UEBM001601

PC290LC, 290NLC-7K

MACHINE MODEL SERIAL NUMBER

PC290LC-7K 00 K40001 AND UP 00

PC290NLC-7K 00 K40001 AND UP 00

• This shop manual may contain attachments and optional equipment that are not avail-
able in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
• PC290LC/NLC-7K mount the SAA6D102E engine.
For details of the engine, see the 102 Series Engine Shop Manual.

© 2008
All Rights Reserved 00-1
Printed in Belgium 06-08
 CONTENTS

No. of page

01 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD. . . . . . 10-1

20 TESTING AND ADJUSTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

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The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Page to be newly added Add

Page to be replaced Replace

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Pages having no marks are those previously revised

or made additions.

LIST OF REVISED PAGES

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PC290-7 00-2-3
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00-2-4 PC290-7
 01 GENERAL

Specification Dimension Drawings . . . 01-2

Specifications
PC290LC-7, PC290NLC-7. . . . . . . . 01-4

Weight Table
PC290LC-7, PC290NLC-7. . . . . . . . 01-6

Fuel, Coolant, And Lubricants. . . . . . . . 01-8

PC290-7 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS

SPECIFICATION
12
DIMENSION DRAWINGS

DIMENSIONS

WORKING RANGES

01-2 PC290-7
GENERAL SPECIFICATION DIMENSION DRAWINGS

DIMENSIONS
12

Item Unit PC290LC-7 PC290NLC-7

A Overall length mm 9,790

B Overall height mm 3,210

C Overall width mm 3,190 2,990

D Track shoe width mm 700 600

E Height of cab mm 3,130

F Tail swing radius mm 2,940

G Track overall length mm 4,625

H Length of track on ground mm 3,700

Min. ground clearance mm 498

WORKING RANGES

Item Unit PC290LC-7 PC290NLC-7

A Max. digging reach mm 10,100

B Max. digging depth mm 6,460

C Max. digging height mm 10,000 10,000

D Max. vertical wall depth mm 5,650

E Max. dumping height mm 7,035

F Min. dumping height mm 3,430

G Max. reach at ground level mm 9,990

PC290-7 01-3
GENERAL SPECIFICATIONS

SPECIFICATIONS

PC290LC-7, PC290NLC-7
Machine model PC290LC-7 PC290NLC-7

Serial Number 40001 and up

Bucket capacity m³ 1.16 1.16

Operating weight kg 28,480 28,080

Max. digging depth mm 6,460 6,460

Working ranges

Max. vertical wall depth mm 5,650 5,650

Max. digging reach mm 10,100 10,100
Max. reach at ground level mm 9,990 9,990
Max. digging height mm 10,000 10,000
Max. dumping height mm 7,035 7,035

Max. digging force kN {kg} 211.8 {21,600} 211.8 {21,600}

Performance

(using power max. function) kN {kg} (226.5 {20,200}) (226.5 {20,200})

Swing speed rpm 10.5 10.5
Swing max. slope angle deg. 21 21
Travel speed km/h Lo: 3.0 ( Mi: 4.1) Lo: 3.0 ( Mi: 4.1)
Hi: 5.5 Hi: 5.5
Gradeability deg. 35 35

Ground pressure kPa {kg/cm²} 50.0 {0.51} 56.9 {0..58}

[standard shoe width] [mm] [700] [600]

Overall length (for transport) mm 9,790 9,790

Overall width mm 2,710 2,710
Overall width of track mm 3,290 2,990
Overall height (for transport) mm 3,210 3,210
Overall height to chassis mm 3,130 3,130
Dimensions

Ground clearance to bottom of upper structure mm 1,186 1,186

Min. ground clearance mm 498 498
Tail swing radius mm 2,940 2,940
Min. swing radius of work equipment mm 3,430 3,430
Height of work equipment at min. swing radius mm 8,520 8,520
Length of track on ground mm 3,700 3,700
Track gauge mm 2,390 2,390
Height of machine cab mm 3,100 3,100

01-4 PC290-7
GENERAL SPECIFICATIONS

12

Machine model PC290LC-7 PC290NLC-7

Serial Number 40001 and up

Model SAA6D102E-2
Type 4-cycle, water-cooled, in-line, vertical, direct injec-
tion, with turbo charger and aftercooler
No. of cylinders - bore x stroke mm 6 - 102 x 120
Piston displacement l {cc} 5.88 {5883}

Flywheel horsepower kW/rpm {HP/rpm} 133.4/2,050 {179/2,050}

Performance

Max. torque Nm/rpm {kgm/rpm} 721/1,500 {73.5/1,500}

Engine

Max. speed at no load rpm 2,260

Min. speed at no load rpm 1,030
Min. fuel consumption g/kWh {g/HPh} 205 {153}

Starting motor 24V, 5.5 kW

Alternator 24V, 60 A
Battery 12V, 95 Ah x 2

Radiator core type CF19-5

Carrier roller 2 on each side

Track roller 7 on each side 7 on each side

carriage
Under-

Assembly-type triple Assembly-type triple

Track shoe grouser, 45 on each grouser, 45 on each
side side
Hydraulic

Type x No. HPV95+95, variable displacement, Piston type x2

pump

Delivery l/min 267.5 x 2

Set pressure MPa (kg/cm²) 37.8 {380}
Control

Type x No. 7-spool type

valve

Control method Hydraulic

HMV160ADT-2, Piston type

Travel motor
Hydraulic

(with brake valve, parking brake): x 2

motor

KMF125ABE-5, Piston type

Hydraulic system

Swing motor
(with safety valve, holding brake): x 1
reverse rotation check valve

Type Boom Arm Bucket

Double acting Double acting Double acting

Hydraulic cylinder

piston piston piston

Inside diameter of cylinder mm 140 150 140

Diameter of piston rod mm 100 110 100
Stroke mm 1,300 1,635 1,009
Max. distance between pins mm 3,150 3,870 3,565
Min. distance between pins mm 1,850 2,235 2,075

Hydraulic tank Closed box type

Hydraulic filter Tank return side
Hydraulic cooler CFT-1 (Air cooled)

PC290-7 01-5
GENERAL WEIGHT TABLE

WEIGHT TABLE

This weight table is for use when handling components or when transporting the machine.

