE CODE [CA2271] .1192
FAILURE CODE [CA2272] .1195
FAILURE CODE [CA2288] .1198
FAILURE CODE [CA2311] .1199
FAILURE CODE [CA2349] .1200
FAILURE CODE [CA2353] .1203
FAILURE CODE [CA2357] .1205
FAILURE CODE [CA2381] .1206
FAILURE CODE [CA2382] .1209
FAILURE CODE [CA2383] .1212
FAILURE CODE [CA2386] .1215
FAILURE CODE [CA2387] .1217
FAILURE CODE [CA2555] .1218
FAILURE CODE [CA2556] .1221
FAILURE CODE [CA2637] .1224
FAILURE CODE [CA2639] .1226
FAILURE CODE [CA2771] .1229
FAILURE CODE [CA2777] .1235
FAILURE CODE [CA2976] .1238
FAILURE CODE [CA3133] .1240
FAILURE CODE [CA3134] .1243
FAILURE CODE [CA3135] .1245
FAILURE CODE [CA3142] .1248
FAILURE CODE [CA3143] .1249
FAILURE CODE [CA3144] .1250
FAILURE CODE [CA3146] .1252
FAILURE CODE [CA3147] .1253
FAILURE CODE [CA3148] .1254
FAILURE CODE [CA3151] .1256
FAILURE CODE [CA3165] .1262
FAILURE CODE [CA3229] .1264
FAILURE CODE [CA3231] .1266
FAILURE CODE [CA3232] .1268
FAILURE CODE [CA3235] .1272
FAILURE CODE [CA3239] .1274
FAILURE CODE [CA3241] .1277
FAILURE CODE [CA3242] .1280
FAILURE CODE [CA3251] .1283
FAILURE CODE [CA3253] .1285
FAILURE CODE [CA3254] .1288
FAILURE CODE [CA3255] .1291
FAILURE CODE [CA3256] .1295
FAILURE CODE [CA3311] .1297
FAILURE CODE [CA3312] .1299
FAILURE CODE [CA3313] .1302
FAILURE CODE [CA3314] .1303
FAILURE CODE [CA3315] .1304
FAILURE CODE [CA3316] .1306
FAILURE CODE [CA3317] .1307
FAILURE CODE [CA3318] .1308
FAILURE CODE [CA3319] .1310
FAILURE CODE [CA3321] .1311
FAILURE CODE [CA3322] .1313
FAILURE CODE [CA3419] .1315
FAILURE CODE [CA3421] .1317
FAILURE CODE [CA3497] .1319
FAILURE CODE [CA3498] .1320
FAILURE CODE [CA3543] .1321
FAILURE CODE [CA3545] .1328
FAILURE CODE [CA3547] .1330
FAILURE CODE [CA3558] .1331
FAILURE CODE [CA3559] .1333
FAILURE CODE [CA3562] .1335
FAILURE CODE [CA3563] .1337
FAILURE CODE [CA3567] .1340
FAILURE CODE [CA3568] .1343
FAILURE CODE [CA3571] .1347
FAILURE CODE [CA3572] .1349
FAILURE CODE [CA3574] .1351
FAILURE CODE [CA3575] .1353
FAILURE CODE [CA3577] .1355
FAILURE CODE [CA3578] .1357
FAILURE CODE [CA3582] .1359
FAILURE CODE [CA3583] .1365
FAILURE CODE [CA3596] .1367
FAILURE CODE [CA3649] .1369
FAILURE CODE [CA3681] .1371
FAILURE CODE [CA3682] .1376
FAILURE CODE [CA3713] .1382
FAILURE CODE [CA3717] .1385
FAILURE CODE [CA3718] .1386
FAILURE CODE [CA3725] .1387
FAILURE CODE [CA3741] .1390
FAILURE CODE [CA3748] .1391
FAILURE CODE [CA3751] .1393
FAILURE CODE [CA3755] .1395
FAILURE CODE [CA3866] .1397
FAILURE CODE [CA3867] .1401
FAILURE CODE [CA3868] .1404
FAILURE CODE [CA3899] .1408
FAILURE CODE [CA3911] .1410
FAILURE CODE [CA3912] .1414
FAILURE CODE [CA3932] .1416
FAILURE CODE [CA3933] .1418
FAILURE CODE [CA3934] .1420
FAILURE CODE [CA3935] .1423
FAILURE CODE [CA3936] .1425
FAILURE CODE [CA4151] .1427
FAILURE CODE [CA4152] .1431
FAILURE CODE [CA4155] .1435
FAILURE CODE [CA4156] .1437
FAILURE CODE [CA4157] .1439
FAILURE CODE [CA4158] .1441
FAILURE CODE [CA4159] .1442
FAILURE CODE [CA4161] .1443
FAILURE CODE [CA4162] .1446
FAILURE CODE [CA4163] .1449
FAILURE CODE [CA4164] .1450
FAILURE CODE [CA4165] .1452
FAILURE CODE [CA4166] .1454
FAILURE CODE [CA4168] .1455
FAILURE CODE [CA4169] .1458
FAILURE CODE [CA4171] .1460
FAILURE CODE [CA4249] .1463
FAILURE CODE [CA4251] .1465
FAILURE CODE [CA4259] .1467
FAILURE CODE [CA4261] .1470
FAILURE CODE [CA4277] .1473
FAILURE CODE [CA4281] .1477
FAILURE CODE [CA4459] .1480
FAILURE CODE [CA4461] .1483
FAILURE CODE [CA4658] .1486
FAILURE CODE [CA4731] .1490
FAILURE CODE [CA4732] .1491
FAILURE CODE [CA4739] .1492
FAILURE CODE [CA4768] .1493
FAILURE CODE [CA4769] .1495
FAILURE CODE [CA4842] .1498
FAILURE CODE [CA4952] .1502
FAILURE CODE [CA5115] .1504
FAILURE CODE [CA5179] .1507
FAILURE CODE [CA5181] .1509
FAILURE CODE [CA5383] .1511
FAILURE CODE [D110KB] .1513
FAILURE CODE [D19JKZ] .1515
FAILURE CODE [D811MC] .1518
FAILURE CODE [D862KA] .1519
FAILURE CODE [D8ALKA] .1521
FAILURE CODE [D8ALKB] .1524
FAILURE CODE [D8AQKR] .1526
FAILURE CODE [D8G1KT] .1533
FAILURE CODE [D8G6KT] .1534
FAILURE CODE [DA20MC] .1535
FAILURE CODE [DA22KK] .1536
FAILURE CODE [DA25KP] .1539
FAILURE CODE [DA26KP] .1542
FAILURE CODE [DA29KQ] .1545
FAILURE CODE [DA2LKA] .1547
FAILURE CODE [DA2LKB] .1550
FAILURE CODE [DA2QKR] .1552
FAILURE CODE [DA2RKR] .1561
FAILURE CODE [DAF0KM] .1562
FAILURE CODE [DAF0MB] .1563
FAILURE CODE [DAF0MC] .1564
FAILURE CODE [DAF8KB] .1565
FAILURE CODE [DAF9KQ] .1567
FAILURE CODE [DAFGMC] .1568
FAILURE CODE [DAFLKA] .1569
FAILURE CODE [DAFLKB] .1572
FAILURE CODE [DAFQKR] .1574
FAILURE CODE [DAZ9KQ] .1582
FAILURE CODE [DAZQKR] .1583
FAILURE CODE [DB2QKR] .1590
FAILURE CODE [DB2RKR] .1598
FAILURE CODE [DBP0KM] .1603
FAILURE CODE [DBP0KT] .1604
FAILURE CODE [DBP5KB] .1605
FAILURE CODE [DBP5KY] .1608
FAILURE CODE [DBPQKR] .1611
FAILURE CODE [DDNRKA] .1619
FAILURE CODE [DDNRKY] .1621
FAILURE CODE [DDNS00] .1623
FAILURE CODE [DFB2KZ] .1625
FAILURE CODE [DFB3L8] .1627
FAILURE CODE [DFB4L8] .1629
FAILURE CODE [DFB5KZ] .1631
FAILURE CODE [DFB6KZ] .1633
FAILURE CODE [DGH2KA] .1635
FAILURE CODE [DGH2KB] .1637
FAILURE CODE [DHA4KA] .1639
