Day: June 9, 2025

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC290LC-6K, PC290NLC-6K, PC290LC-7, PC290LC-8, PC290LC-10, PC290LC-11, PC290NLC-7, PC290NLC-8, PC290LL-11, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC290LC-6K, PC290NLC-6K, PC290LC-7, PC290LC-8, PC290LC-10, PC290LC-11, PC290NLC-7, PC290NLC-8, PC290LL-11 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 15,156 pages
File Format: PDF
Language: English

EEBM001902 – Hydraulic Excavator PC290LC-6K, PC290NLC-6K Shop Manual.pdf
SEN05644-02 – Hydraulic Excavator PC290LC-10 Shop Manual.pdf
SEN06507-01 – Hydraulic Excavator PC290LC-11 Shop Manual.pdf
CEBM025103 – Hydraulic Excavator PC290LC-10 Shop Manual.pdf
CEBM028803 – HYDRAULIC EXCAVATOR PC290LC-11 Shop Manual.pdf
UEBM001600 – Hydraulic Excavator PC290LC-7, PC290NLC-7 Shop Manual.pdf
UEN00001-01 – Hydraulic Excavator PC290LC-8, PC290NLC-8 Shop Manual.pdf
CEBM031404 – Hydraulic LOG LOADER_ROAD BUILDER PC290LL-11 Shop Manual.pdf
EEAM010300 – Hydraulic Excavator PC290LC-6K, PC290NLC-6K Operation & Maintenance Manual.pdf
TEN00523-02 – Hydraulic Excavator PC290LC-10 Operation & Maintenance Manual.pdf
UEAM001603 – Hydraulic Excavator PC290LC-7K, PC290NLC-7K Operation & Maintenance Manual.pdf
UEAM004000 – Hydraulic Excavator PC290LC-6K, PC290NLC-6K Operation & Maintenance Manual.pdf
CEAM025303 – Hydraulic Excavator PC290LC-10 Operation & Maintenance Manual.pdf

CEAM025303 – Hydraulic Excavator PC290LC-10 Operation & Maintenance Manual…2
CEAM025303.pdf…0
CEAM025303_PC290LC-10 S/N A25001 and UP…2
INTRODUCTION…4
FORWARD…5
SAFETY INFORMATION…6
Safety labels…7
INTRODUCTION…8
Directions of Machine…8
Visibilty from Operator’s Seat…8
Structure to Protect the Operator…8
Breaking-in The New Machine…9
Product Information…10
Product Identification Number (Pin)/Machine Serial No. Plate…10
EPA* Regulations, Engine Number Plate…10
Service Meter Location…11
Your Machine Serial Numbers And Distributor…11
Engine Acronyms…11
TABLE OF CONTENTS…12
SAFETY…22
SAFETY LABELS…23
Location Of Safety Labels…23
Safety Labels…24
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…33
Precautions Before Starting Operation…33
Ensuring Safe Operation…33
Understanding The Machine…33
Preparations For Safe Operation…33
Precautions Regarding Safety-related Equipment…33
Inspecting Machine…33
Clothing And Personal Protective Items…33
Keep Machine Clean…34
Keep Operator's Compartment Clean…34
Fire Extinguisher And First Aid Kit…34
Safety Equipment…34
If Problems Are Found…34
Fire Prevention And Explosion Prevention…35
Action If Fire Occurs…36
Handrails and Steps…37
Mounting And Dismounting…37
No Persons On Attachments…37
Leaving Operator's Seat With Lock…38
Emergency Exit From Operator's Cab…38
Do Not Get Caught In Work Equipment…39
Precautions Related To Protective Structures…39
Falling Objects, Flying Objects And Intruding Objects Prevention…39
Unauthorized Modification…40
Precautions Related To Attachments And Options…40
Precautions Related To Cab Glass…40
Precautions When Running Engine Inside Building…40
Safety At Jobsite…41
Working On Loose Ground…41
Distance To High Voltage Cables…41
Ensure Good Visibility…42
Signalman's Signal And Signs…42
Asbestos Dust Hazard Prevention…43
SAFETY MACHINE OPERATION…44
Starting Engine…44
Checks Before Starting Engine…44
Safety Rules For Starting Engine…45
Starting Engine In Cold Weather…45
Starting Engine With Booster Cables…45
Operation…46
Checks Before Operation…46
Safety Rules For Changing Machine Directions…46
Safety Rules For Traveling…47
Traveling On Slopes…48
Operations On Slopes…49
Prohibited Operations…50
Operations On Snow Or Frozen Surfaces…52
Parking Machine…52
TRANSPORTATION…53
Loading and Unloading…53
Shipping the Machine…53
TOWING…54
Safety Rules For Towing…54
LIFTING OBJECTS WITH BUCKET…55
Safety Rules For Lifting Objects…55
SAFETY MAINTENANCE INFORMATION…56
Warning Tag…56
Keep Work Place Clean And Tidy…56
Select Suitable Place For Inspection And Maintenance…56
Only Authorized Personnel…56
Appoint Leader When Working With Others…56
Stop Engine Before Carrying Out Maintenance…57
Precautions When Working At High Places…57
Two Workers For Maintenance When Engine Is Running…58
Attachments…58
Work On Machine…59
Work Under The Machine…59
Proper Tools…59
Battery Disconnect Switch…60
Removing Battery Terminals…60
Welding…60
Battery…60
Battery Hazard Prevention…60
When Using Hammer…61
Precautions With High-temperature Coolant…61
Precautions With High-temperature Oil…62
Safety Rules For High-pressure Oil…62
Precaution For High Fuel Pressure…62
Safety Handling High-pressure Hoses or Piping…62
Precaution For High Voltage…63
Noise…63
Safety First When Using High-pressure Grease To Adjust Track Tension…63
Do Not Disassemble Recoil Springs…64
Accumulator…64
Handling Gas Spring…64
Precautions when using…64
Precautions when discarding…65
Compressed Air…65
Air Conditioner Maintenance…65
Waste Materials…65
Select Window Washer Fluid…65
Personnel…65
Periodic Replacement Of Safety Critical Parts…66
OPERATION…68
MACHINE VIEW ILLUSTRATIONS…69
Overall Machine View…69
General View of Cab…71
CONTROLS AND GAUGES…72
Machine Monitor…73
EXPLANATION OF COMPONENTS…74
Machine Monitor…74
Basic Operation of Machine Monitor…75
Warning Display…80
Meter Display…90
Gauges and Meter…97
Monitor Switches Portion…100
Handling Function Switches…110
User Menu Selector Switch…114
User Menu…115
Machine Settings…126
Maintenance Screen Setting…131
Monitor Setting…133
Screen Adjustment…133
Screen Adjustment (Camera)…134
Clock Adjustment…134
Time…136
SWITCHES…141
Starting Switch…141
Fuel Control Dial…142
Cigarette Lighter…142
Swing Lock Switch…142
Lamp Switch…143
Horn Switch…143
One Touch Power Max. Switch…143
Room Lamp Switch…143
Emergency Pump Drive Switch…144
Swing Brake Cancel Switch…144
Ceiling Window Wiper Switch…145
Seat Heater Switch…145
Engine Shutdown Secondary Switch…146
CONTROL LEVERS AND PEDALS…147
Lock Lever…147
Travel Levers…148
Work Equipment Control Lever…149
SUN ROOF…151
WINDSHIELD…151
EMERGENCY ESCAPE HAMMER…157
DOOR LOCK…158
CAB DOOR HINGE…158
ENGINE HOOD…159
When Opening (Normal Case: Intermediate Lock Position)…159
When Closing (Normal Case: Intermediate Lock Position)…161
CAPS AND COVERS WITH LOCK…163
Open and Close Caps with Lock…163
Opening the Cap…163
Locking the Cap…163
Open and Close Covers with Lock…164
Opening the Cover (Locked Cover)…164
Locking the Cover…164
Lock and Unlock Engine Hood…164
Opening the Hood (Locked Hood)…164
Locking the Hood…164
Lock and Unlock Cab Door…165
Opening the Door (Locked Door)…165
Locking the Door…165
DRINK BOX…166
MAGAZINE BOX…166
CUP HOLDER…166
ASHTRAY…167
AIR CONDITIONER CONTROLS…168
Air Conditioner Control Panel…168
Method of Operation…173
Automatic Operation…173
Stopping Automatic Operation…174
Manual Operation…174
Stop Manual Operation…176
Operation with Cold Air to Face and Warm Air to Feet…176
Defroster Operation…178
Rules for Using Air Conditioner…180
Air Conditioner Maintenance…180
RADIO…181
Control Panel…181
Operation Method…183
Frequency Adjustment…183
Frequency Adjustment (Auto Presetting)…183
Preset Call…183
Preset Memory…183
Sound Adjustment (Balance)…183
Sound Adjustment (Treble)…184
Sound Adjustment (Bass)…184
Time Adjustment…184
AUXILIARY ELECTRIC POWER…185
24 V Power Source…185
12 V Power Source…185
FUSE…186
FUSIBLE LINK…187
TOOL BOX…187
GREASE GUN HOLDER…187
FIRE EXTINGUISHER…187
BATTERY DISCONNECT SWITCH…188
SYSTEM OPERATING LAMP…189
HANDLING KOMATSU DIESEL PARTICULATE FILTER (KDPF)…190
Operation Procedure of Manual Stationary Regeneration…193
Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Procedure…195
While Regeneration is not being Performed: Setting for Regeneration Disable…196
While Regeneration is being Performed: Stopping Regeneration…198
Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Cancel Procedure…199
Handling Komatsu Closed Crankcase Ventilation (KCCV)…199
HANDLING MACHINES EQUIPPED WITH KOMTRAX…200
Basic Precautions…201
MACHINE OPERATIONS AND CONTROLS…202
Before Starting Engine…202
Walk-around Checks…202
Checks Before Starting…204
Adjustment…213
Seat Belt Inspection…222
Seat Belt…223
Operations Before Starting Engine…224
STARTING ENGINE…226
Turbo Protect Function…229
AFTER STARTING ENGINE…230
Engine Warm Up…232
Hydraulic System Warm-Up…234
Operation After Completion Of Warming-Up Operation…241
STOPPING THE ENGINE…243
MACHINE OPERATION…244
Preparations for Moving the Machine…244
Moving Machine Forward…245
Moving Machine Backward…246
Stopping Machine…247
STEERING THE MACHINE…248
Steering…248
Steering the Machine when Stopped…248
Changing Direction of the Machine…249
Counter-rotation Turn (Spin Turn)…249
SWINGING…250
WORK EQUIPMENT CONTROLS AND OPERATIONS…251
WORKING MODE…253
Working Mode Switch…253
One-Touch Power Max. Switch…255
PROHIBITED OPERATIONS…256
GENERAL OPERATION INFORMATION…259
Traveling…259
High Speed Travel…259
Permissible Water Depth…260
TRAVELING ON SLOPES…261
ESCAPE FROM MUD…263
Track on One Side Stuck…263
Tracks on Both Sides Stuck…263
RECOMMENDED APPLICATIONS…264
Backhoe Work…264
Shovel Work…264
Ditching Work…264
Loading Work…265
BUCKET REPLACEMENT AND INVERSION…266
Replacement…266
Inversion…268
PARKING MACHINE…270
MACHINE INSPECTION AFTER DAILY WORK…272
LOCKING…272
TRANSPORTATION…272
Transportation Procedure…272
Loading And Unloading With Trailer…273
Loading…274
Securing Machine…277
Stowing Radio Antenna…279
Rearview Mirrors…279
Remove and Install Handrail…281
Unloading…282
LIFTING MACHINE…284
Standard Specification Machines…284
Machines with Lifting Hook…286
COLD WEATHER OPERATION…287
Cold Weather Operation Information…287
Fuel and Lubricants…287
Coolant…287
Battery…288
AFTER DAILY WORK COMPLETION…289
AFTER COLD WEATHER SEASON…289
LONG TERM STORAGE…290
Before Storage…290
During Storage…290
After Storage…291
Starting Machine After Long-term Storage…291
TROUBLES AND ACTIONS…292
Running Out Of Fuel…292
Phenomena That Are Not Failures…292
Towing The Machine…293
Lightweight Towing Hole…294
Severe Job Condition…294
Discharged Battery…295
Battery Removal and Installation…295
Battery Charges…296
Starting Engine with Booster Cables…297
OTHER TROUBLE…299
Electrical System…299
Chassis…300
Engine…301
Electronic Control System…303
Point of Contact to Telephone when Error Occurs…303
MAINTENANCE…304
MAINTENANCE INFORMATION…305
OUTLINE OF SERVICE…307
Handling Oil, Fuel, Coolant, And Performing Oil Clinic…307
Oil…307
Fuel…308
Coolant And Water For Dilution…308
Grease…309
Carrying Out KOWA (Komatsu Oil Wear Analysis)…309
Storing Oil And Fuel…310
Filters…310
Electric System Maintenance…310
WEAR PARTS…311
Wear Parts List…311
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…312
Lubrication Chart…312
Fuel, Coolant, and Lubricants to Match the Ambient Temperature…314
KDPF (Komatsu Diesel Particulate Filter)…314
Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil…315
TORQUE SPECIFICATIONS…316
Torque List…316
Torque Of Bolts…316
Torque Of Hose Nuts…317
Torque Of Split Flange Bolts…317
Torque For Flared Nuts…318
Torque For O-ring Boss Piping Joints…318
Torque For O-ring Boss Plugs…319
Torque For Hoses (Taper Seal Type And Face Seal Type)…319
SAFETY CRITICAL PARTS…321
Safety Critical Parts List…322
MAINTENANCE SCHEDULE…323
Maintenance Schedule Table…323
Maintenance Interval For Hydraulic Breaker…325
MAINTENANCE PROCEDURE…326
Initial 10 Hours Maintenance…326
Initial 250 Hours Maintenance (Only After The First 250 Hours)…326
Initial 500 Hours Maintenance (Only After The First 500 Hours)…326
When Required…327
Check, Clean And Replace Air Cleaner Element…327
Clean Inside Of Cooling System…334
Check And Tighten Track Shoe Bolts…339
Check And Adjust Track Tension…340
Replace Bucket Teeth (Vertical Pin Type)…342
Replace Bucket Teeth (Horizontal Pin Type)…345
Replace Bucket Side Cutter, Shroud…347
Adjust Bucket Clearance…348
Check Window Washer Fluid Level, Add Fluid…349
Check And Maintenance Air Conditioner…350
Wash Washable Floor…351
Method of Setting Machine at Angle…353
Check Gas Spring…354
Bleeding Air From Hydraulic System…355
Check Before Starting…357
Every 100 Hours Maintenance…358
Lubricating…358
Every 250 Hours Maintenance…359
Check Level Of Battery Electrolyte…359
Check Air Conditioner Compressor Belt Tension, Adjust…361
Every 500 Hours Maintenance…363
Lubricating…363
Change Oil In Engine Oil Pan…365
Replace Engine Oil Filter Cartridge…365
Replace Fuel Pre-filter Cartridge…367
Check Swing Pinion Grease Level, Add Grease…369
Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, And Condenser Fins…370
Clean Air Conditioner Fresh/Recirc Filters…372
Replace Breather Element In Hydraulic Tank…374
Check Oil Level In Swing Machinery Case, Add Oil…375
Check Oil Level In Final Drive Case, Add Oil…376
Every 1000 Hours Maintenance…377
Replace Hydraulic Oil Filter Element…377
Change Oil In Swing Machinery Case…378
Check Oil Level In Damper Case, Add Oil…379
Replace Fuel Main Filter Cartridge…380
Check All Tightening Points Of Engine Exhaust Pipe Clamps…383
Check Fan Belt Tension And Replace Fan Belt…383
Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)…383
Every 2000 Hours Maintenance…384
Change Oil In Final Drive Case…384
Clean Hydraulic Tank Strainer…385
Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)…386
Check Alternator…389
Check Engine Valve Clearance, Adjust…389
Replace Komatsu Closed Crankcase Ventilation (KCCV) Filter Element…390
Every 4000 Hours Maintenance…393
Check Water Pump…393
Check Vibration Damper…393
Check Starting Motor…393
Replace Accumulator (For Control Circuit)…394
Check For Looseness Of High-pressure Piping Clamp, Hardening Of Rubber…395
Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber…395
Check Operating Condition Of Compressor…396
Every 4500 Hours Maintenance…397
Clean Komatsu Diesel Particulate Filter (KDPF)…397
Replace Komatsu Closed Crankcase Ventilation (KCCV) Hose…397
Every 5000 Hours Maintenance…398
Change Oil In Hydraulic Tank…398
Every 8000 Hours Maintenance…399
Replace Fuel Spray Prevention Cap…399
Replace High-pressure Piping Clamp…399
SPECIFICATIONS…400
SPECIFICATIONS…401
OPTIONS, ATTACHMENTS…404
GENERAL PRECAUTIONS FOR SAFETY…405
Precautions When Selecting…405
Read The Operation and Maintenance Manual Thoroughly…405
Precautions When Removing Or Installing…405
Precautions When Using…405
BUCKET WITH HOOK…407
Hook Condition…407
Prohibited Operations…407
CHANGING DIRECTION OF THE MACHINE…408
Straight Travel (Option)…409
CHANGING MACHINE CONTROL PATTERN…410
Control Pattern Change Procedure…410
MACHINE READY FOR ATTACHMENT…412
Locations…412
Stop Valve…412
Selector Valve…413
Attachment Control Pedal…413
Lock Pin…413
Breaker Circuit Additional Oil Filter…414
Accumulator…415
HYDRAULIC CIRCUIT…416
Switching Hydraulic Circuit…416
Switching Between Breaker and General Attachment…416
Hydraulic Circuit Connection…417
Oil Flow Path…418
Replace Additional Breaker Filter Element…419
Replace Additional Breaker Pilot Filter Element…422
ATTACHMENT REMOVAL AND INSTALLATION…425
Attachment Removal…425
Attachment Installation…427
ATTACHMENT OPERATIONS…429
When Using Breaker…429
When Using General Attachment Such as Crusher…432
LONG TERM STORAGE…433
Specifications…433
Attachment Guide…434
Attachment Combinations…434
TRACK SHOES SELECTION…435
BUCKET TEETH SELECTION…436
Selection Guide for Horizontal or Vertical Pin Type Tooth…436
RECOMMENDED ATTACHMENT OPERATIONS…437
Hydraulic Breaker…437
Prohibited Works…439
CEBM025103 – Hydraulic Excavator PC290LC-10 Shop Manual…442
CEBM025103 – PC290LC-10…442
CONTENTS…443
SAFETY…460
Safety Notice…460
Important Safety Notice…460
General Precautions…460
Preparations For Work…461
Precautions During Work…461
GENERAL…464
HOW TO READ THE SHOP MANUAL…465
Volumes…465
Distribution And Updating…465
Filing Method…465
Revised Edition Mark…465
Revisions…465
Symbols…465
HOISTING INSTRUCTIONS…466
Hoisting…466
Making Signs…466
Precautions…466
Precautions for Sling Work…466
Precautions for Using Mobile Crane…467
Precautions for Using Overhead Hoist Crane…467
Selecting Wire Ropes…468
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS…469
Points to Remember When Handling Electric Equipment…469
Points to Remember When Handling Hydraulic Equipment…480
PUSH PULL COUPLER…482
Type 1…482
Disconnection…482
Connection…482
Type 2…483
Disconnection…483
Connection…483
Type 3…484
Disconnection…484
Connection…484
EXPLANATION OF MAINTENANCE STANDARD TERMS…485
HANDLING OF FUEL SYSTEM DEVICES…486
HANDLING OF INTAKE SYSTEM PARTS…487
STANDARD TIGHTENING TORQUE…488
Bolts And Nuts…488
Tightening Torque Of Hose Nuts…489
Tightening Torque Of Split Flange Bolts…489
Tightening Torque For Flared Nuts…489
Tightening Torques for Split Flanged Bolts…490
Tightening Torques For O-ring Boss Piping Joints…490
Table Of Tightening Torques For O-ring Boss Plugs…490
Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)…491
Tightening Torque For Face Seal Joints…491
For 102, 107, and 114 Engine Series (Bolts and Nuts)…491
For 102, 107, and 114 Engine Series (Eye Joints)…492
For 102, 107, and 114 Engine Series (Taper Screws)…492
ELECTRIC WIRE CODE…493
Classification By Thickness…493
Classification By Color And Code…493
How To Read Electric Wire Code…494
PRECAUTIONS FOR OPERATIONS…497
Precautions when Carrying Out Removal Work…497
Precautions when Carrying Out Installation Work…498
Precautions when Completing the Operation…499
CONVERSION TABLES…500
Method Of Using The Conversion Table…500
COATING MATERIALS…506
LIST OF ABBREVIATIONS…509
List of Abbreviations Used in the Shop Manual…509
List of Abbreviations Used in the Circuit Diagrams…513
01 GENERAL…514
01 GENERAL…519
SPECIFICATION DIMENSION DRAWINGS…515
Dimensions…515
Working Ranges…516
SPECIFICATIONS…517
WEIGHT TABLE…521
FUEL, COOLANT AND LUBRICANTS…523
Lubrication Chart…525
10 STRUCTURE AND FUNCTION…526
ENGINE AND COOLING SYSTEM…529
Engine Related Parts…529
Radiator, Oil Cooler, After Cooler, and Fuel Cooler…531
POWER TRAIN…533
Power Train…533
Swing Machinery…535
Swing Circle…537
Final Drive…539
UNDERCARRIAGE AND FRAME…541
Track Frame and Idler Cushion…541
HYDRAULIC SYSTEM…543
Hydraulic Equipment Layout…543
Valve Control…545
Hydraulic Tank…547
Oil Filler Cap…548
CLSS…549
Structure of CLSS…549
Basic Principle…550
Main Pump…553
Operation…557
LS Valve…559
PC Valve…565
LS(PC)-EPC Valve…572
Control Valve…575
Functions and Operation by Valve…587
Hydraulic Circuit Diagram and Name of Valves…587
Unload Valve…591
Introduction of LS Pressure…592
LS By-Pass Plug…593
Pressure Compensation Valve…594
Shuttle Valve In Pressure Compensation Valve…597
Boom Regeneration Circuit…599
Arm Regeneration Circuit…601
Merge-Divider Valve…603
LS Selector Valve…606
Self-Pressure Reducing Valve…607
Travel Junction Valve…611
Travel PPC Shuttle Valve…615
Boom Hydraulic Drift Prevention Valve…617
Arm Hydraulic Drift Prevention Valve (If Equipped)…620
Suction Safety Valve For Drift Prevention Valve…623
Arm Quick Return Valve…625
Variable Back Pressure Valve…627
Main Relief Valve…629
Suction 2-Stage Safety Valve…631
Swing Motor…633
Swing Holding Brake…635
Relief Valve…637
Swing 2-Stage Relief Valve…639
Swing Motor Reverse Prevention Valve…640
Travel Motor…643
Operation of Travel Motor…646
Operation of Parking Brake…648
Brake Valve…649
Counterbalance Valve…650
Suction Safety Valve…651
PPC Valve…654
Work Equipment and Swing PPC Valve…654
Travel PPC Valve…660
1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)…664
EPC Valve (If Equipped)…666
2nd-Line Attachment PPC Valve (If Equipped)…670
Solenoid Valve…672
Attachment Circuit Selector Valve (For High Pressure Circuit) (If Equipped)…676
Attachment Circuit Selector Valve (For Low Pressure Circuit) (If Equipped)…678
Center Swivel Joint…680
Accumulator…681
PPC Accumulator…681
WORK EQUIPMENT…682
Work Equipment…682
Work Equipment Shim…683
Bucket Play Adjustment Shim…683
CAB AND ITS ATTACHMENTS…684
Cab Mount and Cab Tipping Stopper…684
ROPS Cab…686
ELECTRICAL SYSTEM…688
Electrical Control System…688
Machine Control System Diagram…688
Engine Control Function…690
Engine and Pump Combined Control Function…692
Pump and Valve Control Function…698
One-Touch Power Maximizing Function…700
Auto-Deceleration Function…702
Engine Automatic Warm-Up Function…704
Overheat Prevention Function…706
Turbocharger Protection Function…707
Swing Control Function…708
Quick Warm-Up Function…710
Swing 2-Stage Relief Function…710
Travel Control Function…712
PPC Lock Function…714
Attachment Flow Control Function…716
System Component Part…718
Engine Controller…718
Pump Controller…722
Fuel Control Dial…726
Resistor for PC-EPC Valve…727
CAN Terminating Resistor…728
Engine Oil Pressure Switch…729
PPC Oil Pressure Switch…730
MACHINE MONITOR SYSTEM…732
Machine Monitor…734
Input and Output Signals…735
Display…738
Gauges…740
Caution Monitor…742
Pilot Monitor…746
Switches…748
Guidance ICON and Function Switch…750
Operator Mode Function…753
Service Mode Function…755
KOMTRAX SYSTEM…757
Komtrax Terminal…758
Input and Output Signals…759
SENSORS…761
Ambient Pressure Sensor…761
Charge (Boost) Pressure and Temperature Sensor…762
Coolant Temperature Sensor…763
Ne (Crankshaft) Speed Sensor…763
Bkup (Camshaft) Speed Sensor…764
Common Rail Pressure Sensor…764
Exhaust Manifold Pressure Sensor…765
EGR Orifice Temperature Sensor…765
EGR Valve Lift Sensor…766
Turbo Speed Sensor…767
KVGT Position Sensor…768
Mass Air Flow and Temperature Sensor…769
KDPF Differential Pressure and Outlet Pressure Sensor…769
KDOC Inlet Temperature Sensor…770
KDOC Outlet Temperature Sensor…770
KDPF Outlet Temperature Sensor…771
Crankcase Pressure Sensor…771
Engine Oil Level Sensor…772
Fuel Level Sensor…773
Coolant Level Sensor…774
Hydraulic Oil Temperature Sensor…774
Front Pump Oil Pressure Sensor…775
Rear Pump Oil Pressure Sensor…776
PPC Oil Pressure Sensor…777
Air Cleaner Clogging Sensor…778
Front Pump Swash Plate Sensor…779
Rear Pump Swash Plate Sensor…781
Water-In Fuel Sensor…783
20 STANDARD VALUE TABLES…784
STANDARD SERVICE VALUE TABLES…785
Standard Value Table for Engine Related Parts…785
Standard Value Table for Chassis Related Parts…787
Engine Speed…787
Control Valve Spool Stroke…787
Control Lever Stroke…788
Operating Effort of Control Lever and Pedal…788
Hydraulic Pressure…789
Swing…790
Travel…791
Work Equipment…792
Performance in Combined Operation…794
Pump Swash Plate Sensor…794
Characteristics of PC Flow Control…794
Hydraulic Pump…795
Posture of Machine for Measuring Performance and Measurement Procedure…796
Control Valve: Spool Stroke…796
Swing 1: Swing Brake Angle, Time Taken to Start Swing, Time Taken to Swing…796
Swing 2: Hydraulic Drift of Swing…796
Travel 1: Travel Speed, Idle Running (Without Load)…796
Travel 2: Travel Speed (Actual Run), Travel Deviation…797
Travel 3: Travel Deviation…797
Travel 4: Hydraulic Drift of Travel…797
Work Equipment 1: Hydraulic Drift of Work Equipment…797
Work Equipment 2: Boom Speed…798
Work Equipment 3: Arm Speed…798
Work Equipment 4: Bucket Speed…798
Work Equipment 5: Boom Time Lag…798
Work Equipment 6: Arm Time Lag…799
Work Equipment 7: Bucket Time Lag…799
Work Equipment 8: PC Flow Characteristics Control…799
30 TESTING AND ADJUSTING…800
GENERAL INFORMATION ON TESTING AND ADJUSTING…803
Tools for Testing, Adjusting, and Troubleshooting…803
Sketch of Tools for Testing and Adjusting…808
ENGINE AND COOLING SYSTEM…811
Checking Engine Speed…811
Measuring Boost Pressure…813
Measuring Exhaust Gas Color…815
Measuring and Adjusting Valve Clearance…817
Testing…817
Adjusting…820
Measuring Compression Pressure…821
Measuring Blow-By Pressure…827
Measuring Engine Oil Pressure…829
Measuring EGR Valve and KVGT Oil Pressure…831
Measuring Fuel Pressure…833
Testing Low-Pressure Circuit (Fuel Main Filter Inlet Side)…835
Testing Low-Pressure Circuit (Pressure Difference)…836
Testing Return Circuit…837
Testing Negative-Pressure Circuit…838
Measuring Fuel Delivery, Return and Leakage…839
Testing Supply Pump Delivery…841
Testing Supply Pump Return Rate…843
Testing Leakage from Pressure Limiter…844
Testing Injector Return Rate from Injector…845
Bleeding Air from Fuel System…847
Bleeding Air…847
Route for Bleeding Air from Fuel Circuit…848
Checking Fuel Circuit for Leakage…849
Handling Cylinder Cut-Out Mode Operation…850
Handling No-Injection Cranking Operation…850
Checking and Adjusting Air Conditioner Compressor Belt Tension…851
Checking…851
Adjusting…852
Replacing Fan Belt…853
POWER TRAIN…855
Testing Swing Circle Bearing Clearance…855
Testing…855
UNDERCARRIAGE AND FRAME…857
Testing and Adjusting Track Shoe Tension…857
Testing…857
Adjusting…857
HYDRAULIC SYSTEM…859
Releasing Remaining Pressure from Hydraulic Circuit…859
Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits…861
Testing…861
Adjusting…863
Measuring Oil Pressure in Control Circuit…865
Measuring and Adjusting Oil Pressure in Pump PC Control Circuit…867
Testing…867
Adjusting…870
Measuring and Adjusting Oil Pressure in Pump LS Control Circuit…871
Testing…872
Checking Oil Pressure with Sensor Adapter (Special Tool)…876
Adjusting…877
Measuring Solenoid Valve Output Pressure…879
Testing…879
Operating Condition…881
Measuring PPC Valve Output Pressure…883
Adjusting Play of Work Equipment and Swing PPC Valves…885
Testing Pump Swash Plate Sensor…886
Isolating the Parts Causing Hydraulic Drift in Work Equipment…887
Measuring Oil Leakage…889
Bleeding Air From Hydraulic Circuit…892
CAB AND ITS ATTACHMENTS…895
Checking Cab Tipping Stopper…895
Adjusting Mirrors…897
ELECTRICAL SYSTEM…899
Special Functions of Machine Monitor…899
Upper Part of machine monitor (display portion)…900
Upper Part of Machine Monitor (Switch Portion)…900
Lower Part of Machine Monitor (Switch Portion)…900
Ordinary Functions and Special Functions of Machine Monitor…900
Operator Mode (Outline)…903
Service Mode…923
Angle Adjustment of Rear View Camera…988
Handling Voltage Circuit of Engine Controller…990
Handling Battery Disconnect Switch…991
Testing Diodes…992
PM CLINIC…993
PM Clinic Service…993
Check Items Related to Engine…995
Check Items Related to Oil Pressure…996
Check Sheet…997
40 TROUBLESHOOTING…1004
GENERAL INFORMATION ON TROUBLESHOOTING…1013
Points to Remember When Troubleshooting…1013
Sequence of Events in Troubleshooting…1015
Checks Before Troubleshooting…1017
Testing Procedure Before Troubleshooting…1019
Walk-Around Check…1019
Testing in Accordance with Testing Procedure…1021
Check of Water Separator, and Drainage of Water and Sediments…1023
Replacing Fuel Pre-Filter Cartridge…1025
Preparation Work for Troubleshooting of Electrical System…1047
Preparation Work…1047
Classification and Procedure for Troubleshooting…1053
Classification of Troubleshooting…1053
Procedure for Troubleshooting…1053
Symptom of Probable Failure and Troubleshooting No…1057
Information Mentioned in Troubleshooting Table…1061
Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System…1063
Connection Table for Connector Pin Numbers…1067
T-Branch Box and T-Branch Adapter Table…1101
Fuse List and Location…1105
Connection Table of Fuse Box…1105
Locations of Fusible Links…1106
Location of Fuse Box and Fuse Numbers…1106
Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)…1107
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)…1111
Failure Codes Table…1111
Failure Code [879AKA] A/C Inner Sensor Open Circuit…1121
Failure Code [879AKB] A/C Inner Sensor Short Circuit…1121
Failure Code [879BKA] A/C Outer Sensor Open Circuit…1121
Failure Code [879BKB] A/C Outer Sensor Short Circuit…1121
Failure Code [879CKA] Ventilating Sensor Open Circuit…1121
Failure Code [879CKB] Ventilating Sensor Short Circuit…1121
Failure Code [879DKZ] Sunlight Sensor Open or Short Circuit…1121
Failure Code [879EMC] Ventilation Damper Abnormality…1122
Failure Code [879FMC] Air Mix Damper Abnormality…1122
Failure Code [879GKX] Refrigerant Abnormality…1122
Failure Code [989L00] Engine Controller Lock Caution 1…1123
Failure Code [989M00] Engine Controller Lock Caution 2…1123
Failure Code [989N00] Engine Controller Lock Caution 2…1124
Failure Code [A1U0N3] HC Desorb Request 1…1125
Failure Code [A1U0N4] HC Desorb Request 2…1127
Failure Code [AA10NX] Air Cleaner Clogging…1129
Failure Code [AB00KE] Charge Voltage Low…1131
Failure Code [B@BAZG] Engine Oil Pressure Low…1133
Failure Code [B@BAZK] Eng Oil Level Low…1135
Failure Code [B@BCNS] Engine Coolant Overheat…1137
Failure Code [B@BCZK] Radiator Coolant Level Low…1139
Failure Code [B@HANS] Hyd Oil Overheat…1141
Failure Code [CA115] Eng Ne and Bkup Speed Sens Error…1142
Failure Code [CA122] Chg Air Press Sensor High Error…1143
Failure Code [CA123] Chg Air Press Sensor Low Error…1145
Failure Code [CA131] Throttle Sensor High Error…1147
Failure Code [CA132] Throttle Sensor Low Error…1149
Failure Code [CA144] Coolant Temp Sens High Error…1151
Failure Code [CA145] Coolant Temp Sens Low Error…1153
Failure Code [CA153] Chg Air Temp Sensor High Error…1155
Failure Code [CA154] Chg Air Temp Sensor High Error…1157
Failure Code [CA187] Sensor 2 Supply Volt Low Error…1159
Failure Code [CA221] Ambient Press Sensor High Error…1161
Failure Code [CA222] Ambient Press Sensor Low Error…1163
Failure Code [CA227] Sensor 2 Supply Volt High Error…1165
Failure Code [CA234] Eng Overspeed…1166
Failure Code [CA238] Ne Speed Sensor Supply Volt Error…1167
Failure Code [CA239] Ne Speed Sens Supply Volt High Error…1169
Failure Code [CA271] IMV/PCV1 Short Error…1171
Failure Code [CA272] IMV/PCV1 Open Error…1173
Failure Code [CA295] Ambient Press Sens In Range Error…1175
Failure Code [CA322] Inj #1 (L#1) Open/Short Error…1177
Failure Code [CA323] Inj #5 (L#5) Open/Short Error…1179
Failure Code [CA324] Inj #3 (L#3) Open/Short Error…1181
Failure Code [CA325] Inj #6 (L#6) Open/Short Error…1183
Failure Code [CA331] Inj #2 (L#2) Open/Short Error…1185
Failure Code [CA332] Inj #4 (L#4) Open/Short Error…1187
Failure Code [CA343] ECM Critical Internal Failure…1189
Failure Code [CA351] Injectors Drive Circuit Error…1190
Failure Code [CA352] Sensor 1 Supply Volt Low Error…1191
Failure Code [CA356] Mass Air Flow Sensor High Error…1193
Failure Code [CA357] Mass Air Flow Sensor Low Error…1195
Failure Code [CA386] Sensor 1 Supply Volt High Error…1198
Failure Code [CA428] Water in Fuel Sensor High Error…1199
Failure Code [CA429] Water in Fuel Sensor Low Error…1201
Failure Code [CA435] Eng Oil Press Sw Error…1203
Failure Code [CA441] Battery Voltage Low Error…1205
Failure Code [CA442] Battery Voltage High Error…1207
Failure Code [CA449] Rail Press Very High Error…1208
Failure Code [CA451] Rail Press Sensor High Error…1209
Failure Code [CA452] Rail Press Sensor Low Error…1211
Failure Code [CA488] Chg Air Temp High Torque Derate…1213
Failure Code [CA515] Rail Press Sens Sup Volt High Error…1215
Failure Code [CA516] Rail Press Sens Sup Volt Low Error…1217
Failure Code [CA553] Rail Press High Error…1219
Failure Code [CA555] Crankcase Press High Error 1…1220
Failure Code [CA556] Crankcase Press High Error 2…1221
Failure Code [CA559] Rail Press Low Error…1223
Failure Code [CA595] Turbo Speed High Error 2…1224
Failure Code [CA687] Turbo Speed Low Error…1225
Failure Code [CA689] Eng Ne Speed Sensor Error…1227
Failure Code [CA691] Intake Air Temp Sens High Error…1231
Failure Code [CA692] Intake Air Temp Sens Low Error…1233
Failure Code [CA697] ECM Int Temp Sensor High Error…1235
Failure Code [CA698] ECM Int Temp Sensor Low Error…1236
Failure Code [CA731] Eng Bkup Speed Sens Phase Error…1237
Failure Code [CA778] Eng Bkup Speed Sensor Error…1239
Failure Code [CA1117] Persistent Data Lost Error…1243
Failure Code [CA1664] KDOC Malfunction…1245
Failure Code [CA1691] Regeneration Ineffective…1247
Failure Code [CA1695] Sensor 5 Supply High Error…1251
Failure Code [CA1696] Sensor 5 Supply Volt Low Error…1253
Failure Code [CA1843] Crankcase Press Sens High Error…1255
Failure Code [CA1844] Crankcase Press Sens Low Error…1257
Failure Code [CA1879] KDPF Delta P Sensor High Error…1261
Failure Code [CA1881] KDPF Delta P Sensor Low Error…1263
Failure Code [CA1883] KDPF Delta P Sens In Range Error…1267
Failure Code [CA1921] KDPF Soot Load High Error 1…1271
Failure Code [CA1922] KDPF Soot Load High Error 2…1273
Failure Code [CA1942] Crankcase Press Sens In Range Error…1277
Failure Code [CA1993] KDPF Delta Pressure Low Error…1278
Failure Code [CA2185] Throt Sensor Sup Volt High Error…1279
Failure Code [CA2186] Throt Sensor Sup Volt Low Error…1281
Failure Code [CA2249] Rail Press Very Low Error…1283
Failure Code [CA2271] EGR Valve Pos Sens High Error…1285
Failure Code [CA2272] EGR Valve Pos Sens Low Error…1289
Failure Code [CA2288] Turbo Speed High Error 1…1293
Failure Code [CA2311] IMV Solenoid Error…1294
Failure Code [CA2349] EGR Valve Solenoid Open Error…1295
Failure Code [CA2353] EGR Valve Solenoid Short Error…1297
Failure Code [CA2357] EGR Differential Pressure…1299
Failure Code [CA2373] Exh Manifold Press. Sens Volt…1301
Failure Code [CA2374] Exhaust Manifold Press Sens Low Error…1303
Failure Code [CA2375] EGR Orifice Temp Sens High Error…1305
Failure Code [CA2376] EGR Orifice Temp Sens Low Error…1307
Failure Code [CA2381] KVGT Pos Sens High Error…1309
Failure Code [CA2382] KVGT Pos Sens Low Error…1311
Failure Code [CA2383] KVGT Solenoid Open Error…1315
Failure Code [CA2386] KVGT Solenoid Short Error…1317
Failure Code [CA2387] KVGT Servo Error…1319
Failure Code [CA2554] Exh Manifold Press Sens In Range Error…1320
Failure Code [CA2555] Grid Htr Relay Volt Low Error…1321
Failure Code [CA2556] Grid Htr Relay Volt High Error…1325
Failure Code [CA2637] KDOC Face Plugging…1329
Failure Code [CA2639] Manual Stationary Regeneration Request…1331
Failure Code [CA2961] EGR Orifice Temp High Error 1…1333
Failure Code [CA2973] Chg Air Press Sensor In Range Error…1334
Failure Code [CA3133] KDPF Outlet Press Sens High Error…1335
Failure Code [CA3134] KDPF Outlet Press Sens Low Error…1337
Failure Code [CA3135] KDPF Outlet Press Sens In Range Error…1341
Failure Code [CA3251] KDOC Inlet Temp High Error…1345
Failure Code [CA3253] KDOC Temp Error – Non Regeneration…1349
Failure Code [CA3254] KDOC Outlet Temp High Error 1…1351
Failure Code [CA3255] KDPF Temp Error – Non Regeneration…1354
Failure Code [CA3256] KDPF Outlet Temp High Error 1…1355
Failure Code [CA3311] KDOC Outlet Temp High Error 2…1356
Failure Code [CA3312] KDPF Outlet Temp High Error 2…1357
Failure Code [CA3313] KDOC Inlet Temp Sensor Low Error…1361
Failure Code [CA3314] KDOC Inlet Temp Sens High Error…1365
Failure Code [CA3315] KDOC Inlet Temp Sens In Range Error…1369
Failure Code [CA3316] KDOC Outlet Temp Sens Low Error…1373
Failure Code [CA3317] KDOC Outlet Temp Sens High Error…1377
Failure Code [CA3318] KDOC Outlet Temp Sens In Range Error…1381
Failure Code [CA3319] KDPF Outlet Temp Sens High Error…1385
Failure Code [CA3321] KDPF Outlet Temp Sens Low Error…1389
Failure Code [CA3322] KDPF Outlet Temp Sens In Range Error…1393
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error…1397
Failure Code [CA3421] Mass Air Flow Sensor Sup Volt Low Error…1399
Failure Code [CA3741] Rail Press Valve Trip Error…1401
Failure Code [D110KB] Battery Relay Output Voltage…1403
Failure Code [D19JKZ] Personal Code Relay Abnormality…1405
Failure Code [D811MC] KOMTRAX Error…1408
Failure Code [D862KA] GPS Antenna Open Circuit…1408
Failure Code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)…1409
Failure Code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)…1411
Failure Code [D8AQKR] CAN2 Discon (KOMTRAX)…1413
Failure Code [DA20MC] Pump Controller…1414
Failure Code [DA22KK] Pump Solenoid Power Low Error…1415
Failure Code [DA25KP] 5V Sensor 1 Power Abnormality…1417
Failure Code [DA29KQ] Model Selection Abnormality…1421
Failure Code [DA2LKA] Operating Lamp Open Circuit (Pump Con)…1423
Failure Code [DA2LKB] Operating Lamp Short Circuit (Pump Con)…1425
Failure Code [DA2QKR] CAN2 Discon (Pump Con)…1427
Failure Code [DA2QKR] CAN1 Discon (Pump Con)…1430
Failure Code [DAF0MB] Monitor ROM Abnormality…1431
Failure Code [DAF0MC] Monitor Error…1432
Failure Code [DAF8KB] Camera Power Supply Short Circuit…1433
Failure Code [DAF9KQ] Model Selection Abnormality…1435
Failure Code [DAFGMC] GPS Module Error…1436
Failure Code [DAFLKA] Operating Lamp Open Circuit (Monitor)…1437
Failure Code [DAFLKB] Operating Lamp Short Circuit (Monitor)…1439
Failure Code [DAFQKR] CAN2 Discon (Monitor)…1441
Failure Code [DAZ9KQ] A/C Model Selection Abnormality…1442
Failure Code [DAZQKR] CAN2 Discon (Aircon ECU)…1443
Failure Code [DB2QKR] CAN2 Discon (Engine Con)…1447
Failure Code [DB2RKR] CAN1 Discon (Engine Con)…1453
Failure Code [DGH2KB] Hyd Oil Sensor Short Circuit…1457
Failure Code [DHA4KA] Air Cleaner Clog Sensor Open Circuit…1459
Failure Code [DHPAMA] F Pump Press Sensor Abnormality…1461
Failure Code [DHPBMA] R Pump Press Sensor Abnormality…1465
Failure Code [DHS3MA] Arm Curl PPC Press Sensor Abnormality…1469
Failure Code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality…1473
Failure Code [DHS8MA] Boom Raise PPC Press Sensor Abnormality…1477
Failure Code [DHS9MA] Boom Lower PPC Press Sensor Abnormality…1481
Failure Code [DHSAMA] Swing RH PPC Press Sensor Abnormality…1485
Failure Code [DHSBMA] Swing LH PPC Press Sensor Abnormality…1489
Failure Code [DHSCMA] Arm Dump PPC Press Sensor Abnormality…1493
Failure Code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality…1497
Failure Code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality…1501
Failure Code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality…1505
Failure Code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality…1509
Failure Code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality…1513
Failure Code [DKR0MA] F Pump Swash Plate Sensor Abnormality…1517
Failure Code [DKR1MA] R Pump Swash Plate Sensor Abnormality…1521
Failure Code [DR21KX] Camera 2 Picture Rev. Drive Abnormality…1525
Failure Code [DR31KX] Camera 3 Picture Rev. Drive Abnormality…1527
Failure Code [DV20KB] Travel Alarm Short Circuit…1529
Failure Code [DW43KA] Travel Speed Sol Open Circuit…1531
Failure Code [DW43KB] Travel Speed Sol Short Circuit…1533
Failure Code [DW45KA] Swing Brake Sol Open Circuit…1535
Failure Code [DW45KB] Swing Brake Sol Short Circuit…1539
Failure Code [DW91KA] Travel Junction Sol Open Circuit…1543
Failure Code [DW91KB] Travel Junction Sol Short Circuit…1545
Failure Code [DWA2KA] Attachment Sol Open Circuit…1547
Failure Code [DWA2KB] Attachment Sol Short Circuit…1549
Failure Code [DWK0KA] 2-Stage Relief Sol Open Circuit…1551
Failure Code [DWK0KB] 2-Stage Relief Sol Short Circuit…1553
Failure Code [DWK2KA] Variable Back Press Sol Open Circuit…1555
Failure Code [DWK2KB] Variable Back Press Sol Short Circuit…1557
Failure Code [DWK8KA] Swing Press C/O Sol Open Circuit…1559
Failure Code [DWK8KB] Swing Press C/O Sol Short Circuit…1561
Failure Code [DXA8KA] PC-EPC (F) Sol Open Circuit…1563
Failure Code [DXA8KB] PC-EPC (F) Sol Short Circuit…1567
Failure Code [DXA9KA] PC-EPC (R) Sol Open Circuit…1569
Failure Code [DXA9KB] PC-EPC (R) Sol Short Circuit…1573
Failure Code [DXE0KA] LS-EPC Sol Open Circuit…1575
Failure Code [DXE0KB] LS-EPC Sol Short Circuit…1577
Failure Code [DXE4KA] Attachment Flow EPC Open Circuit…1579
Failure Code [DXE4KB] Attachment Flow EPC Short Circuit…1581
Failure Code [DXE5KA] Merge-divide Main Sol Open Circuit…1583
Failure Code [DXE5KB] Merge-divide Main Sol Short Circuit…1585
Failure Code [DXE6KA] Merge-divide LS Sol Open Circuit…1587
Failure Code [DXE6KB] Merge-divide LS Sol Short Circuit…1589
Failure Code [DY20KA] Wiper Working Abnormality…1591
Failure Code [DY20MA] Wiper Parking Abnormality…1595
Failure Code [DY2CKB] Washer Drive Short Circuit…1599
Failure Code [DY2DKB] Wiper Drive (Fwd) Short Circuit…1601
Failure Code [DY2EKB] Wiper Drive (Rev) Short Circuit…1603
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…1605
E-1 Engine Does Not Start (Engine Does Not Rotate)…1605
E-2 Manual Pre-Heating System Does Not Work…1613
E-3 Automatic Pre-Heating System Does Not Work…1617
E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated…1619
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing…1621
E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow…1624
E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow…1624
E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running…1625
E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running…1625
E-10 Charge Level Monitor Lights Up While Engine is Running…1626
E-11 Fuel Level Monitor Lights Up in Red While Engine is Running…1626
E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running…1626
E-13 Water Separator Monitor Lights Up While Engine is Running…1627
E-14 Coolant Temperature Monitor Lights Up in Red While Engine is Running…1627
E-15 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running…1628
E-16 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running…1628
E-17 Fuel Gauge Indicates Either Full or Empty and Does Not Move…1629
E-18 Fuel Gauge Indicates Incorrect Amount (Indicates Neither Full Nor Empty)…1631
E-19 Coolant Temperature Gauge Indicates Either Min or Max and Does Not Move…1632
E-20 Coolant Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Min Nor Max)…1633
E-21 Hydraulic Oil Temperature Gauge Indicates Either Min or Max and Does Not Move…1635
E-22 Hydraulic Oil Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Min nor Max)…1637
E-23 Content of Display on Machine Monitor is Different From That of Actual Machine…1638
E-24 Machine Monitor Does Not Display Some Items…1638
E-25 Function Switch Does Not Work…1638
E-26 Automatic Pre-Heating System Does Not Work (In Cold Season)…1639
E-27 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated…1640
E-28 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated…1641
E-29 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated…1642
E-30 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed…1642
E-31 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated…1643
E-32 Travel Speed Does Not Change When Travel Speed is Shifted…1644
E-33 Alarm Buzzer Does Not Stop Sounding…1645
E-34 When Starting Switch is Turned to OFF Position, Service Meter is Not Displayed…1645
E-35 Service Mode Cannot be Selected…1646
E-36 Any of Work Equipment, Swing and Travel Does Not Work…1647
E-37 Any of Work Equipment, Swing and Travel Can Not be Locked…1649
E-38 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled…1651
E-39 Swing Brake Does Not Operate While Swing Brake Cancel Switch is Locked…1655
E-40 One-Touch Power Maximizing Function Does Not Work Or Monitor is Not Displayed…1657
E-41 One-Touch Power Maximizing Function Cannot be Released…1659
E-42 Travel Alarm Does Not Sound When Machine Travels…1660
E-43 Travel Alarm Does Not Stop Sounding When Machine Stops…1661
E-44 Horn Does Not Sound…1663
E-45 Horn Does Not Stop Sounding…1665
E-46 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated…1666
E-47 Wiper Does Not Operate When Wiper Switch is Operated…1667
E-48 Window Washer Does Not Operate When Window Washer Switch is Operated…1669
E-49 BOOM LOWER Indication is Not Displayed Properly With Monitoring Function…1671
E-50 ARM DUMP Indication is Not Displayed Properly With Monitoring Function…1671
E-51 ARM IN Indication is Not Displayed Properly With Monitoring Function…1671
E-52 BOOM RAISE Indication is Not Displayed Properly With Monitoring Function…1671
E-53 BUCKET CURL Indication is Not Displayed Properly With Monitoring Function…1672
E-54 BUCKET DUMP Indication is Not Displayed Properly With Monitoring Function…1672
E-55 SWING Indication is Not Displayed Properly With Monitoring Function…1672
E-56 TRAVEL Indication is Not Displayed Properly With Monitoring Function…1672
E-57 Service is Not Displayed Properly With Monitoring Function…1673
E-58 Attachment Hydraulic Circuit Cannot be Changed…1676
E-59 KOMTRAX System Does Not Work Properly…1677
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…1679
Information Mentioned in Troubleshooting Table (H Mode)…1679
Failure Mode and Cause Table…1683
H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power…1691
H-2 Engine Speed Lowers Significantly or Engine Stalls…1695
H-3 Any of Work Equipment, Swing and Travel Does Not Work…1697
H-4 Unusual Sound is Heard from Around Hydraulic Pump…1697
H-5 Fine Control Performance or Response is Poor…1698
H-6 Boom Operation Lacks Speed or Power…1699
H-7 Arm Operation Lacks Speed or Power…1701
H-8 Bucket Operation Lacks Speed or Power…1703
H-9 Work Equipment Does Not Move in Single Operation…1704
H-10 Hydraulic Drift of Boom is Large…1704