PC290LC-7, PC290NLC-7
Unit: kg

Machine model PC290LC-7 PC290NLC-7

Serial Number 40001 and up

Engine assembly 749 749

• Engine 598 598

• Damper 6 6

• Hydraulic pump 145 145

Radiator oil cooler assembly 119 119
Hydraulic tank, filter assembly (excluding hydraulic oil) 123 123
Fuel tank (excluding fuel) 121 121
Revolving frame 2,048 2,048
Operator’s cab 278 278
Operator’s seat 35 35
Counterweight 5,800 5,800
Swing machinery 160 160
Control valve 263 263
Swing motor 60 60
Travel motor 164 x 2 164 x 2
Center swivel joint 29.9 29.9
Track frame assembly 7,311 7,979

• Track frame 4,441 4096.79

• Swing circle 487 487

• Idler 169 x 2 169 x 2

• Idler cushion 287.5 x 2 287.5 x 2

• Carrier roller 31.3 x 4 31.3 x 4

• Track roller 52.9 x 14 52.9 x 14

• Final drive (including travel motor) 583 x 2 583 x 2

01-6 PC290-7
GENERAL WEIGHT TABLE

12

Unit: kg

Machine model PC290LC-7 PC290NLC-7

Serial Number 40001 and up

Track shoe assembly

• Standard triple grouser shoe (600 mm) 3,700 3,700

• Standard triple grouser shoe (700 mm) 4,300 4,300

• Wide triple grouser shoe (800 mm) 4,680 4,680

• Road liner (rubber pad type) (600 mm) — —

Boom assembly 1,864 1,864

Arm assembly 902 902

Bucket assembly 848 848

Boom cylinder assembly 223 x 2 223 x 2

Arm cylinder assembly 315 315

Bucket cylinder assembly 191 191

Link assembly (large) 81 81

Link assembly (small) 22 x 2 22 x 2

Boom pin 48 + 8 x 2 + 31 + 10 + 26 48 + 8 x 2 + 31 + 10 + 26

Arm pin 11 + 8 11 + 8

Bucket pin 20 x 2 20 x 2

Link pin 13 x 2 13 x 2

PC290-7 01-7
GENERAL FUEL, COOLANT, AND LUBRICANTS

FUEL, COOLANT, AND LUBRICANTS

12

KIND AMBIENT TEMPERATURE CAPACITY (l)

RESERVOIR OF -22 -4 14 32 50 68 86 104°F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40°C

SAE 30

SAE 10W
Engine oil pan 26.3 24
SAE 10W-30

SAE 15W-40

Damper case .75 —

Swing machinery case 6.6 6.6
Engine
Final drive case (each side) SAE 30 8.0 7.8
oil
Idler (1 each) 0.22 ~ 0.24 0.22 ~ 0.24

Track roller (1 each) 0.25 ~ 0.28 0.25 ~ 0.28

Carrier roller (1 each) 0.145 ~ 0.155 0.145 ~ 0.155

SAE 10W

SAE 10W-30
Hydraulic system 247 143
SAE 15W-40

Hydraulic
H046-HM (★)
oil

ASTM D975 No. 2

Diesel
Fuel tank 400 —
fuel
ASTM D975A
No.1

Cooling system Coolant Add antifreeze 31 —

★ For the H-046-HM, use the oil recommended by Komatsu.

01-8 PC290-7
 10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD

1252
Engine Related Parts . . . . . . . . . . . . . .10-2
Radiator • Oil Cooler • Aftercooler. . . . .10-3
Power Train . . . . . . . . . . . . . . . . . . . . . .10-4
Final Drive . . . . . . . . . . . . . . . . . . . . . . .10-6
Swing Machinery . . . . . . . . . . . . . . . . . .10-8
Swing Circle . . . . . . . . . . . . . . . . . . . .10-10
Track Frame • Recoil Spring . . . . . . . .10-12
Idler . . . . . . . . . . . . . . . . . . . . . . . . . . .10-14
Carrier roller . . . . . . . . . . . . . . . . . . . .10-16
Track roller . . . . . . . . . . . . . . . . . . . . .10-17
Track Shoe . . . . . . . . . . . . . . . . . . . . .10-18
Hydraulic Equipment Layout Drawing
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-22
Hydraulic tank . . . . . . . . . . . . . . . . . . .10-24
Hydraulic Pump . . . . . . . . . . . . . . . . . .10-26
Control Valve. . . . . . . . . . . . . . . . . . . .10-48
Self Pressure Reducing Valve. . . . . . .10-63
CLSS . . . . . . . . . . . . . . . . . . . . . . . . . .10-69
Swing Motor . . . . . . . . . . . . . . . . . . . .10-70
Reverse Prevention Valve. . . . . . . . . .10-75
Centre Swivel Joint . . . . . . . . . . . . . . .10-77
Travel Motor . . . . . . . . . . . . . . . . . . . .10-78
Travel Junction Valve . . . . . . . . . . . . .10-88
Travel PPC Shuttle Valve . . . . . . . . . .10-90
Valve Control. . . . . . . . . . . . . . . . . . . .10-92
Work Equipment • Swing PPC Valve .10-93
Travel PPC Valve . . . . . . . . . . . . . . . .10-97
Service PPC Valve . . . . . . . . . . . . . .10-106
Solenoid Valve . . . . . . . . . . . . . . . . .10-109
PPC Accumulator . . . . . . . . . . . . . . .10-112
Return Oil Filter . . . . . . . . . . . . . . . . .10-113
Boom Hydraulic Drift Prevention Valve . .10-
114
Lift Check Valve . . . . . . . . . . . . . . . .10-117
Attachment Circuit Selector Valve. . .10-118
Hydraulic Cylinder . . . . . . . . . . . . . . .10-120
Work Equipment . . . . . . . . . . . . . . . .10-122
Air Conditioner. . . . . . . . . . . . . . . . . .10-128
Engine Control. . . . . . . . . . . . . . . . . .10-129
Electronic Control System . . . . . . . . .10-136
Multi Monitor System. . . . . . . . . . . . .10-162
Sensor . . . . . . . . . . . . . . . . . . . . . . . .10-184