FAILURE CODE [DHAAMA] .1641
FAILURE CODE [DHACMA] .1643
FAILURE CODE [DHPAMA] .1645
FAILURE CODE [DHPBMA] .1648
FAILURE CODE [DHS3MA] .1651
FAILURE CODE [DHS4MA] .1654
FAILURE CODE [DHS8MA] .1657
FAILURE CODE [DHS9MA] .1660
FAILURE CODE [DHSAMA] .1663
FAILURE CODE [DHSBMA] .1666
FAILURE CODE [DHSCMA] .1669
FAILURE CODE [DHSDMA] .1672
FAILURE CODE [DHSFMA] .1675
FAILURE CODE [DHSGMA] .1678
FAILURE CODE [DHSHMA] .1681
FAILURE CODE [DHSJMA] .1684
FAILURE CODE [DHX1MA] .1687
FAILURE CODE [DHZAMA] .1690
FAILURE CODE [DHZCL8] .1694
FAILURE CODE [DKR0MA] .1695
FAILURE CODE [DKR1MA] .1698
FAILURE CODE [DKULKA] .1701
FAILURE CODE [DKULKB] .1703
FAILURE CODE [DKULKY] .1705
FAILURE CODE [DR10KA] .1707
FAILURE CODE [DR12KA] .1710
FAILURE CODE [DR20KA] .1712
FAILURE CODE [DR21KX] .1714
FAILURE CODE [DR30KA] .1716
FAILURE CODE [DR31KX] .1718
FAILURE CODE [DR40KA] .1720
FAILURE CODE [DUMBKA] .1722
FAILURE CODE [DUMBKB] .1725
FAILURE CODE [DV00KA] .1727
FAILURE CODE [DV00KB] .1728
FAILURE CODE [DV20KB] .1729
FAILURE CODE [DW43KA] .1731
FAILURE CODE [DW43KB] .1733
FAILURE CODE [DW43KY] .1735
FAILURE CODE [DW45KA] .1737
FAILURE CODE [DW45KB] .1740
FAILURE CODE [DW45KY] .1743
FAILURE CODE [DW4CKY] .1745
FAILURE CODE [DW91KA] .1747
FAILURE CODE [DW91KB] .1749
FAILURE CODE [DW91KY] .1751
FAILURE CODE [DWA2KA] .1753
FAILURE CODE [DWA2KB] .1755
FAILURE CODE [DWA2KY] .1757
FAILURE CODE [DWK0KA] .1759
FAILURE CODE [DWK0KB] .1761
FAILURE CODE [DWK0KY] .1763
FAILURE CODE [DWK2KA] .1765
FAILURE CODE [DWK2KB] .1767
FAILURE CODE [DWK2KY] .1769
FAILURE CODE [DWK8KA] .1771
FAILURE CODE [DWK8KB] .1773
FAILURE CODE [DWK8KY] .1775
FAILURE CODE [DWPUKA] .1777
FAILURE CODE [DWPUKB] .1779
FAILURE CODE [DWPUKY] .1781
FAILURE CODE [DXA8KA] .1783
FAILURE CODE [DXA8KB] .1785
FAILURE CODE [DXA9KA] .1787
FAILURE CODE [DXA9KB] .1789
FAILURE CODE [DXE0KA] .1791
FAILURE CODE [DXE0KB] .1792
FAILURE CODE [DXE4KA] .1794
FAILURE CODE [DXE4KB] .1796
FAILURE CODE [DXE4KY] .1798
FAILURE CODE [DXE5KA] .1800
FAILURE CODE [DXE5KB] .1802
FAILURE CODE [DXE6KA] .1804
FAILURE CODE [DXE6KB] .1806
FAILURE CODE [DXE7KA] .1808
FAILURE CODE [DXE7KB] .1810
FAILURE CODE [DXE7KY] .1812
FAILURE CODE [DXE8KA] .1814
FAILURE CODE [DXE8KB] .1816
FAILURE CODE [DXE8KY] .1818
FAILURE CODE [DXE9KA] .1820
FAILURE CODE [DXE9KB] .1822
FAILURE CODE [DXE9KY] .1824
FAILURE CODE [DXEAKA] .1826
FAILURE CODE [DXEAKB] .1828
FAILURE CODE [DXEAKY] .1830
FAILURE CODE [DXEKKA] .1832
FAILURE CODE [DXEKKB] .1834
FAILURE CODE [DXEKKY] .1836
FAILURE CODE [DXELKA] .1838
FAILURE CODE [DXELKB] .1840
FAILURE CODE [DXELKY] .1842
FAILURE CODE [DY20KA] .1844
FAILURE CODE [DY20MA] .1846
FAILURE CODE [DY2CKB] .1848
FAILURE CODE [DY2DKB] .1851
FAILURE CODE [DY2EKB] .1853
FAILURE CODE [F311KA] .1855
FAILURE CODE [F311KB] .1857
FAILURE CODE [F312KA] .1859
FAILURE CODE [F312KB] .1861
FAILURE CODE [F313KA] .1863
FAILURE CODE [F313KB] .1865
FAILURE CODE [F314KA] .1868
FAILURE CODE [F314KB] .1870
FAILURE CODE [F315KB] .1872
FAILURE CODE [F315KY] .1874
FAILURE CODE [F316KB] .1876
FAILURE CODE [F316KY] .1878
FAILURE CODE [F318KB] .1880
FAILURE CODE [F318KY] .1883
FAILURE CODE [F31AKB] .1885
FAILURE CODE [F31AKY] .1887
FAILURE CODE [F31BKB] .1889
FAILURE CODE [F31BKY] .1891
FAILURE CODE [F31CKB] .1893
FAILURE CODE [F31CKY] .1895
FAILURE CODE [F31DKB] .1897
FAILURE CODE [F31DKY] .1899
FAILURE CODE [F31EKB] .1901
FAILURE CODE [F31EKY] .1903
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1905
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1905
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1911
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1914
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1916
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1918
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1921
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1922
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1923
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1924
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1925
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1926
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1927
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1928
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1929
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1930
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1931
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1932
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1934
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1935
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1936
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1937
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1939
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1940
E-24 FUNCTION SWITCH DOES NOT OPERATE .1941
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1942
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1943
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1944
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1945