H-11 Hydraulic Drift of Arm is Large…1705
H-12 Hydraulic Drift of Bucket is Large…1705
H-13 Time Lag of Work Equipment is Large…1706
H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move…1707
H-15 One-Touch Power Maximizing Function Does Not Work…1707
H-16 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower…1708
H-17 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low…1709
H-18 In Combined Operations of Swing and Travel, Travel Speed Drops Largely…1710
H-19 Machine Does Not Travel Straight…1711
H-20 Travel Speed is Too Low…1713
H-21 Machine ishard to Steer or Travel Power is Low…1715
H-22 Travel Speed Does Not Change, or Travel Speed is Too Low or High…1717
H-23 One of Tracks Dose Not Run…1718
H-24 Upper Structure Does Not Swing to the Right or Left…1719
H-25 Upper Structure Swing Only to the Right or Left…1720
H-26 Swing Acceleration is Poor or Swing Speed is Low (Both Right and Left)…1721
H-27 Swing Aceleration is Poor or Swing Speed is Low (Either Right or Left)…1722
H-28 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)…1723
H-29 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)…1724
H-30 Shock is Large When Upper Structure Stops Swinging…1725
H-31 Large Unusual Noise is Heard When Upper Structure Stops Swinging…1725
H-32 Swing Drift on a Slope is Large While Swing Holding Brake is Applied…1726
H-33 Swing Drift On a Slope is Large While Swing Holding Brake is Released…1726
H-34 Attachment Circuit Cannot be Changed While Attachment is Installed…1727
H-35 Oil Flow in Attachment Circuit Cannot be Controlled…1727
TROUBLESHOOTING OF ENGINE (S-MODE)…1728
Information Mentioned in Troubleshooting Table (S-Mode)…1728
S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank…1729
S-2 When Engine Cranks, Smoke Does Not Come Out…1730
S-3 Engine Does Not Start While Fuel is Injected (Incomplete Combustion)…1731
S-4 Startability is Poor…1733
S-5 Engine Does Not Pick Up Smoothly…1735
S-6 Engine Stops During Operation…1737
S-7 Engine Runs Rough or is Unstable…1739
S-8 Engine Lacks Power…1741
S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)…1745
S-10 Engine Oil Consumption is Too Much…1747
S-11 Oil Becomes Contaminated Early…1748
S-12 Fuel Consumption is Excessive…1749
S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)…1750
S-14 Engine Oil Pressure Drops…1751
S-15 Fuel is Contaminated in Engine Oil…1753
S-16 Coolant is Contaminated in Engine Oil (Oil Becomes Cloudy White)…1754
S-17 Coolant Temperature Rises Too High (Overheating)…1755
S-18 Unusual Noise is Heard…1756
S-19 Vibration is Excessive…1757
S-20 Automatic Regeneration is Operated Frequently…1758
S-21 Active Regeneration is Operated for Long…1759
S-22 White Smoke Comes Out in the Process of Active Regeneration…1760
50 DISASSEMBLY AND ASSEMBLY…1762
HOW TO READ THIS SECTION…1767
Removal And Installation Of Assemblies…1767
Special Tools…1767
Removal…1767
Installation…1767
Disassembly And Assembly Of Assemblies…1768
Special Tools…1768
Disassembly…1768
Assembly…1769
Coating Materials List…1770
SKETCHES OF SPECIAL TOOLS…1778
CONNECTOR REPAIR PROCEDURES…1781
Stripping Insulation…1781
Wire Inspection…1781
Contact Terminal Removal (HD30 Type)…1782
Crimping Contact Terminal (HD30 Type)…1783
Insertion Of Contact Terminal (HD30 Type)…1784
Contact Terminal Removal (DT Type)…1785
Crimping Contact Terminal (DT Type)…1786
Insertion Of Contact Terminal (DT Type)…1787
ENGINE AND COOLING SYSTEM…1789
Removal and Installation of Supply Pump Assembly…1789
Special Tools…1789
Removal…1789
Installation…1792
Fuel Injector Assembly…1795
Special Tools…1795
Removal…1795
Installation…1799
Removal and Installation of Cylinder Head Assembly…1807
Special Tools…1807
Removal…1807
Installation…1818
Removal and Installation of Radiator Assembly…1835
Removal…1835
Installation…1837
Removal and Installation of Hydraulic Oil Cooler Assembly…1839
Removal…1839
Installation…1842
Removal and Installation of Aftercooler Assembly…1843
Removal…1843
Installation…1844
Removal and Installation Engine And Main Pump Assembly…1845
Special Tools…1845
Removal…1845
Installation…1857
Removal and Installation of Engine Front Oil Seal…1863
Removal…1863
Installation…1866
Removal and Installation of Engine Rear Oil Seal…1869
Removal…1869
Installation…1870
Removal and Installation of Fuel Cooler Assembly…1873
Removal…1873
Installation…1873
Removal and Installation of Fuel Tank Assembly…1874
Removal…1874
Installation…1877
Removal and Installation of Engine Hood Assembly…1878
Removal…1878
Installation…1879
Removal and Installation of KDPF Assembly…1883
Removal…1883
Installation…1886
Disassembly and Assembly of KDPF…1895
Disassembly…1895
Assembly…1900
Removal and Installation of KCCV Assembly…1905
Removal…1905
Installation…1907
Removal and Installation of Air Cleaner Assembly…1909
Removal…1909
Installation…1911
POWER TRAIN…1913
Removal and Installation of Travel Motor and Final Drive Assembly…1913
Removal…1913
Installation…1914
Disassembly and Assembly of Final Drive…1915
Disassembly…1915
Assembly…1919
Removal and Installation of Swing Motor and Swing Machinery Assembly…1925
Installation…1928
Disassembly and Assembly of Swing Machinery…1929
Disassembly…1929
Assembly…1933
Removal and Installation of Swing Circle Assembly…1939
Removal…1939
Installation…1939
UNDERCARRIAGE AND FRAME…1940
Separation and Connection of Track Shoe Assembly…1940
Separating Track…1940
Connecting Track…1941
Removal and Installation of Sprocket…1943
Removal…1943
Installation…1943
Removal and Installation of Idler and Idler Cushion Assembly…1944
Removal…1944
Installation…1944
Disassembly and Assembly of Idler…1945
Disassembly…1945
Assembly…1946
Disassembly and Assembly of Idler Cushion…1949
Disassembly…1949
Assembly…1950
Disassembly and Assembly of Track Roller…1953
Disassembly…1953
Assembly…1954
Disassembly and Assembly of Carrier Roller…1956
Disassembly…1956
Assembly…1957
Removal and Installation of Revolving Frame Assembly…1961
Removal…1961
Installation…1963
Removal and Installation of Counterweight Assembly…1965
Removal…1965
Installation…1968
HYDRAULIC SYSTEM…1969
Center Swivel Joint…1969
Removal…1969
Installation…1971
Disassembly and Assembly of Swivel Joint…1973
Disassembly…1973
Assembly…1974
Removal and Installation of Hydraulic Tank Assembly…1975
Removal…1975
Installation…1980
Removal and Installation of Main Pump Assembly…1981
Removal…1981
Installation…1985
Removal and Installation of Control Valve…1987
Removal…1987
Installation…1994
Disassembly and Assembly of Control Valve…1997
Procedures for Replacing Pressure Compensation Valve Seal…1997
Assembly of Control Valve Assembly…1999
Disassembly and Assembly of Work Equipment PPC Valve…2005
Disassembly…2005
Assembly…2005
Disassembly and Assembly of Travel PPC Valve…2007
Disassembly…2008
Assembly…2008
WORK EQUIPMENT…2011
Removal and Installation of Work Equipment Assembly…2011
Special Tools…2011
Removal…2011
Installation…2013
Disassembly and Assembly of Work Equipment Cylinder…2015
Disassembly…2015
Assembly…2018
CAB AND ITS ATTACHMENTS…2023
Removal and Installation of Operator's Cab Assembly…2023
Removal…2023
Removal…2023
Installation…2028
Removal and Installation of Operator Cab Glass (Fixed Glass)…2029
Removal…2030
Installation…2031
Removal and Installation of Front Window Assembly…2041
Removal…2041
Installation…2044
Removal and Installation of Floor Frame Assembly…2049
Removal…2049
Installation…2056
Removal and Installation of Air Conditioner Unit Assembly…2057
Removal…2057
Installation…2062
Removal and Installation of Operator’s Seat…2063
Removal…2063
Installation…2064
Removal and Installation of Seat Belt…2067
Removal…2067
Installation…2068
Removal and Installation of Front Wiper Assembly…2069
Removal…2069
Installation…2074
ELECTRICAL SYSTEM…2081
Removal and Installation of Air Conditioner Compressor Assembly…2081
Removal…2081
Installation…2083
Removal and Installation of Air Conditioner Condenser Assembly…2085
Removal…2085
Installation…2086
Removal and Installation of Engine Controller Assembly…2087
Removal…2087
Installation…2088
Removal and Installation of Pump Controller Assembly…2091
Removal…2091
Installation…2093
Removal and Installation of Machine Monitor Assembly…2095
Removal…2095
Installation…2097
Removal and Installation of Pump Swash Plate Sensor…2098
Removal…2098
Installation…2098
Removal and Installation of Mass Air Flow and Temperature Sensor…2099
Removal…2099
Installation…2099
Removal and Installation of KOMTRAX Terminal Assembly…2101
Removal…2101
Installation…2102
60 MAINTENANCE STANDARD…2104
ENGINE AND COOLING SYSTEM…2107
Engine Mounts…2107
Cooling System…2109
POWER TRAIN…2111
Swing Circle…2111
Swing Machinery…2113
Final Drive…2115
Sprocket…2117
UNDERCARRIAGE AND FRAME…2119
Track Frame and Idler Cushion…2119
Idler…2121
Track Roller…2123
Carrier Roller…2125
Track Shoe…2127
Triple Grouser Shoe…2130
HYDRAULIC SYSTEM…2131
Hydraulic Tank…2131
Main Pump…2132
Control Valve…2133
General View…2133
Sectional View (1/5)…2135
Sectional View (2/5)…2137
Sectional View (3/5)…2139
Sectional View (4/5)…2141
Sectional View (5/5)…2143
Swing Motor…2144
Travel Motor…2147
PPC VALVE…2150
Work Equipment and Swing PPC Valve…2150
Travel PPC Valve…2153
1st-Line Attachment PPC Valve (with EPC Valve)…2157
EPC Valve…2159
2nd-Line Attachment PPC Valve…2161
Solenoid Valve…2163
Attachment Circuit Selector Valve…2165
For Low-Pressure Circuit…2165
For High-Pressure Circuit…2166
Center Swivel Joint…2167
WORK EQUIPMENT…2168
Dimensions of Components…2168
Dimensions of Arm…2173
Boom Cylinder…2179
Standard…2179
Large Diameter Piston…2180
Arm Cylinder…2181
Bucket Cylinder…2182
80 AIR CONDITIONING…2184
AIR CONDITIONER…2187
Precautions for Refrigerant…2187
Air Conditioner Component…2189
Structure and Function of Refrigeration System…2191
Overview of Refrigeration System…2192
Air Conditioner Unit…2195
Function…2196
Functions of Major Components…2197
Evaporator…2197
Heater core…2197
Evaporator temperature sensor…2197
Servomotor…2197
Expansion valve…2199
Dual Pressure Switch…2201
Air Conditioner Controller…2201
Air Conditioner Compressor…2202
Air Conditioner Condenser…2203
Sunlight Sensor…2204
Outside Air Temperature Sensor…2204
Inspection and Troubleshooting Procedure of Air Conditioner…2205
Basic Inspection and Troubleshooting Sequence…2205
Air Conditioner Circuit Diagram and Arrangement of Connector Pins…2207
System Diagram…2208
Air Conditioner Controller Input and Output Signals…2209
Parts and Connectors Layout…2211
Layout of Air Conditioner Related Parts and Connectors…2213
Testing Air Leakage (Duct)…2215
Testing with Self-Diagnosis Function…2217
How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor…2219
Testing Vent (Mode) Changeover…2221
Testing FRESH/RECIRC Air Changeover…2223
Testing Sunlight Sensor…2224
Testing (Dual) Pressure Switch for Refrigerant…2225
Testing Relay…2226
Troubleshooting Chart 1…2227
Troubleshooting Chart 2…2228
Information Mentioned in Troubleshooting Table…2231
Information in Troubleshooting Table…2231
Failure Code List Related to Air Conditioner…2233
Failure Code [879AKA] A/C Inner Sensor Open Circuit…2234
Failure Code [879AKB] A/C Inner Sensor Short Circuit…2234
Failure Code [879BKA] A/C Outer Sensor Open Circuit…2235
Failure Code [879BKB] A/C Outer Sensor Short Circuit…2237
Failure Code [879CKA] Ventilating Sensor Open Circuit…2239
Failure Code [879CKB] Ventilating Sensor Short Circuit…2240
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit…2241
Failure Code [879EMC] Ventilation Damper Abnormality…2242
Failure Code [879FMC] Ventilation Damper Abnormality…2243
Failure Code [879GKX] Refrigerant Abnormality…2243
A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)…2245
A-2 Troubleshooting of Compressor System (Air is Not Cooled)…2247
A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)…2251
A-4 Troubleshooting for FRESH/RECIRC Air Changeover…2253
Troubleshooting with Gauge Pressure…2255
[Measurement Condition for Pressure]…2255
Testing Refrigerant Pressure…2258
Check…2259
Troubleshooting Table with Gauge Pressure Indicated by Gauge Manifold…2261
Precautions for Disconnecting and Connecting Refrigerant Piping…2263
Disconnection…2263
Connection…2263
Tightening Torque for Joint Portion of Refrigerant Piping…2264
Filling Compressor Oil…2265
Oil Level Control of Compressor…2265
Refilling of Compressor Oil…2265
Desiccant Replacement…2267
90 DIAGRAMS AND SCHEMATICS…2270
HYDRAULIC SYSTEM…2272
Symbols in Hydraulic Circuit Diagrams…2272
Hydraulic Circuit Diagram and Name of Valves…2273
Hydraulic Circuit Diagram (1/2)…2274
Hydraulic Circuit Diagram (2/2)…2275
ELECTRICAL SYSTEM…2276
Air Conditioner Electrical Circuit…2277
Electrical Control System Diagram…2278
Electrical Diagram (1/5)…2279
Electrical Diagram (2/5)…2280
Electrical Diagram (3/5)…2281
Electrical Diagram (4/5)…2282
Electrical Diagram (5/5)…2283
Connector List and Stereogram…2284
Chassis…2284
Operator's Compartment…2285
Engine Compartment…2286
EEAM010300 – Hydraulic Excavator PC290LC-6K, PC290NLC-6K Operation & Maintenance Manual…2287
EEBM001902 – Hydraulic Excavator PC290LC-6K, PC290NLC-6K Shop Manual…2551
COVER…2551
01 GENERAL…2552
CONTENTS…2552
SAFETY…2556
FORWORD…2559
GENERAL…2559
HOW TO READ THE SHOP MANUAL…2560
HOISTING INSTRUCTIONS…2561
COATING MATERIALS…2562
STANDARD TIGHTENING TORQUE…2563
ELECTRIC WIRE CODE…2565
CONVERSION TABLE…2566
10 STRUCTURE AND FUNCTION…2574
ENGINE RELATED PARTS…2579
RADIATOR – OIL COOLER…2580
POWER TRAIN…2581
FINAL DRIVE…2582
SWING CIRCLE…2583
SWING MACHINERY…2584
TRACK FRAME, RECOIL SPRING…2585
TRACK SHOE…2586
HYDRAULIC TANK – S/N K30001 and up'…2588
HYDRAULIC TANK – S/N K34001 and up…2589
HYDRAULIC PUMP…2590
BASIC PUMP…2590
OUTLINE…2590
FUNCTION…2593
STRUCTURE…2593
OPERATION…2594
LS AND PC VALVE…2597
FUNCTION…2598
OPERATION…2599
CONTROL VALVE…2609
OUTLINE…2609
9-SPOOL VALVE (STANDARD + 3 SERVICE VALVES)…2610
MAIN STRUCTURE…2611
6-SPOOL VALVE (7 SPOOL IS STANDARD)…2614
SAFETY-SUCTION VALVE FOR SERVICE VALVE…2615
SELF REDUCING PRESSURE VALVE…2616
FUNCTION…2618
OPERATION…2618
CLSS…2621
OUTLINE OF CLSS…2621
FEATURES…2621
STRUCTURES…2621
BASIC PRINCIPLE…2622
OPERATION OF EACH FUNCTION AND VALVE…2624
HYDRAULIC CIRCUIT DIAGRAM FOR SYSTEM…2624
UNLOAD VALVE…2627
MAIN RELIEF VALVE (2 STAGE TYPE)…2628
INTRODUCTION OF LS PRESSURE…2630
LS BYPASS VALVE…2631
PRESSURE COMPENSATION VALVE…2632
SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE…2635
VARIABLE TYPE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE)…2636
BOOM REGENERATION CIRCUIT…2638
ARM REGENERATION CIRCUIT…2640
PUMP MERGE-DIVIDER VALVE…2641
LS SELECT VALVE…2643
SPOOL STROKE MODULATION…2644
TIMING VALVE…2645
2 STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD)…2646
OPERATION OF CLSS SYSTEM AS A WHOLE…2648
CENTER SWIVEL JOINT…2663
SWING MOTOR…2664
BASIC MOTOR…2664
TRAVEL MOTOR…2670
OPERATION OF MOTOR…2672
OPERATION OF PARKING BRAKE…2674
OPERATION OF BRAKE VALVE…2675
VALVE CONTROL…2679
WORK EQUIPMENT – SWING PPC VALVE…2680
OPERATION…2682
TRAVEL PPC VALVE…2684
SERVICE PPC VALVE…2688
SAFETY LOCK VALVE…2692
PPC ACCUMULATOR…2692
STRAIGHT-TRAVEL SYSTEM…2693
EPC SOLENOID VALVE…2694
OVERLOAD WARNING DEVICE…2696
HOSE BURST PROTECTION VALVE (BOOM)…2698
WORK EQUIPMENT…2701
ENGINE CONTROL SYSTEM…2703
ELECTRONIC CONTROL SYSTEM…2709
CONTROL FUNCTION…2709
PUMP AND ENGINE MUTUAL CONTROL FUNCTION…2711
PUMP AND VALVE CONTROL FUNCTION…2716
POWER MAXIMIZING – SWIFT SLOW-DOWN FUNCTION…2719
AUTO DECELERATION FUNCTION…2720
AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION…2722
SWING CONTROL SYSTEM…2724
TRAVEL CONTROL FUNCTION'…2726
ACTIVE MODE FUNCTION…2728
COMPONENTS OF SYSTEM…2731
MACHINE MONITOR SYSTEM…2734
FUNCTION…2734
MONITOR PANEL…2735
MONITOR DISPLAY…2736
CONTENT OF DISPLAY…2737
OIL MAINTENANCE FUNCTION…2738
MODE SELECTION SWITCHES…2740
HOW TO SET TELEPHONE NUMBER…2741
SENSORS…2742
20 TESTING AND ADJUSTING…2746
TESTING AND ADJUSTING…2747
STANDARD VALUE TABLE…2753
FOR ENGINE PC290-6K…2753
FOR CHASSIS…2754
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…2770
MEASURING ENGINE SPEED…2771
MEASURING EXHAUST GAS COLOR…2772
ADJUSTING VALVE CLEARANCE…2773
MEASURING COMPRESSION PRESSURE…2774
MEASURING BLOW-BY PRESSURE…2774
TESTING AND ADJUSTING FUEL INJECTION TIMING…2775
MEASURE ENGINE OIL PRESSURE…2776
SEN05644-02 – Hydraulic Excavator PC290LC-10 Shop Manual…3224
COVER…3224
00 Index and foreword…3226
Index…3227
Foreword, safety and general information…3238
Important safety notice…3238
How to read the shop manual…3243
Explanation of terms for maintenance standard…3245
Handling of fuel system devices…3247
Handling of intake system parts…3248
Handling of hydraulic equipment…3249
Method of disconnecting and connecting push-pull type coupler…3251
Handling of electrical equipment…3254
How to read electric wire code…3262
Precautions when performing operation…3265
Standard tightening torque table…3268
List of abbreviation…3272
Conversion table…3276
01 Specification…3282
Specifications…3284
Specification drawings…3284
Working range drawings…3285
Specifications…3286
Weight table…3289
Table of fuel, coolant and lubricants…3290
10 Structure and function…3292
Engine and cooling system…3294
Engine related parts…3294
Cooling system…3296
Power train system…3298
Power train…3298
Swing circle…3300
Swing machinery…3301
Final drive…3303
Undercarriage and frame…3305
Track frame and idler cushion…3305
Hydraulic system…3307
Hydraulic equipment layout drawing…3307
Valve control…3309
Hydraulic tank…3311
CLSS…3313
Main pump…3318
Control valve…3342
Swing motor…3395
Travel motor…3406
PPC valve…3420
Solenoid valve…3441
Attachment circuit selector valve (for high pressure circuit)…3444
Attachment circuit selector valve (for low pressure circuit)…3446
Center swivel joint…3449
Accumulator…3451
Work equipment…3452
Work equipment…3452
Work equipment shim…3453
Bucket play adjustment shim…3454
Cab and its attachments…3455
Cab mount and cab tipping stopper…3455
ROPS cab…3456
Electrical system…3457
Electrical control system…3457
Machine monitor system…3500
KOMTRAX system…3519
Sensors…3521
20 Standard value tablePC290LC-…3538
Standard service value table…3540
Standard value table for engine related parts…3540
Standard value table for chassis related parts…3542
30 Testing Adjusting…3556
General information on testing and adjusting…3558
Tools for testing and adjusting…3558
Sketch of tools for testing and adjusting…3562
Engine and cooling system…3564
Checking engine speed…3564
Measuring boost pressure…3565
Measuring exhaust gas color…3566
Measuring and adjusting valve clearance…3568
Measuring compression pressure…3571
Measuring blowby pressure…3575
Measuring engine oil pressure…3576
Measuring EGR valve and KVGT oil pressure…3577
Measuring fuel pressure…3578
Measuring fuel delivery, return and leakage…3584
Bleeding air from fuel system…3589
Checking fuel circuit for leakage…3591
Handling cylinder cutout mode operation…3592
Handling no injection cranking operation…3593
Checking and adjusting air conditioner compressor belt tension…3594
Replacing fan belt…3595
Power train…3596
Testing swing circle bearing clearance…3596
Undercarriage and frame…3597
Testing and adjusting track shoe tension…3597
Hydraulic system…3598
Releasing remaining pressure from hydraulic circuit…3598
Measuring and adjusting of oil pressure in work equipment, swing, and travel circuits…3599
Measuring oil pressure in control circuit…3603
Measuring and adjusting oil pressure in pump PC control circuit…3604
Measuring and adjusting oil pressure in pump LS control circuit…3607
Measuring solenoid valve output pressure…3612
Measuring PPC valve output pressure…3615
Adjusting play of work equipment and swing PPC valves…3617
Testing pump swash plate sensor…3618
Isolating the parts causing hydraulic drift in work equipment…3619
Measuring oil leakage…3620
Bleeding air from hydraulic circuit…3623
Cab and its attachments…3625
Checking cab tipping stopper…3625
Adjusting mirrors…3626
Electrical system…3628
Special functions of machine monitor…3628
Angle adjustment of rear view camera…3698
Handling voltage circuit of engine controller…3700
Handling battery disconnect switch…3701
Testing diodes…3702
Pm clinic…3703
Pm clinic service…3703
40 Troubleshooting…3714
General information on troubleshooting…3722
Instruction on troubleshooting…3722
How to proceed troubleshooting…3724
Testing before troubleshooting…3725
Testing procedure before troubleshooting…3727
Preparation work for troubleshooting of electrical system…3755
Classification and procedure for troubleshooting…3759
Symptom of probable failure and troubleshooting No…3762
Information mentioned in troubleshooting table…3765
Diagnostic procedure for wiring harness open curcuit of pressure sensor system…3768
Connector list and layout…3770
Connector contact identification…3781
T-branch box and T-branch adapter table…3818
Fuse list and location…3824
Precautions for cleaning and replacing KDPF (KCSF, KDOC)…3826
Failure codes table…3828
Troubleshooting by failure code (Display of code)…3837
Failure code [879AKA] A/C Inner Sensor Open Circuit…3837
Failure code [879AKB] A/C Inner Sensor Short Circuit…3838
Failure code [879BKA] A/C Outer Sensor Open Circuit…3839
Failure code [879BKB] A/C Outer Sensor Short Circuit…3840
Failure code [879CKA] Ventilating Sensor Open Circuit…3841
Failure code [879CKB] Ventilating Sensor Short Circuit…3842
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit…3843
Failure code [879EMC] Ventilation Damper Abnormality…3844
Failure code [879FMC] Air Mix Damper Abnormality…3845
Failure code [879GKX] Refrigerant Abnormality…3846
Failure code [989L00] Engine Controller Lock Caution1…3847
Failure code [989M00] Engine Controller Lock Caution2…3848
Failure code [989N00] Engine Controller Lock Caution3…3849
Failure code [A1U0N3] HC desorb request1…3850
Failure code [A1U0N4] HC desorb request2…3852
Failure code [AA10NX] Air Cleaner Clogging…3854
Failure code [AB00KE] Charge Voltage Low…3856
Failure code [B@BAZG] Engine Oil Pressure Low…3858
Failure code [B@BAZK] Eng Oil Level Low…3859
Failure code [B@BCNS] Engine Coolant Overheat…3860
Failure code [B@BCZK] Radiator Coolant Level Low…3861
Failure code [B@HANS] Hyd Oil Overheat…3863
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…3864
Failure code [CA122] Chg Air Press Sensor High Error…3865
Failure code [CA123] Chg Air Press Sensor Low Error…3867
Failure code [CA131] Throttle Sensor High Error…3869
Failure code [CA132] Throttle Sensor Low Error…3871
Failure code [CA144] Coolant Temp Sens High Error…3873
Failure code [CA145] Coolant Temp Sens Low Error…3875
Failure code [CA153] Chg Air Temp Sensor High Error…3877
Failure code [CA154] Chg Air Temp Sensor Low Error…3879
Failure code [CA187] Sensor 2 Supply Volt Low Error…3881
Failure code [CA221] Ambient Press Sensor High Error…3883
Failure code [CA222] Ambient Press Sensor Low Error…3885
Failure code [CA227] Sensor 2 Supply Volt High Error…3887
Failure code [CA234] Eng Overspeed…3888
Failure code [CA238] Ne Speed Sensor Supply Volt Error…3889
Failure code [CA239] Ne Speed Sens Supply Volt High Error…3890
Failure code [CA271] IMV/PCV1 Short Error…3891
Failure code [CA272] IMV/PCV1 Open Error…3893
Failure code [CA295] Ambient Press Sens In Range Error…3894
Failure code [CA322] Inj #1(L#1) Open/Short Error…3895
Failure code [CA323] Inj #5(L#5) Open/Short Error…3897
Failure code [CA324] Inj #3(L#3) Open/Short Error…3899
Failure code [CA325] Inj #6(L#6) Open/Short Error…3901
Failure code [CA331] Inj #2(L#2) Open/Short Error…3903
Failure code [CA332] Inj #4(L#4) Open/Short Error…3905
Failure code [CA343] ECM Critical Internal Failure…3907
Failure code [CA351] Injectors Drive Circuit Error…3908
Failure code [CA352] Sensor 1 Supply Volt Low Error…3909
Failure code [CA356] Mass Air Flow Sensor High Error…3911
Failure code [CA357] Mass Air Flow Sensor Low Error…3913
Failure code [CA386] Sensor 1 Supply Volt High Error…3915
Failure code [CA428] Water in Fuel Sensor High Error…3916
Failure code [CA429] Water in Fuel Sensor Low Error…3918
Failure code [CA435] Eng Oil Press Sw Error…3920
Failure code [CA441] Battery Voltage Low Error…3921
Failure code [CA442] Battery Voltage High Error…3923
Failure code [CA449] Rail Press Very High Error…3924
Failure code [CA451] Rail Press Sensor High Error…3925
Failure code [CA452] Rail Press Sensor Low Error…3927
Failure code [CA488] Chg Air Temp High Torque Derate…3928
Failure code [CA515] Rail Press Sens Sup Volt High Error…3929
Failure code [CA516] Rail Press Sens Sup Volt Low Error…3931
Failure code [CA553] Rail Press High Error…3933
Failure code [CA555] Crankcase Press High Error 1…3934
Failure code [CA556] Crankcase Press High Error 2…3935
Failure code [CA559] Rail Press Low Error…3936
Failure code [CA595] Turbo Speed High Error 2…3938
Failure code [CA687] Turbo Speed Low Error…3939
Failure code [CA689] Eng Ne Speed Sensor Error…3941
Failure code [CA691] Intake Air Temp Sens High Error…3943
Failure code [CA692] Intake Air Temp Sens Low Error…3945
Failure code [CA697] ECM Int Temp Sensor High Error…3947
Failure code [CA698] ECM Int Temp Sensor Low Error…3948
Failure code [CA731] Eng Bkup Speed Sens Phase Error…3949
Failure code [CA778] Eng Bkup Speed Sensor Error…3950
Failure code [CA1117] Persistent Data Lost Error…3954
Failure code [CA1664] KDOC Malfunction…3955
Failure code [CA1691] Regeneration Ineffective…3957
Failure code [CA1695] Sensor 5 Supply Volt Low Error…3959
Failure code [CA1696] Sensor 5 Supply Volt High Error…3961
Failure code [CA1843] Crankcase Press Sens High Error…3963
Failure code [CA1844] Crankcase Press Sens Low Error…3965
Failure code [CA1879] KDPF Delta P Sensor High Error…3967
Failure code [CA1881] KDPF Delta P Sensor Low Error…3969
Failure code [CA1883] KDPF Delta P Sens In Range Error…3971
Failure code [CA1921] KDPF Soot Load High Error 1…3974
Failure code [CA1922] KDPF Soot Load High Error 2…3976
Failure code [CA1942] Crankcase Press Sens In Range Error…3980
Failure code [CA1993] KDPF Delta Pressure Low Error…3981
Failure code [CA2185] Throt Sensor Sup Volt High Error…3982
Failure code [CA2186] Throt Sensor Sup Volt Low Error…3983
Failure code [CA2249] Rail Press Very Low Error…3984
Failure code [CA2271] EGR Valve Pos Sens High Error…3985
Failure code [CA2272] EGR Valve Pos Sens Low Error…3987
Failure code [CA2288] Turbo Speed High Error 1…3990
Failure code [CA2311] IMV Solenoid Error…3991
Failure code [CA2349] EGR Valve Solenoid Open Error…3992
Failure code [CA2353] EGR Valve Solenoid Short Error…3994
Failure code [CA2357] EGR Differential Pressure…3996
Failure code [CA2373] Exh Manifold Press. Sens Volt…3997
Failure code [CA2374] Exhaust Manifold Press Sens Low Error…3999
Failure code [CA2375] EGR Orifice Temp Sens High Error…4001
Failure code [CA2376] EGR Orifice Temp Sens Low Error…4003
Failure code [CA2381] KVGT Pos Sens High Error…4005
Failure code [CA2382] KVGT Pos Sens Low Error…4007
Failure code [CA2383] KVGT Solenoid Open Error…4009
Failure code [CA2386] KVGT Solenoid Short Error…4011
Failure code [CA2387] KVGT Servo Error…4013
Failure code [CA2554] Exh Manifold Press Sens In Range Error…4014
Failure code [CA2555] Grid Htr Relay Volt Low Error…4015
Failure code [CA2556] Grid Htr Relay Volt High Error…4017
Failure code [CA2637] KDOC Face Plugging…4019
Failure code [CA2639] Manual Stationary Regeneration Request…4021
Failure code [CA2961] EGR Orifice Temp High Error 1…4023
Failure code [CA2973] Chg Air Press Sensor In Range Error…4024
Failure code [CA3133] KDPF Outlet Press Sens High Error…4025
Failure code [CA3134] KDPF Outlet Press Sens Low Error…4027
Failure code [CA3135] KDPF Outlet Press Sens In Range Error…4029
Failure code [CA3251] DOC Inlet Temp High Error…4032
Failure code [CA3253] KDOC Temp Error – Non Regeneration…4035
Failure code [CA3254] KDOC Outlet Temp High Error 1…4036
Failure code [CA3255] KDPF Temp Error – Non Regeneration…4039
Failure code [CA3256] KDPF Outlet Temp High Error 1…4040
Failure code [CA3311] KDOC Outlet Temp High Error 2…4041
Failure code [CA3312] KDPF Outlet Temp High Error 2…4042
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error…4044
Failure code [CA3314] KDOC Inlet Temp Sens High Error…4047
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error…4051
Failure code [CA3316] KDOC Outlet Temp Sens Low Error…4055
Failure code [CA3317] KDOC Outlet Temp Sens High Error…4058
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error…4062
Failure code [CA3319] KDPF Outlet Temp Sens High Error…4066
Failure code [CA3321] KDPF Outlet Temp Sens Low Error…4070
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error…4073
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error…4077
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error…4078
Failure code [CA3741] Rail Press Valve Trip Error…4080
Failure code [D110KB] Battery Relay Output Voltage…4081
Failure code [D19JKZ] Personal Code Relay Abnormality…4083
Failure code [D811MC] KOMTRAX Error…4086
Failure code [D862KA] GPS Antenna Open Circuit…4087
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX)…4088
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)…4090
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)…4091
Failure code [DA20MC] Pump Controller…4092
Failure code [DA22KK] Pump Solenoid Power Low Error…4093
Failure code [DA25KP] 5V Sensor 1 Power Abnormality…4095
Failure code [DA29KQ] Model Selection Abnormality…4098
Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con)…4100
Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con)…4102
Failure code [DA2QKR] CAN2 Discon (Pump Con)…4103
Failure code [DA2QKR] CAN1 Discon (Pump Con)…4105
Failure code [DAF0MB] Monitor ROM Abnormality…4106
Failure code [DAF0MC] Monitor Error…4107
Failure code [DAF8KB] Camera Power Supply Short Circuit…4108
Failure code [DAF9KQ] Model Selection Abnormality…4110
Failure code [DAFGMC] GPS Module Error…4111
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor)…4112
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor)…4114
Failure code [DAFQKR] CAN2 Discon (Monitor)…4115
Failure code [DAZ9KQ] A/C Model Selection Abnormality…4116
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)…4117
Failure code [DB2QKR] CAN2 Discon (Engine Con)…4121
Failure code [DB2RKR] CAN1 Discon (Engine Con)…4126
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit…4130
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit…4132
Failure code [DHPAMA] F Pump Press Sensor Abnormality…4133
Failure code [DHPBMA] R Pump Press Sensor Abnormality…4136
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality…4139
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality…4141
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality…4144
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality…4147
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality…4150
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality…4153
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality…4156
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality…4159
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality…4162
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality…4165
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality…4168
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality…4171
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality…4174
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality…4177
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality…4180
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality…4182
Failure code [DV20KB] Travel Alarm Short Circuit…4184
Failure code [DW43KA] Travel Speed Sol Open Circuit…4186
Failure code [DW43KB] Travel Speed Sol Short Circuit…4188
Failure code [DW45KA] Swing Brake Sol Open Circuit…4190
Failure code [DW45KB] Swing Brake Sol Short Circuit…4192
Failure code [DW91KA] Travel Junction Sol Open Circuit…4195
Failure code [DW91KB] Travel Junction Sol Short Circuit…4197
Failure code [DWA2KA] Attachment Sol Open Circuit…4199
Failure code [DWA2KB] Attachment Sol Short Circuit…4201
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit…4203
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit…4205
Failure code [DWK2KA] Variable Back Press Sol Open Circuit…4207
Failure code [DWK2KB] Variable Back Press Sol Short Circuit…4209
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit…4211
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit…4213
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit…4215
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit…4217
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit…4219
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit…4221
Failure code [DXE0KA] LS-EPC Sol Open Circuit…4223
Failure code [DXE0KB] LS-EPC Sol Short Circuit…4225
Failure code [DXE4KA] Attachment Flow EPC Open Circuit…4227
Failure code [DXE4KB] Attachment Flow EPC Short Circuit…4229
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit…4231
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit…4233
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit…4235
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit…4237
Failure code [DY20KA] Wiper Working Abnormality…4239
Failure code [DY20MA] Wiper Parking Abnormality…4241
Failure code [DY2CKB] Washer Drive Short Circuit…4243
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit…4245
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit…4247
Troubleshooting of electrical system (E-mode)…4249
E-1 Engine does not start (Engine does not rotate)…4249
E-2 Manual preheating system does not work…4255
E-3 Automatic preheating system does not work…4258
E-4 Preheating monitor does not light up when preheater is operated…4260
E-5 When starting switch is turned to ON position, machine monitor displays nothing…4262
E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow…4265
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow…4266
E-8 Coolant temperature monitor lights up in white while engine is running…4267
E-9 Hydraulic oil temperature monitor lights up in white while engine is running…4268
E-10 Charge level monitor lights up while engine is running…4269
E-11 Fuel level monitor lights up in red while engine is running…4270
E-12 Air cleaner clogging monitor lights up in yellow while engine is running…4271
E-13 Water separator monitor lights up while engine is running…4272
E-14 Coolant temperature monitor lights up in red while engine is running…4273
E-15 Hydraulic oil temperature monitor lights up in red while engine is running…4274
E-16 Engine oil pressure monitor lights up in red while engine is running…4275
E-17 Fuel gauge indicate either full or empty and does not move…4276
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)…4277
E-19 Coolant temperature gauge indicate either Min or Max and does not move…4278
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max)…4279
E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move…4280
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max)…4282
E-23 Content of display on machine monitor is different from that of actual machine…4283
E-24 Machine monitor does not display some items…4284
E-25 Function switch does not work…4285
E-26 Automatic preheating system does not work (In cold season)…4286
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated…4287
E-28 Auto-deceleration is not actuated or canceled when lever is operated…4288
E-29 Working mode selector screen selection screen is not diplayed when working mode switch is operated…4290
E-30 Engine or hydraulic pump setting does not change when working mode is changed…4291
E-31 Travel speed monitor does not change when travel speed switch is operated…4292
E-32 Travel speed does not change when travel speed is shifted…4293
E-33 Alarm buzzer does not stop sounding…4294
E-34 When starting switch is turned to OFF position, service meter is notdis played…4295
E-35 Service mode cannot be selected…4296
E-36 Any of work equipment, swing and travel does not work…4297
E-37 Any of work equipment, swing and travel can not be locked…4299
E-38 Machine can not swing while swing brake cancel switch is canceled…4300
E-39 Swing brake does not operate while swing brake cancel switch is locked…4302
E-40 One-touch power maximizing function does not work or monitor is not displayed…4304
E-41 One-touch power maximizing function cannot be released…4306
E-42 Travel alarm does not sound when machine travels…4307
E-43 Travel alarm does not stop sounding when machine stops…4308
E-44 Horn does not sound…4309
E-45 Horn does not stop sounding…4311
E-46 Wiper monitor does not light up or go out when wipper switch is operated…4312
E-47 Wiper does not operate when wipper switch is operated…4313
E-48 Window washer does not operate when window washer switch is operated…4315
E-49 BOOM LOWER indication is not displayed properly with monitoring function…4316
E-50 ARM DUMP indication is not displayed properly with monitoring function…4317
E-51 ARM IN indication is not displayed properly with monitoring function…4318
E-52 BOOM RAISE indication is not displayed properly with monitoring function…4319
E-53 BUCKET CURL indication is not displayed properly with monitoring function…4320
E-54 BUCKET DUMP indication is not displayed properly with monitoring function…4321
E-55 SWING indication is not displayed properly with monitoring function…4322
E-56 TRAVEL indication is not displayed properly with monitoring function…4323
E-57 Service is not displayed properly with monitoring function…4324
E-58 Attachment hydraulic circuit cannot be changed…4327
E-59 KOMTRAX system does not work properly…4328
Troubleshooting of hydraulic and mechanical system (H-mode)…4329
Information mentioned in troubleshooting table (H mode)…4329
System chart for hydraulic system…4330
Failure mode and cause table…4332
H-1 All of work equipment, swing and travel operation lacks speed or power…4340
H-2 Engine speed lowers significantly or engine stalls…4343
H-3 Any of work equipment, swing and travel does not work…4345
H-4 Unusual sound is heard from around hydraulic pump…4346
H-5 Fine control performance or response is poor…4347
H-6 Boom operation lacks speed or power…4348
H-7 Arm operation lacks speed or power…4350
H-8 Bucket operation lacks speed or power…4352
H-9 Work equipment does not move in single operation…4353
H-10 Hydraulic drift of boom is large…4354
H-11 Hydraulic drift of arm is large…4355
H-12 Hydraulic drift of bucket is large…4356
H-13 Time lag of work equipment is large…4357
H-14 When part of work equipment is relieved singly, other parts of work equipment move…4359
E-15 One-touch power maximizing function does not work…4360
H-16 In combined operation of work equipment, equipment having heavier load moves slower…4361
H-17 In combined operations of swing and boom RAISE, boom rising speed is low…4362
H-18 In combined operations of swing and travel, travel speed drops largely…4363
H-19 Machine does not travel straight…4364
H-20 Travel speed is too low…4365
H-21 Machine is hard to steer or travel power is low…4367
H-22 Travel speed does not change, or travel speed is too low or high…4369
H-23 One of tracks dose not run…4370
H-24 Upper structure does not swing to the right or left…4371
H-25 Upper structure swing only to the right or left…4372
H-26 Swing acceleration is poor or swing speed is low (both right and left)…4373
H-27 Swing acceleration is poor or swing speed is low (either right or left)…4374
H-28 Upper structure overruns excessively when it stops swinging (both right and left)…4375
H-29 Upper structure overruns excessively when it stops swinging (either right or left)…4376
H-30 Shock is large when upper structure stops swinging…4377
H-31 Large unusual noise is heard when upper structure stops swinging…4378
H-32 Swing drift on a slope is large while swing holding brake is applied…4379
H-33 Swing drift on a slope is large while swing holding brake is released…4380
H-34 Attachment circuit cannot be changed while attachment is installed…4381
H-35 Oil flow in attachment circuit cannot be controlled…4382
Troubleshooting of engine (S-mode)…4383
Information mentioned in troubleshooting table (S mode)…4383
S-1 When starting switch is turned to START position, engine does not crank…4384
S-2 When engine cranks, smoke does not come out…4385
S-3 Engine does not start while fuel is injected (Incomplete combustion)…4386
S-4 Startability is poor…4387
S-5 Engine does not pick up smoothly…4389
S-6 Engine stops during operation…4390
S-7 Engine runs rough or is unstable…4392
S-8 Engine lacks power…4393
S-9 Exhaust smoke is black (KDPF clogs up early)…4395
S-10 Engine oil consumption is too much…4397
S-11 Oil becomes contaminated early…4398
S-12 Fuel consumption is excessive…4399
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)…4400
S-14 Engine oil pressure drops…4401
S-15 Fuel is contaminated in engine oil…4402
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)…4403
S-17 Coolant temperature rises too high (Overheating)…4404
S-18 Unusual noise is heard…4405
S-19 Vibration is excessive…4406
S-20 Automatic regeneration is operated frequently…4407
S-21 Active regeneration is operated for long…4408
S-22 White smoke comes out in the process of active regeneration…4409
50 Disassembly and assembly…4410
General information on disassembly and assembly…4413
How to read this manual…4413
Coating materials list…4415
Special tools list…4419
Sketches of special tools…4423
Engine and cooling system…4426
Removal and installation of supply pump assembly…4426
Removal and installation of injector assembly…4431
Removal and installation of cylinder head assembly…4440
Removal and installation of radiator assembly…4460
Removal and installation of hydraulic oil cooler assembly…4462
Removal and installation of aftercooler assembly Removal…4465
Removal and installation of engine and main pump assembly…4467
Removal and installation of engine front oil seal…4479
Removal and installation of engine rear oil seal…4483
Removal and installation of fuel cooler assembly…4486
Removal and installation of fuel tank assembly…4487
Removal and installation of engine hood assembly…4490
Removal and installation of KDPF assembly…4493
Disassembly and assembly of KDPF…4501
Removal and installation of KCCV assembly…4509
Removal and installation of air cleaner assembly…4511
Power train system…4514
Removal and installation of travel motor and final drive assembly…4514
Disassembly and assembly of final drive…4515
Removal and installation of swing motor and swing machinery assembly…4523
Disassembly and assembly of swing machinery…4526
Removal and installation of swing circle assembly…4534
Undercarriage and frame…4535
Separation and connection of track shoe assembly…4535
Removal and installation of sprocket…4537
Removal and installation of idler and idler cushion assembly…4538
Disassembly and assembly of idler…4539
Disassembly and assembly of idler cushion…4542
Disassembly and assembly of track roller…4544
Disassembly and assembly of carrier roller…4546
Removal and installation of revolving frame assembly…4549
Removal and installation of counterweight assembly…4551
Hydraulic system…4554
Removal and installation of center swivel joint assembly…4554
Disassembly and assembly of center swivel joint…4556
Removal and installation of hydraulic tank assembly…4557
Removal and installation of main pump assembly…4561
Removal and installation of control valve assembly…4565
Disassembly and assembly of control valve…4572
Disassembly and assembly of work equipment PPC valve…4576
Disassembly and assembly of travel PPC valve…4578
Work equipment…4581
Removal and installation of work equipment assembly…4581
Disassembly and assembly of work equipment cylinder…4584
Cab and its attachments…4590
Removal and installation of operator's cab assembly…4590
Removal and installation of operator cab glass (adhered glass)…4595
Removal and installation of front window assembly…4603
Removal and installation of floor frame assembly…4609
Removal and installation of air conditioner unit assembly…4615
Removal and installation of operator's seat…4619
Removal and installation of seat belt…4621
Removal and installation of front wiper assembly…4623
Electric system…4629
Removal and installation of air conditioner compressor assembly…4629
Removal and installation of air conditioner condenser assembly…4632
Removal and installation of engine controller assembly…4634
Removal and installation of pump controller assembly…4636
Removal and installation of machine monitor assembly…4639