PC290-7 10-1
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE RELATED PARTS

12
ENGINE RELATED PARTS

1. Drive plate 5. Damper assembly OUTLINE

2. Torsion spring 6. Muffler
3. Stopper pin 7. Rear engine mount • The damper assembly is a wet type.
4. Friction plate 8. Front engine mount Oil capacity: 0.75 l

10-2 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD RADIATOR • OIL COOLER • AFTERCOOLER

12
RADIATOR • OIL COOLER • AFTERCOOLER

SWP08671

1. Reservoir tank SPECIFICATIONS

2. Oil cooler
3. Radiator Radiator : CF19-5
4. Fan Oil cooler : CF40-1
5. Radiator inlet hose
6. Radiator outlet hose
7. Radiator cap
8. Net
9. Shroud
10. Aftercooler

PC290-7 10-3
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD POWER TRAIN

12
POWER TRAIN

1. Idler 7. Hydraulic pump (HPV95+95)

2. Centre swivel joint 8. Travel speed solenoid valve
3. Control valve 9. Swing brake solenoid valve
4. Final drive 10. Swing machinery
5. Travel motor (HMV 160ADT-2) 11. Swing motor (KMF125ABE-5)
6. Engine (SAA6D102E-2) 12. Swing circle

10-4 PC290-7
12
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE

12
FINAL DRIVE

10-6 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD FINAL DRIVE

12

1. Level plug
2. Drain plug
3. No. 1 planetary gear (No. of teeth: 42)
4. No. 1 sun gear (No. of teeth: 11)
5. No. 2 sun gear (No. of teeth: 19)
6. No. 1 planetary carrier
7. No. 2 planetary carrier
8. Cover
9. Ring gear (No. of teeth: 97)
10. Hub
11. Sprocket
12. Floating seal
13. Travel motor
14. No. 2 planetary gear (No. of teeth: 38)

SPECIFICATIONS

Reduction ratio:

⎛ 11+ 97 ⎞ ⎛ 19 + 97 ⎞
−⎜ ⎟×⎜ ⎟ = −58.943
⎝ 11 ⎠ ⎝ 19 ⎠

Unit: mm

No. Check item Criteria Remedy

Backlash between No. 1 sun gear and No. Standard clearance Clearance limit Replace
15
1 planetary gear 0.12 ~ 0.44 0.90

Backlash between No. 1 planetary gear

16 0.18 ~ 0.62 1.20
and ring gear

Backlash between No. 2 planetary carrier

17 0.06 ~ 0.25 —
and motor

Backlash between No. 2 sun gear and No.

18 0.15 ~ 0.51 1.00
2 planetary gear

Backlash between No. 2 planetary gear

19 0.19 ~ 0.66 1.30
and ring gear

Backlash between No. 2 planetary carrier

20 0.39 ~ 0.80 1.60
and No. 2 sun gear

21 Amount of wear on sprocket tooth Repair limit: 6

Rebuild or
Standard size Repair limit
22 Width of sprocket tooth replace
87 84

PC290-7 10-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY

12
SWING MACHINERY

10-8 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MACHINERY

12

1. Swing pinion (No. of teeth: 13)

2. Spacer
3. Case
4. No. 2 planetary gear
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
11. No. 1 planetary carrier
12. No. 2 planetary carrier
13. Drain plug

SPECIFICATIONS

Reduction ratio:

⎛ 19 + 68 ⎞ ⎛ 24 + 68 ⎞
⎜ ⎟×⎜ ⎟ = 17.553
⎝ 19 ⎠ ⎝ 24 ⎠

Unit: mm

No. Check item Criteria Remedy

Backlash between swing motor shaft and No. 1 Standard clearance Clearance limit
14
sun gear 0.18 ~ 0.28 —
Backlash between No. 1 sun gear and No. 1
15 0.15 ~ 0.51 1.00
planetary gear
Backlash between No. 1 planetary gear and
16 0.17 ~ 0.60 1.10
ring gear
Backlash between No. 1 planetary carrier and
17 0.40 ~ 0.75 1.20
No. 2 sun gear
Replace
Backlash between No. 2 sun gear and No. 2
18 0.16 ~ 0.55 1.00
planetary gear
Backlash between No. 2 planetary gear and
19 0.17 ~ 0.60 1.10
ring gear
20 Backlash between coupling and swing pinion 0.08 ~ 0.25 —
Backlash between swing pinion and swing cir-
21 0.00 ~ 1.21 2.00
cle
22 Clearance between plate and coupling 0.57 ~ 1.09 —
Standard size Repair limit
Apply hard chrome
Wear of swing pinion surface contacting with
23 0 plating, recondition,
oil seal 145 — or replace
-0.100

PC290-7 10-9
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING CIRCLE

SWING CIRCLE

1. Swing circle inner race (No. of teeth: 90) SPECIFICATIONS

2. Ball
3. Swing circle outer race
90
a. Inner race soft zone S position Reduction ratio: − = −6.923
13
b. Outer race soft zone S position

Amount of grease: 33 l (G2-LI)

Unit: mm

No. Check item Criteria Remedy

Standard clearance Clearance limit

Axial clearance of bearing
4 Replace
(when mounted on chassis) 0.5 ~ 1.6 3.2

10-10 PC290-7
12
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING

TRACK FRAME • RECOIL SPRING

SWP08996

1 Idler • The dimensions and the number of track rollers depend on

2 Track frame the model, but the basic structure is not different.
3 Carrier roller • Number of track rollers
4 Final drive
5 Track roller Model Q’ty
6 Track shoe
7 Centre guard PC290LC-7 8
8 Recoil spring
9 Front guard PC290NLC-7 8

10-12 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK FRAME • RECOIL SPRING

12

Standard shoe

Model
PC290LC-7 PC290NLC-7
Item
Shoe width 700 mm 600 mm

Link pitch 216 mm 216 mm

No. on track (one side) 48 (pieces) 48 (pieces)

Unit: mm

No. Check item Criteria Remedy

Standard
Tolerance Repair limit
size
10 Vertical width of idler guide +2
Track frame 123 127
-1 Rebuild or
Idler support 120 ± 0.5 118 replace