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1946
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1947
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1948
E-32 ALARM BUZZER CANNOT BE CANCELED 1950
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1951
E-34 SERVICE MODE CANNOT BE SELECTED 1952
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1953
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1956
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1958
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1961
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1963
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1966
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1967
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1969
E-43 HORN DOES NOT SOUND 1970
E-44 HORN DOES NOT STOP SOUNDING 1973
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1975
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1976
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1978
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1979
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1980
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1981
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1982
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1983
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1984
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1985
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1986
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1987
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1989
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1990
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1991
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1991
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1992
FAILURE MODE AND CAUSE TABLE 1994
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2003
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .2004
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2007
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .2008
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2009
H-6 SPEED OR POWER OF BOOM IS LOW .2011
H-7 ARM SPEED OR POWER IS LOW .2015
H-8 BUCKET SPEED OR POWER IS LOW 2020
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2023
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .2024
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2026
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2028
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2029
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2030
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2031
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2032
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2033
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2034
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2035
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2036
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .2037
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2039
H-23 TRAVEL SPEED IS LOW 2042
H-24 ONE OF TRACKS DOES NOT RUN .2044
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2045
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2046
H-27 SWINGS ONLY IN ONE DIRECTION .2047
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2048
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2049
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2050
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2051
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2052
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2053
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2054
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2055
TROUBLESHOOTING OF ENGINE (S-MODE) 2056
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2056
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2057
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2058
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2059
S-4 ENGINE STARTABILITY IS POOR .2061
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2063
S-6 ENGINE STOPS DURING OPERATION .2065
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2067
S-8 ENGINE LACKS POWER 2068
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2070
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2072
S-11 OIL BECOMES CONTAMINATED QUICKLY .2073
S-12 FUEL CONSUMPTION IS EXCESSIVE 2074
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2075
S-14 OIL PRESSURE DROPS .2076
S-15 FUEL MIXES INTO ENGINE OIL .2078
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2079
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2080
S-18 UNUSUAL NOISE IS HEARD .2081
S-19 VIBRATION IS EXCESSIVE .2082
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2083
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2084
S-22 ACTIVE REGENERATION TAKES TIME .2086
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2087
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2088