Removal and installation of pump swash plate sensor…4641
Removal and installation of Mass air flow and temperature sensor…4642
Removal and installation of KOMTRAX terminal assembly…4643
60 Maintenance standard…4644
Engine and cooling system…4646
Engine mount…4646
Cooling system…4647
Power train system…4648
Swing circle…4648
Swing machinery…4649
Final drive…4651
Sprocket…4653
Undercarriage and frame…4655
Truck frame and idler cushion…4655
Idler…4657
Track roller…4659
Carrier roller…4661
Truck shoe…4662
Hydraulic system…4665
Hydraulic tank…4665
Main pump…4666
Control valve…4667
Swing motor…4675
Travel motor…4677
PPC valve…4680
Solenoid valve…4689
Attachment circuit selector valve (for high-pressure circuit)…4690
Attachment circuit selector valve (for low-pressure circuit)…4691
Center swivel joint…4692
Work equipment…4693
80 Appendix…4704
Air conditioner…4706
Precautions for refrigerant…4706
Air conditioner component…4707
Configuration and function of refrigeration cycle…4709
Outline of refrigeration cycle…4710
Air conditioner unit…4712
Dual pressure switch…4718
Air conditioner controller…4719
Air conditioner compressor…4720
Air conditioner condenser…4721
Sunlight sensor…4723
Outside air temperature sensor…4724
Procedure for testing and troubleshooting…4725
Circuit diagram and arrangement of connector pins…4727
System diagram…4729
Input and output signals of the air conditioner controller…4730
Parts and connectors layout…4732
Layout of air conditioner related parts and connectors…4733
Testing air leakage (duct)…4736
Testing with self-diagnosis function…4739
How to enter air conditioner "Electrical Systems" screen in service mode of the machine monitor…4740
Testing vent (mode) changeover…4742
Testing FRESH/RECIRC air changeover…4744
Testing sunlight sensor…4745
Testing (dual) pressure switch for refrigerant…4746
Testing relays…4748
Troubleshooting chart 1…4749
Troubleshooting chart 2…4750
Information mentioned in troubleshooting table…4753
Failure code list related to air conditioner…4754
Failure code [879AKA] A/C Inner sensor Open Circuit…4755
Failure code [879AKB] A/C Inner sensor Short Circuit…4756
Failure code [879BKA] A/C Outer sensor Open Circuit…4757
Failure code [879BKB] A/C Outer sensor Short Circuit…4759
Failure code [879CKA] Ventilating sensor Open Circuit…4761
Failure code [879CKB] Ventilating sensor Short Circuit…4762
Failure code [879DKZ] Sunlight sensor Open or Short Circuit…4763
Failure code [879EMC] Ventilating Damper Abnormality…4765
Failure code [879FMC] Air Mix Damper Abnormality…4766
Failure code [879GKX] Refrigerant Abnormality…4767
A-2 Troubleshooting of compressor system (Air is not cooled)…4770
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)…4773
A-4 Troubleshooting for FRESH/RECIRC air changeover…4775
Troubleshooting with gauge pressure…4777
Testing refrigerant pressure…4780
Precautions for disconnecting and connecting air conditioner piping…4783
Handling of compressor oil…4785
Desiccant replacement…4787
90 Diagrams and drawings…4790
Hydraulic circuit diagram…4792
Symbols in hydraulic circuit diagram…4792
Hydraulic circuit diagram…4796
Electric circuit diagram…4797
Symbols in electric circuit diagram…4797
Electrical circuit diagram…4800
Electrical circuit diagram for air conditioner unit…4806
Index…4808
SEN06507-01 – Hydraulic Excavator PC290LC-11 Shop Manual…4818
COVER…4818
00 INDEX AND FOREWORD…4820
INDEX…4821
FOREWORD, SAFETY, BASIC INFORMATION…4837
HOW TO READ THE SHOP MANUAL…4837
SAFETY NOTICE FOR OPERATION…4839
PRECAUTIONS TO PREVENT FIRE…4845
ACTION IF FIRE OCCURS…4847
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…4848
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS…4849
PRECAUTIONS FOR AdBlue/DEF…4850
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING…4850
PRECAUTIONS FOR ADDING…4850
PRECAUTIONS FOR STORING…4850
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE…4850
THE OTHER PRECAUTIONS…4850
STORE AdBlue/DEF…4851
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…4852
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…4854
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT…4860
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…4863
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT…4864
PRACTICAL USE OF KOMTRAX…4865
METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL TYPE COUPLER…4866
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…4866
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…4867
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…4868
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…4869
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR…4873
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…4874
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…4876
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…4877
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE…4879
HOW TO READ ELECTRICAL WIRE CODE…4880
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…4884
LIST OF ABBREVIATION…4887
STANDARD TIGHTENING TORQUE TABLE…4892
CONVERSION TABLE…4899
01 SPECIFICATION…4904
CONTENTS…4905
SPECIFICATIONS…4906
SPECIFICATION DRAWING…4906
SPECIFICATION DRAWING: PC290LC-11…4906
WORKING RANGE DRAWINGS…4907
WORKING RANGE: PC290LC-11…4907
SPECIFICATIONS…4908
SPECIFICATIONS: PC290LC-11…4908
WEIGHT TABLE…4911
WEIGHT TABLE: PC290LC-11…4911
TABLE OF FUEL, COOLANT, AND LUBRICANTS…4913
10 STRUCTURE AND FUNCTION…4914
CONTENTS…4915
UREA SCR SYSTEM…4918
LAYOUT DRAWING OF UREA SCR SYSTEM…4918
UREA SCR SYSTEM DIAGRAM…4924
FUNCTION OF UREA SCR SYSTEM…4925
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM…4925
INDUCEMENT STRATEGY…4927
COMPONENT PARTS OF UREA SCR SYSTEM…4939
AdBlue/DEF MIXING TUBE…4939
SCR ASSEMBLY…4939
AdBlue/DEF TANK…4942
AdBlue/DEF PUMP…4944
AdBlue/DEF INJECTOR…4945
AdBlue/DEF HOSE…4946
AdBlue/DEF TANK HEATING VALVE…4947
BOOT-UP SYSTEM…4948
LAYOUT DRAWING OF BOOT-UP SYSTEM…4948
SYSTEM OPERATING LAMP SYSTEM…4950
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…4950
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM…4950
BATTERY DISCONNECT SWITCH…4951
FUNCTION OF BATTERY DISCONNECT SWITCH…4951
ENGINE SYSTEM…4952
LAYOUT DRAWING OF ENGINE RELATED PARTS…4952
SPECIFICATIONS OF ENGINE RELATED PARTS…4953
FUNCTIONS OF ENGINE RELATED PARTS…4953
ENGINE CONTROL SYSTEM…4954
ENGINE CONTROL SYSTEM DIAGRAM…4954
FUNCTION OF ENGINE CONTROL SYSTEM…4955
AUTO-DECELERATION SYSTEM…4957
AUTO-DECELERATION SYSTEM DIAGRAM…4957
FUNCTION OF AUTO-DECELERATION SYSTEM…4957
OPERATION OF AUTO-DECELERATION SYSTEM…4958
ENGINE AUTOMATIC WARM-UP SYSTEM…4959
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM…4959
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM…4960
OVERHEAT PREVENTION SYSTEM…4961
OVERHEAT PREVENTION SYSTEM DIAGRAM…4961
FUNCTION OF OVERHEAT PREVENTION SYSTEM…4962
TURBOCHARGER PROTECTION SYSTEM…4964
TURBOCHARGER PROTECTION SYSTEM DIAGRAM…4964
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM…4965
AUTOMATIC IDLE STOP SYSTEM…4966
AUTOMATIC IDLE STOP SYSTEM DIAGRAM…4966
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM…4966
COMPONENT PARTS OF ENGINE SYSTEM…4969
KVGT…4969
EGR SYSTEM…4970
EGR VALVE…4972
EGR COOLER…4974
KCCV SYSTEM…4975
KCCV VENTILATOR…4977
KDPF…4978
COOLING SYSTEM…4984
LAYOUT DRAWING OF COOLING SYSTEM…4984
SPECIFICATIONS OF COOLING SYSTEM…4985
CONTROL SYSTEM…4986
LAYOUT DRAWING OF ELECTRICAL CONTROL SYSTEM…4986
MACHINE MONITOR SYSTEM…4989
MACHINE MONITOR SYSTEM DIAGRAM…4989
KOMTRAX SYSTEM…4990
KOMTRAX SYSTEM DIAGRAM…4990
FUNCTION OF KOMTRAX SYSTEM…4990
COMPONENT PARTS OF CONTROL SYSTEM…4991
MACHINE MONITOR…4991
KOMTRAX TERMINAL…5002
PUMP CONTROLLER…5004
REGISTER FOR PC-EPC VALVE…5008
CAN TERMINATING RESISTOR…5009
ENGINE CONTROLLER…5010
FUEL CONTROL DIAL…5016
HYDRAULIC SYSTEM…5018
LAYOUT DRAWING OF HYDRAULIC COMPONENT…5018
CLSS…5024
STRUCTURE OF CLSS…5024
OPERATION OF UNLOAD VALVE AND LS PRESSURE…5026
PUMP SWASH PLATE ANGLE (OILFLOW) CONTROL…5027
PRESSURE COMPENSATION CONTROL…5039
ENGINE AND PUMP COMBINED CONTROL SYSTEM…5042
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM…5042
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM…5043
PUMP AND VALVE CONTROL SYSTEM…5048
PUMP AND VALVE CONTROL SYSTEM DIAGRAM…5048
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM…5049
COMPONENT PARTS OF HYDRAULIC SYSTEM…5051
HYDRAULIC TANK…5051
MAIN PUMP…5053
PC-EPC VALVE…5078
CONTROL VALVE…5079
WORK EQUIPMENT SYSTEM…5135
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM…5135
STRUCTURE OF VALVE CONTROL…5140
ONE-TOUCH POWER MAXIMIZING SYSTEM…5142
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM…5142
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM…5143
MACHINE PUSH-UP SYSTEM…5144
MACHINE PUSH-UP SYSTEM DIAGRAM…5144
FUNCTION OF MACHINE PUSH-UP SYSTEM…5145
PPC LOCK SYSTEM…5146
PPC LOCK SYSTEM DIAGRAM…5146
FUNCTION OF PPC LOCK SYSTEM…5146
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…5147
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…5147
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…5147
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT…5149
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT…5149
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT…5150
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…5151
WORK EQUIPMENT AND SWING PPC VALVE…5151
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)…5156
SOLENOID VALVE…5163
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)…5165
PILOT CIRCUIT ACCUMULATOR…5167
SWING CONTROL SYSTEM…5169
LAYOUT DRAWING OF SWING SYSTEM…5169
SWING CONTROL SYSTEM DIAGRAM…5173
FUNCTION OF SWING CONTROL SYSTEM…5173
OPERATION OF SWING CONTROL SYSTEM…5176
COMPONENT PARTS OF SWING SYSTEM…5177
SWING MOTOR…5177
SWING MACHINERY…5188
SWING CIRCLE…5189
TRAVEL SYSTEM…5191
LAYOUT DRAWING OF TRAVEL SYSTEM…5191
TRAVEL CONTROL SYSTEM DIAGRAM…5195
FUNCTION OF TRAVEL CONTROL SYSTEM…5195
COMPONENT PARTS OF TRAVEL SYSTEM…5197
TRAVEL MOTOR…5197
FINAL DRIVE…5209
TRAVEL PPC VALVE…5210
CENTER SWIVEL JOINT…5215
UNDERCARRIAGE AND FRAME…5217
LAYOUT DRAWING OF UNDERCARRIAGE…5217
SPECIFICATIONS OF UNDERCARRIAGE…5218
WORK EQUIPMENT…5219
STRUCTURE OF WORK EQUIPMENT…5219
FUNCTION OF WORK EQUIPMENT…5220
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…5221
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…5221
BUCKET CLEARANCE ADJUSTMENT SHIM…5222
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM…5222
CAB AND ITS ATTACHMENTS…5223
ROPS CAB…5223
STRUCTURE OF ROPS CAB…5223
FUNCTION OF ROPS CAB…5223
CAB MOUNT…5224
STRUCTURE OF CAB MOUNT…5224
FUNCTION OF CAB MOUNT…5224
CAB TIPPING STOPPER…5225
STRUCTURE OF CAB TIPPING STOPPER…5225
FUNCTION OF CAB TIPPING STOPPER…5225
20 STANDARD VALUE TABLE…5226
CONTENTS…5227
STANDARD VALUE TABLE FOR ENGINE…5228
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11…5228
STANDARD VALUE TABLE FOR MACHINE…5232
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11…5232
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE…5244
STANDARD VALUE TABLE FOR ELECTRICAL…5249
STANDARD VALUE TABLE FOR ELECTRICAL…5249
30 TESTING AND ADJUSTING…5260
CONTENTS…5261
RELATED INFORMATION ON TESTING AND ADJUSTING…5264
TOOLS FOR TESTING AND ADJUSTING…5264
SKETCH OF TOOLS FOR TESTING AND ADJUSTING…5270
ENGINE AND COOLING SYSTEM…5271
TEST ENGINE SPEED…5271
METHOD FOR TESTING ENGINE SPEED…5271
TEST BOOST PRESSURE…5274
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR…5274
METHOD FOR TESTING BOOST PRESSURE…5275
TEST EXHAUST GAS COLOR…5276
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER…5276
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER…5277
TEST AND ADJUST VALVE CLEARANCE…5279
METHOD FOR TESTING VALVE CLEARANCE…5279
METHOD FOR ADJUSTING VALVE CLEARANCE…5280
TEST COMPRESSION PRESSURE…5281
METHOD FOR TESTING COMPRESSION PRESSURE…5281
TEST BLOWBY PRESSURE…5286
METHOD FOR TESTING BLOWBY PRESSURE…5286
TEST ENGINE OIL PRESSURE…5288
METHOD FOR TESTING ENGINE OIL PRESSURE…5288
TEST EGR VALVE AND KVGT OIL PRESSURE…5289
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE…5289
TEST FUEL PRESSURE…5291
METHOD FOR TESTING FUEL PRESSURE…5292
TEST FUEL DISCHARGE, RETURN AND LEAKAGE…5297
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE…5298
BLEEDING AIR FROM FUEL SYSTEM…5303
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM…5303
TEST FUEL CIRCUIT FOR LEAKAGE…5304
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…5304
HANDLE CYLINDER CUT-OUT MODE OPERATION…5306
HANDLE NO-INJECTION CRANKING OPERATION…5307
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION…5308
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT…5308
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT…5308
TEST SCR RELATED FUNCTIONS…5310
TEST AdBlue/DEF PUMP RAISED PRESSURE…5313
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR…5314
TEST AdBlue/DEF LINE HEATER RELAY 1…5318
TEST AdBlue/DEF LINE HEATER RELAY 2…5321
TEST AdBlue/DEF PUMP HEATER RELAY…5323
TEST AdBlue/DEF HEATER VALVE…5326
TEST DENITRATION EFFICIENCY OF SCR…5329
CLEAN AdBlue/DEF TANK…5333
METHOD FOR CLEANING AdBlue/DEF TANK…5333
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK…5337
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK…5337
POWER TRAIN…5339
TEST SWING CIRCLE BEARING CLEARANCE…5339
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE…5339
UNDERCARRIAGE AND FRAME…5340
TEST AND ADJUST TRACK TENSION…5340
METHOD FOR TESTING TRACK TENSION…5340
METHOD FOR ADJUSTING TRACK TENSION…5340
HYDRAULIC SYSTEM…5342
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM…5342
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT…5342
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…5343
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…5344
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…5350
TEST OIL PRESSURE OF CONTROL CIRCUIT…5353
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT…5353
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…5355
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)…5355
TEST PC-EPC VALVE OUTLET PRESSURE…5356
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…5357
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT…5358
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR…5358
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL…5359
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)…5362
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE…5363
METHOD FOR ADJUSTING LS VALVE…5364
TEST OUTLET PRESSURE OF SOLENOID VALVE…5365
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…5365
OPERATING CONDITION OF SOLENOID VALVE…5366
TEST PPC VALVE OUTLET PRESSURE…5369
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE…5369
ADJUST WORK EQUIPMENT AND SWING PPC VALVES…5371
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…5371
TEST PUMP SWASH PLATE SENSOR…5372
METHOD FOR TESTING PUMP SWASH PLATE SENSOR…5372
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…5373
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER…5373
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER…5373
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE…5374
TEST OIL LEAKAGE…5375
TEST OIL LEAKAGE OF BOOM CYLINDER…5375
TEST OIL LEAKAGE OF ARM CYLINDER…5375
TEST OIL LEAKAGE OF BUCKET CYLINDER…5376
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR…5376
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR…5376
BLEED AIR FROM HYDRAULIC CIRCUIT…5378
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT…5379
CAB AND ITS ATTACHMENTS…5381
TEST CAB TIPPING STOPPER…5381
METHOD FOR TESTING CAB TIPPING STOPPER…5381
METHOD FOR ADJUSTING MIRRORS…5382
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)…5382
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)…5383
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)…5384
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)…5385
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)…5386
ELECTRICAL SYSTEM…5388
SET AND OPERATE MACHINE MONITOR…5388
OPERATOR MODE…5391
SERVICE MODE…5396
METHOD FOR STARTING UP KOMTRAX TERMINAL…5462
ADJUST REARVIEW CAMERA ANGLE…5467
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE…5467
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…5470
HANDLE BATTERY DISCONNECT SWITCH…5471
TEST DIODES…5472
METHOD FOR TESTING DIODE USING DIGITAL TESTER…5472
METHOD FOR TESTING DIODE USING ANALOG TESTER…5472
Pm CLINIC…5473
Pm CLINIC SERVICE…5473
Pm CLINIC CHECK SHEET…5474
40 TROUBLESHOOTING…5486
CONTENTS…5487
RELATED INFORMATION ON TROUBLESHOOTING…5497
GENERAL TROUBLESHOOTING POINTS…5497
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM…5498
SEQUENCE OF EVENTS IN TROUBLESHOOTING…5511
CHECKS BEFORE TROUBLESHOOTING…5513
CHECKS BEFORE TROUBLESHOOTING…5515
WALK-AROUND CHECK…5515
TESTING IN ACCORDANCE WITH TESTING PROCEDURE…5517
FUEL – CHECK LEVEL AND TYPE…5517
FUEL – CHECK FOR FOREIGN MATERIAL…5517
FUEL PREFILTER – CHECK…5518
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT…5518
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE…5519
MAIN FILTER – CHECK…5520
OIL PAN – CHECK ENGINE OIL LEVEL…5522
RESERVOIR TANK – CHECK COOLANT LEVEL…5523
AIR CLEANER – CHECK FOR CLOGGING…5523
OUTER ELEMENT – CLEAN…5524
ELEMENTS – REPLACE…5526
HYDRAULIC OIL – CHECK OIL LEVEL…5527
HYDRAULIC OIL STRAINER – CHECK…5528
HYDRAULIC OIL FILTER – CHECK…5529
SWING MACHINERY CASE – CHECK OIL LEVEL…5530
DAMPER CASE – CHECK OIL LEVEL…5530
FINAL DRIVE CASE – CHECK OIL LEVEL…5531
FUEL SYSTEM – BLEED AIR…5531
HYDRAULIC CIRCUIT – BLEED AIR…5531
ELECTRICAL EQUIPMENT – CHECK METHOD…5532
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION…5539
PROCEDURE FOR TESTING AND TROUBLESHOOTING…5549
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS…5552
INFORMATION IN TROUBLESHOOTING TABLE…5556
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…5558
CONNECTOR LIST AND LAYOUT…5561
CONNECTOR PIN NUMBERS – CONNECTION TABLE…5574
T-BOXES AND T-ADAPTERS LIST…5613
FUSE LOCATION TABLE…5619
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE…5621
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])…5625
FAILURE CODES TABLE…5627
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)…5644
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit…5644
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit…5645
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit…5646
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit…5648
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit…5650
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit…5651
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit…5652
FAILURE CODE [879EMC] Ventilation Damper Malfunction…5654
FAILURE CODE [879FMC] Air Mix Damper Malfunction…5655
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range…5656
FAILURE CODE [989L00] Engine Controller Lock Caution 1…5658
FAILURE CODE [989M00] Engine Controller Lock Caution 2…5659
FAILURE CODE [989N00] Engine Controller Lock Caution 3…5660
FAILURE CODE [A1U0N3] HC Desorb Request 1…5661
FAILURE CODE [A1U0N4] HC Desorb Request 2…5663
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3…5665
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1…5666
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2…5667
FAILURE CODE [AA10NX] Air Cleaner Clogging…5668
FAILURE CODE [AB00KE] Charge Voltage Low…5670
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)…5673
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)…5675
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)…5677
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)…5678
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)…5679
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality)…5680
FAILURE CODE [AS00R6] Temporary Recovery of Inducement…5681
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5…5682
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning…5683
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning…5684
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution…5685
FAILURE CODE [B@BAZG] Engine Oil Pressure Low…5686
FAILURE CODE [B@BAZK] Eng Oil Level Low…5687
FAILURE CODE [B@BCNS] Eng Water Overheat…5689
FAILURE CODE [B@BCZK] Eng Water Level Low…5690
FAILURE CODE [B@HANS] Hyd Oil Overheat…5692
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error…5693
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error…5694
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error…5696
FAILURE CODE [CA131] Throttle Sensor High Error…5698
FAILURE CODE [CA132] Throttle Sensor Low Error…5700
FAILURE CODE [CA144] Coolant Temperature Sensor High Error…5702
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error…5704
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error…5706
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error…5709
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error…5711
FAILURE CODE [CA221] Ambient Pressure Sensor High Error…5713
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error…5715
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error…5717
FAILURE CODE [CA234] Engine Overspeed…5718
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error…5719
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error…5721
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error…5723
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error…5725
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error…5727
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error…5729
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error…5731
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error…5733
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error…5735
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error…5737
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error…5739
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error…5741
FAILURE CODE [CA343] Engine Controller Internal Failure…5743
FAILURE CODE [CA351] Injectors Drive Circuit Error…5744
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error…5745
FAILURE CODE [CA356] MAF Sensor High Error…5747
FAILURE CODE [CA357] MAF Sensor Low Error…5749
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error…5751
FAILURE CODE [CA428] Water in Fuel Sensor High Error…5752
FAILURE CODE [CA429] Water in Fuel Sensor Low Error…5754
FAILURE CODE [CA435] Engine Oil Pressure SW Error…5756
FAILURE CODE [CA441] Battery Voltage Low Error…5758
FAILURE CODE [CA442] Battery Voltage High Error…5760
FAILURE CODE [CA449] Common Rail Pressure High Error 2…5761
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error…5762
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error…5764
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate…5766
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error…5767
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error…5769
FAILURE CODE [CA553] Common Rail Pressure High Error 1…5771
FAILURE CODE [CA555] Crankcase Pressure High Error 1…5772
FAILURE CODE [CA556] Crankcase Pressure High Error 2…5773
FAILURE CODE [CA559] Common Rail Pressure Low Error 1…5774
FAILURE CODE [CA595] Turbocharger Speed High Error 2…5777
FAILURE CODE [CA687] Turbocharger Speed Low Error…5778
FAILURE CODE [CA689] Engine NE Speed Sensor Error…5780
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error…5783
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error…5785
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error…5787
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error…5788
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error…5789
FAILURE CODE [CA778] Engine Backup Speed Sensor Error…5791
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error…5796
FAILURE CODE [CA1664] KDOC Abnormality…5797
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error…5799
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3…5800
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error…5801
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error…5802
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error…5803
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error…5805
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error…5807
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error…5809
FAILURE CODE [CA1691] Defective Regeneration…5810
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error…5813
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error…5816
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error…5817
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error…5819
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error…5822
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error…5824
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error…5825
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error…5826
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error…5829
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error…5832
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error…5834
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error…5837
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error…5839
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error…5841
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error…5844
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error…5846
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1…5848
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2…5851
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error…5856
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error…5857
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error…5860
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error…5861
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2…5863
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error…5864
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error…5867
FAILURE CODE [CA2288] Turbocharger Speed High Error 1…5870
FAILURE CODE [CA2311] lMV Solenoid Error…5871
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error…5872
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error…5875
FAILURE CODE [CA2357] EGR Valve Servo Error…5877
FAILURE CODE [CA2381] KVGT Position Sensor High Error…5878
FAILURE CODE [CA2382] KVGT Position Sensor Low Error…5881
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error…5884
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error…5887
FAILURE CODE [CA2387] KVGT Servo Error…5889
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error…5890
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error…5893
FAILURE CODE [CA2637] KDOC Face Plugging…5896
FAILURE CODE [CA2639] Manual Stationary Regeneration Request…5898
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error…5900
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable…5906
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error…5909
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error…5911
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error…5914
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error…5916
FAILURE CODE [CA3142] SCR Temperature Sensor High Error…5919
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error…5920
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error…5921
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error…5923
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error…5924
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error…5925
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2…5927
FAILURE CODE [CA3165] SCR Outlet Temperature High Error…5933
FAILURE CODE [CA3229] SCR Temperature High Error…5935
FAILURE CODE [CA3231] SCR Temperature High Error – Non Regeneration…5937
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error…5939
FAILURE CODE [CA3235] SCR Outlet Temperature High Error – Non Regeneration…5943
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error…5945
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error…5948
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error…5951
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error…5954
FAILURE CODE [CA3253] KDOC Temperature Error – Non Regeneration…5956
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1…5959
FAILURE CODE [CA3255] KDPF Temperature Error – Non Regeneration…5962
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1…5965
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2…5967
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2…5969
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error…5972
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error…5974
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error…5975
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error…5977
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error…5978
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error…5979
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error…5981
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error…5982
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error…5984
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error…5986
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error…5988
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1…5990
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2…5991
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)…5992
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error…5998
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4…6000
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error…6001
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error…6003
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error…6005
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error…6007
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error…6010
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction…6013
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error…6017
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error…6019
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error…6021
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error…6023
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error…6025
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error…6027
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1…6029
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error…6035
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error…6037
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error…6039
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error…6041
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error…6046
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error…6052
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error…6055
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error…6056
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error…6057
FAILURE CODE [CA3741] Rail Press Valve Trip Error…6060
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error…6061
FAILURE CODE [CA3751] SCR Catalyst Degradation Error…6063
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error…6065
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2…6067
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1…6070
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error…6073
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error…6077
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error…6079
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error…6083
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error…6085
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error…6087
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error…6089
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error…6092
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error…6094
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error…6096
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error…6100
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error…6104
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error…6107
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction…6110
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error…6112
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error…6113
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error…6114
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error…6117
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error…6120
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error…6122
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error…6124
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error…6126
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error…6128
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error…6131
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error…6133
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error…6136
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error…6138
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error…6140
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error…6143
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error…6146
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error…6149
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error…6152
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error…6155
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error…6158
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error…6162
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error…6163
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error…6164
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error…6165
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible…6167
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error…6170
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)…6173
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error…6175
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error…6178
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error…6180
FAILURE CODE [CA5383] Ash Accumulation High Error…6182
FAILURE CODE [D110KB] Battery Relay Output Short Circuit…6184
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit…6186
FAILURE CODE [D811MC] KOMTRAX Malfunction…6189
FAILURE CODE [D862KA] GPS Antenna Open Circuit…6190
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)…6191
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX)…6193
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX)…6195
FAILURE CODE [DA20MC] Pump Controller Malfunction…6197
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error…6198
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error…6201
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller)…6204
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)…6206
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller)…6208
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller)…6210
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)…6213
FAILURE CODE [DAF0MB] Monitor ROM Abnormality…6214
FAILURE CODE [DAF0MC] Monitor Malfunction…6215
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit…6216
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor)…6218
FAILURE CODE [DAFGMC] GPS Module Malfunction…6219
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)…6220
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor)…6222
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)…6224
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C)…6225
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)…6226
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller)…6231
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller)…6236
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit…6241
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit…6243
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On…6245
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit…6247
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault…6249
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit…6251
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen…6253
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen…6254
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function…6255
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function…6258
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function…6261
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function…6264
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function…6267
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function…6270
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function…6273
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function…6276
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function…6279
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function…6282
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function…6285
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function…6288
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function…6291
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function…6294
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function…6297
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function…6300
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit…6303
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit…6305
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit…6307
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range…6309
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range…6311
FAILURE CODE [DV20KB] Travel Alarm Short Circuit…6313
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit…6315
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit…6317
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit…6319
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit…6321
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit…6324
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit…6327
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit…6329
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit…6331
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit…6333
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit…6335
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit…6337
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit…6339
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit…6341
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit…6343
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit…6345
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit…6347
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit…6349
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit…6351
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit…6353
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit…6355
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit…6357
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit…6359
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit…6361
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit…6363
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit…6365
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit…6367
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit…6369
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit…6370
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit…6372
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit…6374
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit…6376
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit…6378
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit…6380
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit…6382
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit…6384
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit…6386
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit…6388
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit…6390
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit…6392
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit…6394
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit…6396
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit…6398
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit…6400
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit…6402
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit…6404
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit…6406
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 1 Hot Short Circuit…6408
FAILURE CODE [DY20KA]Wiper Motor Open Circuit…6410
FAILURE CODE [DY20MA] Wiper Motor Defective Function…6412
FAILURE CODE [DY2CKB] Washer Motor Short Circuit…6414
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit…6417
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit…6419
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…6421
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)…6421
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK…6427
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK…6430
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP…6432
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING…6434
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW…6437
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW…6438
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING…6439
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING…6440
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…6441
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…6442
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…6443
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…6444
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…6445
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…6446
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…6447
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…6448
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL…6450
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…6451
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE…6452
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…6453
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE…6455
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED…6456
E-24 FUNCTION SWITCH DOES NOT OPERATE…6457
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)…6458
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF…6460
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER…6461
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED…6462
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED…6463
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE…6464
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE…6465
E-32 ALARM BUZZER CANNOT BE CANCELED…6467
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…6468
E-34 SERVICE MODE CANNOT BE SELECTED…6469
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE…6470
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK…6473
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING…6475
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE…6478
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR…6480
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED…6483
E-41 ALARM DOES NOT SOUND DURING TRAVEL…6484
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED…6486
E-43 HORN DOES NOT SOUND…6487
E-44 HORN DOES NOT STOP SOUNDING…6490
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF…6492
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE…6493
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE…6495
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6496
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6497
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6498
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6499
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6500
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6501
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6502
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6503
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…6504
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED…6506
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…6507
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…6508
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)…6508
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS…6509
FAILURE MODE AND CAUSE TABLE…6511
H-1 All of work equipments, swing and travel operation lack speed or power…6520
H-2 Engine speed lowers significantly or engine stalls…6522