Track frame 266 +3 271

-1
11 Horizontal width of idler guide
Idler support 261 — 259

Standard size Repair limit

Free length Installation Installation Installation

Free length
12 Recoil spring x O.D. length load load Replace

173.3 kN 138.56 kN
795 X 241 648 —
(17,680 kg) (14,140 kg)

PC290-7 10-13
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD IDLER

12

IDLER

10-14 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD IDLER

12

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

1 Outside diameter of protruding
635 —

2 Outside diameter of tread 590 578 Rebuild or

3 Width of protrusion 102 — replace

4 Total width 190 —

5 Width of tread 44 50

Standard Tolerance Standard Clearance

Clearance between shaft and size Shaft Hole clearance limit
6
bushing
-0.225 +0.130
80 0.201 ~ 0.455 1.5
-0.325 -0.024 Replace
Tolerance bushing
Standard Standard Interference
Interference between idler and size Shaft Hole interference limit
7
bushing
+0.087 -0.027
87.6 0.064 ~ 0.166 —
+0.037 -0.079

PC290-7 10-15
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CARRIER ROLLER

12

CARRIER ROLLER

SWP08998

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

1 Outside diameter of flange
175 —

2 Outside diameter of tread 148 106

3 Width of tread 50.3 —

4 Thickness of tread 32 29.5

5 Width of flange 19 —

Standard Tolerance Standard Clearance

Interference between shaft size Shaft Hole interference limit
6 Replace
and bushing
-0.250 +0.099
50 0.218 ~ 0.369 —
-0.270 -0.032

Standard Tolerance Standard Interference

Interference between roller size Shaft Hole interference limit
7
and bushing
+0.117 0
57 0.087 ~ 0.158 —
+0.087 -0.040

Standard clearance Clearance limit

8 Axial clearance of roller
0.60 - 0.80 —

10-16 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK ROLLER

12

TRACK ROLLER

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

1 Outside diameter of flange
216 —

2 Outside diameter of tread 180 168

3 Thickness of tread 44.5 38.5 Rebuild or

4 Overall width 225 — replace

5 Inside width 85 —

6 Width of tread 49 55

7 Width of flange 27 —

Standard Tolerance Standard

Clearance limit
Clearance between shaft and size Shaft Hole clearance
8
bushing
-0.250 +0.186
65 0.186 ~ 0.536 1.5
-0.350 -0.064 Replace
Tolerance bushing
Standard Standard Interference
Interference between roller size Shaft Hole interference limit
9
and bushing
+0.108 -0.006
72 0.014 ~ 0.144 —
+0.008 -0.036

PC290-7 10-17
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE

12
TRACK SHOE

SWP09000

★ P portion shows the link of bushing press fitting end.

10-18 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE

12

Unit: mm

No
Check item Criteria Remedy
.
Standard size Repair limit
1 Link pitch
216.3 219.3
Reverse
When turned
Standard size or replace
2 Bushing outside diameter Normal load Impact load

66.5 — 61.9

Standard size Repair limit Repair or

3 Link height
116 107 replace

Thickness of link metal

4 41.8
(bushing press-fitting portion)

5 178.4 Replace
6 Shoe bolt pitch 140.4

7 76.2

8 Inside width 102

Repair or
9 Link Overall width 47.8
replace
10 Tread width 42.6

11 Protrusion of pin 4.2

12 Protrusion of regular bushing 5.25

Adjust or
13 Overall length of pin 242
replace
14 Overall length of bushing 148.4

15 Thickness of bushing metal 21.9

16 Thickness of spacer —

17 Bushing 98 ~ 264.6 kN {10 ~ 27 ton}

18 Regular pin 147 ~ 362.6 kN {15 ~ 37 ton} —

Press-fitting force

Master pin 98 ~ 215.6 kN {10 ~ 22 ton}

19

: Dry type track link

PC290-7 10-19
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE

12

Unit: mm

No. Check item Criteria Remedy

Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
393 ± 39
Triple shoe 120 ± 10
{40 ± 4} Retighten
Shoe bolt
20 Tightening torque Additional tightening Lower limit torque
b. Master link (Nm {kgm}) angle (deg.) (Nm {kgm})

— — —

PC290LC-7: 48
No. of shoes (each side) —
PC290NLC-7: 48

Standard Tolerance Standard

Interference between size Shaft Hole interference
21
bushing and link
+0.464 +0.074
66.5 0.350 ~ 0.464
+0.424 0

Interference between +0.235 -0.188

22 44.6 0.273 ~ 0.485
regular pin and link +0.085 -0.250

Standard Tolerance Standard

Clearance between regular pin size Shaft Hole clearance
23
and bushing
+0.235 +0.915 Adjust or
44.6 0.180 ~ 0.830
+0.085 +0.415 replace

Standard Tolerance Standard

Interference between master pin size Shaft Hole interference
24 and bushing
+0.03 -0.188
44.6 0.188 ~ 0.280
0 -0.250

Standard Tolerance Standard

Clearance between master pin size Shaft Hole clearance
25 and bushing
+0.050 +0.915
44.3 0.365 ~ 0.965
-0.050 +0.415

Standard size Repair limit Lug welding,

Height of
Triple-grouser rebuild or
grouser 30 16 replace

: Dry type track link

10-20 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRACK SHOE

12
TRIPLE GROUSER SHOE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

1 Height
30 21

2 Thickness 11

3 29
Length of base Rebuild or replace
4 24

5 22

6 Length at tip 16

7 22

PC290-7 10-21
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD hydraulic equipment layout drawing

12
HYDRAULIC EQUIPMENT LAYOUT DRAWING
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler 2
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank
11. L.H. PPC valve
12. Safety lever (electric type)
13. Centre swivel joint
14. R.H. PPC valve
15. Travel PPC valve
16. Attachment circuit selector valve
17. Boom safety valve (Boom burst)
18. Accumulator
19. Solenoid valve assembly
19A PPC lock solenoid
19B Travel junction solenoid
19C Pump merge/divider solenoid 1

19D Travel speed solenoid

19E Swing brake solenoid
19F Machine push-up solenoid
19G 2-stage relief solenoid