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2090
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2091
50 DISASSEMBLY AND ASSEMBLY .2093
CONTENTS 2094
ABBREVIATION LIST .2099
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2105
HOW TO READ THIS MANUAL .2105
COATING MATERIALS LIST 2107
SPECIAL TOOLS LIST 2112
SKETCHES OF SPECIAL TOOLS .2124
ENGINE AND COOLING SYSTEM .2130
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2130
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2130
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2133
REMOVE AND INSTALL INJECTOR ASSEMBLY 2137
METHOD FOR REMOVING INJECTOR ASSEMBLY .2137
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2142
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2150
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2151
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2160
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2176
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2176
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2177
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2180
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2180
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2183
REMOVE AND INSTALL STARTER ASSEMBLY .2188
METHOD FOR REMOVING STARTER ASSEMBLY 2188
METHOD FOR INSTALLING STARTER ASSEMBLY 2190
REMOVE AND INSTALL ALTERNATOR BELT 2192
METHOD FOR REMOVING ALTERNATOR BELT .2192
METHOD FOR INSTALLING ALTERNATOR BELT .2194
REMOVE AND INSTALL RADIATOR ASSEMBLY 2196
METHOD FOR REMOVING RADIATOR ASSEMBLY .2196
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2198
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2200
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2200
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2203
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2206
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2206
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2207
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2209
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2210
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2218
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2229
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2229
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2232
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2236
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2236
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2237
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2240
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2240
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2241
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2242
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2242
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2244
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2250
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2250
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2254
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2260
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2260
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2265
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2271
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2271
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2276
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2282
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2282
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2282
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2289
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2289
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2289
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2290
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2290
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2292
REMOVE AND INSTALL KDPF ASSEMBLY 2295
METHOD FOR REMOVING KDPF ASSEMBLY .2295
METHOD FOR INSTALLING KDPF ASSEMBLY .2297
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2299
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2300
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2303
REMOVE AND INSTALL SCR ASSEMBLY .2308
METHOD FOR REMOVING SCR ASSEMBLY 2308
METHOD FOR INSTALLING SCR ASSEMBLY 2310
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2312
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2312
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2318
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2324
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2324
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2331
REMOVE AND INSTALL KCCV ASSEMBLY 2339
METHOD FOR REMOVING KCCV ASSEMBLY .2339
METHOD FOR INSTALLING KCCV ASSEMBLY .2341
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2346
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2346
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2351
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2356