H-3 Any of work equipment, swing and travel does not work…6524
H-4 Unusual sound is heard from around hydraulic pump…6525
H-5 Fine control performance or response is poor…6526
H-6 Speed or power of boom is low…6527
H-7 Speed or power of arm is low…6531
H-8 Speed or power of bucket is low…6535
H-9 Work equipment does not move in single operation…6538
H-10 Hydraulic drift of boom is large…6539
H-11 Hydraulic drift of arm is large…6541
H-12 Hydraulic drift of bucket is large…6543
H-13 Other work equipment moves when one of work equipment is relieved…6544
H-14 In combined operation of work equipment , equipment having heavier load moves slower…6545
H-15 Time lag of work equipment is large…6546
H-16 Machine does not travel straight…6547
H-17 Machine is hard to steer or travel power is low…6549
H-18 Travel speed is low…6552
H-19 One of tracks does not run…6554
H-20 Travel speed does not change, or travel speed is too low or high…6555
H-21 Upper structure does not swing in both right and left directions…6556
H-22 Upper structure does not swing in only one direction…6557
H-23 Swing acceleration or swing speed of upper structure is low in both right and left directions…6558
H-24 Swing acceleration or swing speed is low in only one direction…6559
H-25 Overrun of upper structure is large in both right and left directions…6560
H-26 Upper structure overruns excessively when it stops swing in only one direction…6561
H-27 Shock is large when upper structure stops swinging…6562
H-28 Large unusual noise is heard when upper structure stops swinging…6563
H-29 Swing drift on a slope is large (while swing parking brake is applied)…6564
H-30 Swing drift on a slope is large (while swing parking brake is released)…6565
H-31 Travel speed drops largely in combined operation of swing and trave…6566
H-32 In combined operation of swing and boom RAISE, boom rising speed is low…6567
H-33 One-touch power maximizing function does not work…6568
H-34 Attachment circuit cannot be changed…6569
H-35 Oil flow in attachment circuit cannot be controlled…6570
TROUBLESHOOTING OF ENGINE (S-MODE)…6571
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)…6571
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION…6572
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT…6573
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)…6574
S-4 ENGINE STARTABILITY IS POOR…6576
S-5 ENGINE DOES NOT PICK UP SMOOTHLY…6578
S-6 ENGINE STOPS DURING OPERATION…6580
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE…6582
S-8 ENGINE LACKS POWER…6583
S-9 KDPF GETS CLOGGED IN A SHORT TIME…6585
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE…6587
S-11 OIL BECOMES CONTAMINATED QUICKLY…6588
S-12 FUEL CONSUMPTION IS EXCESSIVE…6589
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…6590
S-14 OIL PRESSURE DROPS…6591
S-15 FUEL MIXES INTO ENGINE OIL…6593
S-16 WATER MIXES INTO ENGINE OIL (MILKY)…6594
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)…6595
S-18 UNUSUAL NOISE IS HEARD…6596
S-19 VIBRATION IS EXCESSIVE…6597
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…6598
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY…6599
S-22 ACTIVE REGENERATION TAKES TIME…6601
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION…6602
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE…6603
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)…6605
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)…6606
50 DISASSEMBLY AND ASSEMBLY…6608
CONTENTS…6609
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…6614
HOW TO READ THIS MANUAL…6614
COATING MATERIALS LIST…6615
SPECIAL TOOLS LIST…6620
SKETCHES OF SPECIAL TOOLS…6632
ENGINE AND COOLING SYSTEM…6638
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…6638
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY…6638
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY…6641
REMOVE AND INSTALL INJECTOR ASSEMBLY…6645
METHOD FOR REMOVING INJECTOR ASSEMBLY…6645
METHOD FOR INSTALLING INJECTOR ASSEMBLY…6650
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY…6658
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY…6659
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY…6668
REMOVE AND INSTALL EGR VALVE ASSEMBLY…6684
METHOD FOR REMOVING EGR VALVE ASSEMBLY…6684
METHOD FOR INSTALLING EGR VALVE ASSEMBLY…6685
REMOVE AND INSTALL EGR COOLER ASSEMBLY…6688
METHOD FOR REMOVING EGR COOLER ASSEMBLY…6688
METHOD FOR INSTALLING EGR COOLER ASSEMBLY…6691
REMOVE AND INSTALL STARTER ASSEMBLY…6696
METHOD FOR REMOVING STARTER ASSEMBLY…6696
METHOD FOR INSTALLING STARTER ASSEMBLY…6698
REMOVE AND INSTALL ALTERNATOR BELT…6700
METHOD FOR REMOVING ALTERNATOR BELT…6700
METHOD FOR INSTALLING ALTERNATOR BELT…6702
REMOVE AND INSTALL RADIATOR ASSEMBLY…6704
METHOD FOR REMOVING RADIATOR ASSEMBLY…6704
METHOD FOR INSTALLING RADIATOR ASSEMBLY…6706
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…6708
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY…6708
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY…6711
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…6714
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY…6714
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY…6715
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY…6717
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY…6718
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY…6726
REMOVE AND INSTALL ENGINE FRONT OIL SEAL…6737
METHOD FOR REMOVING ENGINE FRONT OIL SEAL…6737
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…6740
REMOVE AND INSTALL ENGINE REAR OIL SEAL…6744
METHOD FOR REMOVING ENGINE REAR OIL SEAL…6744
METHOD FOR INSTALLING ENGINE REAR OIL SEAL…6745
REMOVE AND INSTALL FUEL COOLER ASSEMBLY…6748
METHOD FOR REMOVING FUEL COOLER ASSEMBLY…6748
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY…6749
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…6750
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY…6750
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY…6752
REMOVE AND INSTALL FUEL TANK ASSEMBLY…6757
METHOD FOR REMOVING FUEL TANK ASSEMBLY…6757
METHOD FOR INSTALLING FUEL TANK ASSEMBLY…6761
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY…6765
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY…6765
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY…6770
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…6776
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…6776
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…6781
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR…6787
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR…6787
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR…6787
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER…6789
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER…6789
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER…6789
REMOVE AND INSTALL KDPF ASSEMBLY…6791
METHOD FOR REMOVING KDPF ASSEMBLY…6791
METHOD FOR INSTALLING KDPF ASSEMBLY…6793
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY…6795
METHOD FOR DISASSEMBLING KDPF ASSEMBLY…6796
METHOD FOR ASSEMBLING KDPF ASSEMBLY…6799
REMOVE AND INSTALL SCR ASSEMBLY…6804
METHOD FOR REMOVING SCR ASSEMBLY…6804
METHOD FOR INSTALLING SCR ASSEMBLY…6806
REMOVE AND INSTALL KDPF, SCR ASSEMBLY…6808
METHOD FOR REMOVING KDPF, SCR ASSEMBLY…6808
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY…6814
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET…6820
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET…6820
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET…6827
REMOVE AND INSTALL KCCV ASSEMBLY…6835
METHOD FOR REMOVING KCCV ASSEMBLY…6835
METHOD FOR INSTALLING KCCV ASSEMBLY…6837
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE…6842
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE…6842
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE…6847
REMOVE AND INSTALL AdBlue/DEF INJECTOR…6852
METHOD FOR REMOVING AdBlue/DEF INJECTOR…6852
METHOD FOR INSTALLING AdBlue/DEF INJECTOR…6854
REMOVE AND INSTALL AdBlue/DEF PUMP…6856
METHOD FOR REMOVING AdBlue/DEF PUMP…6856
METHOD FOR INSTALLING AdBlue/DEF PUMP…6858
REMOVE AND INSTALL AdBlue/DEF HOSE…6861
METHOD FOR REMOVING AdBlue/DEF HOSE…6861
METHOD FOR INSTALLING AdBlue/DEF HOSE…6865
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…6871
METHOD FOR REMOVING AIR CLEANER ASSEMBLY…6871
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY…6872
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY…6874
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…6874
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…6876
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY…6879
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY…6879
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY…6880
POWER TRAIN…6881
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…6881
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…6881
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…6882
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY…6883
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY…6883
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY…6887
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY…6895
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY…6895
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY…6897
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY…6901
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY…6901
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY…6905
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY…6912
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY…6912
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY…6912
UNDERCARRIAGE AND FRAME…6914
SEPARATION AND CONNECTION OF TRACK ASSEMBLY…6914
METHOD FOR SEPARATING TRACK ASSEMBLY…6914
METHOD FOR INSTALLING TRACK ASSEMBLY…6916
REMOVE AND INSTALL SPROCKET…6919
METHOD FOR REMOVING SPROCKET…6919
METHOD FOR INSTALLING SPROCKET…6919
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY…6921
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY…6921
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY…6922
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…6923
METHOD FOR DISASSEMBLING IDLER ASSEMBLY…6923
METHOD FOR ASSEMBLING IDLER ASSEMBLY…6924
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY…6928
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY…6929
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY…6930
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY…6931
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…6932
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY…6933
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY…6935
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY…6935
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY…6936
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY…6939
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY…6939
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY…6941
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY…6943
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY…6943
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY…6946
HYDRAULIC SYSTEM…6950
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY…6950
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY…6950
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY…6952
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY…6955
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY…6956
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY…6957
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY…6958
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY…6958
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY…6960
REMOVE AND INSTALL MAIN PUMP ASSEMBLY…6963
METHOD FOR REMOVING MAIN PUMP ASSEMBLY…6963
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY…6966
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…6969
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY…6969
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…6974
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY…6981
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING…6981
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY…6983
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY…6987
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY…6987
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY…6987
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY…6989
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY…6989
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY…6990
WORK EQUIPMENT…6992
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY…6992
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY…6992
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY…6996
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY…7002
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY…7002
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY…7005
CAB AND ITS ATTACHMENTS…7011
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY…7011
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY…7011
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY…7016
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)…7023
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)…7025
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)…7025
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY…7035
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY…7035
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY…7038
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY…7044
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY…7044
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY…7051
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…7058
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY…7058
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY…7063
REMOVE AND INSTALL OPERATOR'S SEAT…7069
METHOD FOR REMOVING OPERATOR'S SEAT…7069
METHOD FOR INSTALLING OPERATOR'S SEAT…7071
REMOVE AND INSTALL SEAT BELT…7074
METHOD FOR REMOVING SEAT BELT…7074
METHOD FOR INSTALLING SEAT BELT…7075
REMOVE AND INSTALL FRONT WIPER ASSEMBLY…7076
METHOD FOR REMOVING FRONT WIPER ASSEMBLY…7076
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY…7081
ELECTRICAL SYSTEM…7089
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY…7089
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY…7089
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY…7090
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY…7092
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY…7092
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY…7096
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…7101
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…7101
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…7104
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR…7108
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR…7108
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR…7109
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR…7110
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR…7110
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR…7110
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR…7112
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR…7112
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR…7113
REMOVE AND INSTALL SCR TEMPERATURE SENSOR…7114
METHOD FOR REMOVING SCR TEMPERATURE SENSOR…7114
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR…7116
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY…7118
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY…7118
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY…7121
60 MAINTENANCE STANDARD…7124
CONTENTS…7125
ENGINE AND COOLING SYSTEM…7126
MAINTENANCE STANDARD OF ENGINE MOUNT…7126
MAINTENANCE STANDARD OF COOLING SYSTEM…7127
POWER TRAIN…7128
MAINTENANCE STANDARD OF SWING CIRCLE…7128
MAINTENANCE STANDARD OF SWING MACHINERY…7129
MAINTENANCE STANDARD OF FINAL DRIVE…7131
MAINTENANCE STANDARD OF SPROCKET…7133
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING…7134
UNDERCARRIAGE AND FRAME…7136
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION…7136
MAINTENANCE STANDARD OF IDLER…7138
MAINTENANCE STANDARD OF TRACK ROLLER…7140
MAINTENANCE STANDARD OF CARRIER ROLLER…7142
MAINTENANCE STANDARD OF TRACK SHOE…7143
MAINTENANCE STANDARD OF TRIPLE SHOE…7146
HYDRAULIC SYSTEM…7147
MAINTENANCE STANDARD OF MAIN PUMP…7147
MAINTENANCE STANDARD OF SWING MOTOR…7148
MAINTENANCE STANDARD OF TRAVEL MOTOR…7151
MAINTENANCE STANDARD OF CONTROL VALVE…7154
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE…7164
MAINTENANCE STANDARD OF TRAVEL PPC VALVE…7167
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)…7170
MAINTENANCE STANDARD OF EPC VALVE…7171
MAINTENANCE STANDARD OF SOLENOID VALVE…7173
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)…7174
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT…7175
WORK EQUIPMENT…7176
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE…7176
DIMENSION OF ARM…7181
DIMENSIONS OF BUCKET…7183
MAINTENANCE STANDARD OF BOOM CYLINDER…7185
MAINTENANCE STANDARD OF BOOM CYLINDER (FOR LARGE DIAMETER PISTON)…7186
MAINTENANCE STANDARD OF ARM CYLINDER…7187
MAINTENANCE STANDARD OF BUCKET CYLINDER…7188
80 APPENDIX…7190
CONTENTS…7191
AIR CONDITIONER SYSTEM…7193
PRECAUTIONS FOR REFRIGERANT…7193
AIR CONDITIONER COMPONENT…7194
SPECIFICATIONS OF AIR CONDITIONER…7196
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE…7197
OUTLINE OF REFRIGERATION CYCLE…7198
COMPONENT PARTS OF AIR CONDITIONER SYSTEM…7200
AIR CONDITIONER UNIT…7200
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT…7200
FUNCTION OF AIR CONDITIONER UNIT…7202
COMPONENT PARTS OF AIR CONDITIONER UNIT…7204
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT…7205
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…7205
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT…7205
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT…7205
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…7206
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…7206
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…7207
FUNCTION OF DUAL PRESSURE SWITCH…7207
AIR CONDITIONER CONTROLLER…7208
STRUCTURE OF AIR CONDITIONER CONTROLLER…7208
COMPRESSOR…7209
STRUCTURE OF COMPRESSOR…7209
SPECIFICATIONS OF COMPRESSOR…7209
FUNCTION OF COMPRESSOR…7210
CONDENSER…7211
STRUCTURE OF CONDENSER…7211
SPECIFICATIONS OF CONDENSER…7211
FUNCTION OF CONDENSER…7211
SENSORS FOR AIR CONDITIONER SYSTEM…7213
STRUCTURE OF SUNLIGHT SENSOR…7213
FUNCTION OF SUNLIGHT SENSOR…7213
STRUCTURE OF AMBIENT TEMPERATURE SENSOR…7213
FUNCTION OF AMBIENT TEMPERATURE SENSOR…7213
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER…7215
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER…7217
AIR CONDITIONER SYSTEM DIAGRAM…7219
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER…7220
FUNCTION OF AIR CONDITIONER CONTROLLER…7221
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS…7222
TESTING AIR LEAKAGE (DUCT)…7226
METHOD FOR TESTING AIR LEAKAGE (DUCT)…7226
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION…7228
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR…7229
TEST VENT (MODE) CHANGEOVER…7230
METHOD FOR TESTING VENT (MODE) CHANGEOVER…7230
TESTING FRESH/RECIRC AIR CHANGEOVER…7232
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER…7232
TEST SUNLIGHT SENSOR…7233
METHOD FOR TESTING SUNLIGHT SENSOR…7233
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT…7234
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT…7234
TEST RELAYS…7235
METHOD FOR TESTING RELAYS…7235
AIR CONDITIONER TROUBLESHOOTING CHART 1…7236
AIR CONDITIONER TROUBLESHOOTING CHART 2…7238
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…7241
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit…7243
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit…7244
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit…7245
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit…7247
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit…7249
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit…7250
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit…7251
FAILURE CODE [879EMC] Ventilation Damper Malfunction…7253
FAILURE CODE [879FMC] Air Mix Damper Malfunction…7254
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range…7255
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)…7257
A-2 TROUBLESHOOTING OF COMPRESSOR SYSTEM (AIR IS NOT COOLED)…7259
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)…7262
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER…7264
TROUBLESHOOTING USING GAUGE PRESSURE…7266
CONNECTION OF SERVICE TOOL…7268
METHOD FOR CONNECTING SERVICE TOOL…7268
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS…7270
HANDLE COMPRESSOR OIL…7272
METHOD FOR REPLACING DESICCANT…7274
90 CIRCUIT DIAGRAMS…7276
CONTENTS…7277
HYDRAULIC CIRCUIT DIAGRAM…7278
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…7278
HYDRAULIC CIRCUIT DIAGRAM (1/2)…7282
HYDRAULIC CIRCUIT DIAGRAM (2/2)…7283
ELECTRICAL CIRCUIT DIAGRAM…7284
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM…7284
ELECTRICAL CIRCUIT DIAGRAM (1/7)…7288
ELECTRICAL CIRCUIT DIAGRAM (2/7)…7289
ELECTRICAL CIRCUIT DIAGRAM (3/7)…7290
ELECTRICAL CIRCUIT DIAGRAM (4/7)…7291
ELECTRICAL CIRCUIT DIAGRAM (5/7)…7292
ELECTRICAL CIRCUIT DIAGRAM (6/7)…7293
ELECTRICAL CIRCUIT DIAGRAM (7/7)…7294
INDEX…7295
TEN00523-02 – Hydraulic Excavator PC290LC-10 Operation & Maintenance Manual…7317
COVER…7317
FOREWORD …7318
BEFORE READING THIS MANUAL …7319
SAFETY INFORMATION …7320
INTRODUCTION …7321
USE OF MACHINE …7321
DIRECTIONS OF MACHINE …7321
VISIBILITY FROM OPERATOR’S SEAT …7321
PRODUCT INFORMATION …7322
PRODUCT IDENTIFICATION NUMBER (PIN)／MACHINE SERIAL NO. PLATE …7322
EPA REGULATIONS, ENGINE NUMBER PLATE …7322
SERVICE METER LOCATION …7323
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR …7323
CONTENTS …7324
SAFETY …7328
SAFETY …7329
SAFETY LABELS …7331
LOCATION OF SAFETY LABELS …7332
SAFETY LABELS …7333
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE …7341
PRECAUTIONS BEFORE STARTING OPERATION …7341
PREPARATIONS FOR SAFE OPERATION …7342
FIRE PREVENTION …7344
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE …7346
DO NOT GET CAUGHT IN WORK EQUIPMENT …7347
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES …7348
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS …7349
UNAUTHORIZED MODIFICATION …7349
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS …7350
PRECAUTIONS RELATED TO CAB GLASS …7350
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING …7350
PRECAUTIONS FOR OPERATION …7351
PRECAUTIONS FOR JOBSITE …7351
STARTING ENGINE …7354
OPERATION …7357
TRANSPORTATION …7364
TOWING …7365
SAFETY RULES FOR LIFTING OPERATIONS …7366
PRECAUTIONS FOR MAINTENANCE …7367
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE …7367
PRECAUTIONS FOR INSPECTION AND MAINTENANCE …7371
OPERATION …7378
GENERAL VIEW …7379
GENERAL VIEW OF MACHINE …7379
GENERAL VIEW OF CAB …7381
GENERAL VIEW OF CONTROLS AND GAUGES …7382
EXPLANATION OF COMPONENTS …7384
MACHINE MONITOR …7384
SWITCHES …7456
CONTROL LEVERS AND PEDALS …7465
OPENING AND CLOSING CEILING WINDOW …7468
OPENING AND CLOSING CAB FRONT WINDOW …7470
EMERGENCY ESCAPE HAMMER …7475
DOOR LOCK …7476
CAB DOOR HINGE …7477
OPENING AND CLOSING ENGINE HOOD …7478
CAPS AND COVERS WITH LOCK …7483
DRINK BOX …7486
MAGAZINE BOX …7486
CUP HOLDER …7486
ASHTRAY …7487
HANDLING AIR CONDITIONER …7488
HANDLING RADIO …7500
AUXILIARY ELECTRIC POWER …7505
FUSE …7506
FUSIBLE LINK …7507
TOOL BOX …7507
GREASE PUMP HOLDER …7507
FIRE EXTINGUISHER …7507
BATTERY DISCONNECT SWITCH …7508
SYSTEM OPERATING LAMP …7509
HANDLING Komatsu Diesel Particulate Filter (KDPF) …7510
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) …7520
HANDLING MACHINES EQUIPPED WITH KOMTRAX …7521
MACHINE OPERATIONS AND CONTROLS …7523
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE …7523
STARTING ENGINE …7544
OPERATIONS AND CHECKS AFTER STARTING ENGINE …7547
STOPPING ENGINE …7559
MACHINE OPERATION …7560
STEERING MACHINE …7564
SWINGING MACHINE …7566
WORK EQUIPMENT CONTROLS AND OPERATIONS …7567
WORKING MODE …7569
PROHIBITED OPERATIONS …7572
RULES FOR OPERATION …7575
TRAVELING ON SLOPES …7577
ESCAPE FROM MUD …7579
RECOMMENDED APPLICATIONS …7580
REPLACING AND INVERTING BUCKET …7582
WHEN PARKING MACHINE …7585
AFTER DAILY WORK COMPLETION …7586
LOCKING …7587
TRANSPORTATION …7588
TRANSPORTATION PROCEDURE …7588
LOADING AND UNLOADING WITH TRAILER …7589
LIFTING MACHINE …7600
COLD WEATHER OPERATION …7604
COLD WEATHER OPERATION INFORMATION …7604
AFTER DAILY WORK COMPLETION …7606
AFTER COLD WEATHER SEASON …7606
LONG-TERM STORAGE …7607
BEFORE STORAGE …7607
DURING STORAGE …7607
AFTER STORAGE …7608
STARTING MACHINE AFTER LONG-TERM STORAGE …7608
TROUBLES AND ACTIONS …7609
RUNNING OUT OF FUEL …7609
PHENOMENA THAT ARE NOT FAILURES …7609
TOWING MACHINE …7610
LIGHTWEIGHT TOWING HOLE …7611
SEVERE JOB CONDITION …7611
DISCHARGED BATTERY …7612
OTHER TROUBLE …7616
MAINTENANCE …7622
RULES FOR MAINTENANCE …7623
SERVICE METER READING …7623
KOMATSU GENUINE REPLACEMENT PARTS …7623
KOMATSU GENUINE LUBRICANTS …7623
ALWAYS USE CLEAN WASHER FLUID …7623
FRESH AND CLEAN LUBRICANTS …7623
CHECK DRAINED OIL AND USED FILTER …7623
CAUTION FOR REFILLING OIL OR FUEL …7623
WELDING INSTRUCTIONS …7623
DO NOT DROP THINGS INSIDE MACHINE …7623
DUSTY JOBSITES …7623
AVOID MIXING OIL …7624
LOCKING INSPECTION COVERS …7624
BLEEDING AIR FROM HYDRAULIC CIRCUIT …7624
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES …7624
CHECKS AFTER INSPECTION AND MAINTENANCE …7624
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE …7624
CLOSE ENGINE HOOD SECURELY …7624
OUTLINE OF SERVICE …7625
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC …7625
HANDLING ELECTRICAL COMPONENTS …7629
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS …7630
TIGHTENING TORQUE LIST …7630
MAINTENANCE SCHEDULE …7632
MAINTENANCE SCHEDULE TABLE …7632
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER …7634
MAINTENANCE PROCEDURE …7635
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) …7635
WHEN REQUIRED …7636
CHECKS BEFORE STARTING …7665
EVERY 100 HOURS MAINTENANCE …7666
EVERY 250 HOURS MAINTENANCE …7667
EVERY 500 HOURS MAINTENANCE …7671
EVERY 1000 HOURS MAINTENANCE …7683
EVERY 2000 HOURS MAINTENANCE …7689
EVERY 4000 HOURS MAINTENANCE …7698
EVERY 4500 HOURS MAINTENANCE …7702
EVERY 5000 HOURS MAINTENANCE …7703
EVERY 8000 HOURS MAINTENANCE …7704
SPECIFICATIONS …7706
SPECIFICATIONS …7707
ATTACHMENTS AND OPTIONS …7710
GENERAL PRECAUTIONS FOR SAFETY …7711
PRECAUTIONS WHEN SELECTING …7711
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY …7711
PRECAUTIONS WHEN REMOVING OR INSTALLING …7711
PRECAUTIONS WHEN USING …7712
BUCKET WITH HOOK …7713
HOOK CONDITION …7713
PROHIBITED OPERATIONS …7713
MACHINE READY FOR INSTALLATION OF ATTACHMENT …7714
EXPLANATION OF COMPONENTS …7714
HYDRAULIC CIRCUIT …7717
REMOVAL AND INSTALLATION OF ATTACHMENT …7724
ATTACHMENT OPERATIONS …7728
LONG-TERM STORAGE …7731
SPECIFICATIONS …7731
ATTACHMENTS AND OPTIONS …7732
ATTACHMENT COMBINATIONS …7732
TRACK SHOES SELECTION …7733
BUCKET TEETH SELECTION …7734
RECOMMENDED ATTACHMENT OPERATIONS …7735
HYDRAULIC BREAKER …7735
REPLACEMENT PARTS …7740
SAFETY CRITICAL PARTS …7741
SAFETY CRITICAL PARTS LIST …7741
CONSUMABLE PARTS …7742
CONSUMABLE PARTS LIST …7742
RECOMMENDED FUEL, COOLANT, AND LUBRICANT …7743
LUBRICATION CHART …7744
FUEL, COOLANT, AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE …7745
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL …7747
INDEX …7748
UEAM001603 – Hydraulic Excavator PC290LC-7K, PC290NLC-7K Operation & Maintenance Manual…7754
FOREWORD…7756
FOREWORD…7757
SAFETY INFORMATION…7758
NOISE…7760
VIBRATION…7760
INTRODUCTION…7761
DIRECTIONS OF MACHINE…7761
PRODUCT INFORMATION…7762
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…7762
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…7762
SERVICE METER LOCATION…7763
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…7763
SAFETY…7770
SAFETY INFORMATION…7771
POSITION FOR ATTACHING SAFETY LABELS…7773
POSITION FOR ATTACHING SAFETY LABELS…7773
SAFETY LABELS…7774
SAFETY INFORMATION…7781
SAFETY RULES…7781
IF ABNORMALITIES ARE FOUND…7781
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…7781
FIRE EXTINGUISHER AND FIRST AID KIT…7781
SAFETY EQUIPMENT…7782
KEEP MACHINE CLEAN…7782
KEEP OPERATOR'S COMPARTMENT CLEAN…7782
LEAVING OPERATOR'S SEAT WITH LOCK…7782
HANDRAILS AND STEPS…7783
MOUNTING AND DISMOUNTING…7784
NO PERSONS ON ATTACHMENTS…7784
BURN PREVENTION…7784
FIRE PREVENTION AND EXPLOSION PREVENTION…7785
ACTION IF FIRE OCCURS…7786
WINDSHIELD WASHER FLUID…7786
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…7786
ATTACHMENT INSTALLATION…7786
ATTACHMENT COMBINATIONS…7787
CAB WIDOW GLASSES…7787
UNAUTHORIZED MODIFICATIONS…7787
SAFETY AT JOBSITE…7787
WORKING ON LOOSE GROUND…7787
DISTANCE TO HIGH VOLTAGE CABLES…7788
ENSURE GOOD VISIBILITY…7788
VENTILATION FOR ENCLOSED AREA…7789
SIGNALMAN'S SIGNAL AND SIGNS…7789
EMERGENCY EXIT FROM OPERATOR'S CAB…7789
ELECTROMAGNETIC INTERFERENCE…7789
ASBESTOS DUST HAZARD PREVENTION…7789
SAFETY MACHINE OPERATION…7790
STARTING ENGINE…7790
CHECKS BEFORE STARTING ENGINE…7790
SAFETY RULES FOR STARTING ENGINE…7791
STARTING ENGINE IN COLD WEATHER…7791
OPERATION…7792
CHECKS AFTER STARTING ENGINE…7792
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…7792
SAFETY RULES FOR TRAVELLING…7793
TRAVELLING ON SLOPES…7794
OPERATIONS ON SLOPES…7795
PROHIBITED OPERATIONS…7795
OPERATIONS ON SNOW…7796
PARKING MACHINE…7797
TRANSPORTATION…7798
SHIPPING THE MACHINE…7798
BATTERY…7799
BATTERY HAZARD PREVENTION…7799
STARTING ENGINE WITH BOOSTER CABLES…7800
TOWING…7801
SAFETY RULES FOR TOWING…7801
LIFTING OBJECTS WITH BUCKET…7802
SAFETY RULES FOR LIFTING OBJECTS…7802
SAFETY MAINTENANCE INFORMATION…7803
WARNING TAG…7803
KEEP WORK PLACE CLEAN AND TIDY…7803
APPOINT LEADER WHEN WORKING WITH OTHERS…7803
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…7804
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…7805
PROPER TOOLS…7805
ACCUMULATOR…7806
PERSONNEL…7806
ATTACHMENTS…7806
WORK UNDER THE MACHINE…7806
NOISE…7807
WHEN USING HAMMER…7807
WELDING WORKS…7807
REMOVING BATTERY TERMINALS…7807
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…7808
DO NOT DISASSEMBLE RECOIL SPRINGS…7808
SAFETY RULES FOR HIGH-PRESSURE OIL…7808
SAFETY HANDLING HIGH-PRESSURE HOSES…7809
WASTE MATERIALS…7809
AIR CONDITIONER MAINTENANCE…7809
COMPRESSED AIR…7809
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…7810
OPERATION…7812
GENERAL VIEW…7813
GENERAL VIEW OF MACHINE…7813
GENERAL VIEW CONTROLS AND GAUGES…7814
EXPLANATION OF COMPONENTS…7815
MACHINE MONITOR…7815
BASIC OPERATION OF MACHINE MONITOR…7816
BASIC CHECK ITEMS…7818
CAUTION ITEMS…7820
EMERGENCY STOP ITEMS…7823
METER DISPLAY PORTION…7825
MONITOR SWITCHES…7829
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)…7830
AUTO-DECELERATION SWITCH…7831
TRAVEL SPEED SELECTOR SWITCH…7832
WIPER SWITCH…7833
WINDOW WASHER SWITCH…7833
MAINTENANCE SWITCH…7834
SELECT SWITCH…7836
BACK SWITCH…7837
UP SWITCH, DOWN SWITCH…7837
INPUT CONFIRMATION SWITCH…7837
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH…7838
SWITCHES…7840
STARTING SWITCH…7840
FUEL CONTROL DIAL…7841
CIGARETTE LIGHTER…7841
SWING LOCK SWITCH…7842
LAMP SWITCH…7842
ALARM BUZZER STOP SWITCH…7843
HORN SWITCH…7843
KNOB SWITCH…7843
ROOM LAMP SWITCH…7844
EMERGENCY PUMP DRIVE SWITCH…7844
SWING BRAKE CANCEL SWITCH…7844
LOWER WIPER SWITCH…7845
REVOLVING WARNING LAMP SWITCH…7845
HEATED OPERATOR SEAT SWITCH…7845
CONTROL LEVERS, PEDALS…7846
SAFETY LOCK LEVER…7846
TRAVEL LEVERS…7847
WORK EQUIPMENT CONTROL LEVER…7848
CEILING WINDOW…7849
FRONT WINDOW…7850
EMERGENCY EXIT FROM OPERATOR'S CAB…7855
DOOR LOCK…7855
CAP, COVER WITH LOCK…7856
METHOD OF OPENING AND CLOSING CAP WITH LOCK…7856
METHOD OF OPENING AND CLOSING COVER WITH LOCK…7856
HOT AND COOL BOX…7857
CAB RADIO…7857
MAGAZINE BOX…7857
ASHTRAY…7858
HANDLING AIR CONDITIONER…7859
GENERAL LOCATIONS OF CONTROL PANEL…7859
METHOD OF OPERATION…7863
PRECAUTIONS WHEN USING AIR CONDITIONER…7870
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…7870
OTHER FUNCTIONS…7871
CAR RADIO…7872
FUSE…7873
FUSE CAPACITIES AND CIRCUIT NAMES…7874
FUSIBLE LINK…7874
CONTROLLER (COMPUTER)…7875
TOOLBOX…7875
GREASE GUN HOLDER…7875
REFUELLING PUMP…7876
HANDLING THE ACCUMULATOR…7876
RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR…7877
MACHINE OPERATIONS AND CONTROLS…7878
BEFORE STARTING ENGINE…7878
WALK-AROUND CHECKS…7878
CHECKS BEFORE STARTING…7879
ADJUST BEFORE OPERATION…7884
SEAT BELT…7887
OPERATIONS BEFORE STARTING ENGINE…7888
STARTING ENGINE…7891
NORMAL STARTING…7891
STARTING ENGINE IN COLD WEATHER…7892
AFTER STARTING ENGINE…7895
BREAKING-IN THE NEW MACHINE…7895
WARMING-UP OPERATION…7896
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)…7899
STOPPING THE ENGINE…7903
CHECK AFTER SHUTTING OFF ENGINE…7903
MACHINE OPERATION…7904
PREPARATIONS FOR MOVING THE MACHINE OFF…7904
MOVING MACHINE FORWARD…7905
MOVING MACHINE BACKWARD…7906
STOPPING MACHINE…7907
STEERING THE MACHINE…7908
Steering…7908
SWINGING…7910
WORK EQUIPMENT CONTROLS AND OPERATIONS…7911
OPERATING WORKING MODE…7912
PROHIBITED OPERATIONS…7913
OPERATIONS USING SWING FORCE…7913
OPERATIONS USING TRAVEL FORCE…7913
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS…7913
OPERATIONS USING BUCKET DROPPING FORCE…7914
OPERATIONS USING MACHINE DROPPING FORCE…7914
DIGGING HARD ROCKY GROUND…7914
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…7914
GENERAL OPERATION INFORMATION…7915
TRAVELLING…7915
HIGH SPEED TRAVEL…7915
PERMISSIBLE WATER DEPTH…7915
TRAVELLING ON SLOPES…7916
TRAVELLING DOWNHILL…7917
ENGINE STOPPED ON SLOPE…7917
PRECAUTIONS ON SLOPES…7917
ESCAPE FROM MUD…7918
STUCK ONE SIDE OF TRACK…7918
STUCK BOTH SIDES OF TRACKS…7918
RECOMMENDED APPLICATIONS…7919
BACKHOE WORK…7919
SHOVEL WORK…7919
DITCHING WORK…7919
LOADING WORK…7920
REPLACEMENT AND INVERSION OF BUCKET…7921
REPLACEMENT…7921
INVERSION…7923
PARKING MACHINE…7924
CHECK AFTER FINISHING WORK…7925
LOCKING…7926
TRANSPORTATION…7927
TRANSPORTATION PROCEDURE…7927
LOADING AND UNLOADING WITH TRAILER…7928
LOADING…7929
SECURING MACHINE…7931
UNLOADING…7933
LIFTING MACHINE…7935
STANDARD SPECIFICATION MACHINE…7935
COLD WEATHER OPERATION…7937
COLD WEATHER OPERATION INFORMATION…7937
FUEL AND LUBRICANTS…7937
COOLING SYSTEM COOLANT…7937
BATTERY…7938
AFTER DAILY WORK COMPLETION…7939
AFTER COLD WEATHER SEASON…7940
LONG TERM STORAGE…7941
BEFORE STORAGE…7941
DURING STORAGE…7941
AFTER STORAGE…7942
STARTING MACHINE AFTER LONG-TERM STORAGE…7942
TROUBLESHOOTING…7943
AFTER RUNNING OUT OF FUEL…7943
PHENOMENA THAT ARE NOT FAILURES…7943
TOWING THE MACHINE…7944
LIGHTWEIGHT TOWING HOOK…7944
PRECAUTIONS ON PARTICULAR JOBSITES…7945
DISCHARGED BATTERY…7946
REMOVAL AND INSTALLATION OF BATTERY…7947
BATTERY CHARGES…7947
STARTING ENGINE WITH BOOSTER CABLES…7948
OTHER TROUBLE…7950
ELECTRICAL SYSTEM…7950
CHASSIS…7951
ENGINE…7952
ELECTRONIC CONTROL SYSTEM…7954
MAINTENANCE…7958
MAINTENANCE INFORMATION…7959
SERVICE METER READING…7959
KOMATSU GENUINE REPLACEMENT PARTS…7959
KOMATSU GENUINE LUBRICANTS…7959
WINDSHIELD WASHER FLUID…7959
FRESH AND CLEAN LUBRICANTS…7959
CHECK DRAINED OIL AND USED FILTER…7959
FUEL STRAINER…7959
WELDING INSTRUCTIONS…7959
DO NOT DROP THINGS INSIDE MACHINE…7960
DUSTY JOBSITE…7960
AVOID MIXING LUBRICANTS…7960
LOCKING THE INSPECTION COVERS…7960
HYDRAULIC SYSTEM – AIR BLEEDING…7960
HYDRAULIC HOSE INSTALLATION…7961
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…7961
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE…7961
LUBRICANTS, COOLANT AND FILTERS…7962
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…7962
OIL…7962
FUEL…7962
COOLING SYSTEM COOLANT…7963
GREASE…7963
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…7963
OIL AND FUEL STORAGE…7964
FILTERS…7965
EXPLANATION OF LUBRICATION CHART DECAL…7966
ELECTRIC SYSTEM MAINTENANCE…7967
HANDLING HYDRAULIC SYSTEM…7968
WEAR PARTS LIST…7969
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…7970
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…7970
TIGHTENING TORQUE SPECIFICATIONS…7973
TIGHTENING TORQUE LIST…7973
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…7974
SAFETY CRITICAL PARTS…7974
MAINTENANCE SCHEDULE…7975
MAINTENANCE SCHEDULE CHART…7975
Initial 250 Hours Maintenance (Only after the first 250 hours)…7975
When Required…7975
Checks Before Starting…7975
Every 100 Hours Maintenance…7975
Every 250 Hours Maintenance…7976
Every 500 Hours Maintenance…7976
Every 1000 Hours Maintenance…7976
Every 2000 Hours Maintenance…7976
Every 4000 Hours Maintenance…7977
Every 5000 Hours Maintenance…7977
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…7978
MAINTENANCE PROCEDURE…7979
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…7979
WHEN REQUIRED…7980
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…7980
CLEAN INSIDE OF COOLING SYSTEM…7985
CHECK AND TIGHTEN TRACK SHOE BOLTS…7988
CHECK AND ADJUST TRACK TENSION…7989
CHECK ELECTRICAL INTAKE AIR HEATER…7991
REPLACE BUCKET TEETH…7992
ADJUST BUCKET CLEARANCE…7992
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…7994
CHECK AND ADJUST AIR CONDITIONER (IF EQUIPPED)…7995
WASHING WASHABLE FLOOR…7996
METHOD OF SETTING MACHINE ANGLE…7998
BLEEDING AIR FROM HYDRAULIC SYSTEM…7999
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…8001
CHECK BEFORE STARTING…8002
EVERY 100 HOURS MAINTENANCE…8003
LUBRICATING…8003
LUBRICATING…8003
EVERY 250 HOURS MAINTENANCE…8004
LUBRICATING…8004
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL…8005
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…8006
CHECK LEVEL OF BATTERY ELECTROLYTE…8007
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…8010
EVERY 500 HOURS MAINTENANCE…8011
LUBRICATING…8011
LUBRICATE SWING CIRCLE (2 POINTS)…8012
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…8013
REPLACE FUEL FILTER CARTRIDGE…8014
CHECK SWING PINION GREASE LEVEL, ADD GREASE…8015
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS…8015
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM…8016
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…8018
EVERY 1000 HOURS MAINTENANCE…8019
REPLACE HYDRAULIC FILTER ELEMENT…8019
CHANGE OIL IN SWING MACHINERY CASE…8020
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…8021
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…8021
CHECK PLAY OF TURBOCHARGER ROTOR…8021
CHECK FAN BELT TENSION AND REPLACE FAN BELT…8021
EVERY 2000 HOURS MAINTENANCE…8022
CHANGE OIL IN FINAL DRIVE CASE…8022
CLEAN HYDRAULIC TANK STRAINER…8023
CLEAN, CHECK TURBOCHARGER…8023
CHECK ALTERNATOR, STARTING MOTOR…8023
CHECK ENGINE VALVE CLEARANCE, ADJUST…8023
CHECK VIBRATION DAMPER…8023
EVERY 4000 HOURS MAINTENENCE…8024
CHECK WATER PUMP…8024
EVERY 5000 HOURS MAINTENANCE…8025
CHANGE OIL IN HYDRAULIC TANK…8025
SPECIFICATIONS…8026
SPECIFICATIONS…8027
WORKING RANGE MONO BOOM…8028
WORKING RANGE 2 PIECE BOOM…8029
EXPLANATION OF LIFTING CAPACITY CHART…8030
EXPLANATION OF LIFTING CAPACITY CHART (PC290LC,NLC-7K 2 PIECE BOOM)…8033
PC290LC-7K 2 PIECE BOOM…8034
PC290NLC-7K 2 PIECE BOOM…8035
ATTACHMENTS AND OPTIONS…8036
GENERAL PRECAUTIONS…8037
PRECAUTIONS RELATED TO SAFETY…8037
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…8039
HANDLING BUCKET WITH HOOK…8040
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…8040
PROHIBITED OPERATIONS…8040
PRECAUTIONS DURING OPERATIONS…8040
MACHINES READY FOR ATTACHMENTS…8041
EXPLANATION OF COMPONENTS…8041
STOP VALVE…8041
SELECTOR VALVE…8042
ATTACHMENT CONTROL PEDAL…8042
LOCK PIN…8042
ADDITIONAL FILTER FOR BREAKER…8043
ACCUMULATOR…8043
HYDRAULIC CIRCUIT…8044
SWITCHING HYDRAULIC CIRCUIT…8044
ADJUSTING OIL FLOW…8044
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT…8044
HYDRAULIC CIRCUIT CONNECTION…8045
PATH OF OIL…8045
REPLACE ADDITIONAL BREAKER FILTER ELEMENT…8046
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…8047
OPERATION…8049
LONG-TERM STORAGE…8051
SPECIFICATIONS…8051
ATTACHMENT GUIDE…8052
COMBINATIONS OF WORK EQUIPMENT…8052
SELECTION OF TRACK SHOES…8054
METHOD OF SELECTING SHOES…8054
SELECTION OF BUCKET TEETH…8055
METHOD OF SELECTING TEETH…8055
Use of vertical pin teeth…8055
Use of horizontal pin teeth…8055
Use of long-life teeth…8055
Self-sharpening teeth (both vertical pin type and horizontal pin type)…8055
STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH…8055
HANDLING OF RUBBER PAD SHOE AND ROAD LINER…8056
WORKING ENVIRONMENT…8056
WORKING CONDITIONS…8056
STORAGE AND MAINTENANCE…8057
EXTENT OF DAMAGE TO RUBBER…8057
CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)…8057
HANDLING TRAPEZOIDAL BUCKET…8058
HOW TO PERFORM EXCAVATION…8058
HANDLING EXTENSION ARM…8059
HANDLING CLAMSHELL BUCKET…8060
PRECAUTIONS WHEN USING…8060
LUBRICATING…8060
RECOMMENDED ATTACHMENT OPERATIONS…8061
HYDRAULIC BREAKER…8061
MAIN APPLICATIONS…8061
PROHIBITED WORKS…8063
GREASING POSITION FOR HYDRAULIC BREAKER…8065
2-PC BOOM…8066
FEATURES OF 2-PIECE BOOM & ARM…8066
OPERATION…8067
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE…8068
TESTING AND ADJUSTING…8069
PERODIC MAINTENANCE…8069
TRANSPORTATION…8070
UEAM004000 – Hydraulic Excavator PC290LC-6K, PC290NLC-6K Operation & Maintenance Manual…8075
FOREWORD…8077
FOREWORD…8078
SAFETY INFORMATION…8079
NOISE…8081
VIBRATION…8081
INTRODUCTION…8082
DIRECTIONS OF MACHINE…8082
BREAKING-IN THE NEW MACHINE…8082
PRODUCT INFORMATION…8083
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…8083
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…8083
SERVICE METER LOCATION…8084
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…8084
SAFETY…8091
SAFETY INFORMATION…8092
POSITION FOR ATTACHING SAFETY LABELS…8094
POSITION FOR ATTACHING SAFETY LABELS…8094
SAFETY LABELS…8095
SAFETY INFORMATION…8102
SAFETY RULES…8102
IF ABNORMALITIES ARE FOUND…8102
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…8102
FIRE EXTINGUISHER AND FIRST AID KIT…8102
SAFETY EQUIPMENT…8103
KEEP MACHINE CLEAN…8103
KEEP OPERATOR'S COMPARTMENT CLEAN…8103
LEAVING OPERATOR'S SEAT WITH LOCK…8103
HANDRAILS AND STEPS…8104
MOUNTING AND DISMOUNTING…8105
NO PERSONS ON ATTACHMENTS…8105
BURN PREVENTION…8105
FIRE PREVENTION AND EXPLOSION PREVENTION…8106
ACTION IF FIRE OCCURS…8107
WINDSHIELD WASHER FLUID…8107
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…8107
ATTACHMENT INSTALLATION…8107
ATTACHMENT COMBINATIONS…8108
CAB WIDOW GLASSES…8108
UNAUTHORIZED MODIFICATIONS…8108
SAFETY AT JOBSITE…8108
WORKING ON LOOSE GROUND…8108
DISTANCE TO HIGH VOLTAGE CABLES…8109
ENSURE GOOD VISIBILITY…8109
VENTILATION FOR ENCLOSED AREA…8110
SIGNALMAN'S SIGNAL AND SIGNS…8110
EMERGENCY EXIT FROM OPERATOR'S CAB…8110
ELECTROMAGNETIC INTERFERENCE…8110
ASBESTOS DUST HAZARD PREVENTION…8110
SAFETY MACHINE OPERATION…8111
STARTING ENGINE…8111
CHECKS BEFORE STARTING ENGINE…8111
SAFETY RULES FOR STARTING ENGINE…8112
STARTING ENGINE IN COLD WEATHER…8112
OPERATION…8113
CHECKS AFTER STARTING ENGINE…8113
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…8113
SAFETY RULES FOR TRAVELLING…8114
TRAVELLING ON SLOPES…8115
OPERATIONS ON SLOPES…8116
PROHIBITED OPERATIONS…8116
OPERATIONS ON SNOW…8117
PARKING MACHINE…8118
TRANSPORTATION…8119
SHIPPING THE MACHINE…8119
BATTERY…8120
BATTERY HAZARD PREVENTION…8120
STARTING ENGINE WITH BOOSTER CABLES…8121
TOWING…8122
SAFETY RULES FOR TOWING…8122
LIFTING OBJECTS WITH BUCKET…8123
SAFETY RULES FOR LIFTING OBJECTS…8123
SAFETY MAINTENANCE INFORMATION…8124
WARNING TAG…8124
KEEP WORK PLACE CLEAN AND TIDY…8124
APPOINT LEADER WHEN WORKING WITH OTHERS…8124
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…8125
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…8126
PROPER TOOLS…8126
ACCUMULATOR…8127
PERSONNEL…8127
ATTACHMENTS…8127
WORK UNDER THE MACHINE…8127
NOISE…8128
WHEN USING HAMMER…8128
WELDING WORKS…8128
REMOVING BATTERY TERMINALS…8128
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…8129
DO NOT DISASSEMBLE RECOIL SPRINGS…8129
SAFETY RULES FOR HIGH-PRESSURE OIL…8129
SAFETY HANDLING HIGH-PRESSURE HOSES…8130
WASTE MATERIALS…8130
AIR CONDITIONER MAINTENANCE…8130
COMPRESSED AIR…8130
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…8131
OPERATION…8133
GENERAL VIEW…8134
GENERAL VIEW OF MACHINE…8134
GENERAL VIEW CONTROLS AND GAUGES…8135
EXPLANATION OF COMPONENTS…8136
MACHINE MONITOR…8136
BASIC OPERATION OF MACHINE MONITOR…8137
BASIC CHECK ITEMS…8139
CAUTION ITEMS…8141
EMERGENCY STOP ITEMS…8144
METER DISPLAY PORTION…8146