10-22 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD hydraulic equipment layout drawing

12

6
5

7
4
3
8

10

11

12

13
17 18
14

15 19A

16 19B
19C 19D 19E 19G 19F 19

PC290-7 10-23
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC TANK

12
HYDRAULIC TANK

SPECIFICATIONS
Tank capacity: 200 l
Amount of oil inside tank: 143 l
1. Sight gauge Pressure valve
2. Hydraulic tank Relief cracking pressure:
3. Oil filler cap 16.7 ± 6.9 kPa
4. Filter element {0.17 ± 0.07 kg/cm²}
5. Strainer Suction cracking pressure:
6. Bypass valve 0 - 0.49 kPa
7. Suction strainer {0 - 0.005 kg/cm²}
Bypass Valve set pressure:
150 ± 30 kPa
{1.5 ± 0.3 kg/cm²}

10-24 PC290-7
12
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12
HYDRAULIC PUMP
HPV95 + 95

1. Front main pump IM : PC mode selector current PENR: Rear pump control pressure detection
2. Rear main pump ISIG : LS set selector current port
3. LS valve PAF : Front pump delivery port PLSF : Front load pressure input port
4. PC valve PFC : Front pump delivery pressure PLSFC: Front load pressure detection port
5. LS-EPC valve detection port PLSR : Rear load pressure input port
6. PC-EPC valve PAR : Rear pump delivery port PLSRC:Rear load pressure detection port
PRC : Rear pump delivery pressure PS : Pump suction port
detection port PLSC : LS set selector pressure detection
PBF : Pump pressure input port port
PD1F: Case drain port PM : PC set selector pressure detection
PENF: Front pump control pressure port
detection port PEPC : EPC basic pressure input port

Outline
• This pump consists of 2 variable capacity swash plate pis-
ton pumps, PC valve, LS valve, and EPC valve.

10-26 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

1. Shaft (Front) 7. Cylinder block

2. Cradle 8. Valve plate
3. Case (Front) 9. End cap
4. Rocker cam 10. Shaft (Rear)
5. Shoe 11. Case (Rear)
6. Piston 12. Servo piston

PC290-7 10-27
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

SWP

Function
• The rotation and torque transmitted to the pump • Rocker cam (4) has flat surface A, and shoe (5)
shaft are converted into hydraulic energy, and is always pressed against this surface while slid-
pressurized oil is discharged according to the ing in a circular movement.
load. Rocker cam (4) brings high pressure oil at cylin-
• It is possible to change the discharge amount by der surface B with cradle (2), which is secured to
changing the swash plate angle. the case, and forms a static pressure bearing
Structure when it slides.
• Cylinder block (7) is supported to shaft (1) by a • Piston (6) carries out relative movement in the
spline, and shaft (1) is supported by the front and axial direction inside each cylinder chamber of
rear bearings. cylinder block (7).
• The tip of piston (6) is a concave ball, and shoe • The cylinder block seals the pressure oil to valve
(5) is caulked to it to form one unit. Piston (6) and plate (8) and carries out relative rotation. This
shoe (5) form a spherical bearing. surface is designed so that the oil pressure bal-
ance is maintained at a suitable level. The oil
inside each cylinder chamber of cylinder block
(7) is sucked in and discharged through valve
plate (8).

10-28 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

Operation
1) Operation of pump
i Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α
between centre line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle α is called the swash plate
angle.)
ii Centre line X of rocker cam (4) maintains
swash plate angle α in relation to the axial
direction of cylinder block (7), and flat surface
A moves as a cam in relation to shoe (5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes E and F is created inside cylinder block
(7). The suction and discharge is carried out
by this difference F - E.
In other words, when cylinder block (7) rotates
and the volume of chamber E becomes
smaller, the oil is discharged during that
stroke. On the other hand, the volume of
chamber F becomes larger, and as the volume
becomes bigger, the oil is sucked in.
iii If centre line X of rocker cam (4) is in line with
the axial direction of cylinder block (7) (swash
plate angle = 0), the difference between vol-
umes E and F inside cylinder block (7)
becomes 0, so the pump does not carry out
any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)

PC290-7 10-29
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12
2) Control of discharge amount
• If the swash plate angle α becomes larger,
the difference between volumes E and F
becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement (↔) according to the signal pres-
sure from the PC and LS valves. This
straight line movement is transmitted
through rod (13) to rocker cam (4), and
rocker cam (4), which is supported by the
cylindrical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving the
pressure is different on the left and the right,
so main pump discharge pressure (self pres-
sure) PP is always brought to the chamber
receiving the pressure at the small diameter
piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the pres-
sure at the large diameter end. The relation-
ship in the size of pressure PP at the small
diameter piston end and pressure Pen at the
large diameter end, and the ratio between
the area receiving the pressure of the small
diameter piston and the large diameter pis-
ton controls the movement of servo piston
(12).

10-30 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12
LS VALVE

1. Plug PA : Pump port

2. Locknut PP : Pump port
3. Sleeve PDP : Drain port
4. Spring PLP : LS control pressure output port
5. Seat PLS : LS pressure input port
6. Spool PPL : PC control pressure input port
7. Piston PSIG : LS mode selection pilot port
8. Sleeve

PC VALVE

PA : Pump port
1. Servo piston assembly
PA2 : Pump pressure pilot port
2. Plug
PDP : Drain port
3. Pin
PM : PC mode selector pressure pilot port
4. Spool
PPL : PC control pressure output port
5. Retainer
PPL2: LS control pressure output port
6. Seat
7. Cover
8. Wiring

PC290-7 10-31
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12
Function
(1) LS valve
The LS valve detects the load and controls the
discharge amount.
This valve controls main pump discharge amount
Q according to differential pressure ΔPLS (=PP -
09141
PLS) [called the LS differential pressure] (the dif-
ference between main pump pressure PP and
control valve outlet port pressure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control valve
output, and pressure Psig {called the LS selector
pressure} from the proportional solenoid valve
enter this valve. The relationship between dis-
charge amount Q and differential pressure
ΔPLS, (the difference between main pump pres-
sure PP and LS pressure PLS) (= PP - PLS)
changes as shown in the diagram at the right
according to LS pressure selector current isig of
the LS-EPC valve.
When isig changes between 0 and 1A, the set
pressure of the spring changes according to this,
and the selector point for the pump discharge
amount changes at the rated central valve
between 0.98 ↔ 2.5 MPa {10 ↔ 25 kg/cm²}.