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2356
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2358
REMOVE AND INSTALL AdBlue/DEF PUMP 2360
METHOD FOR REMOVING AdBlue/DEF PUMP .2360
METHOD FOR INSTALLING AdBlue/DEF PUMP .2362
REMOVE AND INSTALL AdBlue/DEF HOSE 2365
METHOD FOR REMOVING AdBlue/DEF HOSE .2365
METHOD FOR INSTALLING AdBlue/DEF HOSE .2373
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2379
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2379
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2380
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2382
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2382
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2384
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2387
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2387
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2388
POWER TRAIN .2389
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2389
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2389
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2390
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2391
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2391
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2395
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2404
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2404
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2406
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2410
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2410
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2414
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2421
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2421
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2421
UNDERCARRIAGE AND FRAME .2423
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2423
METHOD FOR SEPARATING TRACK ASSEMBLY 2423
METHOD FOR INSTALLING TRACK ASSEMBLY 2425
REMOVE AND INSTALL SPROCKET .2428
METHOD FOR REMOVING SPROCKET 2428
METHOD FOR INSTALLING SPROCKET 2428
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2430
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2430
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2431
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2432
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2432
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2433
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2437
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2438
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2439
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2440
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2441
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2442
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2444
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2444
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2445
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2448
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2448
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2450
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2452
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2452
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2455
HYDRAULIC SYSTEM 2459
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2459
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2459
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2461
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2464
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2465
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2466
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2467
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2467
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2470
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2474
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2474
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2477
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2481
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2481
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2488
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2496
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2496
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2498
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2502
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2502
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2502
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2504
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2504
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2505
WORK EQUIPMENT 2507
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2507
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2507
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2509
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM .2510
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2510
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2512