MONITOR SWITCHES…8150
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)…8151
AUTO-DECELERATION SWITCH…8152
TRAVEL SPEED SELECTOR SWITCH…8153
WIPER SWITCH…8154
WINDOW WASHER SWITCH…8154
MAINTENANCE SWITCH…8155
SELECT SWITCH…8157
BACK SWITCH…8158
UP SWITCH, DOWN SWITCH…8158
INPUT CONFIRMATION SWITCH…8158
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH…8159
SWITCHES…8161
STARTING SWITCH…8161
FUEL CONTROL DIAL…8162
CIGARETTE LIGHTER…8162
SWING LOCK SWITCH…8163
LAMP SWITCH…8163
ALARM BUZZER STOP SWITCH…8164
HORN SWITCH…8164
KNOB SWITCH…8164
ROOM LAMP SWITCH…8165
EMERGENCY PUMP DRIVE SWITCH…8165
SWING BRAKE CANCEL SWITCH…8165
LOWER WIPER SWITCH…8166
REVOLVING WARNING LAMP SWITCH…8166
HEATED OPERATOR SEAT SWITCH…8166
CONTROL LEVERS, PEDALS…8167
SAFETY LOCK LEVER…8167
TRAVEL LEVERS…8168
WORK EQUIPMENT CONTROL LEVER…8169
CEILING WINDOW…8170
FRONT WINDOW…8171
EMERGENCY EXIT FROM OPERATOR'S CAB…8176
DOOR LOCK…8176
CAP, COVER WITH LOCK…8177
METHOD OF OPENING AND CLOSING CAP WITH LOCK…8177
METHOD OF OPENING AND CLOSING COVER WITH LOCK…8177
HOT AND COOL BOX…8178
CAB RADIO…8178
MAGAZINE BOX…8178
ASHTRAY…8179
HANDLING AIR CONDITIONER…8180
GENERAL LOCATIONS OF CONTROL PANEL…8180
VENT SELECTOR SWITCH…8182
METHOD OF OPERATION…8184
PRECAUTIONS WHEN USING AIR CONDITIONER…8191
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…8191
OTHER FUNCTIONS…8192
CAR RADIO…8193
FUSE…8195
FUSE CAPACITIES AND CIRCUIT NAMES…8196
FUSIBLE LINK…8196
CONTROLLER (COMPUTER)…8197
TOOLBOX…8197
GREASE GUN HOLDER…8197
REFUELLING PUMP…8198
HANDLING THE ACCUMULATOR…8198
RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR…8199
MACHINE OPERATIONS AND CONTROLS…8200
BEFORE STARTING ENGINE…8200
WALK-AROUND CHECKS…8200
CHECKS BEFORE STARTING…8201
ADJUST BEFORE OPERATION…8206
SEAT BELT…8209
OPERATIONS BEFORE STARTING ENGINE…8210
STARTING ENGINE…8213
NORMAL STARTING…8213
STARTING ENGINE IN COLD WEATHER…8214
AFTER STARTING ENGINE…8217
BREAKING-IN THE NEW MACHINE…8217
WARMING-UP OPERATION…8218
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)…8221
STOPPING THE ENGINE…8225
CHECK AFTER SHUTTING OFF ENGINE…8225
MACHINE OPERATION…8226
PREPARATIONS FOR MOVING THE MACHINE OFF…8226
MOVING MACHINE FORWARD…8227
MOVING MACHINE BACKWARD…8228
STOPPING MACHINE…8229
STEERING THE MACHINE…8230
Steering…8230
SWINGING…8232
WORK EQUIPMENT CONTROLS AND OPERATIONS…8233
OPERATING WORKING MODE…8234
PROHIBITED OPERATIONS…8235
OPERATIONS USING SWING FORCE…8235
OPERATIONS USING TRAVEL FORCE…8235
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS…8235
OPERATIONS USING BUCKET DROPPING FORCE…8236
OPERATIONS USING MACHINE DROPPING FORCE…8236
DIGGING HARD ROCKY GROUND…8236
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…8236
GENERAL OPERATION INFORMATION…8237
TRAVELLING…8237
HIGH SPEED TRAVEL…8237
PERMISSIBLE WATER DEPTH…8237
TRAVELLING ON SLOPES…8238
TRAVELLING DOWNHILL…8239
ENGINE STOPPED ON SLOPE…8239
PRECAUTIONS ON SLOPES…8239
ESCAPE FROM MUD…8240
STUCK ONE SIDE OF TRACK…8240
STUCK BOTH SIDES OF TRACKS…8240
RECOMMENDED APPLICATIONS…8241
BACKHOE WORK…8241
SHOVEL WORK…8241
DITCHING WORK…8241
LOADING WORK…8242
REPLACEMENT AND INVERSION OF BUCKET…8243
REPLACEMENT…8243
INVERSION…8245
PARKING MACHINE…8246
CHECK AFTER FINISHING WORK…8247
LOCKING…8248
TRANSPORTATION…8249
TRANSPORTATION PROCEDURE…8249
LOADING AND UNLOADING WITH TRAILER…8250
LOADING…8251
SECURING MACHINE…8253
UNLOADING…8255
LIFTING MACHINE…8257
STANDARD SPECIFICATION MACHINE…8257
COLD WEATHER OPERATION…8259
COLD WEATHER OPERATION INFORMATION…8259
FUEL AND LUBRICANTS…8259
COOLING SYSTEM COOLANT…8259
BATTERY…8260
AFTER DAILY WORK COMPLETION…8261
AFTER COLD WEATHER SEASON…8262
LONG TERM STORAGE…8263
BEFORE STORAGE…8263
DURING STORAGE…8263
AFTER STORAGE…8264
STARTING MACHINE AFTER LONG-TERM STORAGE…8264
TROUBLESHOOTING…8265
AFTER RUNNING OUT OF FUEL…8265
PHENOMENA THAT ARE NOT FAILURES…8265
TOWING THE MACHINE…8266
LIGHTWEIGHT TOWING HOOK…8266
PRECAUTIONS ON PARTICULAR JOBSITES…8267
DISCHARGED BATTERY…8268
REMOVAL AND INSTALLATION OF BATTERY…8269
BATTERY CHARGES…8269
STARTING ENGINE WITH BOOSTER CABLES…8270
OTHER TROUBLE…8272
ELECTRICAL SYSTEM…8272
CHASSIS…8273
ENGINE…8274
ELECTRONIC CONTROL SYSTEM…8276
MAINTENANCE…8279
MAINTENANCE INFORMATION…8280
SERVICE METER READING…8280
KOMATSU GENUINE REPLACEMENT PARTS…8280
KOMATSU GENUINE LUBRICANTS…8280
WINDSHIELD WASHER FLUID…8280
FRESH AND CLEAN LUBRICANTS…8280
CHECK DRAINED OIL AND USED FILTER…8280
FUEL STRAINER…8280
WELDING INSTRUCTIONS…8280
DO NOT DROP THINGS INSIDE MACHINE…8281
DUSTY JOBSITE…8281
AVOID MIXING LUBRICANTS…8281
LOCKING THE INSPECTION COVERS…8281
HYDRAULIC SYSTEM – AIR BLEEDING…8281
HYDRAULIC HOSE INSTALLATION…8282
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…8282
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE…8282
LUBRICANTS, COOLANT AND FILTERS…8283
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…8283
OIL…8283
FUEL…8283
COOLING SYSTEM COOLANT…8284
GREASE…8284
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)…8284
OIL AND FUEL STORAGE…8285
FILTERS…8286
EXPLANATION OF LUBRICATION CHART DECAL…8287
ELECTRIC SYSTEM MAINTENANCE…8288
HANDLING HYDRAULIC SYSTEM…8289
WEAR PARTS LIST…8290
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…8291
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…8291
TIGHTENING TORQUE SPECIFICATIONS…8294
TIGHTENING TORQUE LIST…8294
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…8295
SAFETY CRITICAL PARTS…8295
MAINTENANCE SCHEDULE…8296
MAINTENANCE SCHEDULE CHART…8296
Initial 250 Hours Maintenance (Only after the first 250 hours)…8296
When Required…8296
Checks Before Starting…8296
Every 100 Hours Maintenance…8296
Every 250 Hours Maintenance…8297
Every 500 Hours Maintenance…8297
Every 1000 Hours Maintenance…8297
Every 2000 Hours Maintenance…8297
Every 4000 Hours Maintenance…8298
Every 5000 Hours Maintenance…8298
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…8299
MAINTENANCE PROCEDURE…8300
EVERY 10 HOURS MAINTENANCE (FOR THE FIRST 50 HOURS)…8300
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…8300
WHEN REQUIRED…8301
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…8301
CLEAN INSIDE OF COOLING SYSTEM…8306
CHECK AND TIGHTEN TRACK SHOE BOLTS…8309
CHECK AND ADJUST TRACK TENSION…8310
CHECK ELECTRICAL INTAKE AIR HEATER…8312
REPLACE BUCKET TEETH…8313
ADJUST BUCKET CLEARANCE…8313
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…8315
CHECK AND ADJUST AIR CONDITIONER (IF EQUIPPED)…8316
WASHING WASHABLE FLOOR…8317
METHOD OF SETTING MACHINE ANGLE…8319
BLEEDING AIR FROM HYDRAULIC SYSTEM…8320
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…8322
CHECK BEFORE STARTING…8323
EVERY 100 HOURS MAINTENANCE…8324
LUBRICATING…8324
LUBRICATING…8324
EVERY 250 HOURS MAINTENANCE…8325
LUBRICATING…8325
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL…8326
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…8327
CHECK LEVEL OF BATTERY ELECTROLYTE…8328
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…8331
EVERY 500 HOURS MAINTENANCE…8332
LUBRICATING…8332
LUBRICATE SWING CIRCLE (2 POINTS)…8333
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…8334
REPLACE FUEL FILTER CARTRIDGE…8335
CHECK SWING PINION GREASE LEVEL, ADD GREASE…8336
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS…8336
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM…8337
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…8339
EVERY 1000 HOURS MAINTENANCE…8340
REPLACE HYDRAULIC FILTER ELEMENT…8340
CHANGE OIL IN SWING MACHINERY CASE…8341
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…8342
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…8342
CHECK PLAY OF TURBOCHARGER ROTOR…8342
CHECK FAN BELT TENSION AND REPLACE FAN BELT…8342
EVERY 2000 HOURS MAINTENANCE…8343
CHANGE OIL IN FINAL DRIVE CASE…8343
CLEAN HYDRAULIC TANK STRAINER…8344
CLEAN, CHECK TURBOCHARGER…8344
CHECK ALTERNATOR, STARTING MOTOR…8344
CHECK ENGINE VALVE CLEARANCE, ADJUST…8344
CHECK VIBRATION DAMPER…8344
EVERY 4000 HOURS MAINTENENCE…8345
CHECK WATER PUMP…8345
EVERY 5000 HOURS MAINTENANCE…8346
CHANGE OIL IN HYDRAULIC TANK…8346
SPECIFICATIONS…8347
SPECIFICATIONS…8348
WORKING RANGE MONO BOOM…8349
WORKING RANGE 2 PIECE BOOM…8350
EXPLANATION OF LIFTING CAPACITY CHART…8351
EXPLANATION OF LIFTING CAPACITY CHART (PC290LC,NLC-7K 2 PIECE BOOM)…8354
PC290LC-7K 2 PIECE BOOM…8355
PC290NLC-7K 2 PIECE BOOM…8356
ATTACHMENTS AND OPTIONS…8357
GENERAL PRECAUTIONS…8358
PRECAUTIONS RELATED TO SAFETY…8358
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…8360
HANDLING BUCKET WITH HOOK…8361
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…8361
PROHIBITED OPERATIONS…8361
PRECAUTIONS DURING OPERATIONS…8361
MACHINES READY FOR ATTACHMENTS…8362
EXPLANATION OF COMPONENTS…8362
STOP VALVE…8362
SELECTOR VALVE…8363
ATTACHMENT CONTROL PEDAL…8363
LOCK PIN…8363
ADDITIONAL FILTER FOR BREAKER…8364
ACCUMULATOR…8364
HYDRAULIC CIRCUIT…8365
SWITCHING HYDRAULIC CIRCUIT…8365
ADJUSTING OIL FLOW…8365
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT…8365
HYDRAULIC CIRCUIT CONNECTION…8366
PATH OF OIL…8366
REPLACE ADDITIONAL BREAKER FILTER ELEMENT…8367
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…8368
OPERATION…8370
LONG-TERM STORAGE…8372
SPECIFICATIONS…8372
ATTACHMENT GUIDE…8373
COMBINATIONS OF WORK EQUIPMENT…8373
SELECTION OF TRACK SHOES…8375
METHOD OF SELECTING SHOES…8375
SELECTION OF BUCKET TEETH…8376
METHOD OF SELECTING TEETH…8376
Use of vertical pin teeth…8376
Use of horizontal pin teeth…8376
Use of long-life teeth…8376
Self-sharpening teeth (both vertical pin type and horizontal pin type)…8376
STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH…8376
HANDLING OF RUBBER PAD SHOE AND ROAD LINER…8377
WORKING ENVIRONMENT…8377
WORKING CONDITIONS…8377
STORAGE AND MAINTENANCE…8378
EXTENT OF DAMAGE TO RUBBER…8378
CHECK ROAD LINER (MACHINES EQUIPPED WITH ROAD LINER)…8378
HANDLING TRAPEZOIDAL BUCKET…8379
HOW TO PERFORM EXCAVATION…8379
HANDLING EXTENSION ARM…8380
HANDLING CLAMSHELL BUCKET…8381
PRECAUTIONS WHEN USING…8381
LUBRICATING…8381
RECOMMENDED ATTACHMENT OPERATIONS…8382
HYDRAULIC BREAKER…8382
MAIN APPLICATIONS…8382
PROHIBITED WORKS…8384
GREASING POSITION FOR HYDRAULIC BREAKER…8386
2-PC BOOM…8387
FEATURES OF 2-PIECE BOOM & ARM…8387
OPERATION…8388
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE…8389
TESTING AND ADJUSTING…8390
PERODIC MAINTENANCE…8390
TRANSPORTATION…8391
UEBM001600 – Hydraulic Excavator PC290LC-7, PC290NLC-7 Shop Manual…8396
01.pdf…0
SPECIFICATION DIMENSION DRAWINGS…8399
DIMENSIONS…8399
WORKING RANGES…8399
DIMENSIONS…8400
Working ranges…8400
SPECIFICATIONS…8401
PC290LC-7, PC290NLC-7…8401
WEIGHT TABLE…8403
PC290LC-7, PC290NLC-7…8403
FUEL, COOLANT, AND LUBRICANTS…8405
10.pdf…0
ENGINE RELATED PARTS…8407
RADIATOR • OIL COOLER • AFTERCOOLER…8408
POWER TRAIN…8409
FINAL DRIVE…8411
SWING MACHINERY…8413
SWING CIRCLE…8415
TRACK FRAME • RECOIL SPRING…8417
IDLER…8419
CARRIER ROLLER…8421
TRACK ROLLER…8422
TRACK SHOE…8423
TRIPLE GROUSER SHOE…8426
hydraulic equipment layout drawing…8427
HYDRAULIC TANK…8429
HYDRAULIC PUMP…8431
HPV95 + 95…8431
LS VALVE…8436
PC VALVE…8436
LS(pc)-EPC VALVE…8449
CONTROL VALVE…8453
SELF PRESSURE REDUCING VALVE…8468
MAIN RELIEF VALVE…8471
Variable pressure compensation valve…8472
CLSS…8474
OUTLINE OF CLSS…8474
SWING MOTOR…8475
REVERSE PREVENTION VALVE…8480
CENTER SWIVEL JOINT…8482
TRAVEL MOTOR…8483
TRAVEL JUNCTION VALVE…8493
TRAVEL PPC SHUTTLE VALVE…8495
VALVE CONTROL…8497
WORK EQUIPMENT • SWING PPC VALVE…8498
TRAVEL PPC VALVE…8502
SERVICE PPC VALVE…8511
air conditioner…8533
air conditioner piping…8533
ENGINE CONTROL…8534
Governor motor…8537
Engine throttle and pump controller…8538
ELECTRONIC CONTROL SYSTEM…8541
Total system diagram…8543
mULTI MONITOR SYSTEM…8567
SENSOR…8589
2. Dimension of bucket…8531
return oil filter…8518
For Breaker…8518
BOOM HYDRAULIC DRIFT PREVENTION VALVE…8519
LIFT CHECK VALVE…8522
attachment circuit selector valve…8523
HYDRAULIC CYLINDER…8525
pc290LC-7, pc290Nlc-7…8525
BOOM CYLINDER…8525
ARM CYLINDER…8525
BUCKET CYLINDER…8525
work equipmeNT…8527
SOLENOID VALVE…8514
1.Dimension of arm…8529
PPC ACCUMULATOR…8517
20-001.pdf…0
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…8593
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…8594
20_101.pdf…0
TESTING AND ADJUSTING…8602
INSPECTION AND ADJUSTMENT OF ENGINE RPM…8603
MEASUREMENT OF EXHAUST GAS COLOR…8605
ADJUSTMENT OF VALVE CLEARANCE…8606
MEASUREMENT OF COMPRESSION PRESSURE…8608
MEASUREMENT OF BLOW-BY PRESSURE…8609
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING…8610
MEASUREMENT OF ENGINE OIL PRESSURE…8612
ADJUSTMENT OF ENGINE SPEED SENSOR…8613
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION…8613
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM…8614
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…8615
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION…8616
INSPECTION OF WEAR ON SPROCKET…8616
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWIN…8617
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE…8621
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE…8622
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE…8625
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE…8629
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE…8632
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE…8633
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT…8634
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT…8635
MEASUREMENT OF OIL LEAKAGE AMOUNT…8636
AIR BLEEDING OF VARIOUS PARTS…8638
INSPECTION PROCEDURES FOR DIODE…8640
SPECIAL FUNCTION OF MULTI-MONITOR PANEL…8641
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM…8665
20_201.pdf…0
TROUBLESHOOTING…8670
POINTS TO REMEMBER WHEN TROUBLESHOOTING…8671
SEQUENCE OF EVENTS IN TROUBLESHOOTING…8672
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…8673
CHECKS BEFORE TROUBLESHOOTING…8681
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING…8843
Classification of troubleshooting…8682
Steps for troubleshooting…8682
Failure-looking Phenomenon and Troubleshooting No…8683
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM…8687
Connector table…8687
CONNECTOR LOCATION STEREOGRAM…8693
Monitor Panel System Circuit Diagram (M Circuit)…8699
Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller…8701
Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller…8703
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…8705
20_301.pdf…0
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE IN…8728
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…8731
Service Code in Electrical System (Abnormal data in Error History)…8733
Service Code in Electrical System (Short-circuiting in normal rotation system of windshield wiper…8735
Service Code in Electrical System (Short-circuiting in reverse rotation system of windshield wipe…8737
Service Code in Electrical System (Short-circuiting in window washer drive system)…8739
Service Code in Electrical System (Abnormal Windshield Wiper Motion)…8741
Service Code in Electrical System (Abnormality in retracting windshield wiper)…8743
Service Code in Electrical System (Short-circuiting in travel interlocking solenoid)…8745
Service Code in Electrical System (Short-circuiting in swing and parking brake solenoid – in gove…8747
Service Code in Electrical System (Short-circuiting in merge/divide solenoid)…8749
Service Code in Electrical System (Short-circuiting in 2-stage relief solenoid)…8460
Service Code in Electrical System (Short-circuiting in travel speed shifting solenoid)…8753
Service Code in Electrical System (Disconnection in travel interlocking solenoid)…8755
Service Code in Electrical System (Disconnection in Swing Parking Brake Solenoid)…8757
Service Code in Electrical System (Disconnection of merge/divide solenoid)…8759
Service Code in Electrical System (Disconnection in 2-stage relief solenoid)…8761
Service Code in Electrical System (Disconnection in travel speed shifting solenoid)…8763
Service Code in Electrical System (Abnormality in inputting model code)…8765
Service Code in Electrical System Disconnection of S-NET signal)…8663
Service Code in Electrical System (Short-circuiting in LS-EPC solenoid)…8771
Service Code in Electrical System (Disconnection in LS-EPC solenoid system)…8607
Service Code in Electrical System (Abnormality in F pump pressure sensor)…8773
Service Code in Electrical System (Abnormality in R pump pressure sensor)…8775
Service Code in Electrical System (Abnormality in Pressure sensor power source)…8777
Service Code in Electrical System (Abnormality in engine rotation sensor in governor • pump contr…8779
Service Code in Electrical System (Short-circuiting in attachment return switching relay)…8780
Service Code in Electrical System (Short-circuiting in PC-EPC Solenoid…8781
Service Code in Electrical System (Disconnection in PC-EPC solenoid system)…8783
Service Code in Electrical System (Disconnection in attachment return switching relay)…8785
Service Code in Electrical Equipment (Short-circuiting in attachment oil flow rate adjusting EPC)…8787
Service Code in Electrical System (Disconnection in attachment oil flow rate adjusting EPC) (Mult…8788
Service Code in Electrical System (Incorrect nonvolatile memory data)…8789
Service Code in Electrical System (Abnormality in governor potentiometer)…8791
Service Code in Electrical System (Abnormality in fuel dial)…8793
Service Code in Electrical System (Short-circuiting in battery relay)…8795
Service Code in Electrical System (Step-out in governor motor)…8797
Service Code in Electrical System (Disconnection in governor motor Phase A and B)…8799
Service Code in Electrical System (Short-circuiting in governor motor Phase A and Phase B)…8801
Service Code in Electrical System ("Model Selection" function not provided yet)…8803
Service Mode in Electrical System (Model selecting signal fault)…8804
Failure Code in Mechanical System (Out-of-rate engine rotation at high idling)…8805
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)…8805
Failure Code in Mechanical System (Air cleaner clogging)…8806
Failure Code in Mechanical System (Abnormally lowered charging voltage)…8807
Failure Code in Mechanical System (Abnormally lowered engine oil pressure)…8809
Failure Code in Mechanical System (Abnormally lowered engine oil level)…8810
Failure Code in Mechanical System (Engine cooling water overheating)…8811
Failure Code in Mechanical System (Abnormally lowered radiator water level)…8812
Failure Code in Mechanical System (Hydraulic oil overheating)…8813
20_501.pdf…0
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…8728
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…8739
E-1 Engine does not start (Engine does not rotate)…8816
E-2 Engine stops while in operation…8819
E-3 Engine speed is irregular, or there is hunting…8820
E-4 Engine does not stop…8822
E-5 Auto-decelerator does not work…8824
E-6 Auto engine warm-up device does not work…8825
E-7 Preheater does not work…8826
E-8 All work equipment, swing and travel do not move…8828
E-9 One-touch Power Max Switch does not work…8830
E-10 No display in monitor panel at all…8831
E-11 Part of display on monitor panel is missing…8832
E-12 Monitor panel displays contents irrelevant to the model…8771
E-13 Fuel level monitor red lamp lights up while engine is running…8833
E-14 Engine cooling water temperature gauge does not indicate correctly…8834
E-15 Hydraulic oil temperature gauge does not display correctly…8835
E-16 Fuel gauge does not display correctly…8836
E-17 Swing lock monitor does not display correctly…8837
E-18 When the monitor switch is operated, no display appears…8839
E-19 Windshield wiper does not work…8467
E-20 Alarming buzzer cannot be cancelled…8842
E-21 "Boom RAISE" is not correctly displayed in monitor function…8843
E-22 "Boom LOWER" is not correctly displayed in monitor function…8844
E-23 "Arm DIGGING" is not correctly displayed in monitor function…8845
E-24 "Arm DUMPING" is not correctly displayed in monitor function…8846
E-25 "Bucket DIGGING" is not correctly displayed in monitor function…8847
E-26 "Bucket DUMPING" is not correctly displayed in monitor function…8848
E-27 "SWING" is not correctly displayed in monitor function…8849
E-28 "TRAVEL" is not correctly displayed in monitor function…8851
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function…8853
E-30 "Service" is not correctly displayed in monitor function…8855
E-31 Air Conditioner does not work…8857
E-32 Travel alarm does not sound…8858
20_601.pdf…0
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…8728
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS…8861
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…8863
H-1 All work equipment lack power, or travel and swing speeds are slow…8453
H-2 Engine speed sharply drops or engine stalls…8865
H-3 No work equipment, travel or swing move…8866
H-4 Abnormal noise is heard from around hydraulic pump…8866
H-5 Auto-decelerator does not work…8867
H-6 Fine control mode does not function…8867
H-7 Boom moves slowly or lacks power…8868
H-8 Arm moves slowly or lacks power…8869
H-9 Bucket moves slowly or lacks power…8870
H-10 Work equipment does not move in its single operation…8870
H-11 Work equipment has a bit too fast hydraulic drift…8871
H-12 Work equipment has big time lag…8872
H-13 Other work equipment moves when relieving single circuit…8872
H-14 One-touch power max. switch does not operate…8816
H-15 In compound operation, work equipment with larger load moves slowly…8873
H-16 In swing + boom RAISE operation, boom moves slowly…8873
ing + travel, travel speed drops sharply…8873
H-18 Machine swerves in travel…8875
H-19 Machine travels slowly…8876
H-20 Machine cannot be easily steered or lacks power…8877
H-21 Travel speed does not shift, or it is too slow or fast…8460
H-22 Track shoe does not turn (on one side only)…8879
H-23 Machine does not swing…8880
H-24 Swing acceleration is poor, or swing speed is slow…8881
H-25 Excessive overrun when stopping swing…8882
H-26 There is big shock when stopping swing…8883
H-27 There is big abnormal noise caused when stopping swing…8883
H-28 Swing natural drift is too big…8884
UEBM001600_A2.pdf…0
hydraulic circuit diagram…8888
electrical circuit diagram (1/4)…8890
FOR multi monitor…8890
electrical circuit diagram (2/4)…8892
FOR multi monitor…8892
electrical circuit diagram (3/4)…8894
FOR multi monitor…8894
electrical circuit diagram (4/4)…8896
FOR multi monitor…8896
UEBM001601 – Hydraulic Excavator PC290LC, 290NLC-7K Shop Manual…8898
GENERAL…8904
SPECIFICATION DIMENSION DRAWINGS…8905
SPECIFICATIONS…8907
WEIGHT TABLE…8909
FUEL, COOLANT, AND LUBRICANTS…8911
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD…8912
ENGINE RELATED PARTS…8913
RADIATOR • OIL COOLER • AFTERCOOLER…8914
POWER TRAIN…8915
FINAL DRIVE…8917
SWING MACHINERY…8919
SWING CIRCLE…8921
TRACK FRAME • RECOIL SPRING…8923
IDLER…8925
CARRIER ROLLER…8927
TRACK ROLLER…8928
TRACK SHOE…8929
HYDRAULIC EQUIPMENT LAYOUT DRAWING…8933
HYDRAULIC TANK…8935
HYDRAULIC PUMP…8937
CONTROL VALVE…8959
SELF PRESSURE REDUCING VALVE…8974
CLSS…8980
SWING MOTOR…8981
REVERSE PREVENTION VALVE…8986
CENTRE SWIVEL JOINT…8988
TRAVEL MOTOR…8989
TRAVEL JUNCTION VALVE…8999
TRAVEL PPC SHUTTLE VALVE…9001
VALVE CONTROL…9003
WORK EQUIPMENT • SWING PPC VALVE…9004
TRAVEL PPC VALVE…9008
SERVICE PPC VALVE…9017
SOLENOID VALVE…9020
PPC ACCUMULATOR…9023
RETURN OIL FILTER…9024
BOOM HYDRAULIC DRIFT PREVENTION VALVE…9025
LIFT CHECK VALVE…9028
ATTACHMENT CIRCUIT SELECTOR VALVE…9029
HYDRAULIC CYLINDER…9031
WORK EQUIPMENT…9033
AIR CONDITIONER…9039
ENGINE CONTROL…9040
ELECTRONIC CONTROL SYSTEM…9047
MULTI MONITOR SYSTEM…9073
SENSOR…9095
TESTING AND ADJUSTING…9098
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…9099
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…9100
INSPECTION AND ADJUSTMENT OF ENGINE RPM…9109
MEASUREMENT OF EXHAUST GAS COLOR…9111
ADJUSTMENT OF VALVE CLEARANCE…9112
MEASUREMENT OF COMPRESSION PRESSURE…9114
MEASUREMENT OF BLOW-BY PRESSURE…9115
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING…9116
MEASUREMENT OF ENGINE OIL PRESSURE…9118
ADJUSTMENT OF ENGINE SPEED SENSOR…9119
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION…9119
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM…9120
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…9121
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION…9122
INSPECTION OF WEAR ON SPROCKET…9122
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL…9123
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE…9127
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE…9128
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE…9131
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE…9135
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE…9138
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE…9139
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT…9140
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT…9141
MEASUREMENT OF OIL LEAKAGE AMOUNT…9142
AIR BLEEDING OF VARIOUS PARTS…9144
INSPECTION PROCEDURES FOR DIODE…9146
SPECIAL FUNCTION OF MULTI-MONITOR PANEL…9147
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM…9171
TROUBLESHOOTING…9176
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED…9234
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…9320
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…9366
DISASSEMBLY AND ASSEMBLY…9392
HOW TO READ THIS MANUAL…9394
PRECAUTIONS WHEN PERFORMING OPERATION…9396
STARTING MOTOR…9398
FUEL INJECTION PUMP…9399
ENGINE FRONT SEAL…9403
ENGINE REAR SEAL…9405
CYLINDER HEAD…9407
RADIATOR ASSEMBLY…9413
HYDRAULIC OIL COOLER…9415
ENGINE AND HYDRAULIC PUMP…9417
FINAL DRIVE…9423
SWING MOTOR AND SWING MACHINERY…9436
CARRIER ROLLER…9444
TRACK ROLLER…9445
IDLER…9446
RECOIL SPRING…9449
SPROCKET…9451
TRACK SHOE…9452
SWING CIRCLE…9454
REVOLVING FRAME…9455
CENTER SWIVEL JOINT…9457
HYDRAULIC TANK…9460
CONTROL VALVE…9462
HYDRAULIC PUMP…9468
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT…9471
WORK EQUIPMENT PPC VALVE…9472
TRAVEL PPC VALVE…9473
HYDRAULIC CYLINDER…9474
WORK EQUIPMENT…9480
AIR CONDITIONER UNIT…9483
COUNTERWEIGHT…9486
OPERATOR’S CAB…9487
MONITOR ASSEMBLY…9490
GOVERNOR PUMP CONTROLLER…9491
OTHERS…9492
HYDRAULIC CIRCUIT DIAGRAM…9494
ELECTRICAL CIRCUIT DIAGRAM (1/4)…9496
ELECTRICAL CIRCUIT DIAGRAM (2/4)…9498
ELECTRICAL CIRCUIT DIAGRAM (3/4)…9500
ELECTRICAL CIRCUIT DIAGRAM (4/4)…9502
UEN00001-01 – Hydraulic Excavator PC290LC-8, PC290NLC-8 Shop Manual…9504
00 Index and foreword…9506
Index…9506
Organization list of the shop manual…9507
Table of contents…9509
00 Index and foreword…9518
Foreword and general information…9518
Foreword and general information…9519
Safety notice…9519
How to read the shop manual…9523
Explanation of terms for maintenance standard…9525
Handling electric equipment and hydraulic component…9527
How to read electric wire code…9535
Method of disassembling and connecting push-pull type coupler…9538
Standard tightening torque table…9541
Conversion table…9545
01 Specification…9552
Specification and technical data…9552
Specification and technical data…9553
Specification dimension drawings…9553
Working range diagram…9554
Specifications…9555
Weight table…9557
Table of fuel, coolant and lubricants…9559
10 Structure, function and maintenance standard…9562
Engine and cooling system…9562
Engine and cooling system…9563
Engine related parts…9563
Radiator, oil cooler, aftercooler and fuel cooler…9564
10 Structure, function and maintenance standard…9566
Power train…9566
Power train…9567
Power train…9567
Final drive…9569
Swing machinery…9571
Swing circle…9573
10 Structure, function and maintenance standard…9576
Undercarriage and frame…9576
Undercarriage and frame…9577
Track frame and recoil spring…9577
Idler…9579
Carrier roller…9581
Track roller…9582
Track shoe…9583
10 Structure, function and maintenance standard…9588
Hydraulic system, Part 1…9588
Hydraulic system, Part 1…9589
Hydraulic equipment layout drawing…9589
Hydraulic tank and filter…9591
Hydraulic pump…9593
Pilot oil filter…9615
10 Structure, function and maintenance standard…9618
Hydraulic system, Part 2…9618
Hydraulic system, Part 2…9619
Control valve…9619
CLSS…9630
Functions and operation by valve…9635
Hydraulic drift prevention valve…9660
10 Structure, function and maintenance standard…9672
Hydraulic system, Part 3…9672
Hydraulic system, Part 3…9674
Swing motor…9674
Center swivel joint…9683
Travel motor…9686
PPC valve…9699
Valve control…9721
ATT EPC Valve Assembly…9723
Solenoid valve…9725
PPC Accumulator…9727
Return oil filter…9728
Attachment circuit selector valve…9729
Quick coupler control valve…9731
Quick coupler control valve…9733
Hydraulic cylinder…9735
10 Structure, function and maintenance standard…9738
Work equipment…9738
Work equipment…9739
Dimensions of components…9739
10 Structure, function and maintenance standard…9746
Cab and its attachments…9746
Cab and its attachments…9747
Air conditioner piping…9747
10 Structure, function and maintenance standard…9750
Electrical system…9750
Electrical system…9752
Engine control…9752
Electrical control system…9761
Monitor system…9786
Sensor…9817
PPC Levers…9820
KOMTRAX terminal system…9822
20 Standard value table…9826
Standard service value table…9826
Standard service value table…9827
Standard value table for engine related parts…9827
Standard value table for chassis related parts…9828
30 Testing and adjusting…9840
Testing and adjusting, Part 1…9840
Testing and adjusting, Part 1…9842
Tools for testing, adjusting, and troubleshooting…9842
Measuring engine speed…9845
Measuring intake air pressure (boost pressure)…9846
Checking exhaust gas color…9847
Adjusting valve clearance…9848
Measuring compression pressure…9850
Measuring blow-by pressure…9852
Measuring engine oil pressure…9853
Handling fuel system parts…9854
Releasing residual pressure from fuel system…9854
Measuring fuel pressure…9855
Measuring fuel return rate and leakage…9857
Bleeding air from fuel circuit…9859
Checking fuel circuit for leakage…9861
Checking and adjusting air conditioner compressor belt tension…9862
Measuring swing circle bearing clearance…9863
Checking and adjusting track shoe tension…9864
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits…9866
Measuring control circuit basic pressure…9869
Measuring and adjusting oil pressure in pump PC control circuit…9870
Measuring and adjusting oil pressure in pump LS control circuit…9873
Measuring solenoid valve output pressure…9877
Measuring PPC valve output pressure…9880
Adjusting play of work equipment and swing PPC valves…9882
Measuring and adjusting quick coupler control valve output pressure…9883
Checking parts which cause hydraulic drift of work equipment…9884
Releasing residual pressure from hydraulic circuit…9885
Measuring oil leakage…9886
Bleeding air from each part…9889
Checking cab tipping stopper…9891
Adjusting mirrors…9893
30 Testing and adjusting…9896
Testing and adjusting, Part 2…9896
Testing and adjusting, Part 2…9897
Special functions of machine monitor…9897
30 Testing and adjusting…9954
Testing and adjusting, Part 3…9954
Testing and adjusting, Part 3…9955
Handling high-voltage circuit of engine controller…9955
Preparation work for troubleshooting of electrical system…9956
Procedure for testing diodes…9960
Pm Clinic service…9962
40 Troubleshooting…9970
General information on troubleshooting…9970
General information on troubleshooting…9971
Points to remember when troubleshooting…9971
Sequence of events in troubleshooting…9972
Check before troubleshooting…9973
Classification and procedures for troubleshooting…9974
How to read electric wire code…9978
Connection table for connector pin numbers…9981
T-boxes and T-adapters table…10004
40 Troubleshooting…10008
Troubleshooting by failure code (Display of code), Part 1…10008
Troubleshooting by failure code (Display of code), Part 1…10010
Failure codes table…10010
Before carrying out troubleshooting when failure code is displayed…10015
Information in troubleshooting table…10019
Failure code [989L00] Engine Controller Lock Caution 1…10021
Failure code [989M00] Engine Controller Lock Caution 2…10021
Failure code [989N00] Engine Controller Lock Caution 3…10022
Failure code [AA10NX] Air Cleaner Clogging…10022
Failure code [AB00KE] Charge Voltage Low…10023
Failure code [B@BAZG] Eng Oil Press. Low…10025
Failure code [B@BAZK] Eng Oil Level Low…10025
Failure code [B@BCNS] Eng Water Overheat…10026
Failure code [B@BCZK] Eng Water Level Low…10026
Failure code [B@HANS] Hydr Oil Overheat…10027
Failure code [CA111] EMC Critical Internal Failure…10027
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…10028
Failure code [CA122] Chg Air Press Sensor High Error…10029
Failure code [CA123] Chg Air Press Sensor Low Error…10031
Failure code [CA131] Throttle Sensor High Error…10033
Failure code [CA132] Throttle Sensor Low Error…10035
Failure code [CA144] Coolant Temp Sens High Error…10037
Failure code [CA145] Coolant Temp Sens Low Error…10039
Failure code [CA153] Chg Air Temp Sensor High Error…10041
Failure code [CA154] Chg Air Temp Sensor Low Error…10043
Failure code [CA155] Chg Air Temp High Speed Derate…10045
Failure code [CA187] Sens Supply 2 Volt Low Error…10047
Failure code [CA221] Ambient Press Sens High Error…10049
Failure code [CA222] Ambient Press Sens Low Error…10051
Failure code [CA227] Sens Supply 2 Volt High Error…10053
Failure code [CA234] Eng Overspeed…10054
Failure code [CA238] Ne Speed Sens Supply Volt Error…10055
Failure code [CA271] IMV/PCV1 Short Error…10056
Failure code [CA272] IMV/PCV1 Open Error…10057
Failure code [CA322] Inj #1 (L#1) Open/Short Error…10059
Failure code [CA323] Inj #5 (L#5) Open/Short Error…10061
Failure code [CA324] Inj #3 (L#3) Open/Short Error…10063
Failure code [CA325] Inj #6 (L#6) Open/Short Error…10065
Failure code [CA331] Inj #2 (L#2) Open/Short Error…10067
Failure code [CA332] Inj #4 (L#4) Open/Short Error…10069
40 Troubleshooting…10072
Troubleshooting by failure code (Display of code), Part 2…10072
Troubleshooting by failure code (Display of code), Part 2…10074
Failure code [CA342] Calibration Code Incompatibility…10074
Failure code [CA351] Injectors Drive Circuit Error…10075
Failure code [CA352] Sens Supply 1 Volt Low Error…10077
Failure code [CA386] Sens Supply 1 Volt High Error…10079
Failure code [CA428] Water in Fuel Sensor High Error…10081
Failure code [CA429] Water in Fuel Sensor Low Error…10083
Failure code [CA435] Eng Oil Press Sw Error…10085
Failure code [CA441] Battery Voltage Low Error…10086
Failure code [CA442] Battery Voltage High Error…10089
Failure code [CA449] Rail Press Very High Error…10091
Failure code [CA451] Rail Press Sensor High Error…10093
Failure code [CA452] Rail Press Sensor Low Error…10095
Failure code [CA488] Chg Air Temp High Torque Derate…10097
Failure code [CA553] Rail Press High Error…10097
Failure code [CA559] Rail Press Low Error…10098
Failure code [CA689] Eng Ne Speed Sensor Error…10099
Failure code [CA731] Eng Bkup Speed Sens Phase Error…10101
Failure code [CA757] All Continuous Data Lost Error…10103
Failure code [CA778] Eng Bkup Speed Sensor Error…10105
Failure code [CA1633] KOMNET Datalink Timeout Error…10107
Failure code [CA2185] Throt Sens Sup Volt High Error…10109
Failure code [CA2186] Throt Sens Sup Volt Low Error…10110
Failure code [CA2249] Rail Press Very Low Error…10111
Failure code [CA2311] IMV Solenoid Error…10113
Failure code [CA2555] Grid Htr Relay Volt High Error…10115
Failure code [CA2556] Grid Htr Relay Volt Low Error…10117
Failure code [D19JKZ] Personal Code Relay Abnormality…10119
Failure code [D862KA] GPS Antenna Discon…10121
Failure code [DA25KP] 5V Sensor 1 Power Abnormality…10122
Failure code [DA29KQ] Model Selection Abnormality…10129
40 Troubleshooting…10132
Troubleshooting by failure code (Display of code), Part 3…10132
Troubleshooting by failure code (Display of code), Part 3…10135
Failure code [DA2RMC] CAN Discon (Pump Con Detected)…10135
Failure code [DAFGMC] GPS Module Error…10137
Failure code [DAFRMC] CAN Discon (Monitor Detected)…10139
Failure code [DGH2KB] Hydr Oil Sensor Short…10141
Failure code [DHPAMA] F Pump Press Sensor Abnormality…10143
Failure code [DHPBMA] R Pump Press Sensor Abnormality…10145
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality…10147
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality…10149
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality…10151
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality…10153
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality…10155
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality…10157
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)…10159
Failure code [DW43KA] Travel Speed Sol Discon…10161
Failure code [DW43KB] Travel Speed Sol Short…10163
Failure code [DW45KA] Swing Brake Sol Discon…10165
Failure code [DW45KB] Swing Brake Sol Short…10167
Failure code [DW91KA] Travel Junction Sol Discon…10169
Failure code [DW91KB] Travel Junction Sol Short…10171
Failure code [DWA2KA] Service Sol Discon…10173
Failure code [DWA2KB] Service Sol Short…10174
Failure code [DWK0KA] 2-stage Relief Sol Discon…10175
Failure code [DWK0KB] 2-stage Relief Sol Short…10177
40 Troubleshooting…10180
Troubleshooting by failure code (Display of code), Part 4…10180
Troubleshooting by failure code (Display of code), Part 4…10183
Failure code [DXA8KA] PC-EPC (F) Sol Discon…10183
Failure code [DXA8KB] PC-EPC (F) Sol Short…10185
Failure code [DXA9KA] PC-EPC (R) Sol Discon…10187
Failure code [DXA9KB] PC-EPC (R) Sol Short…10189
Failure code [DXE0KA] LS-EPC Sol Discon…10191
Failure code [DXE0KB] LS-EPC Sol Short…10193
Failure code [DXE4KA] Service Current EPC Discon…10195
Failure code [DXE4KB] Service Current EPC Short…10197
Failure code [DXE5KA] Merge-divider Main Sol Discon…10199
Failure code [DXE5KB] Merge-divider Main Sol Short…10201
Failure code [DXE6KA] Merge-divider LS Sol Discon…10203
Failure code [DXE6KB] Merge-divider LS Sol Short…10205
Failure code [DY20KA] Wiper Working Abnormality…10207
Failure code [DY20MA] Wiper Parking Abnormality…10209
Failure code [DY2CKA] Washer Drive Discon…10211
Failure code [DY2CKB] Washer Drive Short…10213
Failure code [DY2DKB] Wiper Drive (For) Short…10215
Failure code [DY2EKB] Wiper Drive (Rev) Short…10217
40 Troubleshooting…10220
Troubleshooting of electrical system (E-mode)…10220
Troubleshooting of electrical system (E-mode)…10222
Before carrying out troubleshooting of electrical system…10222
Information in troubleshooting table…10224
E-1 When starting switch turned ON, machine monitor displays nothing…10225
E-2 When starting switch turned ON (before starting engine), basic check item lights up…10227
E-3 Engine does not start (Engine does not turn)…10230
E-4 Preheater does not operate…10233
E-5 Automatic warm-up system does not operate (in cold season)…10235
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked…10237
E-7 Precaution lights up while engine is running…10239
E-8 Emergency stop item lights up while engine is running…10244
E-9 Engine coolant temperature gauge does not indicate normally…10245
E-10 Hydraulic oil temperature gauge does not indicate normally…10246
E-11 Fuel level gauge does not indicate normally…10248
E-12 Contents of display by machine monitor are different from applicable machine…10250
E-13 Machine monitor does not display some items…10250
E-14 Function switch does not work…10250
E-15 Auto-decelerator does not operate normally…10251
E-16 Working mode does not change…10252
E-17 Travel speed does not change…10253
E-18 Alarm buzzer cannot be stopped…10254
E-19 Windshield wiper and window washer do not operate…10255
E-20 Power maximizing function does not operate normally…10257
E-21 Swing holding brake does not operate normally…10259
E-22 Travel alarm does not sound or does not stop sounding…10261
E-23 Air conditioner does not operate normally (including air conditioner abnormality record)…10263
E-24 When starting switch is turned OFF, service meter is not displayed…10275
E-25 Machine monitor cannot be set in service mode…10275
E-26 Monitoring function does not display lever control signal normally…10276
E-27 KOMTRAX system does not operate normally…10284
40 Troubleshooting…10286
Troubleshooting of hydraulic and mechanical system (H-mode)…10286
Troubleshooting of hydraulic and mechanical system (H-mode)…10289
System diagram of hydraulic and mechanical system…10289
Information in troubleshooting table…10291
H-1 Speed or power of whole work equipment, swing, and travel is low…10292
H-2 Engine speed lowers extremely or engine stalls…10294
H-3 Work equipment, swing, and travel systems do not work…10295
H-4 Abnormal sound comes out from around hydraulic pump…10295
H-5 Auto-decelerator does not operate…10296
H-6 Fine control performance or response is low…10296
H-7 Speed or power of boom is low…10297
H-8 Speed or power of arm is low…10298
H-9 Speed or power of bucket is low…10299
H-10 Work equipment does not move singly…10299
H-11 Hydraulic drift of work equipment is large…10300
H-12 Time lag of work equipment is large…10302
H-13 When part of work equipment is relieved singly, other parts of work equipment move…10302
H-14 Power maximizing function does not work…10303
H-15 In compound operation of work equipment, speed of part loaded more is low…10303
H-16 When machine swings and raises boom simultaneously, boom rising speed is low…10304
H-17 When machine swings and travels simultaneously, travel speed lowers largely…10304
H-18 Machine deviates during travel…10305
H-19 Travel speed is low…10306
H-20 Machine is not steered well or steering power is low…10307
H-21 Travel speed does not change or travel speed is low/high…10308
H-22 Travel system does not move (only one side)…10309
H-23 Upper structure does not swing…10310
H-24 Swing acceleration or swing speed is low…10312
H-25 Upper structure overruns remarkably when it stops swinging…10313
H-26 Large shock is made when upper structure stops swinging…10314
H-27 Large sound is made when upper structure stops swinging…10314
H-28 Hydraulic drift of swing is large…10315
H-29 Attachment circuit is not changed…10316
H-30 Oil flow in attachment circuit cannot be controlled…10316
Quick coupler…10317
40 Troubleshooting…10320
Troubleshooting of engine (S-mode)…10320
Troubleshooting of engine (S-mode)…10322
Method of using troubleshooting chart…10322
S-1 Starting performance is poor…10325
S-2 Engine does not start…10326
S-3 Engine does not pick up smoothly…10329
S-4 Engine stops during operations…10330
S-5 Engine does not rotate smoothly…10331
S-6 Engine lack output (or lacks power)…10332
S-7 Exhaust smoke is black (incomplete combustion)…10333
S-8 Oil consumption is excessive (or exhaust smoke is blue)…10334
S-9 Oil becomes contaminated quickly…10335
S-10 Fuel consumption is excessive…10336
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…10337
S-12 Oil pressure drops…10338
S-13 Oil level rises (Entry of coolant/fuel)…10339
S-14 Coolant temperature becomes too high (overheating)…10340
S-15 Abnormal noise is made…10341
S-16 Vibration is excessive…10342
50 Disassembly and assembly…10344
General information on disassembly and assembly…10344
General information on disassembly and assembly…10345
How to read this manual…10345
Coating materials list…10347
Special tool list…10350
Sketches of special tools…10355
50 Disassembly and assembly…10358
Engine and cooling system…10358
Engine and cooling system…10359
Removal and installation of fuel supply pump assembly…10359
Removal and installation of fuel injector assembly…10361
Removal and installation of engine front seal…10368
Removal and installation of engine rear seal…10371
Removal and installation of cylinder head assembly…10374
Removal and installation of radiator assembly…10386
Removal and installation of hydraulic oil cooler assembly…10389
Removal and installation of aftercooler assembly…10391
Removal and installation of fuel cooler assembly…10393
Removal and installation of engine and hydraulic pump assembly…10394
50 Disassembly and assembly…10404
Power train…10404
Power train…10405
Removal and installation of final drive assembly…10405
Disassembly and assembly of final drive assembly…10406
Removal and installation of swing motor and swing machinery assembly…10415
Disassembly and assembly of swing motor and swing machinery assembly…10417
Removal and installation of swing circle assembly…10426
50 Disassembly and assembly…10428
Undercarriage and frame…10428
Undercarriage and frame…10429
Disassembly and assembly of carrier roller assembly…10429