(2) PC valve
When the pump discharge pressure PP1 (self-
pressure) and PP2 (other pump pressure) are
high, the PC valve controls the pump so that no
more oil than the constant flow (in accordance
with the discharge pressure) flows even if the
stroke of the control valve becomes larger. In this
09142
way, it carries out equal horsepower control so
that the horsepower absorbed by the pump does
not exceed the engine horsepower.
In other words, If the load during the operation
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount from
the pump; and if the pump discharge pressure
drops, it increases the discharge amount from
the pump. The relationship between the average
of the front and rear pump discharge pressures
(average discharge amount of F, R pumps (PP1
+ PP2)/2) and pump discharge amount Q is
shown on the right, with the current given to the
PC-EPC valve solenoid shown as a parameter.
The controller senses the actual speed of the
engine, and if the speed drops because of an
increase in the load, it reduces the pump dis- the set value, the command current to the PC-
charge amount to allow the speed to recover. In EPC valve solenoid from the controller increases
other words, when the load increases and the according to the drop in the engine speed to
engine speed drops below reduce the pump swash plate angle.

10-32 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12
OPERATION

SDP08884

(1) LS valve the piston, so the swash plate is moved to the

1) When control valve is at neutral position minimum angle by the difference in the area of
• The LS valve is a three-way selector valve, with the piston (12).
pressure PLS (LS pressure) from the inlet port of
the control valve brought to spring chamber B,
and main pump discharge pressure PP brought
to port H of sleeve (8). The size of this LS pres-
sure PLS + force Z of spring (4) and the main
pump pressure (self pressure) PP determines
the position of spool (6). However, the size of the
output pressure PSIG (the LS selection pres-
sure) of the EPC valve for the LS valve entering
port G also changes the position of spool (6).
(The set pressure of the spring changes).
• Before the engine is started, servo piston (11) is
pushed to the right. (See the diagram on the
right)
• When the engine is started and the control lever
is at the neutral position, LS pressure PLS is 0
MPa {0 kg/cm²}. (It is interconnected with the
drain circuit through the control valve spool.)

At this point, spool (6) is pushed to the left,and

port C and port D are connected. Pump pressure
PP enters the large diameter end of the piston
from port K and the same pump pressure PP
also enters port J at the small diameter end of

PC290-7 10-33
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

SDP08885

2) Operation in increase direction for pump dis-

charge amount • For this reason, the pressure at the large diame-
• When the difference between the main pump ter end of servo piston (12) becomes drain pres-
pressure PP and LS pressure PLS, in other sure PT, and pump pressure PP enters port J at
words, LS differential pressure ΔPLS, becomes the small diameter end, so servo piston (12) is
smaller (for example, when the area of opening pushed to the right. Therefore, the swash plate
of the control valve becomes larger and pump moves in the direction to make the discharge
PP drops), spool (6) is pushed to the right by the amount larger. If the output pressure of the EPC
combined force of LS pressure PLS and the valve for the LS valve enters port G, this pressure
force of spring (4). creates a force to move piston (7) to the left. If
• When spool (6) moves, port D and port E are piston (7) is pushed to the left, it acts to make the
joined and connected to the PC valve. When this set pressure of spring (4) weaker, and the differ-
happens, the PC valve is connected to the drain ence between PLS and PP changes when ports
port, so circuit D - K becomes drain pressure PT. D and E of spool (6) are connected.
(The operation of the PC valve is explained
later).

10-34 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

SDP08886

3) Operation in decrease direction for pump dis- • Main pump pressure PP also enters port J at the
charge amount small diameter end of the piston, but because of
• The following explains the situation if the servo the difference in area between the large diameter
piston (12) moves to the left (the discharge end and the small diameter end of servo piston
amount becomes smaller). When LS differential (12), servo piston (12) is pushed to the left.
pressure ΔPLS becomes larger (for example, • As a result, the swash plate moves in the direc-
when the area of opening of the control valve tion to make angle smaller.
becomes smaller and pump pressure PP rises), • If LS selection pressure PSIG enters port G, it
pump pressure PP pushes spool (6) to the left. acts to make the set pressure of spring (4)
• When spool (6) moves, main port pressure PP weaker.
flows from port C and port D and from port K, it
enters the large diameter end of the piston.

PC290-7 10-35
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

SDP08887

4) When servo piston is balanced • At this point, the relationship between the area
• Let us take the area receiving the pressure at the receiving the pressure at both ends of piston (12)
large diameter end of the piston as A1, the area is A0 : A1 = 1:2, so the pressure applied to both
receiving the pressure at the small diameter end ends of the piston when it is balanced becomes
as A0, and the pressure flowing into the large PP : Pen = 2:1.
diameter end of the piston as Pen. If the main • The position where spool (6) is balanced and
pump pressure PP of the LS valve and the com- stopped is the standard centre, and the force of
bined force of force Z of spring (4) and LS pres- spring (4) is adjusted so that it is determined
sure PLS are balanced, and the relationship is when PP - PLS = 2.5 MPa {25 kg/cm²}. However,
A0 x PP = A1 x Pen, servo piston (12) will stop in if PSIG (the output pressure of 0 ↔ 2.9 MPa {0
that position, and the swash plate will be kept at ↔ 30 kg/cm²} of the EPC valve of the LS valve)
an intermediate position. (It will stop at a position is applied to port G, the balance stop position will
where the opening of the throttle from port D to change in proportion to pressure PSIG between
port E and from port C to port D of spool (6) is PP - PLS = 2.5 ↔ 0.98 MPa {25 ↔ 10 kg/cm²}.
approximately the same.)