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .2513
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY .2513
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2513
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2514
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2514
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2518
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2524
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2524
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2527
CAB AND ITS ATTACHMENTS .2533
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2533
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2533
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2539
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2546
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2548
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2548
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2558
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2558
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2561
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2567
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2567
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2573
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2581
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2581
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2587
REMOVE AND INSTALL OPERATOR’S SEAT 2594
METHOD FOR REMOVING OPERATOR’S SEAT .2594
METHOD FOR INSTALLING OPERATOR’S SEAT .2596
REMOVE AND INSTALL SEAT BELT 2599
METHOD FOR REMOVING SEAT BELT .2599
METHOD FOR INSTALLING SEAT BELT .2600
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2601
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2601
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2606
ELECTRICAL SYSTEM .2615
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2615
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2615
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2616
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2618
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2618
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2622
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2627
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2627
METHOD FOR INSTALLING KomVision CONTROLLER 2628
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2630
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2630
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2633
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2637
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2637
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2638
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2639
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2639
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2639
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2641
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2641
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2642
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2644
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2644
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2646
REMOVE AND INSTALL KomVision CAMERA .2649
METHOD FOR REMOVING KomVision CAMERA 2649
METHOD FOR INSTALLING KomVision CAMERA 2652
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2655
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2655
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2660
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2665
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS .2665
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS .2673
REMOVE AND INSTALL COMMUNICATION TERMINAL .2682
METHOD FOR REMOVING COMMUNICATION TERMINAL 2682
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2684
60 MAINTENANCE STANDARD .2687
CONTENTS 2688
ABBREVIATION LIST .2689
ENGINE AND COOLING SYSTEM .2695
MAINTENANCE STANDARD OF ENGINE MOUNT 2695
MAINTENANCE STANDARD OF COOLING SYSTEM 2696
POWER TRAIN .2697
MAINTENANCE STANDARD OF SWING CIRCLE 2697
MAINTENANCE STANDARD OF SWING MACHINERY .2698
MAINTENANCE STANDARD OF FINAL DRIVE .2700
MAINTENANCE STANDARD OF SPROCKET 2702
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2703
UNDERCARRIAGE AND FRAME .2705
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2705
MAINTENANCE STANDARD OF IDLER .2707
MAINTENANCE STANDARD OF TRACK ROLLER 2709
MAINTENANCE STANDARD OF CARRIER ROLLER 2711
MAINTENANCE STANDARD OF TRACK SHOE 2712
MAINTENANCE STANDARD OF TRIPLE SHOE .2715
HYDRAULIC SYSTEM 2716
MAINTENANCE STANDARD OF HYDRAULIC TANK 2716
MAINTENANCE STANDARD OF MAIN PUMP .2717
MAINTENANCE STANDARD OF LS-EPC VALVE 2718
MAINTENANCE STANDARD OF PC-EPC VALVE 2719
MAINTENANCE STANDARD OF SWING MOTOR .2720
MAINTENANCE STANDARD OF TRAVEL MOTOR 2723
MAINTENANCE STANDARD OF CONTROL VALVE .2726
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2735
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2737