Disassembly and assembly of track roller assembly…10430
Disassembly and assembly of idler assembly…10431
Disassembly and assembly of recoil spring assembly…10434
Removal and installation of sprocket…10436
Expansion and installation of track shoe assembly…10437
Removal and installation of revolving frame assembly…10439
Removal and installation of counterweight assembly…10441
50 Disassembly and assembly…10444
Hydraulic system…10444
Hydraulic system…10445
Removal and installation of center swivel joint assembly…10445
Disassembly and assembly of center swivel joint assembly…10447
Removal and installation of hydraulic tank assembly…10448
Removal and installation of control valve assembly…10451
Disassembly and assembly of control valve assembly…10456
Removal and installation of hydraulic pump assembly…10460
Removal and installation of oil seal in hydraulic pump input shaft…10464
Disassembly and assembly of work equipment PPC valve assembly…10465
Disassembly and assembly of travel PPC valve assembly…10466
Disassembly and assembly of hydraulic cylinder assembly…10467
Disassembly and Assembly of Quick Coupler Valve…10473
50 Disassembly and assembly…10476
Work equipment…10476
Work equipment…10477
Removal and installation of work equipment assembly…10477
50 Disassembly and assembly…10482
Cab and its attachments…10482
Cab and its attachments…10483
Removal and installation of operator's cab assembly…10483
Removal and installation of operator cab glass (stuck glass)…10486
Removal and installation of front window assembly…10496
Removal and installation of floor frame assembly…10503
50 Disassembly and assembly…10508
Electrical system…10508
Electrical system…10509
Removal and installation of air conditioner unit assembly…10509
Removal and installation of KOMTRAX communication modem assembly…10512
Removal and installation of monitor assembly…10513
Removal and installation of pump controller assembly…10515
Removal and installation of engine controller assembly…10516
90 Diagrams and drawings…10518
Hydraulic diagrams and drawings…10518
Hydraulic diagrams and drawings (For PC290-8 K50001 ~ K50104)…10520
Hydraulic circuit diagram 1/2…10520
Hydraulic circuit diagram 2/2…10522
Hydraulic diagrams and drawings (For PC290-8 K50105 and up))…10524
Hydraulic circuit diagram 1/2…10524
Hydraulic circuit diagram 2/2…10526
90 Diagrams and drawings…10530
Electrical diagrams and drawings…10530
Electrical circuit diagram (For PC290-8 K50001 ~ K50104)…10532
Electrical circuit diagram (1/5)…10532
Electrical circuit diagram (2/5)…10534
Electrical circuit diagram (3/5)…10536
Electrical circuit diagram (4/5)…10538
Electrical circuit diagram (5/5)…10540
Electrical diagrams and drawings (For PC290 K50105 and up)…10542
Electrical circuit diagram (1/5)…10542
Electrical circuit diagram (2/5)…10544
Electrical circuit diagram (3/5)…10546
Electrical circuit diagram (4/5)…10548
Electrical circuit diagram (5/5)…10550

Komatsu Hydraulic Excavators PC290LC-6K, PC290NLC-6K, PC290LC-7, PC290LC-8, PC290LC-10, PC290LC-11, PC290NLC-7, PC290NLC-8, PC290LL-11 Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC270-8, PC270LC-8, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC270-8, PC270LC-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBM007202 – Hydraulic Excavator PC270LC-8 Shop Manual.pdf
SEN00420-13 – Hydraulic Excavator PC270-8, PC270LC-8 Shop Manual.pdf
CEAM003400 – Hydraulic Excavator PC270LC-6 Operation & Maintenance Manual.pdf
CEAM007202 – Hydraulic Excavator PC270LC-8 Operation & Maintenance Manual.pdf
TEN00148-03 – Hydraulic Excavator GALEO PC270-8 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 3,134 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
CEAM003400 – Hydraulic Excavator PC270LC-6 Operation & Maintenance Manual…2
COVER…2
INTRODUCTION…5
1. FORWARD…6
2. SAFETY INFORMATION…7
3. INTRODUCTION…8
3.1 INTENDED USE…8
3.2 FEATURES…8
3.3 BREAKING IN THE MACHINE…8
4. LOCATION OF PLATES, TABLE TO ENTER P.I.N AND DISTRIBUTOR…9
4.1 P.I.N. PLATE LOCATION…9
4.2 ENGINE SERIAL NUMBER PLATE…9
4.3 TABLE TO ENTER NUMBERS AND DISTRIBUTOR…9
5. TABLE OF CONTENTS…10
SAFETY…17
6. GENERAL PRECAUTIONS…18
7. PRECAUTIONS DURING OPERATION…26
7.1 BEFORE STARTING ENGINE…26
7.2 OPERATING MACHINE…28
7.3 TRANSPORTATION…34
7.4 BATTERY…36
7.5 TOWING…38
7.6 BUCKET WITH HOOK…39
8. PRECAUTIONS FOR MAINTENANCE…40
8.1 BEFORE CARRYING OUT MAINTENANCE…40
8.2 DURING MAINTENANCE…44
9. POSITION FOR ATTACHING SAFETY LABELS…50
OPERATION…54
10. GENERAL VIEW…55
10.1 GENERAL VIEW OF MACHINE…55
10.2 GENERAL VIEW OF OPERATORS COMPARTMENT…56
10.3 GENERAL VIEW OF MONITOR PANEL…57
11. EXPLANATION OF COMPONENTS…58
11.1 MACHINE MONITOR…58
11.1.1 MONITOR LIGHT GROUP…60
11.1.2 METER DISPLAY PORTION…62
11.1.3 SWITCHES…65
11.2 SWITCHES…68
11.2.1 STARTING SWITCH…68
11.2.2 FUEL CONTROL DIAL…69
11.2.3 CIGARETTE LIGHTER…69
11.2.4 SWING LOCK SWITCH…69
11.2.5 WIPER SWITCH…69
11.2.6 LIGHT SWITCH…70
11.2.7 ALARM BUZZER STOP SWITCH…70
11.2.8 CAB HEATER FAN SWITCH…70
11.2.9 HORN SWITCH…70
11.2.10 KNOB SWITCH…70
11.2.11 CAB LIGHT SWITCH…70
11.2.12 PUMP CONTROL OVERRIDE SWITCH…71
11.2.13 SWING LOCK OVERRIDE SWITCH…71
11.3 CONTROL LEVERS AND PEDALS…72
11.3.1 SAFETY LOCK LEVER…72
11.3.2 TRAVEL LEVERS…73
11.3.3 LEFT WORK EQUIPMENT CONTROL LEVER…73
11.3.4 RIGHT WORK EQUIPMENT CONTROL LEVER…74
11.3.5 ATTACHMENT CONTROL PEDAL…75
11.3.6 SELECTOR VALVES FOR BREAKER AND GENERAL ATTACHMENT (crusher etc.)…75
11.4 SEAT BELT…76
11.4.1 FASTEN THE BELT AND REMOVE IT…76
11.4.2 ADJUST THE BELT LENGTH…77
11.5 ROOF VENT…77
11.6 FRONT WINDOW WARNING…78
11.6.1 WHEN OPENING…78
11.6.2 WHEN CLOSING…79
11.6.3 FRONT BOTTOM WINDOW…80
11.7 DOOR LOCK…81
11.8 CAP, COVER WITH LOCK…81
11.8.1 METHOD OF OPENING AND CLOSING LOCK CAP…81
11.8.2 METHOD OF OPENING AND CLOSING COVER LOCK…82
11.9 HOT AND COOL BOX…82
11.10 STORAGE BOX…82
11.11 ASHTRAY…82
11.12 AIR CONDITIONER…83
11.12.1 GENERAL LOCATIONS ON CONTROL PANEL…83
11.12.2 PRECAUTIONS WHEN USING AIR CONDITIONER…85
11.12.3 CHECK, MAINTAIN AIR CONDITIONER…85
11.13 CAB HEATER…86
11.13.1 GENERAL LOCATIONS…86
11.14 PREPARATION FOR CAB HEATER…87
11.15 AM/FM RADIO…88
11.15.1 EXPLANATION OF COMPONENTS…88
11.15.2 METHOD OF OPERATION…90
11.15.3 PRECAUTIONS WHEN USING…91
11.15.4 SPECIFICATIONS…92
11.16 ELECTRIC POWER TAKE OUT ADAPTER…92
11.17 FUSE…93
11.18 FUSIBLE LINK…94
11.19 CONTROLLERS…94
11.20 TOOL BOX…94
11.21 GREASE GUN HOLDER…94
11.22 HANDLING ACCUMULATOR WARNING…95
12. OPERATION…96
12.1 CHECK BEFORE STARTING ENGINE…96
12.1.1 WALK AROUND CHECK…96
12.1.2 CHECK BEFORE STARTING…98
12.1.3 ADJUST BEFORE OPERATION…101
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE…105
12.2 STARTING ENGINE…107
12.2.1 NORMAL STARTING…107
12.2.2 STARTING IN COLD WEATHER…108
12.3 OPERATIONS AND CHECKS AFTER ENGINE STARTS WARNING…110
12.3.1 WHEN NORMAL…110
12.3.2 IN COLD AREAS (AUTOMATIC WARM UP OPERATION)…112
12.4 MOVING MACHINE…116
12.4.1 MOVING MACHINE FORWARD…116
12.4.2 MOVING MACHINE REARWARD…118
12.5 STEERING MACHINE…120
12.5.1 STEERING (CHANGING DIRECTION)…120
12.6 STOPPING MACHINE WARNING…122
12.7 SWINGING WARNING…123
12.8 OPERATION OF WORK EQUIPMENT WARNING…124
12.9 HANDLING ACTIVE MODE…125
12.10 HANDLING WORKING MODE…127
12.10.1 WORKING MODE…127
12.10.2 POWER MAX., SWIFT SLOW DOWN…128
12.11 PROHIBITED OPERATIONS WARNING…129
12.11.1 USING SWING FORCE…129
12.11.2 USING TRAVEL FORCE…129
12.11.3 OPERATE CYLINDERS TO END OF STROKE…129
12.11.4 USING DROPPING FORCE OF BUCKET…130
12.11.5 USING DROPPING FORCE OF MACHINE…130
12.11.6 DIGGING ROCKY GROUND…130
12.11.7 SUDDEN LEVER SHIFT DURING HI-SPEED TRAVEL…130
12.12 PRECAUTIONS FOR OPERATION…131
12.12.1 PRECAUTIONS WHEN TRAVELING…131
12.12.2 PRECAUTIONS AT HI-SPEED TRAVEL…131
12.12.3 PERMISSIBLE WATER DEPTH…131
12.13 PRECAUTIONS WHEN TRAVELING ON HILLS WARNING…132
12.13.1 BRAKING WHEN TRAVELING DOWNHILL…133
12.13.2 IF SHOES SLIP…133
12.13.3 IF ENGINE STOPS…133
12.13.4 PRECAUTIONS ON SLOPES…133
12.14 HOW TO ESCAPE FROM MUD…134
12.14.1 WHEN ONE SIDE IS STUCK…134
12.14.2 WHEN BOTH SIDES ARE STUCK…134
12.15 WORK POSSIBLE WITH HYDRAULIC EXCAVATOR…134
12.15.1 BACKHOE WORK…134
12.15.2 SHOVEL WORK…135
12.15.3 DITCHING WORK…135
12.15.4 LOADING WORK…135
12.16 REPLACE OR INVERT BUCKET WARNING…136
12.16.1 REPLACEMENT…136
12.16.2 INVERSION…137
12.17 PARKING MACHINE WARNING…138
12.18 CHECK AFTER FINISHING WORK…139
12.19 STOPPING ENGINE…140
12.20 CHECK AFTER STOPPING ENGINE…140
12.21 LOCKING…141
13.TRANSPORTATION…142
13.1 TRANSPORTATION PROCEDURE…142
13.2 LOADING, UNLOADING OF TRAILERS WARNING…142
13.2.1 LOADING…143
13.2.2 UNLOADING…144
13.2.3 SECURING MACHINE…145
13.2.4 REMOVAL, INSTALLATION OF MIRRORS…146
13.2.5 METHOD OF LIFTING MACHINE…147
13.3 PRECAUTIONS FOR TRANSPORTATION…148
14. COLD WEATHER OPERATION…149
14.1 PRECAUTIONS FOR LOW TEMPERATURE…149
14.1.1 FUEL AND LUBRICANTS…149
14.1.2 COOLANT…149
14.1.3 BATTERY…149
14.2 PRECAUTIONS AFTER COMPLETION OF WORK …151
14.3 AFTER COLD WEATHER…151
15. LONG TERM STORAGE…152
15.1 BEFORE STORAGE…152
15.2 DURING STORAGE WARNING…152
15.3 AFTER STORAGE…153
15.4 STARTING MACHINE AFTER LONG TERM STORAGE…153
16. TROUBLESHOOTING…154
16.1 PHENOMENA THAT ARE NOT FAILURES…154
16.2 METHOD OF TOWING MACHINE WARNING…154
16.3 METHOD FOR LIGHT WEIGHT TOWING WARNING…154
16.4 PRECAUTION ON PARTICULAR JOB SITES…154
16.5 IF BATTERY IS DISCHARGED WARNING…155
16.5.1 REMOVING AND INSTALLING BATTERY…155
16.5.2 PRECAUTIONS FOR CHARGING BATTERY…156
16.5.3 STARTING ENGINE WITH BOOSTER CABLE…156
16.6 OTHER TROUBLE…158
16.6.1 ELECTRICAL SYSTEM…158
16.6.2 CHASSIS…159
16.6.3 ENGINE…160
16.6.4 ELECTRONIC CONTROL SYSTEM…161
MAINTENANCE…162
17. GUIDES TO MAINTENANCE…163
18. OUTLINES OF SERVICE…165
18.1 OUTLINE OF OIL, FUEL, COOLANT…165
18.1.1 OIL…165
18.1.2 FUEL…165
18.1.3 COOLANT…166
18.1.4 GREASE…166
18.1.5 STORING OIL AND FUEL…166
18.1.6 FILTERS…166
18.2 OUTLINE OF ELECTRICAL SYSTEM…167
18.3 OUTLINE OF HYDRAULIC SYSTEM…167
18.4 OUTLINE OF FUEL SYSTEM…168
18.4.1 FUEL INJECTION PUMP…168
18.4.2 FUEL TANK…168
19. WEAR PARTS LIST…169
20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…170
20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…170
20.2 ENGINE OIL SPECIFICATIONS…171
20.2.1 NORMAL OPERATION…171
20.2.2 ARCTIC OPERATION…172
20.3 DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYDRAULIC SYSTEM OIL SPECIFIC…172
20.4 FINAL DRIVE OIL SPECIFICATIONS…172
20.5 DIESEL FUEL SPECIFICATIONS WARNING…172
20.6 COOLANT SPECIFICATIONS…173
20.6.1 GENERAL…173
20.6.2 WATER…173
20.6.3 ANTIFREEZE…174
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…176
21.1 INTRODUCTION OF NECESSARY TOOLS…176
21.2 TORQUE LIST…177
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…178
23. MAINTENANCE SCHEDULE CHART…181
23.1 SCHEDULED MAINTENANCE CHART…181
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…183
24. SERVICE PROCEDURE…184
24.1 INITIAL 250 HOURS SERVICE…184
24.1.1 REPLACE FUEL FILTER CARTRIDGE…184
24.2 WHEN REQUIRED…185
24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…185
24.2.2 CLEAN INSIDE OF COOLING SYSTEM…188
24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS…192
24.2.4 CHECK AND ADJUST TRACK TENSION…193
24.2.5 CHECK ELECTRICAL INTAKE AIR HEATER…194
24.2.6 INSTALLATION OF BUCKET TEETH…195
24.2.7 REMOVAL OF BUCKET TEETH…197
24.2.8 ADJUST BUCKET CLEARANCE…199
24.2.9 CHECK WINDOW WASHER FLUID…200
24.2.10 CHECK, MAINTAIN AIR CONDITIONER…201
24.2.11 REPLACE ADD ON BREAKER FILTER ELEMENT…202
24.2.12 CLEAN IN LINE FILTER…203
24.3 CHECK BEFORE STARTING…204
24.3.1 CHECK COOLANT LEVEL, ADD COOLANT…204
24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN…204
24.3.3 CHECK FUEL LEVEL…205
24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK…205
24.3.5 CHECK AIR CLEANER FOR CLOGGING…206
24.3.6 CHECK ELECTRICAL WIRING…206
24.3.7 CHECK FUNCTION OF HORN…206
24.3.8 DRAIN WATER FROM FUEL WATER SEPARATOR…207
24.4 EVERY 100 HOURS SERVICE…208
24.4.1 LUBRICATION…208
24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE…210
24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK…210
24.5 EVERY 250 HOURS SERVICE…211
24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…211
24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE…211
24.5.3 REPLACE HYDRAULIC FILTER ELEMENT…212
24.5.4 LUBRICATE SWING CIRCLE (3 POINTS)…213
24.5.5 CHECK FAN BELT TENSION, ADJUST…214
24.5.6 AIR CONDITIONER COMPRESSOR BELT TENSION…215
24.6 EVERY 500 HOURS SERVICE…216
24.6.1 REPLACE FUEL FILTER CARTRIDGE AND FUEL- WATER SEPARATOR…216
24.6.2 CHECK SWING PINION GREASE LEVEL, ADD GREASE…218
24.6.3 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AI…219
24.6.4 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER…220
24.6.5 REPLACE HYDRAULIC TANK BREATHER ELEMENT…220
24.6.6 CHANGE ENGINE OIL, REPLACE FILTER…221
24.6.7 REPLACE IN LINE FUEL STRAINER…223
24.7 EVERY 1000 HOURS SERVICE…224
24.7.1 CHANGE OIL IN SWING MACHINERY CASE…224
24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…225
24.7.3 CHECK TIGHTENING PARTS OF TURBOCHARGER…225
24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR…225
24.7.5 CHECK DRIVE BELT, TENSIONER BEARING AND FAN HUB…226
24.8 EVERY 2000 HOURS SERVICE…227
24.8.1 CHANGE OIL IN FINAL DRIVE CASE…227
24.8.2 CLEAN HYDRAULIC TANK STRAINER…228
24.8.3 CLEAN, CHECK TURBOCHARGER…228
24.8.4 CHECK ALTERNATOR, STARTING MOTOR…228
24.8.5 CHECK VIBRATION DAMPER…228
24.8.6 CHANGE ANTIFREEZE…228
24.8.7 CHECK AND ADJUST VALVE CLEARANCE…229
24.9 EVERY 4000 HOURS SERVICE…231
24.9.1 CHECK WATER PUMP…231
24.10 EVERY 5000 HOURS SERVICE…232
24.10.1 CHANGE OIL IN HYDRAULIC TANK…232
SPECIFICATIONS…236
25. MACHINE SPECIFICATIONS…237
25.1 GENERAL…237
25.2 WORKING RANGE…239
OPTIONS, ATTACHMENTS…241
26. GENERAL PRECAUTIONS…242
26.1 PRECAUTIONS RELATED TO SAFETY…242
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS WARNING…243
27. BUCKET WITH HOOK…244
27.1 CHECKING FOR DAMAGE…244
27.2 PROHIBITED OPERATIONS…244
27.3 PRECAUTIONS DURING OPERATIONS…244
28. HANDLING HEATER…245
28.1 GENERAL LOCATIONS…245
28.2 PREPARATION FOR CAR HEATER…246
29. HANDLING AIR CONDITIONER…247
29.1 DEFROSTER SELECTOR LEVER…247
29.2 PRECAUTIONS WHEN USING AIR CONDITIONER…248
30. MACHINES READY FOR ATTACHMENT…249
30.1 GENERAL LOCATIONS…249
30.1.1 STOP VALVE…249
30.1.2 SELECTOR VALVE…250
30.1.3 CONTROL PEDAL…250
30.1.4 LOCK PIN…250
30.1.5 ADDITIONAL FILTER FOR BREAKER…250
30.1.6 ACCUMULATOR…251
30.2 HYDRAULIC CIRCUIT…251
30.2.1 SWITCHING TO FILTER CIRCUIT…251
30.2.2 CONNECTING HYDRAULIC CIRCUIT…252
30.2.3 PATH OF OIL FLOW…252
30.3 PROCEDURE FOR REMOVAL AND…252
30.3.1 PROCEDURE FOR REMOVAL…253
30.3.2 PROCEDURE FOR INSTALLATION…253
30.4 OPERATION WARNING…254
30.4.1 WHEN USING BREAKER…254
30.4.2 WHEN USING GENERAL ATTACHMENT…255
30.5 LONG TERM STORAGE…255
30.6 SPECIFICATIONS…255
31. INTRODUCTION OF ATTACHMENTS…256
31.1 BUCKET SELECTION…256
31.1.1 STANDARD DUTY PLATE BUCKET…256
31.1.2 HEAVY DUTY PLATE BUCKET…256
31.1.3 HEAVY DUTY CAST LIP BUCKET…256
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…257
31.2.1 PC270LC-6…257
31.3 SELECTION OF TRACK SHOES…258
31.4 BACKHOE CONTROL PATTERN CONVERSION…259
32. EXTENDING MACHINE SERVICE LIFE…260
32.1 HYDRAULIC BREAKER…260
32.1.1 MAIN FIELDS OF APPLICATION…260
32.1.2 MISTAKEN METHODS OF USE…261
32.1.3 GREASING POSITION FOR HYDRAULIC BREAKER…263
32.2 CRUSHER…263
32.2.1 MAIN FIELDS OF APPLICATION…263
32.2.2 MISTAKEN METHODS OF USE…264
32.3 GRAB FORK…265
32.3.1 MAIN FIELDS OF APPLICATION…265
32.3.2 MISTAKEN METHODS OF USE…265
32.4 GRAPPLE BUCKET…266
32.4.1 MAIN FIELDS OF APPLICATION…266
32.4.2 MISTAKEN METHODS OF USE…266
32.5 SCRAP GRAPPLE…267
32.5.1 MAIN FIELDS OF APPLICATION…267
32.5.2 MISTAKEN METHODS OF USE…267
32.6 CRUSHER AND CUTTER…268
32.6.1 MAIN FIELDS OF APPLICATION…268
32.6.2 MISTAKEN METHODS OF USE…268
32.7 HYDRAULIC PILE DRIVER…269
32.7.1 MAIN FIELDS OF APPLICATION…269
32.7.2 MISTAKEN METHODS OF USE…269
CEAM007202 – Hydraulic Excavator PC270LC-8 Operation & Maintenance Manual…272
INTRODUCTION…274
FORWARD…275
SAFETY INFORMATION…276
INTRODUCTION…278
Directions of Machine…278
Breaking-in the New Machine…279
Product Information…280
Product Identification Number (Pin) / Machine Serial No. Plate…280
EPA* Regulations, Engine Number Plate…280
Service Meter Location…281
Your Machine Serial Numbers and Distributor…281
TABLE OF CONTENTS…282
SAFETY…292
SAFETY LABELS…293
Location of Safety Labels…294
Safety Labels…295
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE…302
Precautions Before Starting Operation…302
Ensuring Safe Operation…302
Understanding the Machine…302
Preparations for Safe Operation…302
Precautions Regarding Safety-Related Equipment…302
Inspecting Machine…302
Clothing and Personal Protective Items…302
Keep Machine Clean…303
Keep Operator's Compartment Clean…303
Fire Extinguisher and First Aid Kit…303
Safety Equipment…303
If Problems are Found…303
Fire Prevention and Explosion Prevention…304
Action if Fire Occurs…304
Handrails and Steps…305
Mounting and Dismounting…305
No Persons on Attachments…305
Leaving Operator's Seat with Lock…306
Emergency Exit from Operator's Cab…306
Do Not Get Caught in Work Equipment…307
Precautions Related to Protective Structures…307
Falling Objects, Flying Objects and Intruding Objects Prevention…307
Unauthorized Modification…308
Precautions Related to Attachments and Options…308
Precautions Related to Cab Glass…308
Precautions When Running Engine Inside Building…308
Burn Prevention…309
Hot coolant…309
Hot oil…309
Windshield Washer Fluid…309
Safety at Jobsite…310
Working on Loose Ground…310
Distance to High Voltage Cables…310
Ensure Good Visibility…311
Signalman's Signal and Signs…311
Asbestos Dust Hazard Prevention…312
SAFETY MACHINE OPERATION…313
Starting Engine…313
Checks Before Starting Engine…313
Safety Rules for Starting Engine…314
Starting Engine in Cold Weather…314
Starting Engine with Booster Cables…314
Operation…315
Checks Before Operation…315
Safety Rules for Changing Machine Directions…315
Safety Rules for Traveling…316
Traveling on Slopes…317
Operations on Slopes…318
Prohibited Operations…318
Operations on Snow or Frozen Surfaces…320
Parking Machine…320
TRANSPORTATION…321
Loading and Unloading…321
Shipping the Machine…321
TOWING…322
Safety Rules for Towing…322
LIFTING OBJECTS WITH BUCKET…323
Safety Rules for Lifting Objects…323
SAFETY MAINTENANCE INFORMATION…324
Warning Tag…324
Keep Work Place Clean and Tidy…324
Select Suitable Place for Inspection and Maintenance…324
Only Authorized Personnel…324
Appoint Leader when Working with Others…324
Stop Engine before Carrying Out Maintenance…325
Precautions when Working at High Places…325
Two Workers for Maintenance when Engine is Running…326
Proper Tools…326
Accumulator…326
Battery…327
Battery Hazard Prevention…327
Handling Gas Spring…328
Precautions when using…328
Precautions when discarding…328
Personnel…328
Attachments…329
Work Under the Machine…329
Noise…329
When using Hammer…329
Welding…329
Removing Battery Terminals…330
Safety First when using High-Pressure Grease to Adjust Track Tension…330
Do Not Disassemble Recoil Springs…330
Precautions with High-temperature Coolant…331
Precautions with High-temperature Oil…331
Safety Rules for High-pressure Oil…331
Precaution for High Fuel Pressure…332
Safety Handling High-pressure Hoses…332
Precaution for High Voltage…332
Waste Materials…332
Air Conditioner Maintenance…333
Compressed Air…333
Periodic Replacement of Safety Critical Parts…333
OPERATION…334
MACHINE VIEW ILLUSTRATIONS…335
Overall Machine View…335
CONTROLS AND GAUGES…336
Machine Monitors…337
DETAILED CONTROLS AND GAUGES…338
Monitoring System…338
Basic Operation of Machine Monitor…339
Emergency Monitors…344
Caution Monitors…346
Basic Check Monitors…349
Meter Display Portion…351
Pilot Display…351
Gauges and Meter…355
Function Switches…367
Handling Function Switches…368
Service Meter/Clock Display Selector Switch…374
Maintenance Selector Switch…375
User Mode Selector Switch…378
SWITCHES…408
Starting Switch…408
Fuel Control Dial…409
Cigarette Lighter…409
Swing Lock Switch…409
Lamp Switch…410
Horn Switch…410
One Touch Power Max. Switch…410
Room Lamp Switch…410
Emergency Pump Drive Switch…411
Swing Brake Cancel Switch…411
Revolving Warning Lamp Switch…411
Large Capacity Airflow Air Conditioner Blower Switch…412
CONTROL LEVERS AND PEDALS…413
Lock Lever…413
Travel Levers…414
Work Equipment Control Lever…415
SUN ROOF…416
WINDSHIELD…416
EMERGENCY ESCAPE HAMMER…422
DOOR LOCK…423
COVER WITH LOCK…423
CAP WITH LOCK…424
DRINK BOX…425
MAGAZINE BOX…425
ASHTRAY…425
AIR CONDITIONER CONTROLS…426
Air Conditioner Control Panel…426
Method of Operation…431
Automatic Operation…431
Stopping Automatic Operation…432
Manual Operation…432
Stopping Manual Operation…434
Operation with Cold Air to Face and Warm Air to Feet…434
Defroster Operation…436
Use Air Conditioner with Care…438
Air Conditioner Maintenance…438
RADIO…439
Control Panel…439
Controls of Radio…441
Preset Station Buttons…441
Method of Operating Mode…442
Setting Correct Time…442
Use Radio with Care…443
AUXILIARY ELECTRIC POWER…444
24 V power source…444
12 V power source…444
FUSE…445
FUSIBLE LINK…446
CONTROLLER…446
TOOL BOX…446
GREASE GUN HOLDER…446
FIRE EXTINGUISHER…447
MACHINE OPERATIONS AND CONTROLS…448
Before Starting Engine…448
Walk-around Checks…448
Checks Before Starting…449
Adjustment…458
Seat Belt Inspection…464
Operations Before Starting Engine…466
STARTING ENGINE…468
Turbo Protect Function…471
AFTER STARTING ENGINE…472
Engine Warm Up…474
Hydraulic System Warm-Up…476
Operation After Completion of Warming-Up Operation…482
STOPPING THE ENGINE…484
MACHINE OPERATION…485
Preparations for Moving the Machine…485
Moving Machine Forward…486
Moving Machine Backward…487
Stopping Machine…488
STEERING THE MACHINE…489
Steering…489
Steering the Machine when Stopped…489
Changing Direction of the Machine…490
Counter-rotation Turn (Spin Turn)…490
SWINGING…491
WORK EQUIPMENT CONTROLS AND OPERATIONS…492
WORKING MODE…494
Working Mode Switch…494
One-Touch Power Max. Switch…495
PROHIBITED OPERATIONS…496
GENERAL OPERATION INFORMATION…498
Traveling…498
High Speed Travel…498
Permissible Water Depth…499
TRAVELING ON SLOPES…500
ESCAPE FROM MUD…502
Track on One Side Stuck…502
Tracks on Both Sides Stuck…502
RECOMMENDED APPLICATIONS…503
Backhoe Work…503
Shovel Work…503
Ditching Work…503
Loading Work…504
BUCKET REPLACEMENT AND INVERSION…505
Replacement…505
Inversion…507
PARKING MACHINE…509
MACHINE INSPECTION AFTER DAILY WORK…511
LOCKING…511
TRANSPORTATION…511
Transportation Procedure…511
Loading And Unloading With Trailer…512
Loading…513
Securing Machine…516
Stowing Radio Antenna…517
Rearview Mirrors…517
Unloading…519
LONG DISTANCE TRANSPORT MODE…521
Normal Mode Display…521
Long Distance Transport Mode Display…521
LIFTING MACHINE…523
COLD WEATHER OPERATION…525
Cold Weather Operation Information…525
Fuel and Lubricants…525
Cooling System Coolant…525
Battery…526
AFTER DAILY WORK COMPLETION…527
AFTER COLD WEATHER SEASON…527
LONG TERM STORAGE…528
Before Storage…528
During Storage…528
After Storage…529
Starting Machine After Long-term Storage…529
TROUBLES AND ACTIONS…530
Running Out Of Fuel…530
Phenomena That Are Not Failures…530
Towing the Machine…531
Lightweight Towing Hole…532
Severe Job Condition…532
Discharged Battery…533
Battery Removal and Installation…533
Battery Charges…534
Starting Engine with Booster Cables…535
OTHER TROUBLE…537
Electrical System…537
Chassis…538
Engine…539
Electronic Control System…540
Point of Contact to Telephone when Error Occurs…541
MAINTENANCE…542
MAINTENANCE INFORMATION…543
OUTLINE OF SERVICE…545
Handling Oil, Fuel, Coolant, and Performing Oil Clinic…545
Oil…545
Fuel…546
Coolant and Water for Dilution…546
Grease…547
Carrying Out KOWA (Komatsu Oil Wear Analysis)…547
Storing Oil and Fuel…548
Filters…548
Electric System Maintenance…548
WEAR PARTS…549
Wear Parts List…549
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…550
Recommended Brands, Recommended Quality for Products Other Than Komatsu Genuine Oil…552
TORQUE SPECIFICATIONS…553
Torque List…553
Torque of Bolts…553
Torque of Hose Nuts…554
Torque of Split Flange Bolts…554
Torque for Flared Nuts…555
Torque for O-ring Boss Piping Joints…555
Torque for O-ring Boss Plugs…556
Torque for Hoses (Taper Seal Type And Face Seal Type)…556
SAFETY CRITICAL PARTS…557
Safety Critical Parts List…558
MAINTENANCE SCHEDULE…559
Maintenance Schedule Chart…559
Maintenance Interval for Hydraulic Breaker…561
MAINTENANCE PROCEDURE…562
Initial 10 Hours Maintenance…562
Initial 250 Hours Maintenance (Only After the First 250 Hours)…562
Initial 500 Hours Maintenance (Only After the First 500 Hours)…562
When Required…563
Check, Clean and Replace Air Cleaner Element…563
Clean Inside of Cooling System…570
Check and Tighten Track Shoe Bolts…574
Check and Adjust Track Tension…575
Replace Bucket Teeth (Vertical Pin Type)…577
Replace Bucket Teeth (Horizontal Pin Type)…580
Adjust Bucket Clearance…582
Check Window Washer Fluid Level, Add Fluid…583
Check and Maintenance Air Conditioner…584
Wash Washable Floor…585
Check Gas Spring…589
Bleeding Air From Hydraulic System…590
Check Before Starting…592
Every 100 Hours Maintenance…593
Lubricating…593
Every 250 Hours Maintenance…595
Check Level of Battery Electrolyte…595
Check Air Conditioner Compressor Belt Tension, Adjust…597
Every 500 Hours Maintenance…599
Lubricating…599
Change Oil in Engine Oil Pan…601
Replace Engine Oil Filter Cartridge…601
Replace Fuel Pre-filter Cartridge…603
Check Swing Pinion Grease Level, Add Grease…605
Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Condenser Fins (Only Machines Equipped With Air Conditioner)…606
Clean Air Conditioner Fresh/Recirc Filters…609
Replace Breather Element in Hydraulic Tank…610
Replace Hydraulic Tank Additional Breather Element…611
Check Oil Level in Swing Machinery Case, Add Oil…612
Check Oil Level in Final Drive Case, Add Oil…613
Every 1000 Hours Maintenance…614
Replace Hydraulic Oil Filter Element…614
Change Oil in Swing Machinery Case…615
Check Oil Level in Damper Case, Add Oil…616
Replace Fuel Main Filter Cartridge…617
Check All Tightening Points of Engine Exhaust Pipe Clamps…619
Check Fan Belt Tension and Replace Fan Belt…619
Check Nitrogen Gas Charge Pressure in Accumulator (For Breaker)…619
Every 2000 Hours Maintenance…620
Change Oil in Final Drive Case…620
Clean Hydraulic Tank Strainer…621
Checking Charge Pressure of Nitrogen Gas in Accumulator (for Control Circuit)…622
Check Alternator, Starting Motor…625
Check Engine Valve Clearance, Adjust…625
Every 4000 Hours Maintenance…626
Check Water Pump…626
Check Vibration Damper…626
Check Starting Motor…626
Replace Accumulator (for Control Circuit)…627
Check for Looseness of High-pressure Piping Clamp, Hardening Of Rubber…628
Check for Missing Fuel Spray Prevention Cap, Hardening Of Rubber…628
Check Operating Condition of Compressor…629
Every 5000 Hours Maintenance…630
Change Oil in Hydraulic Tank…630
Every 8000 Hours Maintenance…631
Replace Fuel Spray Prevention Cap…631
Replace High-pressure Piping Clamp…631
SPECIFICATIONS…632
SPECIFICATIONS…633
OPTIONS, ATTACHMENTS…636
GENERAL PRECAUTIONS FOR SAFETY…637
Precautions When Selecting…637
Read the Instruction Manual Thoroughly…637
Precautions When Removing or Installing…637
Precautions When Using…637
BUCKET WITH HOOK…638
Hook Condition…638
Prohibited Operations…638
MACHINE READY FOR ATTACHMENT…639
Locations…639
Stop Valve…639
Selector Valve…640
Attachment Control Pedal…640
Lock Pin…641
Breaker Circuit Additional Oil Filter…641
Accumulator…642
HYDRAULIC CIRCUIT…643
Switching Hydraulic Circuit…643
Adjusting Oil Flow…643
Switching Between Breaker and General Attachment…643
Hydraulic Circuit Connection…644
Oil Flow Path…645
Replace Additional Breaker Filter Element…646
Replace Additional Breaker Pilot Filter Element…649
ATTACHMENT REMOVAL AND INSTALLATION…652
Attachment Removal…652
Attachment Installation…654
ATTACHMENT OPERATIONS…656
When Using Breaker…656
When Using General Attachment Such as Crusher…658
LONG TERM STORAGE…660
Specifications…660
Attachment Guide…661
Attachment Combinations…661
TRACK SHOES SELECTION…663
BUCKET TEETH SELECTION…664
Selection Guide for Horizontal or Vertical Pin Type Tooth…664
RECOMMENDED ATTACHMENT OPERATIONS…665
Hydraulic Breaker…665
Prohibited Works…667
HANDLING MACHINES EQUIPPED WITH KOMTRAX…670
Basic Precautions…670
CEBM007202 – Hydraulic Excavator PC270LC-8 Shop Manual…672
CEBM007202 – PC270LC-8 sn A87001 and up…672
CONTENTS…673
REVISED PAGES…674
SAFETY…684
SAFETY NOTICE…684
IMPORTANT SAFETY NOTICE…684
GENERAL PRECAUTIONS…684
PREPARATIONS FOR WORK…684
PRECAUTIONS DURING WORK…684
GENERAL…687
HOW TO READ THE SHOP MANUAL…688
VOLUMES…688
DISTRIBUTION AND UPDATING…688
FILING METHOD…688
REVISED EDITION MARK…688
REVISIONS…688
SYMBOLS…688
HOISTING INSTRUCTIONS…689
HOISTING…689
WIRE ROPES…689
PUSH PULL COUPLER…690
TYPE 1…690
DISCONNECTION…690
CONNECTION…690
TYPE 2…691
DISCONNECTION…691
CONNECTION…691
TYPE 3…692
DISCONNECTION…692
CONNECTION…692
COATING MATERIALS…693
EXPLANATION OF MAINTENANCE STANDARD TERMS…695
STANDARD TIGHTENING TORQUE…697
Bolts and Nuts…697
Hose Nuts…698
Split Flange Bolts…698
Flared Nuts…698
O-ring Boss Piping Joints…699
O-ring Boss Plugs…699
Hoses (Taper Seal Type and Face Seal Type)…699
ELECTRIC WIRE CODE…700
Classification by Thickness…700
Classification by Color and Code…700
How To Read Electric Wire Code…701
CONVERSION TABLES…704
Method of Using the Conversion Table…704
01 GENERAL…710
SPECIFICATION AND TECHNICAL DATA…711
Specification Dimension Drawings…711
Working Range Diagram…712
Specifications…713
Weight table…715
TABLE OF FUEL, COOLANT AND LUBRICANTS…717
Lubrication Chart…719
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD…720
ENGINE AND COOLING…722
Engine related parts…722
Radiator, oil cooler, aftercooler and fuel cooler…723
POWER TRAIN…724
Power train…724
Final drive…725
Swing machinery…729
Swing circle…731
UNDERCARRIAGE AND FRAME…733
Track frame and recoil spring…733
Standard shoe…734
Idler…735
Carrier roller…737
Track roller…738
Track shoe…741
Triple grouser shoe…743
HYDRAULIC SYSTEM…745
Hydraulic equipment layout drawing…745
Hydraulic tank and filter…747
Hydraulic pump…749
Type: HPV95+95…749
Pilot oil filter…771
For breaker…771
Control valve…773
Sectional view (1/5)…775
Sectional view (2/5)…777
Sectional view (3/5)…779
Sectional view (4/5)…781
Sectional view (5/5)…783
CLSS…785
Functions and operation by valve…789
Unload valve…791
Introduction of LS pressure…793
LS bypass plug…794
Pressure compensation valve…795
Pressure compensation valve inner shuttle valve…798
Boom regeneration circuit…800
Arm regeneration circuit…802
Merge-divider valve…804
LS select valve…806
Self pressure reducing valve…807
Travel junction valve…810
Travel PPC shuttle valve…812
Boom drift preventive valve…814
Arm drift preventive valve (if equipped)…817
When abnormally high pressure is generated…820
Quick return valve…821
Lift check valve…823
Main relief valve…824
2-stage safety-suction valve…825
Swing Motor…827
Center swivel joint…837
Travel motor…839
PPC valve…852
Work equipment and swing PPC valve…852
Travel PPC valve…857
Service PPC valve (with EPC valve)…867
Service PPC valve…873
Control valve…875
Solenoid valve…877
PPC Accumulator…879
Return oil filter…880
For breaker…880
Attachment circuit selector valve…881
Hydraulic cylinder…883
Boom cylinder…883
Arm cylinder…883
Bucket cylinder…883
WORK EQUIPMENT…885
Dimensions of components…885
CAB AND ITS ATTACHMENTS…891
Air conditioner piping…891
ELECTRICAL SYSTEM…892
Engine control…892
Engine controller…895
Coolant temperature sensor…898
Oil pressure switch…898
Rotation sensor…899
Boost pressure and temperature sensor…899
WIF (water-in-fuel detection) sensor…900
Engine oil level sensor…900
Electrical control system…901
Machine control system diagram…901
MONITOR SYSTEM…925
Machine monitor…926
Monitor control, display portion…929
Switches…935
SENSORS…952
Fuel level sensor…952
Air cleaner clogging sensor…953
Coolant level sensor…953
KOMTRAX TERMINAL SYSTEM…954
KOMTRAX communication modem…955
20 STANDARD VALUE TABLES…956
STANDARD SERVICE VALUE TABLE…957
Engine related parts…957
Chassis related parts…958
30 TESTING AND ADJUSTING…972
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…974
Sketch of special tool…978
ENGINE SPEED…979
INTAKE AIR PRESSURE (BOOST PRESSURE)…981
EXHAUST GAS COLOR…982
VALVE CLEARANCE…984
COMPRESSION PRESSURE…986
Determining A Defective Cylinder…989
Procedures…989
Determining Cylinder Group…989
Isolating The Defective Cylinder…989
BLOW-BY PRESSURE…990
ENGINE OIL PRESSURE…991
HANDLING FUEL SYSTEM PARTS…992
Releasing Residual Pressure From Fuel System…992
Fuel Pressure…993
Fuel Return Rate And Leakage…996
Bleeding Air From Fuel Circuit…1001
Fuel Circuit – Checking For Leakage…1002
AIR CONDITIONER COMPRESSOR BELT…1003
FAN BELT…1004
SWING CIRCLE BEARING…1005
TRACK CHAIN TENSION…1006
WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS OIL PRESSURE…1007
CONTROL CIRCUIT BASIC PRESSURE…1011
OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…1013
Measuring…1013
Adjusting…1015
OIL PRESSURE IN PUMP LS CONTROL CIRCUIT…1016
Measuring…1016
Adjusting…1020
SOLENOID VALVE OUTPUT PRESSURE…1021
Measuring…1021
PPC Lock Solenoid Valve Operation Table…1023
2-Stage Relief Solenoid Valve Operation Table…1023
Swing Holding Brake Solenoid Valve Operation Table…1023
Travel Speed Shifting Solenoid Valve Operation Table…1023
Travel Junction Solenoid Valve Operation Table…1024
ATT Return Selector Solenoid Valve Operation Table…1024
PPC VALVE OUTPUT PRESSURE…1025
WORK EQUIPMENT AND SWING PPC VALVES…1028
HYDRAULIC DRIFT OF WORK EQUIPMENT…1029
RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT…1030
OIL LEAKAGE…1031
BLEEDING AIR FROM EACH PART…1034
CAB TIPPING STOPPER…1037
MIRRORS…1038
SPECIAL FUNCTIONS OF MACHINE MONITOR…1042
Long Distance Transport Mode…1105
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…1107
PREPARATION WORK FOR ELECTRICAL SYSTEM…1108
PROCEDURE FOR TESTING DIODES…1113
PM CLINIC SERVICE…1115
40 TROUBLESHOOTING…1124
GENERAL INFORMATION…1128
Points To Remember…1128
Sequence Of Events In Troubleshooting…1130
Handling Electric Equipment and Hydraulic Components…1131
New Connectors for Tier 3 Engines…1139
Check Before Troubleshooting…1143
Classification And Troubleshooting Steps…1144
Troubleshooting Classification…1144
Troubleshooting steps…1144
Information In Troubleshooting Table…1145
Related Circuit Diagram…1146
Possible Problems and Troubleshooting No…1147
How To Read Electric Wire Code…1150
Connection Table For Connector Pin Numbers…1153
T-branch boxes and T-branch adapters Table…1189
FAILURE CODE (DISPLAY OF CODE)…1192
Failure Codes Table…1192
Before Troubleshooting With Failure Code Displayed…1197
Fuse Box Connection Table…1197
Locations Of Fusible Links…1198
Location Of Fuse Box And Fuse Nos…1198
Trouble That Occurs When Power Supply Of Pump Controller Is Defective…1199
989L00 Engine Controller Lock Caution 1…1201
989M00 Engine Controller Lock Caution 2…1201
989N00 Engine Controller Lock Caution 3…1202
AA10NX Air Cleaner Clogging…1202
AB00KE Charge Voltage Low…1203
B@BAZG Eng Oil Press. Low…1205
B@BAZK Eng Oil Level Low…1205
B@BCNS Eng Water Overheat…1206
B@BCZK Eng Water Level Low…1206
B@HANS Hyd Oil Overheat…1207
CA111 EMC Critical Internal Failure…1207
CA115 Eng Ne and Bkup Speed Sens Error…1208
CA122 Chg Air Press Sensor High Error…1209
CA123 Chg Air Press Sensor Low Error…1211
CA131 Throttle Sensor High Error…1213
CA132 Throttle Sensor Low Error…1215
CA144 Coolant Temp Sens High Error…1217
CA145 Coolant Temp Sens Low Error…1219
CA153 Chg Air Temp Sensor High Error…1221
CA154 Chg Air Temp Sensor Low Error…1223
CA155 Chg Air Temp High Speed Derate…1225
CA187 Sens Supply 2 Volt Low Error…1227
CA221 Ambient Press Sens High Error…1229
CA222 Ambient Press Sens Low Error…1231
CA227 Sens Supply 2 Volt High Error…1233
CA234 Eng Overspeed…1234
CA238 Ne Speed Sens Supply Volt Error…1235
CA271 IMV/PCV1 Short Error…1236
CA272 IMV/PCV1 Open Error…1237
CA322 Inj #1 Open/Short Error…1239
CA323 Inj #5 Open/Short Error…1241
CA324 Inj #3 Open/Short Error…1243
CA325 Inj #6 Open/Short Error…1245
CA331 Inj #2 Open/Short Error…1247
CA332 Inj #4 Open/Short Error…1249
CA342 Calibration Code Incompatibility…1251
CA351 Injectors Drive Circuit Error…1253
CA352 Sens Supply 1 Volt Low Error…1255
CA386 Sens Supply 1 Volt High Error…1257
CA428 Water in Fuel Sensor High Error…1259
CA429 Water in Fuel Sensor Low Error…1261
CA435 Eng Oil Press Sw Error…1263
CA441 Battery Voltage Low Error…1264
CA442 Battery Voltage High Error…1267
CA449 Rail Press Very High Error…1269
CA451 Rail Press Sensor High Error…1271
CA452 Rail Press Sensor Low Error…1273
CA488 Chg Air Temp High Torque Derate…1275
CA553 Rail Press High Error…1275
CA559 Rail Press Low Error…1276
CA689 Eng Ne Speed Sensor Error…1277
CA731 Eng Bkup Speed Sens Phase Error…1279
CA757 All Continuous Data Lost Error…1281
CA778 Eng Bkup Speed Sensor Error…1283
CA1633 KOMNET Datalink Timeout Error…1285
CA2185 Throt Sens Sup Volt High Error…1286
CA2186 Throt Sens Sup Volt Low Error…1287
CA2249 Rail Press Very Low Error…1288
CA2311 IMV Solenoid Error…1289
CA2555 Grid Htr Relay Volt High Error…1291
CA2556 Grid Htr Relay Volt Low Error…1293
D19JKZ Personal Code Relay Abnormality…1295
D862KA GPS Antenna Discon…1297
DA22KK Pump Solenoid Power Low Error…1299
DA25KP 5 V Sensor 1 Power Abnormality…1301
DA29KQ Model Selection Abnormality…1307
DA2RMC CAN Discon (Pump Con Detected)…1309
DAF8KB Short Circuit In Camera Power Supply…1317
DAFGMC GPS Module Error…1319
DAFRMC CAN Discon (Monitor Detected)…1320
DGH2KB Hydr Oil Sensor Short…1327
DHPAMA F Pump Press Sensor Abnormality…1329
DHPBMA R Pump Press Sensor Abnormality…1331
DHS3MA Arm Curl PPC Press Sensor Abnormality…1333
DHS4MA Bucket Curl PPC Press Sensor Abnormality…1335
DHS8MA Boom Raise PPC Press Sensor Abnormality…1337
DHSAMA Swing RH PPC Press Sensor Abnormality…1339
DHSBMA Swing LH PPC Press Sensor Abnormality…1341
DHSDMA Bucket Dump PPC Press Sensor Abnormality…1343
DHX1MA Overload Sensor Abnormality (Analog)…1345
DW43KA Travel Speed Sol Discon…1349
DW43KB Travel Speed Sol Short…1351
DW45KA Swing Brake Sol Discon…1353
DW45KB Swing Brake Sol Short…1355
DW91KA Travel Junction Sol Discon…1357
DW91KB Travel Junction Sol Short…1359
DWA2KA Service Sol Discon…1361
DWA2KB Service Sol Short…1362
DWK0KA 2-Stage Relief Sol Discon…1363
DWK0KB 2-Stage Relief Sol Short…1365
DXA8KA PC-EPC (F) Sol Discon…1367
DXA8KB PC-EPC (F) Sol Short…1369
DXA9KA PC-EPC (R) Sol Discon…1371
DXA9KB PC-EPC (R) Sol Short…1373
DXE0KA LS-EPC Sol Discon…1375
DXE0KB LS-EPC Sol Short…1377
DXE4KA Service Current EPC Discon…1379
DXE4KB Service Current EPC Short…1381
DXE5KA Merge-divider Main Sol Discon…1383
DXE5KB Merge-divider Main Sol Short…1385
DXE6KA Merge-divider LS Sol Discon…1387
DXE6KB Merge-divider LS Sol Short…1389
DY20KA Wiper Working Abnormality…1391
DY20MA Wiper Parking Abnormality…1393
DY2CKA Washer Drive Discon…1395
DY2CKB Washer Drive Short…1397
DY2DKB Wiper Drive (For) Short…1399
DY2EKB Wiper Drive (Rev) Short…1401
ELECTRICAL SYSTEM (E-MODE)…1403
Troubleshooting Table…1403
E-1 No Machine Monitor Display When Starting Switch Is Turned On…1405
E-2 Basic Check Item Lights Up When Starting Switch Turned On (Before Starting Engine)…1407
E-3 Engine Does Not Start…1410
E-4 Preheater Does Not Operate…1415
E-5 Automatic Warm-up System Does Not Operate (In Cold Season)…1419
E-6 All Work Equipment, Swing, And Travel Mechanism Do Not Move Or Cannot Be Locked…1421
E-7 Precaution Lights Up While Engine Is Running…1423
E-8 Emergency Stop Item Lights Up While Engine Is Running…1428
E-9 Engine Coolant Temperature Gauge Does Not Indicate Normally…1429
E-10 Hydraulic Oil Temperature Gauge Does Not Indicate Normally…1431
E-11 Fuel Level Gauge Does Not Indicate Normally…1435
E-12 Machine Monitor Content Displays Are Different From Applicable Machine…1438
E-13 Machine Monitor Does Not Display Some Items…1438
E-14 Function Switch Does Not Work…1438
E-15 Auto-decelerator Does Not Operate Normally…1439
E-16 Working Mode Does Not Change…1440
E-17 Travel Speed Does Not Change…1441
E-18 Alarm Buzzer Cannot be Stopped…1442
E-19 Windshield Wiper and Window Washer Do Not Operate…1443
E-20 Power Maximizing Function Does Not Operate Normally…1445
E-21 Swing Holding Brake Does Not Operate Normally…1447
E-22 Travel Alarm Does Not Sound or Does Not Stop…1449
E-23 Air Conditioner Does Not Operate Normally (Including Air Conditioner Abnormality Record)…1451
E-24 Service Meter Is Not Display While Starting Switch Is In OFF Position…1463
E-25 Machine Monitor Cannot Be Set In Service Mode…1463
E-26 Monitoring Function Does Not Display Lever Control Signal Normally…1464
E-27 KOMTRAX System Does Not Operate Normally…1473
HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…1475
System Diagram of Hydraulic and Mechanical System…1475
Information In Troubleshooting Table…1477
H-1 All Work Equipment Lack Power, or Swing and Travel Speeds Are Slow…1478
H-2 Engine Speed Drops Sharply or Engine Stalls…1480
H-3 Work Equipment, Swing, and Travel Systems Do Not Work…1481
H-4 Abnormal Noise Is Heard Around Hydraulic Pump…1481
H-5 Auto-decelerator Does Not Work…1482
H-6 Fine Control Mode Does Not Function or Responds Slow…1482
H-7 Boom Moves Slowly or Lacks Power…1483
H-8 Arm Moves Slowly or Lacks Power…1484
H-9 Bucket Moves Slowly or Lacks Power…1485
H-10 Work Equipment Does Not Move In Its Single Operation…1485
H-11 Work Equipment Hydraulic Drift Is Too Fast…1486
H-12 Work Equipment Has Big Time Lag…1488
H-13 Other Work Equipment Moves When Relieving Single Circuit…1488
H-14 Power Maximizing Function Does Not Work…1489
H-15 In Compound Operation, Work Equipment With Larger Load Moves Slowly…1489
H-16 In Swing and Boom Raise Operation, Boom Moves Slowly…1490
H-17 In Swing and Travel Operation, Travel Speed Drops Sharply…1490
H-18 Machine Swerves In Travel…1491
H-19 Machine Travels Slowly…1492
H-20 Machine Steers With Difficulty or Lacks Power…1493
H-21 Travel Speed Does Not Shift or Is Too Slow or Too Fast…1494
H-22 Track Shoe Does Not Turn (On One Side Only)…1495
H-23 Machine Does Not Swing…1496
H-24 Swing Acceleration Is Poor or Swing Speed Is Slow…1498
H-25 Excessive Overrun When Stopping Swing…1500
H-26 The Machine Jerks When Stopping Swing…1501
H-27 Loud Sound Occurs When Upper Structure Stops Swinging…1501
H-28 Swing Hydraulic Drift Is Too Big…1502
H-29 Attachment Circuit Is Not Changed…1503
H-30 Oil Flow In Attachment Circuit Cannot Be Controlled…1503
50 DISASSEMBLY AND ASSEMBLY…1504
HOW TO READ THIS SECTION…1508
Removal And Installation Of Assemblies…1508
Removal…1508
Installation…1508
Disassembly And Assembly Of Assemblies…1509
Disassembly…1509
Assembly…1510
SPECIAL TOOLS LIST…1511
SKETCHES OF SPECIAL TOOLS…1516
CONNECTOR REPAIR PROCEDURES…1520
Stripping Insulation…1520
Wire Inspection…1520
Contact Terminal Removal (HD30 Type)…1521
Crimping Contact Terminal (HD30 Type)…1522
Insertion Of Contact Terminal (HD30 Type)…1523
Contact Terminal Removal (DT Type)…1524
Crimping Contact Terminal (DT Type)…1525
Insertion Of Contact Terminal (DT Type)…1526
ENGINE AND COOLING SYSTEM…1527
Fuel Supply Pump…1527
Removal…1527
Installation…1531
Fuel Injector Assembly…1533
Removal…1533
Installation…1538
Engine Front Seal…1544
Removal…1544
Installation…1546
Engine Rear Seal…1548
Removal…1548
Installation…1549
Cylinder Head Assembly…1552
Removal…1552
Installation…1560
Radiator Assembly…1570
Removal…1570
Installation…1572
Hydraulic Oil Cooler Assembly…1574
Removal…1574
Installation…1576
Aftercooler Assembly…1577
Removal…1577
Installation…1579
Fuel Cooler Assembly…1580
Removal…1580
Installation…1580
Engine And Hydraulic Pump Assembly…1581
Removal…1581
Installation…1590
POWER TRAIN…1594
Final Drive Assembly…1594
Removal…1594
Installation…1595
Final Drive…1596
Disassembly…1596
Assembly…1600
Swing Motor and Swing Machinery Assembly…1607
Removal…1607
Installation…1609
Swing Motor and Swing Machinery Assembly…1610
Disassembly…1610
Assembly…1615
Swing Circle Assembly…1621
Removal…1621
Installation…1621
UNDERCARRIAGE AND FRAME…1622
Carrier Roller…1622
Assembly…1622
Track Roller…1623
Assembly…1623
Idler, Recoil Spring…1624
Removal…1624
Installation…1624
Idler…1625
Disassembly…1625
Assembly…1626
Recoil Spring…1629
Disassembly…1629
Assembly…1630
Sprocket…1632
Removal…1632
Installation…1632
Track Shoe…1633
Expanding Track Shoe…1633
Installation…1634
Revolving Frame…1635
Removal…1635
Installation…1637
Counterweight…1638
Removal…1638
Installation…1640
HYDRAULIC SYSTEM…1641
Center Swivel Joint…1641
Removal…1641
Installation…1643