10-36 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

09143

(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is small and • the pressure (pressure of port C) output from
pump pressures PP1 and PP2 are low the PC valve changes according to this posi-
➀ Movement of PC-EPC solenoid (1) tion.
• The command current from the pump con- • The size of command current X is deter-
troller flows to PC-EPC solenoid (1).This mined by the nature of the operation (lever
command current acts on the PC-EPC valve operation), the selection of the working
and outputs the signal pressure. When this mode, and the set value and actual value for
signal pressure is received, the force push- the engine speed.
ing piston (2) is changed.
★ Other pump pressure
• On the opposite side to the force pushing
This is the pressure of the pump at the oppo-
this piston (2) is the spring set pressure of
site end.
springs (4) and (6) and pump pressure PP1
For the F pump, it is the R pump pressure
(self pressure) and PP2 (other pump pres-
For the R pump, it is the F pump pressure
sure) pushing spool (3). Piston (2) stops at a
position where the combined force pushing
spool (3) is balanced, and

PC290-7 10-37
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

09144

➁ Action of spring • If the command circuit input to PC-EPC valve

• The spring load of springs (4) and (6) in the PC solenoid (1) changes further, the force pushing
valve is determined by the swash plate position. piston (2) changes, and the spring load of
• If piston (9) moves to the left, spring (6) is com- springs (4) and (6) also changes according to the
pressed, and if it moves further to the left, spring valve of the PC-EPC valve solenoid command
(6) contacts seat (5) and is fixed in position. In current.
other words, the spring load is changed by piston
(9) extending or compressing springs (4) and (6).

10-38 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

• Port C of the PC valve is connected to port E of

the LS valve (see (1) LS valve). Self pressure
PP1 enters port B and the small diameter end of
servo piston (9), and other pump pressure PP2
enters port A.
• When pump pressures PP1 and PP2 are small,
spool (3) is on the right. At this point, port C and
D are connected, and the pressure entering the
LS valve becomes drain pressure PT. If port E
and port G of the LS valve are connected (see
(1) LS valve), the pressure entering the large
diameter end of the piston from port J becomes
drain pressure PT, and servo piston (9) moves to
the right. In this way, the pump discharge amount
moves in the direction of increase.
• As servo piston (9) moves further, springs (4)
and (6) expand and the spring force becomes
weaker. When the spring force becomes weaker,
spool (3) moves to the left, so the connection
between port C and port D is cut, and the pump
discharge pressure ports B and C are con-
nected. As a result, the pressure at port C rises,
and the pressure at the large diameter end of the
piston also rises, so the movement of piston (9)
to the right is stopped.
• In other words, the stop position for piston (9) (=
pump discharge amount) is decided at the point
where the force of springs (4) and (6) and the
pushing force from the PC-EPC valve solenoid
and the pushing force created by the pressures
PP1 and PP2 acting on the spool (3) are in bal-
ance.

PC290-7 10-39
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

09145

b. When load on actuator is large and pump dis- • If main pump pressure PP increases further
charge pressure is high and spool (3) moves further to the left, main
• When the load is large and pump discharge pump pressure PP1 flows to port C and acts
pressures PP1 and PP2 are high, the force to make the discharge amount the minimum.
pushing spool (3) to the left becomes larger When piston (9) moves to the left, springs (4)
and spool (3) moves to the position in the and (6) are compressed and push back
diagram above. When this happens, as spool (3). When spool (3) moves to the left,
shown in the diagram above, part of the the opening of port C and port D becomes
pressurized oil from port B flows out through larger. As a result, the pressure at port C (=
port C where the LS valve is actuated to port J) drops, and piston (9) stops moving to the
D, and the pressurized oil flowing from port C left.
to the LS valve becomes approximately half • The position in which piston (9) stops when
of main pump pressure PP. this happens is further to the left than the
• When port E and port G of the LS valve are position when pump pressures PP1 and PP2
connected (see (1) LS valve), the pressure are low.
from port J enters the large diameter end of
servo piston (9), and servo piston (9) stops.

10-40 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

• The relation of average pump pressure

(PP1 + PP2)/2 and the position of servo
piston (9) forms a bent line because of the
double-spring effect of springs (4) and (6).
The relationship between average pump
pressure (PP1 + PP2)/2 and pump dis-
charge amount Q is shown in the figure at
the right.

• If command voltage X sent to PC-EPC

valve solenoid (1) increases further, the
relationship between average pump pres-
sure (PP1 + PP2)/2, and pump discharge
amount Q is proportional to the pushing
force of the PC-EPC valve solenoid and
moves in parallel. In other words, the push-
ing force of PC-EPC solenoid (1) is added
to the force pushing to the left because of
the pump pressure applied to the spool (3),
so the relationship between the average
pump pressure (PP1 + PP2)/2 and Q
moves from ➀ to ➁ in accordance with the
increase in X.

PC290-7 10-41
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

09146

2) When pump controller is abnormal and PC

prolix switch is ON • At this point, port C is connected to the drain
a. When load on main pump is light pressure of port D, and the large diameter
• If there is a failure in the pump controller, end of the piston of servo piston (9) also
turn emergency pump drive switch ON to becomes the drain pressure PT through the
switch to the resistor side. In this case, the LS valve. When this happens, the pressure
power source is taken directly from the bat- at the small diameter end of the piston is
tery. But if the current is used as it is, it is too large, so servo piston (9) moves in the direc-
large, so use the resistor to control the cur- tion to make the discharge amount larger.
rent flowing to PC-EPC valve solenoid (1).
• When this is done, the current becomes con-
stant, so the force pushing piston (2) is also
constant.
• If the main pump pressure PP1 and PP2 are
low, the combined force of the pump pres-
sure and the force of PC-EPC valve solenoid
(1) is weaker than the spring set force, so
spool (3) is balanced at a position to the left.