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2739
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2742
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2745
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2747
MAINTENANCE STANDARD OF SOLENOID VALVE 2748
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2749
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2750
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2751
WORK EQUIPMENT 2752
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2752
DIMENSION OF ARM 2757
DIMENSIONS OF BUCKET 2759
MAINTENANCE STANDARD OF BOOM CYLINDER .2761
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2762
MAINTENANCE STANDARD OF ARM CYLINDER 2763
MAINTENANCE STANDARD OF BUCKET CYLINDER .2764
80 APPENDIX .2765
CONTENTS 2766
ABBREVIATION LIST .2768
AIR CONDITIONER SYSTEM 2774
PRECAUTIONS FOR REFRIGERANT .2774
AIR CONDITIONER COMPONENT .2775
SPECIFICATIONS OF AIR CONDITIONER .2777
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2778
OUTLINE OF REFRIGERATION CYCLE 2779
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2781
AIR CONDITIONER UNIT 2781
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2781
FUNCTION OF AIR CONDITIONER UNIT 2783
COMPONENT PARTS OF AIR CONDITIONER UNIT .2785
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2786
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2786
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2786
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2786
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2787
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2787
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2787
FUNCTION OF DUAL PRESSURE SWITCH 2788
AIR CONDITIONER CONTROLLER 2789
STRUCTURE OF AIR CONDITIONER CONTROLLER .2789
COMPRESSOR 2790
STRUCTURE OF COMPRESSOR .2790
SPECIFICATIONS OF COMPRESSOR 2790
FUNCTION OF COMPRESSOR 2790
CONDENSER .2791
STRUCTURE OF CONDENSER 2791
SPECIFICATIONS OF CONDENSER .2791
FUNCTION OF CONDENSER .2791
SENSORS FOR AIR CONDITIONER SYSTEM 2793
STRUCTURE OF SUNLIGHT SENSOR 2793
FUNCTION OF SUNLIGHT SENSOR .2793
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2793
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2793
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2795
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2797
AIR CONDITIONER SYSTEM DIAGRAM 2799
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2800
FUNCTION OF AIR CONDITIONER CONTROLLER 2801
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2802
TESTING AIR LEAKAGE (DUCT) 2806
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2806
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2808
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2809
TEST VENT (MODE) CHANGEOVER .2810
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2810
TESTING FRESH/RECIRC AIR CHANGEOVER .2812
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2812
TEST SUNLIGHT SENSOR 2813
METHOD FOR TESTING SUNLIGHT SENSOR 2813
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2814
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2814
TEST RELAYS .2815
METHOD FOR TESTING RELAYS .2815
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2816
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2817
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2820
FAILURE CODE [879AKA] .2822
FAILURE CODE [879AKB] .2823
FAILURE CODE [879BKA] .2824
FAILURE CODE [879BKB] .2826
FAILURE CODE [879CKA] .2828
FAILURE CODE [879CKB] .2829
FAILURE CODE [879DKZ] .2830
FAILURE CODE [879EMC] .2832
FAILURE CODE [879FMC] .2833
FAILURE CODE [879GKX] .2834
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2836
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2838
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2841
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2843
TROUBLESHOOTING USING GAUGE PRESSURE 2845
CONNECTION OF SERVICE TOOL 2848
METHOD FOR CONNECTING SERVICE TOOL 2848
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2850
HANDLE COMPRESSOR OIL .2852
METHOD FOR REPLACING DESICCANT 2854
90 CIRCUIT DIAGRAMS .2857
CONTENTS 2858
ABBREVIATION LIST .2859
HYDRAULIC CIRCUIT DIAGRAM .2865
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2865
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2869
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2871
ELECTRICAL CIRCUIT DIAGRAM 2873
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2873
ELECTRICAL CIRCUIT DIAGRAM (1/10) .2877
ELECTRICAL CIRCUIT DIAGRAM (2/10) .2879
ELECTRICAL CIRCUIT DIAGRAM (3/10) .2881
ELECTRICAL CIRCUIT DIAGRAM (4/10) .2883
ELECTRICAL CIRCUIT DIAGRAM (5/10) .2885
ELECTRICAL CIRCUIT DIAGRAM (6/10) .2887
ELECTRICAL CIRCUIT DIAGRAM (7/10) .2889
ELECTRICAL CIRCUIT DIAGRAM (8/10) .2891
ELECTRICAL CIRCUIT DIAGRAM (9/10) .2893
ELECTRICAL CIRCUIT DIAGRAM (10/10) 2895
INDEX 2897

DESCRIPTION:

Komatsu PC290LC-11E0 Hydraulic Excavator Shop Manual SEN06950-00 –  PDF DOWNLOAD

• SERIAL NUMBERS 35268 and up

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

G.B 28/12/24