Disassembly…1644
Assembly…1645
Hydraulic Tank Assembly…1646
Removal…1646
Installation…1649
Control Valve…1650
Removal…1650
Installation…1655
Precautions for Replacing Pressure Compensation Valve Seal…1657
Precautions for Assembling Control Valve…1659
Hydraulic Pump…1662
Removal…1662
Installation…1666
Oil Seal In Hydraulic Pump Input Shaft…1667
Removal…1667
Installation…1667
Work Equipment PPC Valve…1668
Disassembly…1668
Assembly…1668
Travel PPC Valve…1670
Disassembly…1670
Assembly…1671
Hydraulic Cylinder…1673
Disassembly…1674
Assembly…1676
WORK EQUIPMENT…1680
Work Equipment…1680
Removal…1680
Installation…1682
CAB AND ITS ATTACHMENTS…1683
Operator's Cab…1683
Removal…1683
Installation…1686
Operator Cab Glass (Fixed Glass)…1687
Removal…1688
Installation…1689
Front Window…1698
Removal…1698
Installation…1701
Floor Frame…1706
Removal…1706
Installation…1710
ELECTRICAL SYSTEM…1711
Air Conditioner Unit…1711
Removal…1711
Installation…1715
KOMTRAX Communication Modem…1716
Removal…1716
Installation…1716
Monitor…1717
Removal…1717
Installation…1718
Pump Controller…1719
Removal…1719
Installation…1720
Engine Controller…1722
Removal…1722
Installation…1723
60 AIR CONDITIONER…1724
STRUCTURE AND FUNCTION…1727
Air Conditioner Component…1727
Configuration and Function of Refrigerating cycle…1729
Outline of Refrigerating Cycle…1730
Air Conditioner Unit…1733
Functions of Major Components in the Air Conditioner Unit…1735
Control Plate…1737
Compressor…1740
Condenser and Receiver Drier…1741
TESTING AND ADJUSTING…1742
Caution About Refrigerant…1742
Troubleshooting Procedure…1743
Block Diagram…1744
Circuit Diagram and Arrangement of Connector Pins…1745
Detail of Air Conditioner Unit…1747
Part and Connector Locations…1749
Testing Air Leakage (Ducts)…1753
Testing with Self-diagnosis Function…1755
Testing Temperature Control…1758
Testing Vent (Mode) Changeover…1761
Testing Recirc/Fresh Changeover…1765
Testing Inner Sensor…1767
Testing Evaporator Temperature Sensor…1768
Testing Sunlight Sensor…1770
Testing (Dual) Pressure Switch for Refrigerant…1771
Testing Relays…1773
TROUBLESHOOTING…1775
Troubleshooting Chart 1…1775
Troubleshooting Chart 2…1776
Troubleshooting for Electrical System (E mode)…1779
E-1 Power Supply System (Air Conditioner does not Operate)…1780
E-2 Compressor System (Air is Not Cooled)…1784
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)…1787
E-4 Temperature Cannot be Controlled…1791
E-5 Vent (Mode) Cannot be Changed Over…1794
E-6 Recirc/Fresh Air Cannot be Changed Over…1797
Troubleshooting With Gauge Pressure…1800
Connection of Service Tool…1803
Precautions for connecting air conditioner piping…1805
Handling of Compressor Oil…1806
Control of Compressor Oil…1806
Adding of Compressor Oil…1806
Compressor Replacement…1807
Applying Compressor Oil for O-ring…1807
Desiccant Replacement Procedure…1808
90 DIAGRAMS AND SCHEMATICS…1810
HYDRAULIC SYSTEM…1812
Hydraulic Circuit Diagram…1812
ELECTRICAL SYSTEM…1813
Electrical Circuit Diagram (1/5)…1813
Electrical Circuit Diagram (2/5)…1814
Electrical Circuit Diagram (3/5)…1815
Electrical Circuit Diagram (4/5)…1816
Electrical Circuit Diagram (5/5)…1817
Electrical Connector Arrangement Diagram…1818
SEN00420-13 – Hydraulic Excavator PC270-8, PC270LC-8 Shop Manual…1819
COVER…1819
00 Index and foreword…0
Index…1821
Composition of shop manual…1822
Table of contents…1824
Foreword and general information…1833
Safety notice…1834
How to read the shop manual…1839
Explanation of terms for maintenance standard…1841
Handling of electric equipment and hydraulic component…1843
Handling of connectors newly used for engines…1852
How to read electric wire code…1855
Precautions when carrying out operation…1858
Method of disassembling and connecting push-pull type coupler…1861
Standard tightening torque table…1864
Conversion table…1868
01 Specification…0
Specification and technical data…1875
Specification dimension drawings…1876
Working range diagram…1877
Specifications…1878
Weight table…1880
Table of fuel, coolant and lubricants…1882
10 Structure, function and maintenance standard…0
Engine and cooling system…1885
Engine and cooling system…1886
Engine related parts…1886
Radiator, oil cooler, aftercooler and fuel cooler…1887
Power train…1889
Power train…1890
Final drive…1892
Swing machinery…1894
Swing circle…1896
Undercarriage and frame…1899
Undercarriage and frame…1900
Track frame and recoil spring…1900
Idler…1902
Carrier roller…1904
Track roller…1905
Track shoe…1906
Hydraulic system, Part 1…1911
Hydraulic system, Part 1…1912
Hydraulic equipment layout drawing…1912
Hydraulic tank and filter…1914
Hydraulic pump…1916
Pilot oil filter…1938
Hydraulic system, Part 2…1941
Hydraulic system, Part 2…1942
Control valve…1942
CLSS…1953
Functions and operation by valve…1958
Hydraulic system, Part 3…1997
Swing motor…1998
Center swivel joint…2008
Travel motor…2011
PPC valve…2024
Valve control…2046
Solenoid valve…2048
PPC accumulator…2050
Return oil filter…2051
Attachment circuit selector valve…2052
Hydraulic cylinder…2054
Work equipment…2057
Work equipment…2058
Dimensions of components…2058
Cab and its attachments…2065
Air conditioner piping…2066
Electrical system…2069
Engine control…2070
Electrical control system…2078
Monitor system…2101
Sensor…2128
KOMTRAX system…2131
20 Standard value table…0
Standard service value table…2135
Standard service value table…2136
Standard value table for engine related parts…2136
Standard value table for chassis related parts…2137
30 Testing and adjusting…0
Testing and adjusting, Part 1…2149
Testing and adjusting, Part 1…2151
Tools for testing, adjusting, and troubleshooting…2151
Sketch of special tool…2155
Testing engine speed…2156
Testing intake air pressure (boost pressure)…2157
Checking exhaust gas color…2158
Adjusting valve clearance…2159
Testing compression pressure…2161
Testing blow-by pressure…2163
Testing engine oil pressure…2164
Handling fuel system parts…2165
Releasing residual pressure from fuel system…2165
Testing fuel pressure…2166
Testing fuel delivery, return and leak amount…2169
Bleeding air from fuel circuit…2172
Checking fuel circuit for leakage…2173
Checking and adjusting air conditioner compressor belt tension…2174
Replacing fan belt…2175
Testing swing circle bearing clearance…2176
Checking and adjusting track shoe tension…2177
Testing and adjusting oil pressure in work equipment, swing, and travel circuits…2179
Testing control circuit basic pressure…2182
Testing and adjusting oil pressure in pump PC control circuit…2183
Testing and adjusting oil pressure in pump LS control circuit…2186
Testing solenoid valve output pressure…2191
Testing PPC valve output pressure…2194
Adjusting play of work equipment and swing PPC valves…2196
Checking parts which cause hydraulic drift of work equipment…2197
Releasing residual pressure from hydraulic circuit…2199
Testing oil leakage…2200
Bleeding air from each part…2203
Checking cab tipping stopper…2205
Installation and adjustment of mirrors…2206
Testing and adjusting, Part 2…2211
Special functions of machine monitor…2212
Testing and adjusting, Part 3…2269
Testing and adjusting, Part 3…2270
Handling voltage circuit of engine controller…2270
Preparation work for troubleshooting of electrical system…2271
Procedure for testing diodes…2276
Pm Clinic service…2277
40 Troubleshooting…0
Failure code table and fuse locations…2285
Failure codes table…2286
Fuse locations…2291
General Information on troubleshooting…2297
General information on troubleshooting…2298
Points to remember when troubleshooting…2298
Sequence of events in troubleshooting…2299
Check before troubleshooting…2300
Classification and procedures for troubleshooting…2301
How to read electric wire code…2305
Information in troubleshooting table…2308
Connection table for connector pin numbers…2310
T- branch box and T- branch adapter table…2346
Troubleshooting by failure code (Display of code), Part 1…2351
Failure code [989L00] Engine Controller Lock Caution 1…2354
Failure code [989M00] Engine Controller Lock Caution 2…2354
Failure code [989N00] Engine Controller Lock Caution 3…2355
Failure code [AA10NX] Air Cleaner Clogging…2355
Failure code [AB00KE] Charge Voltage Low…2356
Failure code [B@BAZG] Eng Oil Press. Low…2358
Failure code [B@BAZK] Eng Oil Level Low…2358
Failure code [B@BCNS] Eng Water Overheat…2359
Failure code [B@BCZK] Eng Water Level Low…2359
Failure code [B@HANS] Hydr Oil Overheat…2360
Failure code [CA111] EMC Critical Internal Failure…2360
Failure code [CA115] Eng Ne and Bkup Speed Sens Error…2361
Failure code [CA122] Chg Air Press Sensor High Error…2362
Failure code [CA123] Chg Air Press Sensor Low Error…2364
Failure code [CA131] Throttle Sensor High Error…2366
Failure code [CA132] Throttle Sensor Low Error…2368
Failure code [CA144] Coolant Temp Sens High Error…2370
Failure code [CA145] Coolant Temp Sens Low Error…2372
Failure code [CA153] Chg Air Temp Sensor High Error…2374
Failure code [CA154] Chg Air Temp Sensor Low Error…2376
Failure code [CA155] Chg Air Temp High Speed Derate…2378
Failure code [CA187] Sens Supply 2 Volt Low Error…2380
Failure code [CA221] Ambient Press Sens High Error…2382
Failure code [CA222] Ambient Press Sens Low Error…2384
Failure code [CA227] Sens Supply 2 Volt High Error…2386
Failure code [CA234] Eng Overspeed…2387
Failure code [CA238] Ne Speed Sens Supply Volt Error…2388
Failure code [CA271] IMV/PCV1 Short Error…2389
Failure code [CA272] IMV/PCV1 Open Error…2390
Failure code [CA322] Inj #1 Open/Short Error…2392
Failure code [CA323] Inj #5 Open/Short Error…2394
Failure code [CA324] Inj #3 Open/Short Error…2396
Failure code [CA325] Inj #6 Open/Short Error…2398
Failure code [CA331] Inj #2 Open/Short Error…2400
Failure code [CA332] Inj #4 Open/Short Error…2402
Troubleshooting by failure code (Display of code), Part 2…2405
Troubleshooting by failure code (Display of code), Part 2…2407
Failure code [CA342] Calibration Code Incompatibility…2407
Failure code [CA351] Injectors Drive Circuit Error…2408
Failure code [CA352] Sens Supply 1 Volt Low Error…2410
Failure code [CA386] Sens Supply 1 Volt High Error…2412
Failure code [CA428] Water in Fuel Sensor High Error…2414
Failure code [CA429] Water in Fuel Sensor Low Error…2416
Failure code [CA435] Eng Oil Press Sw Error…2418
Failure code [CA441] Battery Voltage Low Error…2419
Failure code [CA442] Battery Voltage High Error…2422
Failure code [CA449] Rail Press Very High Error…2424
Failure code [CA451] Rail Press Sensor High Error…2426
Failure code [CA452] Rail Press Sensor Low Error…2428
Failure code [CA488] Chg Air Temp High Torque Derate…2430
Failure code [CA553] Rail Press High Error…2431
Failure code [CA559] Rail Press Low Error…2432
Failure code [CA689] Eng Ne Speed Sensor Error…2434
Failure code [CA731] Eng Bkup Speed Sens Phase Error…2436
Failure code [CA757] All Continuous Data Lost E…2438
Failure code [CA778] Eng Bkup Speed Sensor Error…2440
Failure code [CA1633] KOMNET Datalink Timeout Error…2442
Failure code [CA2185] Throt Sens Sup Volt High Error…2443
Failure code [CA2186] Throt Sens Sup Volt Low Error…2444
Failure code [CA2249] Rail Press Very Low Error…2445
Failure code [CA2311] IMV Solenoid Error…2446
Failure code [CA2555] Grid Htr Relay Volt High Error…2448
Failure code [CA2556] Grid Htr Relay Volt Low Error…2450
Failure code [D19JKZ] Personal Code Relay Abnormality…2452
Failure code [D862KA] GPS Antenna Discon…2454
Failure code [DA22KK] Pump Solenoid Power Low Error…2456
Failure code [DA25KP] 5V Sensor 1 Power Abnormality…2458
Failure code [DA29KQ] Model Selection Abnormality…2464
Troubleshooting by failure code (Display of code), Part 3…2467
Troubleshooting by failure code (Display of code), Part 3…2469
Failure code [DA2RMC] CAN Discon (Pump Con Detected)…2469
Failure code [DAF8KB] Short circuit in camera power supply…2476
Failure code [DAFGMC] GPS Module Error…2478
Failure code [DAFRMC] CAN Discon (Monitor Detected)…2479
Failure code [DGH2KB] Hydr Oil Sensor Short…2484
Failure code [DHPAMA] F Pump Press Sensor Abnormality…2486
Failure code [DHPBMA] R Pump Press Sensor Abnormality…2488
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality…2490
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality…2492
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality…2494
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality…2496
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality…2498
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality…2500
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)…2502
Failure code [DW43KA] Travel Speed Sol Discon…2506
Failure code [DW43KB] Travel Speed Sol Short…2508
Failure code [DW45KA] Swing Brake Sol Discon…2510
Failure code [DW45KB] Swing Brake Sol Short…2512
Failure code [DW91KA] Travel Junction Sol Discon…2514
Failure code [DW91KB] Travel Junction Sol Short…2516
Failure code [DWA2KA] Service Sol Discon…2518
Failure code [DWA2KB] Service Sol Short…2519
Failure code [DWK0KA] 2-stage Relief Sol Discon…2520
Failure code [DWK0KB] 2-stage Relief Sol Short…2522
Troubleshooting by failure code (Display of code), Part 4…2525
Troubleshooting by failure code (Display of code), Part 4…2526
Failure code [DXA8KA] PC-EPC (F) Sol Discon…2526
Failure code [DXA8KB] PC-EPC (F) Sol Short…2528
Failure code [DXA9KA] PC-EPC (R) Sol Discon…2530
Failure code [DXA9KB] PC-EPC (R) Sol Short…2532
Failure code [DXE0KA] LS-EPC Sol Discon…2534
Failure code [DXE0KB] LS-EPC Sol Short…2536
Failure code [DXE4KA] Service Current EPC Discon…2538
Failure code [DXE4KB] Service Current EPC Short…2540
Failure code [DXE5KA] Merge-divider Main Sol Discon…2542
Failure code [DXE5KB] Merge-divider Main Sol Short…2544
Failure code [DXE6KA] Merge-divider LS Sol Discon…2546
Failure code [DXE6KB] Merge-divider LS Sol Short…2548
Failure code [DY20KA] Wiper Working Abnormality…2550
Failure code [DY20MA] Wiper Parking Abnormality…2552
Failure code [DY2CKA] Washer Drive Discon…2554
Failure code [DY2CKB] Washer Drive Short…2556
Failure code [DY2DKB] Wiper Drive (For) Short…2558
Failure code [DY2EKB] Wiper Drive (Rev) Short…2560
Troubleshooting of electrical system (E-mode)…2563
Troubleshooting of electrical system (E-mode)…2565
Before carrying out troubleshooting of electrical system…2565
Information in troubleshooting table…2567
E-1 When starting switch turned ON, machine monitor displays nothing…2568
E-2 When starting switch turned ON (before starting engine), basic check item lights up…2570
E-3 Engine does not start (Engine does not turn)…2573
E-4 Preheater does not operate…2577
E-5 Automatic warm-up system does not operate (in cold season)…2581
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked…2582
E-7 Precaution lights up while engine is running…2584
E-8 Emergency stop item lights up while engine is running…2589
E-9 Engine coolant temperature gauge does not indicate normally…2590
E-10 Hydraulic oil temperature gauge does not indicate correctly…2591
E-11 Fuel level gauge does not indicate correctly…2594
E-12 Contents of display by machine monitor are different from applicable machine…2596
E-13 Machine monitor does not display some items…2596
E-14 Function switch does not work…2596
E-15 Auto-decelerator does not operate normally…2597
E-16 Working mode does not change…2598
E-17 Travel speed does not change…2599
E-18 Alarm buzzer cannot be stopped…2600
E-19 Windshield wiper and window washer do not operate…2601
E-20 Power maximizing function does not operate normally…2603
E-21 Swing holding brake does not operate normally…2605
E-22 Travel alarm does not sound or does not stop sounding…2607
E-23 Air conditioner does not operate normally (including air conditioner abnormality record)…2609
E-24 While starting switch is in OFF position, service meter is not displayed…2621
E-25 Machine monitor cannot be set in service mode…2621
E-26 Monitoring function does not display lever control signal normally…2622
E-27 KOMTRAX system does not operate normally…2630
Troubleshooting of hydraulic and mechanical system (H-mode)…2633
Troubleshooting of hydraulic and mechanical system (H-mode)…2636
System diagram of hydraulic and mechanical system…2636
Information in troubleshooting table…2638
H-1 Speed or power of whole work equipment, swing, and travel is low…2639
H-2 Engine speed lowers extremely or engine stalls…2641
H-3 Work equipment, swing, and travel systems do not work…2642
H-4 Abnormal sound comes out from around hydraulic pump…2642
H-5 Auto-decelerator does not operate…2643
H-6 Fine control performance or response is low…2643
H-7 Speed or power of boom is low…2644
H-8 Speed or power of arm is low…2645
H-9 Speed or power of bucket is low…2646
H-10 Work equipment does not move singly…2646
H-11 Hydraulic drift of work equipment is large…2647
H-12 Time lag of work equipment is large…2649
H-13 When part of work equipment is relieved singly, other parts of work equipment move…2649
H-14 Power maximizing function does not work…2650
H-15 In compound operation of work equipment, speed of part loaded more is low…2650
H-16 When machine swings and raises boom simultaneously, boom rising speed is low…2651
H-17 When machine swings and travels simultaneously, travel speed is low…2651
H-18 Machine deviates during travel…2652
H-19 Travel speed is low…2653
H-20 Machine is not steered well or steering power is low…2654
H-21 Travel speed does not change or travel speed is low/high…2655
H-22 Travel system does not move (only one side)…2656
H-23 Upper structure does not swing…2657
H-24 Swing acceleration or swing speed is low…2659
H-25 Upper structure overruns remarkably when it stops swinging…2660
H-26 Large shock is made when upper structure stops swinging…2661
H-27 Large sound is made when upper structure stops swinging…2661
H-28 Hydraulic drift of swing is large…2662
H-29 Attachment circuit is not changed…2663
H-30 Oil flow in attachment circuit cannot be controlled…2663
Troubleshooting of engine (S-mode)…2665
Troubleshooting of engine (S-mode)…2668
Method of using troubleshooting chart…2668
S-1 Starting performance is poor…2672
S-2 Engine does not start…2673
S-3 Engine does not pick up smoothly…2676
S-4 Engine stops during operations…2677
S-5 Engine does not rotate smoothly…2678
S-6 Engine lack output (or lacks power)…2679
S-7 Exhaust smoke is black (incomplete combustion)…2680
S-8 Oil consumption is excessive (or exhaust smoke is blue)…2681
S-9 Oil becomes contaminated quickly…2682
S-10 Fuel consumption is excessive…2683
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)…2684
S-12 Oil pressure drops…2685
S-13 Oil level rises (Entry of coolant/fuel)…2686
S-14 Coolant temperature becomes too high (overheating)…2687
S-15 Abnormal noise is made…2688
S-16 Vibration is excessive…2689
50 Disassembly and assembly…0
General information on disassembly and assembly…2691
How to read this manual…2692
Coating materials list…2694
Special tools list…2697
Sketches of special tools…2701
Engine and cooling system…2707
Removal and installation of fuel supply pump assembly…2708
Removal and installation of fuel injector assembly…2712
Removal and installation of engine front seal…2721
Removal and installation of engine rear seal…2724
Removal and installation of cylinder head assembly…2727
Removal and installation of radiator assembly…2741
Removal and installation of hydraulic oil cooler assembly…2744
Removal and installation of aftercooler assembly…2746
Removal and installation of fuel cooler assembly…2748
Removal and installation of engine and hydraulic pump assembly…2749
Power train…2759
Removal and installation of final drive assembly…2760
Disassembly and assembly of final drive assembly…2761
Removal and installation of swing motor and swing machinery assembly…2770
Disassembly and assembly of swing motor and swing machinery assembly…2772
Removal and installation of swing circle assembly…2781
Undercarriage and frame…2783
Disassembly and assembly of carrier roller assembly…2784
Disassembly and assembly of track roller assembly…2785
Disassembly and assembly of idler assembly…2786
Disassembly and assembly of recoil spring assembly…2789
Removal and installation of sprocket…2791
Expansion and installation of track shoe assembly…2792
Removal and installation of revolving frame assembly…2794
Removal and installation of counterweight assembly…2796
Hydraulic system…2799
Removal and installation of center swivel joint assembly…2800
Disassembly and assembly of center swivel joint assembly…2802
Removal and installation of hydraulic tank assembly…2803
Removal and installation of control valve assembly…2807
Disassembly and assembly of control valve assembly…2812
Removal and installation of hydraulic main pump assembly…2816
Removal and installation of oil seal in hydraulic pump input shaft…2820
Disassembly and assembly of work equipment PPC valve assembly…2821
Disassembly and assembly of travel PPC valve assembly…2823
Disassembly and assembly of hydraulic cylinder assembly…2826
Work equipment…2833
Work equipment…2834
Removal and installation of work equipment assembly…2834
Cab and its attachments…2838
Removal and installation of operator's cab assembly…2839
Removal and installation of operator cab glass (stuck glass)…2842
Removal and installation of front window assembly…2852
Removal and installation of floor frame assembly…2859
Electrical system…2864
Removal and installation of air conditioner unit assembly…2865
Removal and installation of KOMTRAX communication modem assembly…2868
Removal and installation of monitor assembly…2869
Removal and installation of pump controller assembly…2871
90 Diagrams and drawings…0
Hydraulic diagrams and drawings…2874
Hydraulic circuit diagram PC270, 270LC-8…2876
Electrical diagrams and drawings…2879
Electrical circuit diagram…2881
Connector arrangement diagram…2886
TEN00148-03 – Hydraulic Excavator GALEO PC270-8 Operation & Maintenance Manual…2889
COVER…2889
FOREWORD…2890
FOREWORD…2891
SAFETY INFORMATION…2894
INTRODUCTION…2896
DIRECTIONS OF MACHINE…2896
BREAKING-IN THE NEW MACHINE…2896
PRODUCT INFORMATION…2897
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…2897
EPA REGULATIONS, ENGINE NUMBER PLATE…2897
SERVICE METER LOCATION…2898
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…2898
CONTENTS…2899
SAFETY…2902
SAFETY INFORMATION…2903
SAFETY LABELS…2905
LOCATION OF SAFETY LABELS…2906
SAFETY LABELS…2907
SAFETY INFORMATION…2913
SAFETY RULES…2913
IF PROBLEMS ARE FOUND…2913
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…2913
FIRE EXTINGUISHER AND FIRST AID KIT…2913
SAFETY EQUIPMENT…2913
KEEP MACHINE CLEAN…2914
KEEP OPERATOR'S COMPARTMENT CLEAN…2914
LEAVING OPERATOR'S SEAT WITH LOCK…2914
HANDRAILS AND STEPS…2915
PRECAUTIONS WHEN WORKING IN HIGH PLACES…2915
MOUNTING AND DISMOUNTING…2915
NO PERSONS ON ATTACHMENTS…2915
DO NOT GET CAUGHT IN ARTICULATED PORTION…2916
BURN PREVENTION…2916
FIRE PREVENTION AND EXPLOSION PREVENTION…2917
ACTION IF FIRE OCCURS…2918
WINDSHIELD WASHER FLUID…2918
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…2918
ATTACHMENT INSTALLATION…2918
ATTACHMENT COMBINATIONS…2918
CAB WINDOW GLASSES…2918
UNAUTHORIZED MODIFICATIONS…2919
SAFETY AT JOBSITE…2919
WORKING ON LOOSE GROUND…2919
DISTANCE TO HIGH VOLTAGE CABLES…2920
ENSURE GOOD VISIBILITY…2920
VENTILATION FOR ENCLOSED AREA…2921
SIGNALMAN'S SIGNAL AND SIGNS…2921
EMERGENCY EXIT FROM OPERATOR'S CAB…2921
ASBESTOS DUST HAZARD PREVENTION…2921
SAFETY MACHINE OPERATION…2922
STARTING ENGINE…2922
CHECKS BEFORE STARTING ENGINE…2922
SAFETY RULES FOR STARTING ENGINE…2923
STARTING ENGINE IN COLD WEATHER…2923
OPERATION…2924
CHECKS BEFORE OPERATION…2924
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…2924
SAFETY RULES FOR TRAVELING…2925
TRAVELING ON SLOPES…2925
OPERATIONS ON SLOPES…2926
PROHIBITED OPERATIONS…2927
OPERATIONS ON SNOW…2928
PARKING MACHINE…2929
TRANSPORTATION…2930
LOADING AND UNLOADING…2930
SHIPPING THE MACHINE…2930
BATTERY…2931
BATTERY HAZARD PREVENTION…2931
STARTING ENGINE WITH BOOSTER CABLES…2932
TOWING…2933
SAFETY RULES FOR TOWING…2933
LIFTING OBJECTS WITH BUCKET…2934
SAFETY RULES FOR LIFTING OBJECTS…2934
SAFETY MAINTENANCE INFORMATION…2935
WARNING TAG…2935
KEEP WORK PLACE CLEAN AND TIDY…2935
APPOINT LEADER WHEN WORKING WITH OTHERS…2935
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…2936
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…2937
PROPER TOOLS…2937
ACCUMULATOR, GAS SPRING…2938
PERSONNEL…2938
ATTACHMENTS…2938
WORK UNDER THE MACHINE…2938
NOISE…2938
WHEN USING HAMMER…2939
WELDING WORKS…2939
REMOVING BATTERY TERMINALS…2939
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…2939
DO NOT DISASSEMBLE RECOIL SPRINGS…2940
SAFETY RULES FOR HIGH-PRESSURE OIL…2940
PRECAUTION FOR HIGH FUEL PRESSURE…2940
SAFETY HANDLING HIGH-PRESSURE HOSES…2940
PRECAUTION FOR HIGH VOLTAGE…2941
WASTE MATERIALS…2941
AIR CONDITIONER MAINTENANCE…2941
COMPRESSED AIR…2941
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…2941
OPERATION…2942
MACHINE VIEW ILLUSTRATIONS…2943
OVERALL MACHINE VIEW…2943
CONTROLS AND GAUGES…2944
DETAILED CONTROLS AND GAUGES…2946
MONITORING SYSTEM…2946
SWITCHES…3012
CONTROL LEVERS AND PEDALS…3017
SUN ROOF…3020
WINDSHIELD…3020
EMERGENCY ESCAPE HAMMER…3026
DOOR LOCK…3026
CAP WITH LOCK…3027
DRINK BOX…3029
MAGAZINE BOX…3029
ASHTRAY…3029
AIR CONDITIONER CONTROLS…3030
RADIO…3043
AUXILIARY ELECTRIC POWER…3048
FUSE…3049
FUSIBLE LINK…3050
CONTROLLER…3050
TOOL BOX…3050
GREASE PUMP HOLDER…3050
FIRE EXTINGUISHER…3051
MACHINE OPERATIONS AND CONTROLS…3052
BEFORE STARTING ENGINE…3052
STARTING ENGINE…3069
AFTER STARTING ENGINE…3072
STOPPING THE ENGINE…3083
MACHINE OPERATION…3084
STEERING THE MACHINE…3088
SWINGING…3090
WORK EQUIPMENT CONTROLS AND OPERATIONS…3091
WORKING MODE…3093
PROHIBITED OPERATIONS…3095
GENERAL OPERATION INFORMATION…3097
TRAVELING ON SLOPES…3099
ESCAPE FROM MUD…3101
RECOMMENDED APPLICATIONS…3102
BUCKET REPLACEMENT AND INVERSION…3104
PARKING MACHINE…3108
MACHINE INSPECTION AFTER DAILY WORK…3109
LOCKING…3110
TRANSPORTATION…3111
TRANSPORTATION PROCEDURE…3111
LOADING AND UNLOADING WITH TRAILER…3112
LIFTING MACHINE…3121
COLD WEATHER OPERATION…3124
COLD WEATHER OPERATION INFORMATION…3124
AFTER DAILY WORK COMPLETION…3126
AFTER COLD WEATHER SEASON…3126
LONG TERM STORAGE…3127
BEFORE STORAGE…3127
DURING STORAGE…3127
AFTER STORAGE…3128
STARTING MACHINE AFTER LONG-TERM STORAGE…3128
TROUBLES AND ACTIONS…3129
RUNNING OUT OF FUEL…3129
PHENOMENA THAT ARE NOT FAILURES…3129
TOWING THE MACHINE…3130
LIGHTWEIGHT TOWING HOLE…3131
SEVERE JOB CONDITION…3131
DISCHARGED BATTERY…3132
OTHER TROUBLE…3136
MAINTENANCE…3141
MAINTENANCE INFORMATION…3142
OUTLINE OF SERVICE…3144
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…3144
ELECTRIC SYSTEM MAINTENANCE…3147
WEAR PARTS…3148
WEAR PARTS LIST…3148
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…3149
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…3151
TIGHTENING TORQUE SPECIFICATIONS…3152
TIGHTENING TORQUE LIST…3152
SAFETY CRITICAL PARTS…3153
SAFETY CRITICAL PARTS LIST…3154
MAINTENANCE SCHEDULE…3155
MAINTENANCE SCHEDULE CHART…3155
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…3157
MAINTENANCE PROCEDURE…3158
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)…3158
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)…3158
WHEN REQUIRED…3159
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…3159
CLEAN INSIDE OF COOLING SYSTEM…3165
CHECK AND TIGHTEN TRACK SHOE BOLTS…3169
CHECK AND ADJUST TRACK TENSION…3170
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…3172
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…3175
ADJUST BUCKET CLEARANCE…3177
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…3178
CHECK AND MAINTENANCE AIR CONDITIONER…3179
WASH WASHABLE FLOOR…3180
CHECK GAS SPRING…3183
BLEEDING AIR FROM HYDRAULIC SYSTEM…3184
CHECK BEFORE STARTING…3186
EVERY 100 HOURS MAINTENANCE…3187
LUBRICATING…3187
EVERY 250 HOURS MAINTENANCE…3189
CHECK LEVEL OF BATTERY ELECTROLYTE…3189
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…3191
EVERY 500 HOURS MAINTENANCE…3192
LUBRICATE SWING CIRCLE…3192
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…3193
REPLACE FUEL PRE-FILTER CARTRIDGE…3195
CHECK SWING PINION GREASE LEVEL, ADD GREASE…3197
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS…3198
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…3200
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…3202
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT…3203
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…3204
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…3205
EVERY 1000 HOURS MAINTENANCE…3206
REPLACE HYDRAULIC OIL FILTER ELEMENT…3206
CHANGE OIL IN SWING MACHINERY CASE…3207
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…3208
REPLACE FUEL MAIN FILTER CARTRIDGE…3209
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS…3211
REPLACE CORROSION RESISTOR CARTRIDGE…3211
CHECK FAN BELT TENSION AND REPLACE FAN BELT…3211
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)…3211
EVERY 2000 HOURS MAINTENANCE…3212
CHANGE OIL IN FINAL DRIVE CASE…3212
CLEAN HYDRAULIC TANK STRAINER…3213
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)…3214
CHECKING FUNCTION OF ACCUMULATOR…3215
CHECK ALTERNATOR…3218
CHECK ENGINE VALVE CLEARANCE, ADJUST…3218
EVERY 4000 HOURS MAINTENANCE…3219
CHECK WATER PUMP…3219
CHECK VIBRATION DAMPER…3219
CHECK STARTING MOTOR…3219
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)…3220
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER…3221
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…3221
CHECK OPERATING CONDITION OF COMPRESSOR…3222
EVERY 5000 HOURS MAINTENANCE…3223
CHANGE OIL IN HYDRAULIC TANK…3223
EVERY 8000 HOURS MAINTENANCE…3224
REPLACE HIGH-PRESSURE PIPING CLAMP…3224
REPLACE FUEL SPRAY PREVENTION CAP…3224
SPECIFICATIONS…3225
SPECIFICATIONS…3226
ATTACHMENTS, OPTIONS…3228
GENERAL PRECAUTIONS FOR SAFETY…3229
PRECAUTIONS WHEN SELECTING…3229
READ THE INSTRUCTION MANUAL THOROUGHLY…3229
PRECAUTIONS WHEN REMOVING OR INSTALLING…3229
PRECAUTIONS WHEN USING…3229
BUCKET WITH HOOK…3230
HOOK CONDITION…3230
PROHIBITED OPERATIONS…3230
MACHINE READY FOR ATTACHMENT…3231
LOCATIONS…3231
HYDRAULIC CIRCUIT…3235
ATTACHMENT REMOVAL AND INSTALLATION…3242
ATTACHMENT OPERATIONS…3246
LONG TERM STORAGE…3249
SPECIFICATIONS…3249
ATTACHMENT GUIDE…3250
ATTACHMENT COMBINATIONS…3250
TRACK SHOES SELECTION…3251
BUCKET TEETH SELECTION…3252
RECOMMENDED ATTACHMENT OPERATIONS…3253
HYDRAULIC BREAKER…3253
HANDLING MACHINES EQUIPPED WITH KOMTRAX…3257
BASIC PRECAUTIONS…3257
INDEX…3258

Komatsu Hydraulic Excavator PC270, PC270LC Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC270LC-6LE, PC270LC-7L, PC270LL-7L, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC270LC-6LE, PC270LC-7L, PC270LL-7L workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBD003001 – Hydraulic Excavator PC270LC-6LE Shop Manual.pdf
CEBM005905 – Hydraulic Excavator PC270LC-7L Shop Manual.pdf
CEBM014600 – Logging Excavator GALEO PC270LL-7L Shop Manual.pdf
CEAM008702 – Hydraulic Excavator PC270LC-7L Operation & Maintenance Manual.pdf
CEAM014700 – Hydraulic Excavator GALEO PC270LC-7L Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 2,654 pages
File Format: PDF
Language: English

CEAM008702 – Hydraulic Excavator PC270LC-7L Operation & Maintenance Manual…2
INTRODUCTION…4
FOREWORD…5
SAFETY INFORMATION…6
Signal Words…6
Other Signal Words…6
INTRODUCTION…7
DIRECTIONS OF MACHINE…7
PRODUCT INFORMATION…8
Machine Serial Number Plate And Its Location…8
Engine Serial Number Plate And Its Location…8
Service Meter Location…9
Your Machine Serial Numbers And Distributor…9
TABLE OF CONTENTS…10
SAFETY…20
SAFETY LABELS…21
Position For Attaching Safety Labels…21
Safety Labels…22
SAFETY INFORMATION…28
Safety Rules…28
If Abnormalities Are Found…28
Working Wear And Personal Protective Items…28
Fire Extinguisher And First Aid Kit…28
Safety Equipment…28
Keep Machine Clean…29
Keep Operator's Compartment Clean…29
Leaving Operator's Seat With Lock…29
Handrails And Steps…30
Mounting And Dismounting…30
No Persons On Attachments…30
Burn Prevention…31
Hot Coolant…31
Hot Oil…31
Fire Prevention And Explosion Prevention…31
Fire Caused By Fuel Or Oil…31
Fire Caused By Accumulation Of Flammable Material…32
Fire Coming From Electric Wiring…32
Fire Coming From Hydraulic Line…32
Explosion Caused By Lighting Equipment…32
Action If Fire Occurs…32
Windshield Washer Fluid…32
Falling Objects, Flying Objects And Intruding Objects Prevention…32
Attachment Installation…33
Attachment Combinations…33
Cab Widow Glass…33
Unauthorized Modifications…33
Safety At Jobsite…33
Working On Loose Ground…34
Distance To High Voltage Cables…34
Ensure Good Visibility…35
Ventilation For Enclosed Area…35
Signalman's Signal And Signs…35
Emergency Exit From Operator's Cab…35
Asbestos Dust Hazard Prevention…35
SAFE MACHINE OPERATION…36
Starting Engine…36
Checks Before Starting Engine…36
Safety Rules For Starting Engine…36
Starting Engine In Cold Weather…36
OPERATION…37
Checks After Starting Engine, Before Operation…37
Safety Rules For Changing Machine Directions…37
Safety Rules For Traveling…38
Traveling On Slopes…38
Operations On Slopes…39
Prohibited Operations…40
Operations On Snow…41
Parking Machine…42
Transportation…43
Loading And Unloading…43
Shipping The Machine…44
Battery…45
Battery Hazard Prevention…45
Starting Engine With Booster Cables…46
Towing…47
Safety Rules For Towing…47
Lifting Objects With Bucket…48
Lifting Work Using Bucket With Hook…48
Safety Rules For Lifting Objects…48
SAFETY MAINTENANCE INFORMATION…49
Warning Tag…49
Keep Work Place Clean And Tidy…49
Appoint Leader When Working With Others…49
Stop Engine Before Carrying Out Maintenance…50
Two Workers For Maintenance When Engine Is Running…51
Proper Tools…51
Accumulator…52
Personnel…53
Attachments…53
Noise…53
When Using Hammer…53
Welding…54
Removing Battery Terminals…54
Adjusting Track Tension…54
Do Not Disassemble Recoil Springs…54
Safety Rules For High-pressure Oil…54
Safety Handling High-pressure Hoses…55
Waste Materials…55
Air Conditioner Maintenance…55
Compressed Air…55
Periodic Replacement Of Safety Critical Parts…55
OPERATION…56
GENERAL VIEW…57
General View Of Machine…57
General View Controls And Gauges…58
EXPLANATION OF COMPONENTS…59
Machine Monitor…59
Basic Operation Of Machine Monitor…60
If There Is Abnormality When Starting Engine…60
If Any Abnormality Occurs During Operation…61
Basic Check Items…62
Radiator Coolant Level Monitor…62
Engine Oil Level Monitor…63
Maintenance Interval Monitor…63
Caution Items…64
Charge Monitor…64
Fuel Level Monitor…65
Air Cleaner Clogging Monitor…65
Engine Coolant Temperature Monitor…65
Hydraulic Oil Temperature Monitor…65
Emergency Stop Items…66
Engine Coolant Temperature Monitor…66
Hydraulic Oil Temperature Monitor…67
Engine Oil Pressure Monitor…67
Meter Display Portion…68
Pilot Display…68
Gauges and Meters…70
Monitor Switches…72
Working Mode Selector Switch (Basic Switch)…73
Auto-deceleration Switch…74
Travel Speed Selector Switch…75
Wiper Switch…76
Window Washer Switch…76
Maintenance Switch…77
Select Switch…79
Back Switch…80
Up Switch, Down Switch…80
Input Confirmation Switch…80
Liquid Crystal Monitor Adjustment Switch…81
Switches…83
Starting Switch…83
Fuel Control Dial…84
Cigarette Lighter…84
Swing Lock Switch…84
Lamp Switch…85
Alarm Buzzer Stop Switch…85
Horn Switch…85
Knob Switch…85
Room Lamp Switch…86
Emergency Pump Drive Switch…86
Swing Brake Cancel Switch…86
Rotating Lamp Switch…86
Control Levers, Pedals…87
Safety Lock Lever…87
Travel Levers…88
Work Equipment Control Lever…89
Ceiling Window…90
Front Window…90
Emergency Exit From Operator's Cab…95
Door Lock…96
Cap, Cover With Lock…97
Method Of Opening And Closing Cap With Lock…97
Method Of Opening And Closing Cover With Lock…97
Hot And Cool Box…98
Magazine Box With Cup Holder…98
Ashtray…98
Air Conditioner…99
General Location Of Control Panel…99
Operation…104
Precautions When Using Air Conditioner…110
Check, Maintain Machine Equipped With Air Conditioner…110
Other Functions…111
Car Radio…112
Explanation Of Components…112
Method Of Operation…115
Power Pick-up Port…117
Fuse…117
Fuse Capacities And Circuit Names…118
Fusible Link…118
Controller…119
Toolbox…119
Grease Gun Holder…119
Handling The Accumulator…120
Releasing Pressure In Control Circuit…121
MACHINE OPERATIONS AND CONTROLS…122
Before Starting Engine…122
Walk-Around Checks…122
Checks Before Starting…123
Adjustments Before Operation…130
Seat Belt…132
Before Starting Engine…133
Starting Engine…136
Normal Starting…136
Starting Engine In Cold Weather…138
After Starting Engine…140
Breaking-in The New Machine…140
Warm-up Operation…141
In Cold Areas (Automatic Warm-up Operation)…145
Stopping The Engine…150
Check After Shutting Off Engine…150
Machine Operation…151
Preparations For Moving The Machine…151
Moving Machine Forward…152
Moving Machine Backward…153
Stopping Machine…154
Steering The Machine…155
Steering The Machine When Stopped…155
Changing Direction Of The Machine…156
Counter-rotation Turn (Spin Turn)…156
Swinging…157
Work Equipment Controls And Operations…158
Operating Working Mode…159
Working Mode…159
One-touch Power Max. Switch…159
Prohibited Operations…160
Swing Force…160
Travel Force…160
Hydraulic Cylinder Stroke Ends…160
Bucket Dropping Force…161
Machine Dropping Force…161
Digging Hard Rocky Ground…161
Sudden Lever Shifting High Speed Travel…161
General Operation Information…162
Traveling…162
High Speed Travel…162
Permissible Water Depth…162
Traveling On Slopes…163
Traveling Downhill…164
Engine Stopped On Slope…164
Precautions On Slopes…164
Escape From Mud…165
Stuck One Side Of Track…165
Stuck Both Sides Of Tracks…165
Recommended Applications…166
Backhoe Work…166
Shovel Work…166
Ditching Work…166
Loading Work…167
Replacement And Inversion Of Bucket…168
Replacement…168
Inversion…170
Parking Machine…172
Check After Shut Off Engine…173
Machine Inspection After Daily Work…173
Locking…174
TRANSPORTATION…174
Transportation Procedure…174
Loading And Unloading With Trailer…175
Loading…176
Securing Machine…178
Unloading…180
Lifting Machine…182
COLD WEATHER OPERATION…184
Fuel And Lubricants…184
Cooling System Coolant…184
Battery…185
Monitor…186
After Operations…187
After Cold Weather Season…187
LONG TERM STORAGE…188
Before Storage…188
During Storage…188
After Storage…188
Starting Machine…188
TROUBLESHOOTING…189
After Running Out Of Fuel…189
Phenomena That Are Not Failures…189
Towing The Machine…190
Lightweight Towing Hook…191
Precautions On Particular Jobsites…191
Discharged Battery…192
Removal And Installation Of Battery…193
Battery Charges…193
Starting Engine With Booster Cables…194
Other Trouble…196
Electrical System…196
Chassis…197
Engine…197
Electronic Control System…199
MAINTENANCE…202
MAINTENANCE INFORMATION…203
Service Meter Reading…203
Komatsu Genuine Replacement Parts…203
Komatsu Genuine Lubricants…203
Windshield Washer Fluid…203
Fresh And Clean Lubricants…203
Check Drained Oil And Used Filter…203
Fuel Strainer…203
Welding Instructions…203
Do Not Drop Things Inside Machine…203
Dusty Jobsite…204
Avoid Mixing Lubricants…204
Locking The Inspection Covers…204
Hydraulic System – Air Bleeding…204
Hydraulic Hose Installation…204
Checks After Inspection And Maintenance Works…204
Selecting Fuel And Lubricants To Match Ambient Temperature…205
LUBRICANTS, COOLANT AND FILTERS…205
Handling Oil, Fuel, Coolant, And Performing Oil Clinic…205
Oil…205
Fuel…205
Cooling System Coolant…206
Grease…206
Carrying Out Kowa (Komatsu Oil Wear Analysis)…206
Oil And Fuel Storage…207
Filters…207
Lubrication Chart Decal Explanation…208
Electric System Maintenance…210
Handling Hydraulic System…210
WEAR PARTS LIST…211
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…212
Proper Selection Of Fuel, Coolant And Lubricants…212
TIGHTENING TORQUE SPECIFICATIONS…214
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…215
Safety Critical Parts…215
MAINTENANCE SCHEDULE…216
Maintenance Schedule Chart…216
Maintenance Interval For Hydraulic Breaker…218
Replacing Hydraulic Element…218
Changing Oil In Hydraulic Tank…218
Replacing Additional Filter Element For Breaker…218
MAINTENANCE PROCEDURE…219
Initial 250 Hours Maintenance…219
Initial 1000 Hours Maintenance (Only After The First 1000 Hours)…219
When Required…220
Check, Clean And Replace Air Cleaner Element…220
Clean Inside Of Cooling System…224
Check And Tighten Track Shoe Bolts…227
Check And Adjust Track Tension…228
Check Electrical Intake Air Heater…229
Replace Bucket Teeth (Vertical Pin Type)…230
Replace Bucket Teeth (Horizontal Pin Type)…233
Adjust Bucket Clearance…234
Check Window Washer Fluid Level, Add Fluid…235
Check And Adjust Air Conditioner…236
Cleaning Cab Floor…237
Bleeding Air From Hydraulic System…240
Releasing Internal Pressure In Hydraulic Circuit…242
Check Nitrogen Gas Charge Pressure In Accumulator (Control Circuit)…243
Check Before Starting…244
Every 100 Hours Maintenance…245
Lubricating…245
Every 250 Hours Maintenance…246
Check Oil Level In Machinery Case, Add Oil…246
Check Oil Level In Final Drive Case, Add Oil…246
Check Level Of Battery Electrolyte…247
Check, Adjust Tension Of Air Conditioner Compressor Belt…249
Every 500 Hours Maintenance…250
Lubricating…250
Lubricate Swing Circle (2 Points)…252
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge…253
Replace Fuel Filter Cartridge…254
Check Swing Pinion Grease Level, Add Grease…255
Clean & Inspect Radiator Fins, Oil Cooler Fins & Condenser Fins…256
Clean Internal & External Air Filters Of Air Conditioner System…257
Replace Breather Element In Hydraulic Tank…258
Every 1000 Hours Maintenance…259
Replace Hydraulic Filter Element…259
Change Oil In Swing Machinery Case…261
Check Oil Level In Damper Case, Add Oil…262
Check All Tightening Parts Of Turbocharger…262
Check Play Of Turbocharger Rotor…262
Replace Corrosion Resistor Cartridge…263
Check Fan Belt Tension And Replace Fan Belt…263
Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)…263
Every 2000 Hours Maintenance…264
Change Oil In Final Drive Case…264
Clean Hydraulic Tank Strainer…265
Clean, Check Turbocharger…265
Check Alternator, Starting Motor…265
Check Engine Valve Clearance, Adjust…265
Check Vibration Damper…265
Every 4000 Hours Maintenance…266
Check Water Pump…266
Every 5000 Hours Maintenance…267
Change Oil In Hydraulic Tank…267
SPECIFICATIONS…268
SPECIFICATIONS…269
OPTIONS, ATTACHMENTS…272
GENERAL PRECAUTIONS…273
Precautions Related To Safety…273
Precautions When Selecting…273
Read The Instruction Manual Thoroughly…273
Precautions When Removing Or Installing…273
Precautions When Using…273
Precautions When Installing Attachments…275
HANDLING BUCKET WITH HOOK…276
Checking For Damage To Bucket With Hook…276
Prohibited Operations…276
Precautions During Operations…276
MACHINES READY FOR ATTACHMENTS…277
Explanation Of Components…277
Stop Valve…277
Selector Valve…278
Attachment Control Pedal…278
Lock Pin…278
Additional Filter For Breaker…279
Accumulator…279
Hydraulic Circuit…280
Switching The Hydraulic Circuit…280
Adjusting Oil Flow…280
Switching Between Breaker And General Attachment…280
Hydraulic Circuit Connection…281
Oil Flow…282
Replace Additional Breaker Filter Element…283
Attachment Installation And Removal Procedure…284
Removal Procedure…284
Installation Procedure…285
Operation…286
When Using Breaker…286
When Using Crusher Or Other General Attachment…287
Long-term Storage…288
Specifications…288
ATTACHMENT GUIDE…289
Selection Of Track Shoes…289
Method Of Selecting Shoes…289
Selection Of Bucket Teeth…290
Selecting Teeth…290
Standards For Selecting Vertical And Horizontal Pin Type Teeth…291
Handling Trapezoidal Bucket…292
How To Excavate…292
Ditch Gradient Of 45…292
Ditch Gradient Of 40 And 38…293
Handling Extension Arm…293
Handling Clamshell Bucket…294
How To Perform Excavation…294
Precautions When Using…294
Lubricating…294
RECOMMENDED ATTACHMENT OPERATIONS…295
Hydraulic Breaker…295
Main Applications…295
Prohibited Operations…297
Greasing Position For Hydraulic Breaker…299
CEAM014700 – Hydraulic Excavator GALEO PC270LC-7L Operation & Maintenance Manual…300
COVER…300
INTRODUCTION…306
FOREWORD…307
SAFETY INFORMATION…308
SIGNAL WORDS…308
OTHER SIGNAL WORDS…308
INTRODUCTION…309
INTENDED USE…309
DIRECTIONS OF MACHINE…309
BREAKING IN THE MACHINE…309
PRODUCT INFORMATION…310
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION…310
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION…310
SERVICE METER LOCATION…311
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR…311
TABLE OF CONTENTS…312
SAFETY…322
SAFETY LABELS…323
POSITION FOR ATTACHING SAFETY LABELS…323
UNIQUE SAFETY DECALS FOR LOG LOADER AND ROAD BUILDER EXCAVATORS…329
SAFETY INFORMATION…335
SAFETY RULES…335
IF ABNORMALITIES ARE FOUND…335
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS…335
FIRE EXTINGUISHER AND FIRST AID KIT…335
SAFETY EQUIPMENT…335
KEEP MACHINE CLEAN…336
KEEP OPERATOR'S COMPARTMENT CLEAN…336
LEAVING OPERATOR'S SEAT WITH LOCK…336
HANDRAILS AND STEPS…337
MOUNTING AND DISMOUNTING…337
NO PERSONS ON ATTACHMENTS…337
BURN PREVENTION…338
HOT COOLANT…338
HOT OIL…338
FIRE PREVENTION AND EXPLOSION PREVENTION…338
FIRE CAUSED BY FUEL OR OIL…338
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL…339
FIRE COMING FROM ELECTRIC WIRING…339
FIRE COMING FROM HYDRAULIC LINE…339
EXPLOSION CAUSED BY LIGHTING EQUIPMENT…339
ACTION IF FIRE OCCURS…339
WINDSHIELD WASHER FLUID…339
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION…339
PROTECTION AGAINST FALLING OR FLYING OBJECTS…340
ATTACHMENT INSTALLATION…341
ATTACHMENT COMBINATIONS…341
CAB WIDOW GLASS…341
UNAUTHORIZED MODIFICATIONS…341
SAFETY AT JOBSITE…341
WORKING ON LOOSE GROUND…342
DISTANCE TO HIGH VOLTAGE CABLES…342
ENSURE GOOD VISIBILITY…343
VENTILATION FOR ENCLOSED AREA…343
SIGNALMAN'S SIGNAL AND SIGNS…343
EMERGENCY EXIT FROM OPERATOR'S CAB…343
ASBESTOS DUST HAZARD PREVENTION…344
SAFE MACHINE OPERATION…345
STARTING ENGINE…345
CHECKS BEFORE STARTING ENGINE…345
SAFETY RULES FOR STARTING ENGINE…345
STARTING ENGINE IN COLD WEATHER…345
OPERATION…346
CHECKS AFTER STARTING ENGINE, BEFORE OPERATION…346
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS…346
SAFETY RULES FOR TRAVELING…347
TRAVELING ON SLOPES…347
OPERATIONS ON SLOPES…348
PROHIBITED OPERATIONS…348
OPERATIONS ON SNOW…349
PARKING MACHINE…350
TRANSPORTATION…351
SHIPPING THE MACHINE…351
BATTERY…352
BATTERY HAZARD PREVENTION…352
STARTING ENGINE WITH BOOSTER CABLES…353
TOWING…354
SAFETY RULES FOR TOWING…354
LIFTING OBJECTS WITH BUCKET…355
SAFETY RULES FOR LIFTING OBJECTS…355
SAFETY MAINTENANCE INFORMATION…356
WARNING TAG…356
KEEP WORK PLACE CLEAN AND TIDY…356
APPOINT LEADER WHEN WORKING WITH OTHERS…356
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE…357
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…358
PROPER TOOLS…358
ACCUMULATOR…358
PERSONNEL…359
ATTACHMENTS…359
NOISE…359
WELDING…360
REMOVING BATTERY TERMINALS…360
DO NOT DISASSEMBLE RECOIL SPRINGS…361
SAFETY RULES FOR HIGH-PRESSURE OIL…361
SAFETY HANDLING HIGH-PRESSURE HOSES…361
WASTE MATERIALS…362
AIR CONDITIONER MAINTENANCE…362
COMPRESSED AIR…362
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…362
OPERATION…364
GENERAL VIEW…365
GENERAL VIEW OF LOG LOADER MACHINE…365
GENERAL VIEW OF ROAD BUILDER MACHINE…366
GENERAL VIEW CONTROLS AND GAUGES…367
EXPLANATION OF COMPONENTS…368
MACHINE MONITOR…368
BASIC OPERATION OF MACHINE MONITOR…369
IF THERE IS ABNORMALITY WHEN STARTING ENGINE…369
IF ANY ABNORMALITY OCCURS DURING OPERATION…370
BASIC CHECK ITEMS…371
RADIATOR WATER LEVEL MONITOR…371
ENGINE OIL LEVEL MONITOR…372
MAINTENANCE INTERVAL MONITOR…372
CAUTION ITEMS…373
CHARGE MONITOR…373
FUEL LEVEL MONITOR…374
AIR CLEANER CLOGGING MONITOR…374
ENGINE WATER TEMPERATURE MONITOR…374
EMERGENCY STOP ITEMS…375
ENGINE WATER TEMPERATURE MONITOR…375
HYDRAULIC OIL TEMPERATURE MONITOR…376
ENGINE OIL PRESSURE MONITOR…376
METER DISPLAY PORTION…377
PILOT DISPLAY…377
METERS…379
MONITOR SWITCHES…381
WORKING MODE SELECTOR SWITCH (BASIC SWITCH)…382
AUTO-DECELERATION SWITCH…383
TRAVEL SPEED SELECTOR SWITCH…384
WIPER SWITCH…385
WINDOW WASHER SWITCH…385
MAINTENANCE SWITCH…386
SELECT SWITCH…388
BACK SWITCH…389
UP SWITCH, DOWN SWITCH…389
INPUT CONFIRMATION SWITCH…389
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH…390
SWITCHES…393
STARTING SWITCH…394
FUEL CONTROL DIAL…395
CIGARETTE LIGHTER…395
SWING LOCK SWITCH…395
LAMP SWITCH…396
ALARM BUZZER STOP SWITCH…396
HORN SWITCH…396
LOG LOADER GRAPPLE ROTATION CW SWITCH…396
LOG LOADER GRAPPLE CLOSE SWITCH…396
POWER MAX SWITCH…397
LOG LOADER GRAPPLE ROTATION CCW SWITCH…397
LOG LOADER GRAPPLE OPEN SWITCH…397
ROOM LAMP SWITCH…397
EMERGENCY PUMP DRIVE SWITCH…398
SWING BRAKE CANCEL SWITCH…398
CONTROL LEVERS, PEDALS…399
SAFETY LOCK LEVER…399
TRAVEL LEVERS…400
WORK EQUIPMENT CONTROL LEVER…401
CEILING WINDOW…402
FRONT WINDOW…402
EMERGENCY EXIT FROM OPERATOR'S CAB – FROM INSIDE…407
EMERGENCY EXIT FROM OPERATOR'S CAB – FROM OUTSIDE…407
DOOR LOCK…409
CAP, COVER WITH LOCK…409
METHOD OF OPENING AND CLOSING CAP WITH LOCK…409
METHOD OF OPENING AND CLOSING COVER WITH LOCK…410
HOT AND COOL BOX…410
MAGAZINE BOX WITH CUP HOLDER…410
ASHTRAY…410
AIR CONDITIONER…411
GENERAL LOCATION OF CONTROL PANEL…411
METHOD OF OPERATION…415
PRECAUTIONS WHEN USING AIR CONDITIONER…422
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…422
OTHER FUNCTIONS…423
CAR RADIO…424
EXPLANATION OF COMPONENTS…424
METHOD OF OPERATION…427
POWER PICK-UP PORT…429
FUSE…429
FUSE CAPACITIES AND CIRCUIT NAMES…430
FUSIBLE LINK…430
CONTROLLER…431
TOOLBOX…431
GREASE GUN HOLDER…431
HANDLING THE ACCUMULATOR…432
RELEASING PRESSURE IN CONTROL CIRCUIT…432
MACHINE OPERATIONS AND CONTROLS…433
BEFORE STARTING ENGINE…433
WALK-AROUND CHECKS…433
CHECKS BEFORE STARTING…434
ADJUSTMENTS BEFORE OPERATION…441
ADJUSTMENT OF MIRRORS…442
SEAT BELT…443
BEFORE STARTING ENGINE…444
STARTING ENGINE…447
NORMAL STARTING…447
STARTING ENGINE IN COLD WEATHER…448
AFTER STARTING ENGINE…451
BREAKING-IN THE NEW MACHINE…451
WARM-UP OPERATION…452
AUTOMATIC WARM-UP OPERATION…456
STOPPING THE ENGINE…460
CHECK AFTER SHUTING OFF ENGINE…460
MACHINE OPERATION…461
PREPARATIONS FOR MOVING THE MACHINE…461
MOVING MACHINE FORWARD…462
MOVING MACHINE BACKWARD…463
STOPPING MACHINE…464
STEERING THE MACHINE…465
STEERING THE MACHINE WHEN STOPPED…465
CHANGING DIRECTION OF THE MACHINE…466
COUNTER-ROTATION TURN (SPIN TURN)…466
SWINGING…467
WORK EQUIPMENT CONTROLS AND OPERATIONS…468
OPERATING WORKING MODE…469
WORKING MODE…469
ONE-TOUCH POWER MAX. SWITCH…469
PROHIBITED OPERATIONS…470
OPERATIONS USING SWING FORCE…470
OPERATIONS USING TRAVEL FORCE…470
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS…470
OPERATIONS USING BUCKET DROPPING FORCE…471
OPERATIONS USING MACHINE DROPPING FORCE…471
DIGGING HARD ROCKY GROUND…471
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…471
GENERAL OPERATION INFORMATION…472
TRAVELING…472
HIGH SPEED TRAVEL…472
PERMISSIBLE WATER DEPTH…472
TRAVELING ON SLOPES…473
TRAVELING DOWNHILL…474
ENGINE STOPPED ON SLOPE…474
PRECAUTIONS ON SLOPES…474
ESCAPE FROM MUD…475
STUCK ONE SIDE OF TRACK…475
STUCK BOTH SIDES OF TRACKS…475
ROAD BUILDER RECOMMENDED APPLICATIONS…476
BACKHOE WORK…476
SHOVEL WORK…476
DITCHING WORK…476
LOADING WORK…477
REPLACEMENT AND INVERSION OF BUCKET…478
REPLACEMENT…478
INVERSION…480
PARKING MACHINE…481
CHECK AFTER FINISHING WORK…483
LOCKING…484
TRANSPORTATION…485
TRANSPORTATION PROCEDURE…485
LOADING AND UNLOADING WITH TRAILER…486
LOADING…486
SECURING THE MACHINE…489
MACHINES WITH CAB RISER…491
UNLOADING…493
LIFTING THE MACHINE…496
COLD WEATHER OPERATION…497
FUEL AND LUBRICANTS…497
COOLING SYSTEM COOLANT…497
BATTERY…498
AFTER OPERATIONS…499
AFTER COLD WEATHER SEASON…499
LONG TERM STORAGE…500
BEFORE STORAGE…500
DURING STORAGE…500
AFTER STORAGE…500
STARTING MACHINE…501
TROUBLESHOOTING…501
AFTER RUNNING OUT OF FUEL…501
PHENOMENA THAT ARE NOT FAILURES…501
TOWING THE MACHINE…502
LIGHTWEIGHT TOWING HOOK…502
PRECAUTIONS ON PARTICULAR JOBSITES…503
DISCHARGED BATTERY…503
REMOVAL AND INSTALLATION OF BATTERY…504
BATTERY CHARGES…504
STARTING ENGINE WITH BOOSTER CABLES…505
OTHER TROUBLE…507
ELECTRICAL SYSTEM…507
CHASSIS…508
ENGINE…508
ELECTRONIC CONTROL SYSTEM…510
MAINTENANCE…512
MAINTENANCE INFORMATION…513
SERVICE METER READING…513
KOMATSU GENUINE REPLACEMENT PARTS…513
KOMATSU GENUINE LUBRICANTS…513
WINDSHIELD WASHER FLUID…513
FRESH AND CLEAN LUBRICANTS…513
CHECK DRAINED OIL AND USED FILTER…513
FUEL STRAINER…513
WELDING INSTRUCTIONS…513
DO NOT DROP THINGS INSIDE MACHINE…513
DUSTY JOBSITE…514
AVOID MIXING LUBRICANTS…514
LOCKING THE INSPECTION COVERS…514
HYDRAULIC SYSTEM – AIR BLEEDING…514
HYDRAULIC HOSE INSTALLATION…514
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…514
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE…515
LUBRICANTS, COOLANT AND FILTERS…515
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…515
OIL…515
FUEL…515
COOLING SYSTEM COOLANT…516
GREASE…516
CARRYING OUT KOWA…516
OIL AND FUEL STORAGE…517
FILTERS…517
ELECTRIC SYSTEM MAINTENANCE…518
HANDLING HYDRAULIC SYSTEM…518
WEAR PARTS LIST…519
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…520
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…520
TIGHTENING TORQUE SPECIFICATIONS…522
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…523
SAFETY CRITICAL PARTS…523
MAINTENANCE SCHEDULE…524
MAINTENANCE SCHEDULE CHART…524
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…527
REPLACING HYDRAULIC ELEMENT…527
CHANGING OIL IN HYDRAULIC TANK…527
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER…527
MAINTENANCE PROCEDURE…528
INITIAL 10 HOURS MAINTENANCE…528
LUBRICATION ROAD BUILDER MACHINE…528
INITIAL 250 HOURS MAINTENANCE…530
WHEN REQUIRED…531
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…531
CLEAN INSIDE OF COOLING SYSTEM…534
CHECK AND TIGHTEN TRACK SHOE BOLTS…536
CHECK AND ADJUST TRACK TENSION…537
CHECK ELECTRICAL INTAKE AIR HEATER…538
ADJUST BUCKET CLEARANCE…539
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…540
CHECK AND ADJUST AIR CONDITIONER…541
CLEANING CAB FLOOR…543
BLEEDING AIR FROM HYDRAULIC SYSTEM…545
RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT…547
CHECK BEFORE STARTING…548
EVERY 100 HOURS MAINTENANCE…549
LUBRICATING…549
EVERY 250 HOURS MAINTENANCE…550
LUBRICATION…550
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL…550
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…551
CHECK LEVEL OF BATTERY ELECTROLYTE…552
LUBRICATE SWING CIRCLE (3 POINTS)…554
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…554
EVERY 500 HOURS MAINTENANCE…555
LUBRICATION…555
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…556
REPLACE FUEL FILTER CARTRIDGE…557
CHECK SWING PINION GREASE LEVEL, ADD GREASE…558
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS…559
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM…560
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…561
EVERY 1000 HOURS MAINTENANCE…562
REPLACE HYDRAULIC FILTER ELEMENT…562
CHANGE OIL IN SWING MACHINERY CASE…563
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…564
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…564
CHECK PLAY OF TURBOCHARGER ROTOR…564
CHECK FAN BELT TENSION AND REPLACE FAN BELT…564
EVERY 2000 HOURS MAINTENANCE…565
CHANGE OIL IN FINAL DRIVE CASE…565
CLEAN HYDRAULIC TANK STRAINER…566
CLEAN, CHECK TURBOCHARGER…566
CHECK ALTERNATOR, STARTING MOTOR…566
CHECK ENGINE VALVE CLEARANCE, ADJUST…566
CHECK VIBRATION DAMPER…566
EVERY 4000 HOURS MAINTENENCE…567
CHECK WATER PUMP…567
EVERY 5000 HOURS MAINTENANCE…568
CHANGE OIL IN HYDRAULIC TANK…568
SPECIFICATIONS…570
SPECIFICATIONS…571
DIMENSIONS…571
WORKING RANGE…573
WORKING RANGE – ROAD BUILDER…573
LIFTING CAPACITY- ROAD BUILDER…575
OPTIONS, ATTACHMENTS…578
CEBD003001 – Hydraulic Excavator PC270LC-6LE Shop Manual…582
COVER…582
CONTENTS…583
00 FOREWORD…590
SAFETY…593
GENERAL…595
HOW TO READ THE SHOP MANUAL…596
HOISTING INSTRUCTIONS…597
COATING MATERIALS…598
STANDARD TIGHTENING TORQUE…599
ELECTRIC WIRE CODE…601
CONVERSION TABLES…602
01 GENERAL…608
GENERAL ASSEMBLY DRAWING …609
SPECIFICATIONS…610
WEIGHT TABLE…613
FUEL, COOLANT AND LUBRICANTS…615
ENGINE OIL SPECIFICATIONS…616
NORMAL OPERATION…616
ARCTIC OPERATION…616
DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYDRAULIC SYSTEM OIL SPECIFICATION…617
FINAL DRIVE OIL SPECIFICATIONS…617
DIESEL FUEL SPECIFICATIONS…617
COOLANT SPECIFICATIONS…618
GENERAL…618
WATER…618
ANTIFREEZE…618
10 STRUCTURE AND FUNCTION…620
ENGINE RELATED PARTS…623
RADIATOR AND OIL COOLER…624
POWER TRAIN…625
FINAL DRIVE…626
SWING CIRCLE…628
SWING MACHINERY…630
TRACK FRAME AND RECOIL SPRING…631
TRACK SHOE…632
HYDRAULIC PIPING DRAWING…634
HYDRAULIC CIRCUIT DIAGRAM…636
HYDRAULIC TANK…638
HYDRAULIC PUMP…639
BASIC PUMP…639
LS (LOADING SENSING) AND PC (POWER CONTROL) VALVE…645
IN-LINE OIL FILTER…657
CONTROL VALVE…658
OUTLINE…658
NINE-SPOOL VALVE (STANDARD PLUS THREE SERVICE VALVES)…659
MAIN STRUCTURE…660
SIX-SPOOL VALVE (STANDARD)…663
SAFETY-SUCTION VALVE FOR SERVICE VALVE…664
SELF-REDUCING PRESSURE VALVE…664
FUNCTION…667
OPERATION…667
CLSS…670
OUTLINE OF CLSS…670
OPERATION OF EACH FUNCTION AND VALVE…673
OPERATION OF CLSS SYSTEM AS A WHOLE…699
SWING MOTOR…715
BASIC MOTOR…715
SWING LOCK VALVE…717
RELIEF VALVE PORTION…718
REVERSE PREVENTION VALVE (SWING DAMPENING)…719
CENTER SWIVEL JOINT…721
TRAVEL MOTOR…722
VALVE CONTROL…730
WORK EQUIPMENT AND SWING PPC VALVE…731
OPERATION…733
TRAVEL PPC VALVE…735
OPERATION…737
SERVICE PPC VALVE…739
OPERATION…739
SAFETY LOCK VALVE…741
STRAIGHT-TRAVEL SYSTEM…742
FUNCTION…742
EPC VALVE…743
OPERATION…744
BOOM LOCK VALVE…745
OPERATION…746
ADDITIONAL FILTER FOR BREAKER…748
WORK EQUIPMENT…749
AIR CONDITIONER…750
BASIC INFORMATION ON AIR CONDITIONERS…751
UNITS RELATED TO REFRIGERATION…751
PRINCIPLE OF COOLING…755
REFRIGERANTS…760
SAFETY PRECAUTIONS…760
REFRIGERATOR OIL (LUBE OIL)…760
AIR CONDITIONING CONDENSER…762
FUNCTION…762
GENERAL DESCRIPTION…762
AIR CONDITIONER COMPRESSOR…765
RECEIVER WITH SIGHT GLASS…766
AIR CONDITIONER UNIT…768
OUTLINE…768
ELECTRICAL WIRING DIAGRAM…770
ELECTRICAL CIRCUIT DIAGRAM…772
ENGINE CONTROL SYSTEM…776
FUNCTION…776
OPERATION OF SYSTEM…777
COMPONENTS OF SYSTEM…778
ELECTRONIC CONTROL SYSTEM…782
TOTAL SYSTEM DIAGRAM…783
PUMP AND ENGINE MUTUAL CONTROL FUNCTION…784
PUMP AND VALVE CONTROL FUNCTION…789
POWER MAXIMIZING AND SWIFT SLOW-DOWN FUNCTION…792
AUTO-DECELERATION FUNCTION…793
AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION…795
SWING CONTROL FUNCTION…797
TRAVEL CONTROL FUNCTIONACTIVE MODE FUNCTION…799
ACTIVE MODE FUNCTION…801
COMPONENTS OF SYSTEM…803
MACHINE MONITOR SYSTEM…806
FUNCTION…806
MONITOR PANEL…807
MONITOR DISPLAY…808
OIL MAINTENANCE FUNCTION…810
SWITCHES…812
SENSORS…813
COOLANT LEVEL SENSOR…813
ENGINE OIL LEVEL SENSOR…814
HYDRAULIC OIL SENSOR…814
ENGINE OIL PRESSURE SENSOR…814
COOLANT TEMPERATURE SENSOR…815
FUEL LEVEL SENSOR…815
AIR CLEANER CLOGGING SENSOR…815
20 TESTING, ADJUSTING AND TROUBLESHOOTING…816
TESTING AND ADJUSTING…821
STANDARD VALUES TABLE…822
FOR ENGINE – PC270LC-6LE…822
FOR CHASSIS…823
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING…842
MEASURING ENGINE SPEED…843
MEASURING EXHAUST GAS COLOR…844
ADJUSTING VALVE CLEARANCE…845
MEASURING COMPRESSION PRESSURE…846
MEASURING BLOW-BY PRESSURE…847
TESTING AND ADJUSTING FUEL INJECTION TIMING…848
MEASURING ENGINE OIL PRESSURE…849
TESTING AND ADJUSTING FAN BELT TENSION…850
TESTING AND ADJUSTING A/C COMPRESSOR BELT TENSION…851
ADJUSTING THE ENGINE SPEED SENSOR…852
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE…853
MEASURING EQUIPMENT CYCLE TIMES…854
TESTING AND ADJUSTING PILOT OIL PRESSURE …855
TESTING AND ADJUSTING MAIN HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT…857
TESTING SERVO PISTON INPUT PRESSURE…861
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE…863
TESTING AND ADJUSTING PC VALVE…865
TESTING SOLENOID VALVE OUTPUT PRESSURES (LS-EPC, PC-EPC AND ON/OFF SOLENOID VALUES)…867
MEASURING PPC VALVE OUTPUT PRESSURE…871
PRESSURE SWITCH PIPING DIAGRAM…872
ADJUSTING WORK EQUIPMENT * SWING PPC VALVE…873
TESTING TRAVEL DEVIATION…874
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…875
MEASURING OIL LEAKAGE…877
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…879
TESTING CLEARANCE OF SWING CIRCLE BEARING…880
TESTING AND ADJUSTING TRACK SHOE TENSION…881
BLEEDING AIR…883
TROUBLESHOOTING…885
POINTS TO REMEMER WHEN TROUBLESHOOTING…886
SEQUENCE OF EVENTS IN TROUBLESHOOTING…887
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…888
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT…888
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS…893
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…894
CHECKS BEFORE TROUBLESHOOTING…896
CONNECTOR TYPES AND MOUNTING LOCATIONS…897
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…901
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM…911
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL…912
METHOD OF USING JUDGEMENT TABLE…921
METHOD OF USING TROUBLESHOOTING CHARTS…923
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…925
SERVICE CODE TABLE…930
TROUBLESHOOTING OF COMMUNICATION ABNOMALITY SYSTEM (N MODE)…931
N-1 [E218] COMMUNICATIONS ABNORMALITY…931
TROUBLESHOOTING OF ENGINE THROTTLE – PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)(E MODE)…934
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE – PUMP CONTROLLER SYSTEM…934
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…935
JUDGEMENT TABLE FOR ENGINE THROTTLE – PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS…939
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM…941
E-1 ABNOMALITY IN ENGINE THROTTLE – PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)…943
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…944
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED…945
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED…946
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…947
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…948
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED…949
E-8 ENGINE DOES NOT START…951
E-9 ENGINE SPEED IS IRREGULAR…955
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED TO LOW)…959
E-11 ENGINE DOES NOT STOP…961
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOE NOT STOP)…963
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…965
METHOD OF USING TROUBLESHOOTING CHARTS…965
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…969
S-2 ENGINE DOES NOT START…971
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…974
S-4 ENGINE STOPS DURING OPERATIONS …975
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…976
S-6 ENGINE LACKS OUTPUT (NO POWER)…977
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…978
S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…979
S-9 OIL BECOMES CONTAMINATED QUICKLY…980
S-10 FUEL CONSUMPTION IS EXCESSIVE…981
S-11 OIL IS IN COOLANT, OR COLLANT SPURTS BACK, OR COOLANT LEVLE GOES DOWN…982
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…983
S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL)…984
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…985
S-15 ABNORMAL NOISE IS MADE…986
S-16 VIBRATION IS EXCESSIVE…987
TROUBLESHOOTING OF ENGINE THROTTLE – PUMP CONTROLLER (PUMP CONTROL SYSTEM)(C MODE)…988
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…988
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…989
JUDGEMENT TABLE FOR ENGINE THROTTLE – PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS…997
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE AND F MODE…999
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)…1001
C-2 [E232] SHORT CIRCUIT IN PUMP EPC SOLENOID SYSTEM IS DISPLAYED…1003
C-3 [E233] DISCONNECTION IN PC-EPC SOLENOID SYSTEM IS DISPLAYED…1005
C-4 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED…1007
C-5 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED…1009
C-6 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED…1011
C-7 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED…1012
C-8 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYEDPC270LC-6LE…1013
C-9 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED…1014
C-10 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED…1015
C-11 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED…1016
C-12 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…1017
C-13 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…1018
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED…1019
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…1021
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…1022
C-17 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…1023
C-18 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…1024
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED…1025
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…1026
TROUBLESHOOTING OF ENGINE THROTTLE – PUMP CONTROLLER (INPUT SIGNAL SYSTEM (F MODE)…1028
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP…1028
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…1029
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP…1030
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP…1031
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP…1032
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP…1033
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP…1034
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP …1035
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP…1036
F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP…1037
F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP…1038
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…1039
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM…1039
PUMP MERGE/DIVIDER LOGIC…1043
SOLENOID ACTUATION TABLE…1044
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW…1045
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…1047
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…1047
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…1048
H-5 AUTO-DECELERATION DOES NOT WORK (PPC SHUTTLE VALVE IS EQUIPPED ONLY IN TRAVEL PPC VALVE)…1048
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…1049
H-7 BOOM IS SLOW OR LACKS POWER…1051
H-8 ARM IS SLOW OR LACKS POWER…1053
H-9 BUCKET IS SLOW OR LACKS POWER…1055
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…1056
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…1056
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…1057
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…1057
H-14 LACK OF POWER WHEN PRESSURE RISES…1058
H-15 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED …1059
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGE LOAD IS SLOW…1059
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…1060
H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY…1060
H-19 TRAVEL DEVIATION…1060
H-20 TRAVEL SPEED IS SLOW…1061
H-21 STEERING DOES NOT TURN EASILY OR LACKS POWER…1063
H-22 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…1065
H-23 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…1065
H-24 DOES NOT SWING…1066
H-25 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW…1067
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING…1069
H-27 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…1069
H-28 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…1070
H-29 EXCESSIVE HYDRAULIC DRIFT OF SWING…1070
H-30 SWING SPEED IS FASTER THAN SPECIFIED SPEED IN L/O AND F/O MODES…1071
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M CODE)…1073
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…1073
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM…1075
M-1 [E101] ABNORMALITY IN ERRO DATA IS DISPLAYED; [E102] ERROR IN CLOCK DATA IS DISPLAYED…1077
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED…1078
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED…1079
M-4 [E108] ENGINE COOLANT TEMPERATURE 105 C (221F) DETECTED IS DISPLAYED…1079
M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS…1081
M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT…1083
M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE MODEL…1083
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH…1085
M-9 PREHEATING IS NOT BEING USED BUT PREHEATING MONITOR LIGHTS UP…1088
M-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH…1089
M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE L…1091
M-12 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMAL…1093
M-13 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR SECOND. CAUTION ITEM FLASHES BUT BUZZER D…1097
M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS…1097
M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…1098
M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE…1099
M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF THE GAUGE LAMPS LIGHT UP DURING OPERATION)…1100
M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…1101
M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…1101
M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT SWING LOCK MONITOR DOES NOT LIGHT UP…1102
M-21 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH…1103
M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING…1104
M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED…1104
M-24 DEFECTIVE FUEL LEVER SENSOR SYSTEM…1105
M-25 DEFECTIVE COOLANT TEMPERATUER SENSOR SYSTEM…1106
M-26 DEFECTIVE ENGINE OIL SENSOR SYSTEM…1107
M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…1108
M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM…1109
M-29 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…1111
M-30 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED…1117
30 DISASSEMBLY AND ASSEMBLY…1120
METHOD OF USING MANUAL…1125
WHEN REMOVING OR INSTALLING UNIT ASSEMBLIES…1125
GENERAL PRECAUTIONS…1125
LISTING OF SPECIAL TOOLS…1125
PRECAUTIONS WHEN CARRYING OUT OPERATION…1126
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK…1126
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK…1127
PRECAUTIONS WHEN COMPLETING OPERATIONS…1127
SPECIAL TOOLS LIST…1128
SPECIAL TOOL SKETCH…1132
STARTER MOTOR…1134
REMOVAL…1134
INSTALLATION…1134
ALTERNATOR…1135
REMOVAL…1135
INSTALLATION…1135
AIR CONDITIONER COMPRESSOR…1136
REMOVAL…1136
INSTALLATION…1136
AIR CONDITIONER CONDENSER…1137
REMOVAL…1137
INSTALLATION…1137
RECEIVER DRIER…1138
REMOVAL…1138
INSTALLATION…1138
FUEL INJECTION PUMP…1139
REMOVAL…1139
INSTALLATION…1140
WATER PUMP…1141
REMOVAL…1141
INSTALLATION…1142
NOZZLE HOLDER…1143
REMOVAL…1143
INSTALLATION…1143
TURBOCHARGER…1144
REMOVAL…1144
INSTALLATION…1144
THERMOSTAT…1145
REMOVAL…1145
INSTALLATION…1145
GOVERNOR MOTOR…1146
REMOVAL…1146
INSTALLATION…1146
CYLINDER HEAD ASSEMBLY…1147
REMOVAL…1147
INSTALLATION…1149
RADIATOR – HYDRAULIC OIL COOLER…1151
REMOVAL…1151
INSTALLATION…1152
ENGINE, MAIN PUMP…1153
REMOVAL…1153
INSTALLATION…1156
DAMPER…1157
REMOVAL…1157
INSTALLATION…1157
FUEL TANK…1158
REMOVAL…1158
INSTALLATION…1158
CENTER SWIVEL JOINT…1159
REMOVAL…1159
INSTALLATION…1160
DISASSEMBLY…1161
ASSEMBLY…1161
FINAL DRIVE…1163
REMOVAL…1163
INSTALLATION…1163
DISASSEMBLY…1164
ASSEMBLY…1167
SPROCKET…1171
REMOVAL…1171
INSTALLATION…1171
SWING MOTOR AND MACHINERY…1173
REMOVAL…1173
INSTALLATION…1174
SWING MACHINERY…1175
DISASSEMBLY…1175
ASSEMBLY…1178
REVOLVING FRAME…1183
REMOVAL…1183
INSTALLATION…1184
SWING CIRCLE…1185
REMOVAL…1185
INSTALLATION…1185
IDLER-RECOIL SPRING…1186
REMOVAL…1186
INSTALLATION…1186
IDLER RECOIL SPRING…1187
DISASSEMBLY…1187
ASSEMBLY…1188
IDLER…1189
DISASSEMBLY…1189
ASSEMBLY…1190
TRACK ROLLER…1193
REMOVAL…1193
INSTALLATION…1194
DISASSEMBLY…1195
ASSEMBLY…1196
CARRIER ROLLER…1199
REMOVAL…1199
INSTALLATION…1199
DISASSEMBLY…1200
ASSEMBLY…1201
TRACK SHOE…1203
REMOVAL…1203
INSTALLATION…1203
HYDRAULIC TANK…1205
REMOVAL…1205
INSTALLATION…1206
MAIN PUMP…1207
REMOVAL…1207
INSTALLATION…1209
MAIN PUMP INPUT SHAFT OIL SEAL…1210
REMOVAL…1210
INSTALLATION…1210
CONTROL VALVE…1211
REMOVAL…1211
INSTALLATION…1213
DISASSEMBLY…1214
ASSEMBLY…1219
PUMP MERGER-DIVIDER VALVE…1222
DISASSEMBLY…1222
ASSEMBLY…1222
MAIN RELIEF VALVE…1223
DISASSEMBLY…1223
ASSEMBLY…1223
PC VALVE…1224
REMOVAL…1224
INSTALLATION…1224
LS VALVE…1225
REMOVAL…1225
INSTALLATION…1225
PC-EPC, LS-EPC VALVES…1226
REMOVAL…1226
INSTALLATION…1226
SOLENOID VALVE…1227
REMOVAL…1227
INSTALLATION…1227
WORK EQUIPMENT – SWING PPC VALVE…1229
REMOVAL…1229
INSTALLATION…1229
DISASSEMBLY …1230
ASSEMBLY…1231
TRAVEL PPC VALVE…1233
REMOVAL…1233
INSTALLATION…1234
DISASSEMBLY…1235
ASSEMBLY…1236
BOOM LOCK VALVE…1237
REMOVAL…1237
INSTALLATION…1237
BOOM CYLINDER…1239
REMOVAL…1239
INSTALLATION…1240
ARM CYLINDER…1241
REMOVAL…1241
INSTALLATION…1242
BUCKET CYLINDER…1243
REMOVAL…1243
INSTALLATION…1244
HYDRAULIC CYLINDER…1245
DISASSEMBLY…1245
ASSEMBLY…1247
WORK EQUIPMENT…1251
REMOVAL…1251
INSTALLATION…1252
BUCKET…1253
REMOVAL…1253
INSTALLATION…1254
ARM…1255
REMOVAL…1255
INSTALLATION…1256
BUCKET – ARM…1257
REMOVAL…1257
INSTALLATION…1258
BOOM…1259
REMOVAL…1259
INSTALLLATION…1260
OPERATOR'S CAB…1261
REMOVAL…1261
INSTALLATION…1262
COUNTERWEIGHT…1263
REMOVAL…1263
INSTALLATION…1263
ENGINE THROTTLE – PUMP CONTROLLER…1264
REMOVAL…1264
INSTALLATION…1264
CONTROL STAND CASE…1265
REMOVAL…1265
INSTALLATION…1266
MONITOR…1267
REMOVAL…1267
INSTALLATION…1267
40 MAINTENANCE STANDARD…1268
SWING MACHINERY…1271
SWING CIRCLE…1274
FINAL DRIVE…1275
TRACK FRAME AND RECOIL SPRING…1277
CARRIER ROLLER…1278
IDLER…1279
TRACK ROLLER…1282
TRACK SHOE…1283
HYDRAULIC PUMP…1285
CONTROL VALVE…1286
VARIABLE PRESSURE COMPENSATION VALVE…1292
SAFETY-SUCTION VALVE FOR SERVICE VALVE…1293
SELF-REDUCING PRESSURE VALVE…1294
SWING MOTOR…1295
TRAVEL MOTOR…1296
WORK EQUIPMENT AND SWING PPC VALVES…1297
TRAVEL PPC VALVE…1298
SERVICE PPC VALVE…1299
EPC SOLENOID VALVE…1300
CENTER SWIVEL JOINT…1301
BOOM LOCK VALVE…1302
HYDRAULIC CYLINDER…1303
WORK EQUIPMENT…1305
DIMENSION OF WORK EQUIPMENT…1307
ARM PORTION…1307
BUCKET PORTION…1309
CEBM005905 – Hydraulic Excavator PC270LC-7L Shop Manual…1313
CONTENTS…1314
SAFETY…1327
Safety Notice…1327
IMPORTANT SAFETY NOTICE…1327
General Precautions…1327
Preparations For Work…1327
Precautions During Work…1327
GENERAL…1330
HOW TO READ THE SHOP MANUAL…1331
Volumes…1331
Distribution And Updating…1331
Filing Method…1331
Revised Edition Mark…1331
Revisions…1331
Symbols…1331
HOISTING INSTRUCTIONS…1332
Hoisting…1332
Wire Ropes…1332
PUSH-PULL TYPE COUPLER…1333
COATING MATERIALS…1335
STANDARD TIGHTENING TORQUE…1337
Standard Tightening Torque Of Bolts And Nuts…1337
Tightening Torque Of Split Flange Bolts…1338
Tightening Torque For Flared Nuts…1338
Table Of Tightening Torques For O-ring Boss Piping Joints…1338
Table Of Tightening Torques For O-ring Boss Plugs…1339
Tightening Torque For 102 And 114 Engine Series…1339
Tightening Torque Table For Hoses (Taper Seal Type And Face Seal Type)…1340
ELECTRIC WIRE CODE…1341
Classification By Thickness…1341
Classification By Color And Code…1341
CONVERSION TABLES…1342
Method Of Using The Conversion Table…1342
SPECIFICATION DIMENSION DRAWINGS…1350
Dimensions…1350
Working Ranges…1351
SPECIFICATIONS…1352
WEIGHT TABLE…1354
FUEL, COOLANT AND LUBRICANTS…1356
Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil…1357
ENGINE RELATED PARTS…1361
RADIATOR . OIL COOLER . AFTERCOOLER…1362
POWER TRAIN…1363
FINAL DRIVE…1364
SWING MACHINERY…1366
SWING CIRCLE…1369
TRACK FRAME . RECOIL SPRING…1370
IDLER…1372
CARRIER ROLLER…1374
CEBM014600 – Logging Excavator GALEO PC270LL-7L Shop Manual…2151
COVER…2151
CONTENTS…2152
FOREWORD…2152
SAFETY…2155
SAFETY NOTICE…2155
IMPORTANT SAFETY NOTICE…2155
GENERAL PRECAUTIONS…2155
PREPARATIONS FOR WORK…2155
PRECAUTIONS DURING WORK…2155
GENERAL…2157
HOW TO READ THE SHOP MANUAL…2158
VOLUMES…2158
DISTRIBUTION AND UPDATING…2158
FILING METHOD…2158
REVISED EDITION MARK…2158
REVISIONS…2158
SYMBOLS…2158
HOISTING INSTRUCTIONS…2159
HOISTING…2159
WIRE ROPES…2159
COATING MATERIALS…2160
STANDARD TIGHTENING TORQUE…2162
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS…2162
TIGHTENING TORQUE OF HOSE NUTS…2163
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…2163
TIGHTENING TORQUE FOR FLARED NUTS…2163
ELECTRIC WIRE CODE…2164
CLASSIFICATION BY THICKNESS…2164
CLASSIFICATION BY COLOR AND CODE…2164
CONVERSION TABLES…2165
METHOD OF USING THE CONVERSION TABLE…2165
01 GENERAL…2171
SPECIFICATION DIMENSION DRAWINGS…2172
PC270LL-7L…2172
DIMENSIONS…2172
WORKING RANGES…2174
WEIGHT TABLE…2177
FUEL, COOLANT AND LUBRICANTS…2179
PC270LL-7L…2179
10 STRUCTURE AND FUNCTION…2181
ENGINE RELATED PARTS…2183
RADIATOR . OIL COOLER . AFTERCOOLER…2184
POWER TRAIN…2185
FINAL DRIVE…2187
SWING CIRCLE…2191
TRACK FRAME . RECOIL SPRING…2193
IDLER…2195
TRACK ROLLER…2197
TRACK SHOE…2198
TRIPLE GROUSER SHOE…2200
HYDRAULIC EQUIPMENT…2201
HYDRAULIC TANK…2203
HYDRAULIC PUMP…2205
HPV95 + 95…2205
LS VALVE…2210
PC VALVE…2210
LS(PC)-EPC VALVE…2223
CONTROL VALVE…2227
SELF PRESSURE REDUCING VALVE…2243
MAIN RELIEF VALVE…2246
VARIABLE PRESSURE COMPENSATION VALVE…2247
CLSS…2249
SWING MOTOR…2250
RELIEF VALVE PORTION…2253
SWING LOCK…2254
REVERSE PREVENTION VALVE…2255
CENTER SWIVEL JOINT…2258
TRAVEL MOTOR…2260
PARKING BRAKE…2265
TRAVEL JUNCTION VALVE…2271
VALVE CONTROL…2273
CONNECTIONS…2273
LEVER POSITIONS…2274
WORK EQUIPMENT . SWING PPC VALVE…2275
TRAVEL PPC VALVE…2280
SERVICE VALVE…2289
SOLENOID VALVE…2292
ATTACHMENT SOLENOID VALVE…2293
PPC ACCUMULATOR…2295
BOOM HYDRAULIC DRIFT PREVENTION VALVE…2296
LIFT CHECK VALVE…2299
HYDRAULIC CYLINDERS…2300
BOOM CYLINDER…2300
ARM CYLINDER…2300
BUCKET CYLINDER…2300
WORK EQUIPMENT…2302
100 HOURS…2303
500 HOURS…2303
DIMENSION OF ARM…2304
DIMENSION OF BUCKET…2306
AIR CONDITIONER…2308
PIPING…2308
ENGINE CONTROL…2309
FUEL CONTROL DIAL…2311
GOVERNOR MOTOR…2312
ENGINE THROTTLE AND PUMP CONTROLLER…2314
INPUT AND OUTPUT SIGNALS…2315
ELECTRONIC CONTROL SYSTEM…2317
MACHINE CONTROL SYSTEM DIAGRAM…2318
ENGINE AND PUMP CONTROL FUNCTION…2320
SWING CONTROL FUNCTION WITH SOFT SWING…2335
MULTI MONITOR SYSTEM…2343
MONITOR PANEL…2344
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION…2346
MONITOR ITEMS AND DISPLAY…2347
MAINTENANCE FUNCTION…2356
SENSORS…2361
ENGINE OIL LEVEL SENSOR…2362
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)…2362
COOLANT TEMPERATURE SENSOR…2362
HYDRAULIC OIL TEMPERATURE SENSOR…2362
FUEL LEVEL SENSOR…2363
AIR CLEANER CLOGGING SENSOR…2363
CAB RISER AND RELATED PARTS…2364
POWER CONTROL…2365
CAB RISER HYDRAULIC SYSTEM…2366
20 TESTING, ADJUSTING AND TROUBLESHOOTING…2381
STANDARD VALUE TABLES…2369
ENGINE…2369
CHASSIS…2370
TESTING AND ADJUSTING…2381
SERVICE TOOLS…2383
ENGINE…2384
COMPRESSION PRESSURE…2384
BLOW-BY PRESSURE…2384
OIL PRESSURE…2384
RPM…2384
SPEED SENSOR…2384
EXHAUST GAS COLOR…2384
FUEL INJECTION TIMING…2384
VALVE CLEARANCE…2384
BELT TENSION – AIR COMPRESSOR…2385
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE…2386
SWING CIRCLE BEARINGS…2387
TRACK SHOE TENSION…2388
SPROCKET…2388
OIL PRESSURE…2389
WORK EQUIPMENT, SWING AND TRAVEL…2389
CONTROL CIRCUIT…2393
PUMP PC CONTROL CIRCUIT…2394
PUMP LS CONTROL CIRCUIT…2397
SOLENOID VALVE OUTPUT PRESSURE…2402
TABLE FOR FUNCTIONING CONDITIONS…2403
PPC LOCK SOLENOID VALVE…2403
SWING AND PARKING BRAKE SOLENOID…2403
TRAVEL INTERCONNECTION SOLENOID VALVE…2403
ATTACHMENT SOLENOID VALVE OUTPUT…2406
PPC VALVE OUTPUT PRESSURE…2407
ATTACHMENT PPC VALVE OUTPUT…2408
WORK EQUIPMENT AND SWING PPC VALVE…2409
WORK EQUIPMENT – HYDRAULIC DRIFT…2410
RELEASING PRESSURE IN HYDRAULIC CIRCUIT…2412
OIL LEAKAGE…2413
AIR BLEEDING OF VARIOUS PARTS…2416
SOFT SWING ADJUSTMENTS…2418
DIODE INSPECTION PROCEDURES…2419
CAB DOOR STOP ADJUSTMENT…2421
MULTI-MONITOR PANEL…2422
TABLE FOR SERVICE AND FAILURE CODE NUMBERS…2429
SERVICE MENU…2431
WAY OF SWITCHING TO SERVICE MENU…2431
ELECTRICAL SYSTEM TROUBLESHOOTING…2447
PM TUNE UP SERVICE…2448
TROUBLESHOOTING…2453
TROUBLESHOOTING GENERAL…2453
POINTS TO REMEMBER WHEN TROUBLESHOOTING…2455
SEQUENCE OF EVENTS IN TROUBLESHOOTING…2457
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…2458
CHECKS BEFORE TROUBLESHOOTING…2466
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING…2467
CLASSIFICATION OF TROUBLESHOOTING…2467
STEPS FOR TROUBLESHOOTING…2467
FAILURE-LOOKING PHENOMENON AND TROUBLESHOOTING NO…2468
CONNECTOR LOCATION CHART…2471
CONNECTOR TABLE…2471
CONNECTOR LOCATION DIAGRAM…2478
ELECTRICAL CIRCUIT DIAGRAMS…2483
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2484
CONNECTOR REPAIR PROCEDURES…2507
CONTACT TERMINAL REMOVAL (HD30 TYPE)…2507
STRIPPING INSULATION…2508
CRIMPING CONTACT TERMINAL (HD30 TYPE)…2509
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…2510
CONTACT TERMINAL REMOVAL (DT TYPE)…2511
STRIPPING INSULATION…2512
CRIMPING CONTACT TERMINAL (DT TYPE)…2513
INSERTION OF CONTACT TERMINAL (DT TYPE)…2514
TROUBLESHOOTING ELECTRICAL SYSTEM (E-MODE)…2515
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM…2519
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF…2519
USER CODE MEMORY RETENTION FUNCTION…2519
INFORMATION CONTAINED IN TESTING PROCEDURES…2520
(E101)…2522
ABNORMAL DATA IN ERROR HISTORY…2522
(E112)…2524
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION…2524
SHORT IN GUARD WIPER MOTOR DRIVE FORWARD ROTATION…2525
(E113)…2527
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION…2527
SHORT IN GUARD WIPER MOTOR DRIVE REVERSE ROTATION…2528
(E114)…2530
SHORT OR OPEN IN WINDOW WASHER SYSTEM…2530
SHORT OR OPEN IN GUARD WASHER SYSTEM…2531
(E115)…2533
ABNORMAL WINDSHIELD WIPER MOTION…2533
ABNORMAL GUARD WIPER MOTION…2534
(E116)…2536
ABNORMALITY IN PARKING WIPER ARM…2536
ABNORMALITY IN PARKING WIPER ARM (GUARD)…2537
(E201)…2540
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID…2540
(E203)…2542
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM…2542
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM (WITH SOFT SWING)…2544
(E204)…2546
SHORT IN MERGE/DIVIDE SOLENOID…2546
(E205)…2548
SHORT IN 2 STAGE RELIEF SOLENOID…2548
(E206)…2550
SHORT IN TRAVEL SPEED SHIFT SOLENOID…2550
(E211)…2552
OPEN IN TRAVEL INTERLOCKING SOLENOID…2552
(E213)…2554
OPEN IN SWING PARKING BRAKE SOLENOID…2554
OPEN IN SWING PARKING BRAKE SOLENOID (WITH SOFT SWING)…2556
NO CODE…2558
SHORT OR OPEN IN SOFT SWING SOLENOID SYSTEM…2558
(E214)…2562
OPEN OF MERGE/DIVIDE SOLENOID…2562
(E215)…2564
OPEN IN 2 STAGE RELIEF SOLENOID…2564
(E216)…2566
OPEN IN TRAVEL SPEED SOLENOID…2566
(E217)…2568
ABNORMAL INPUT FOR MODEL CODE…2568
(E218)…2570
OPEN IN S-NET SIGNAL…2570
(E222)…2572
SHORT IN LS-EPC SOLENOID…2572
(E223)…2574
OPEN IN LS-EPC SOLENOID SYSTEM…2574
(E224)…2576
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL…2576
(E225)…2578
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL…2578
(E226)…2580
ABNORMAL PRESSURE SENSOR POWER SUPPLY…2580
(E227)…2582
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER…2582
(E228)…2584
SHORT IN ATTACHMENT RETURN SWITCHING RELAY…2584
NO CODE…2586
SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM…2586
NO CODE…2590
OPEN IN CAB TILT SYSTEM…2590
(E232)…2592
SHORT IN PC-EPC SOLENOID…2592
(E233)…2594
OPEN IN PC-EPC SOLENOID SYSTEM…2594
(E238)…2596
OPEN IN ATTACHMENT RETURN SWITCH RELAY…2596
(E245)…2598
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM…2598
(E246)…2600
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM…2600
(E256)…2602
INCORRECT NON-VOLATILE MEMORY DATA…2602
(E306)…2604
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS…2604
(E308)…2606
ABNORMAL FUEL DIAL SIGNALS…2606
(E315)…2608
SHORT IN BATTERY RELAY SYSTEM…2608
(E316)…2610
STEP OUT IN GOVERNOR MOTOR…2610
(E317)…2612
OPEN IN GOVERNOR MOTOR PHASE "A" AND "B"…2612
(E318)…2614
SHORT IN GOVERNOR MOTOR PHASE "A" AND "B"…2614
(E501)…2616
MODEL SELECTION FUNCTION NOT PROVIDED…2616
(E502)…2617
MODEL SELECTING SIGNAL FAULT…2617
(A000N1)…2618
ENGINE SPEED OUT OF RANGE AT HIGH IDLE…2618
(A000N2)…2619
ENGINE SPEED OUT OF RANGE AT LOW IDLE…2619
(AA10NX)…2620
AIR CLEANER CLOG INDICATOR FAILURE…2620
(AB00KE)…2622
LOW CHARGING VOLTAGE INDICATED…2622
(B@BAZG)…2624
ABNORMAL ENGINE OIL PRESSURE…2624
(B@BAZK)…2626
ABNORMAL ENGINE OIL LEVEL…2626
(B@BCNS)…2628
ENGINE COOLANT INDICATING OVERHEAT CONDITION…2628
(B@BCZK)…2630
ABNORMAL COOLANT LEVEL INDICATION…2630
(B@HANS)…2632
HYDRAULIC OIL OVERHEAT INDICATION…2632
TROUBLESHOOTING MONITOR ELECTRICAL (E-MODE)…2635
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM…2637
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF…2637
USER CODE MEMORY RETENTION FUNCTION…2637
INFORMATION CONTAINED IN TESTING PROCEDURES…2638
(E-1)…2640
ENGINE WILL NOT CRANK…2640
(E-2)…2642
ENGINE STOPS WHILE IN OPERATION…2642
(E-3)…2644
ENGINE SPEED IRREGULAR, OR HUNTING…2644
(E-4)…2646
ENGINE DOES NOT STOP…2646
(E-5)…2648
AUTO DECELERATOR DOES NOT WORK…2648
(E-6)…2649
AUTO ENGINE WARM UP DEVICE DOES NOT WORK…2649
(E-7)…2650
COLD START PREHEATER DOES NOT WORK…2650
(E-8)…2652
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE…2652
(E-9)…2654
ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE…2654
(E-10)…2656
NO DISPLAY ON MONITOR PANEL…2656
(E-11)…2658
PART OF DISPLAY ON MONITOR PANEL IS MISSING…2658
(E-12)…2659
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL…2659
(E-13)…2660
FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL…2660
(E-14)…2662
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY…2662
(E-15)…2664
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY…2664
(E-16)…2666
FUEL GAUGE DOES NOT DISPLAY CORRECTLY…2666
(E-17)…2668
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY…2668
(E-18)…2670
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS…2670
(E-19)…2672
WINDSHIELD WIPER DOES NOT WORK…2672
GUARD WIPER DOES NOT WORK…2673
(E-20)…2676
ALARM BUZZER CANNOT BE CANCELLED…2676
(E-21)…2678
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR…2678
(E-22)…2680
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR…2680
(E-23)…2682
ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR…2682
(E-24)…2684
ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR…2684
(E-25)…2686
BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR…2686
(E-26)…2688
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR…2688
(E-27)…2690
SWING NOT CORRECTLY DISPLAYED ON MONITOR…2690
(E-28)…2692
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR…2692
(E-29)…2694
TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR…2694
(E-30)…2696
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR…2696
(E-31)…2698
AIR CONDITIONER SYSTEM DOES NOT WORK…2698
(E-32)…2702
TRAVEL ALARM DOES NOT SOUND…2702
30 DISASSEMBLY AND ASSEMBLY…2705
METHOD OF USING MANUAL…2709
PRECAUTIONS DURING OPERATION…2710
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK…2710
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK…2711
PRECAUTIONS WHEN COMPLETING THE OPERATIONS…2712
OTHER PRECAUTIONS…2712
SPECIAL TOOL LIST…2713
SKETCHES OF SPECIAL TOOLS…2717
ENGINE…2718
ALTERNATOR…2718
CYLINDER HEAD…2718
ENGINE FRONT SEAL…2718
ENGINE OIL COOLER…2718
ENGINE REAR SEAL…2718
FUEL INJECTION PUMP…2718
NOZZLE HOLDER…2718
STARTING MOTOR…2718
THERMOSTAT…2718
TURBOCHARGER…2718
WATER PUMP…2718
RADIATOR…2719
REMOVAL…2719
INSTALLATION…2720
HYDRAULIC OIL COOLER…2721
REMOVAL…2721
INSTALLATION…2722
ENGINE AND HYDRAULIC PUMPS…2723
REMOVAL…2723
INSTALLATION…2728
TRAVEL MOTOR AND FINAL DRIVE…2730
REMOVAL…2730
INSTALLATION…2730
FINAL DRIVE…2731
DISASSEMBLY…2731
ASSEMBLY…2736
REMOVAL…2741
INSTALLATION…2742
DISASSEMBLY…2743
ASSEMBLY…2746
TRACK AND CARRIER ROLLER…2752
REMOVAL…2752
INSTALLATION…2752
DISASSEMBLY…2753
ASSEMBLY…2754
IDLER AND RECOIL SPRING…2757
REMOVAL…2757
INSTALLATION…2757
IDLER…2758
DISASSEMBLY…2758
ASSEMBLY…2759
RECOIL SPRING…2762
DISASSEMBLY…2762
ASSEMBLY…2763
TRACK ROLLER…2764
REMOVAL…2764
INSTALLATION…2764
DISASSEMBLY…2765
ASSEMBLY…2766
SPROCKET…2769
REMOVAL…2769
INSTALLATION…2769
TRACK SHOE…2770
EXPANSION OF TRACK SHOE…2770
ASSEMBLY…2771
SWING CIRCLE…2772
REMOVAL…2772
INSTALLATION…2772
REVOLVING FRAME…2773
REMOVAL…2773
INSTALLATION…2775
CENTER SWIVEL JOINT…2776
REMOVAL…2776
INSTALLATION…2777
DISASSEMBLY…2778
ASSEMBLY…2779
HYDRAULIC TANK…2780
REMOVAL…2780
INSTALLATION…2782
CONTROL VALVE…2783
REMOVAL…2783
INSTALLATION…2786
DISASSEMBLY…2787
ASSEMBLY…2788
HYDRAULIC PUMP…2789
REMOVAL…2789
INSTALLATION…2791
HYDRAULIC PUMP INPUT SHAFT – OIL SEAL…2792
REMOVAL…2792
INSTALLATION…2792
PPC VALVE…2793
WORK EQUIPMENT…2793
ASSEMBLY…2793
TRAVEL…2794
ASSEMBLY…2794
HYDRAULIC CYLINDER…2795
DISASSEMBLY…2795
ASSEMBLY…2797
WORK EQUIPMENT…2801
REMOVAL…2801
INSTALLATION…2803
AIR CONDITIONER…2804
REMOVAL…2804
INSTALLATION…2807
COUNTERWEIGHT…2808
REMOVAL…2808
INSTALLATION…2808
CAB…2809
REMOVAL…2809
INSTALLATION…2811
MONITOR…2812
REMOVAL…2812
INSTALLATION…2812
GOVERNOR PUMP CONTROLLER…2813
REMOVAL…2813
INSTALLATION…2813
90 OTHERS…2815
ELECTRICAL…2817
CIRCUIT DIAGRAM SHEET 1 (PART 1 OF 3)…2817
CIRCUIT DIAGRAM SHEET 1 (PART 2 OF 3)…2819
CIRCUIT DIAGRAM SHEET 1 (PART 3 OF 3)…2821
CIRCUIT DIAGRAM SHEET 2 (PART 1 OF 1)…2823
CIRCUIT DIAGRAM SHEET 3 (PART 1 OF 2)…2825
CIRCUIT DIAGRAM SHEET 3 (PART 2 OF 2)…2827
CIRCUIT DIAGRAM SHEET 4 (PART 1 OF 2)…2829
CIRCUIT DIAGRAM SHEET 4 (PART 2 OF 2)…2831
HYDRAULIC…2835
HYDRAULIC DIAGRAM (SHEET 1 OF 4) – FOLDOUT 11…2835
HYDRAULIC DIAGRAM (SHEET 2 OF 4) – FOLDOUT 12…2837
HYDRAULIC DIAGRAM (SHEET 3 OF 4) – FOLDOUT 13…2839

Komatsu Hydraulic Excavator PC270LC-LE, PC270LC-L, PC270LL-L Repair Service Manuals

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