10-42 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

09147B

b. When main pump load is heavy and discharge amount Q is determined as

• In the same way as in the previous item, shown in the diagram for the valve of the cur-
when the emergency pump drive switch is rent sent to the PC-EPC valve solenoid
ON, the command current sent to PC-EPC through the resistor.
valve solenoid (1) becomes constant. For The curve when the PC prolix switch is ON is
this reason, the force of piston (2) pushing curve ➁, which is to the left of curve ➀ for
spool (3) is constant. when the pump controller is normal.
• If main pump pressures PP1 and PP2
increase, spool (3) moves further to the left
than when the main pump load is light, and is
balanced at the position in the diagram
above.
• In this case, the pressure from port B flows
to port C, so servo piston (9) moves to the
left (to make the discharge amount smaller)
by the same mechanism as explained in item
2)-b, and stops at a position to the left of the
position when the load on the pump is light.
In other words, even when the emergency
pump drive switch is ON, the curve for the
pump pressure PP

PC290-7 10-43
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12

LS(PC)-EPC VALVE

1. Body 5. Coil PSIG(PM) : To LS(PC) valve

2. Spool 6. Plunger PT : To tank
3. Spring 7. Connector PEPC : From self-reducing pressure valve
4. Rod

10-44 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

12O

FUNCTION

• The EPC valve consists of the proportional

solenoid portion and the hydraulic valve por-
tion.
• When it receives signal current i from the
pump controller, it generates the EPC output
pressure in proportion to the size of the signal,
and outputs it to the LS valve.

OPERATION

1. When signal current is 0 (coil de-ener-

gized)
• When there is no signal current flowing from
the controller to coil (5), coil (5) is generalized.
• For this reason, spool (2) is pushed to the
right in the direction of the arrow by spring (3).
• As a result, port PEPC closes and the pressu-
rized oil from the main pump does not flow to
the LS valve.
At the same time, the pressurized oil from the
LS valve passes from port PSIG(PM) through
port PT and is drained to the tank. 08890

SJP08890A

PC290-7 10-45
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC PUMP

2. When signal current is very small (coil

energized)
• When a very small signal current flows to coil
(5), coil (5) is energized, and a propulsion
force is generated which pushes plunger (6) to
the left.
• Push pin (4) pushes spool (2) to the left, and
pressurized oil flows from port PEPC to port
PSIG(PM).
• When the pressure at port PSIG(PM) rises
and the load of spring (3) + the force acting on
surface a of spool (2) becomes greater than
the propulsion force of plunger (6), spool (2) is 08891
pushed to the right. The circuit between port
PEPC and port PSIG(PM) is shut off, and at
the same time, port PSIG(PM) and port PT are
connected.
• As a result, spool (2) is moved up or down
until the propulsion force of plunger (6) is bal-
anced with the load of spring (3) + pressure of
port PSIG(PM).
• Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in
proportion to the size of the signal current. SJP08891A

3. When signal current is maximum (coil

energized)
• When the signal current flows to coil (5), coil
(5) is energized.
• When this happens, the signal current is at its
maximum, so the propulsion force of plunger 08892
(6) is also at its maximum.
• For this reason, spool (2) is pushed fully to the
left by push pin (4).
• As a result, the maximum flow of pressurized
oil from port PEPC flows to port PSIG(PM),
and the circuit pressure between the EPC
valve and LS valve becomes the maximum.
At the same time, port PT closes and stops
the oil from flowing to the tank.

SJP08892A

10-46 PC290-7
12
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

CONTROL VALVE

1. 6-spool valve OUTLINE

2. Cover 1
3. Cover 2 • This control valve consists of a 6-spool valve
4. Pump merge-divider valve (unit type), 1 service valves, a pump merge-
5. Back pressure valve divider valve, a back pressure valve, and a
6. Boom lock valve boom hydraulic drift prevention valve.
7. Service valve • Since all the valves are assembled together
with connecting bolts and their passes are
connected to each other inside the assembly,
the assembly is small in size and easy to
maintain.
• Since one spool of this control valve is used
for one work equipment unit, its structure is
simple.

A1 : To bucket cylinder head

A2 : To left travel motor
A3 : To boom cylinder bottom P-1 : From service PPC valve
A4 : To swing motor P-2 : From service PPC valve
A5 : To right travel motor BP1 : Boom RAISE PPC output pressure
A6 : To arm cylinder head BP5 : From attachment circuit selector solenoid
A-1 : To attachment valve
B1 : To bucket cylinder bottom PLS1: To rear pump control
B2 : To left travel motor PLS2: To front pump control
B3 : To bottom cylinder head PP1 : From rear main pump
B4 : To swing motor PP2 : From front main pump
B5 : To right travel motor PR : To solenoid valve, PPC valve, EPC valve
B6 : To arm cylinder bottom PS : From pump merge-divider solenoid valve
B-1 : To attachment PST : From travel junction valve
P1 : From bucket PPC valve PX1 : From 2-stage solenoid valve
P2 : From bucket PPC valve PX2 : From 2-stage solenoid valve
P3 : From left travel PPC valve SA : Pressure sensor fitting port
P4 : From left travel PPC valve SB : Pressure sensor fitting port
P5 : From boom PPC valve T : To tank
P6 : From boom PPC valve TS : To tank
P7 : From swing PPC valve TSW : To swing motor
P8 : From swing PPC valve
P9 : From right travel PPC valve
P10 : From right travel PPC valve
P11 : From arm PPC valve

10-48 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

12
7-spool valve
(7-spool valve + 1 service valves)

(1/9)

PC290-7 10-49
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

12

(2/9)

10-50 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE
12

(3/9)

1. Unload valve
2. Pressure compensation valve (Arm OUT)
3. Pressure compensation valve (Right travel 9. Pressure compensation valve (Service)
Reverse) 10. Pressure compensation valve (Bucket CURL)
4. Pressure compensation valve (Left swing) 11. Pressure compensation valve (Left travel for-
5. Pressure compensation valve (Boom RAISE) ward)
6. Pressure compensation valve (Left travel 12. Pressure compensation valve (Boom LOWER)
reverse) 13. Pressure compensation valve (Right swing)
7. Pressure compensation valve (Bucket DUMP) 14. Pressure compensation valve (Right travel for-
8. Pressure compensation valve (Service) ward)
15. Pressure compensation valve (Arm IN)
16. Main relief valve

PC290-7 10-51
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

12

(4/9)

1. Spool (Arm) 7. Spool (Service)

2. Spool (Right travel) 8. Unload valve
3. Spool (Swing) 9. Main relief valve
4. Spool (Boom) 10. Spool return spring
5. Spool (Left travel)
6. Spool (Bucket)
Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
11 Spool return spring side diameter length load length load
416.5 N 333.2 N If damaged or
54.2 x 34.8 51.2 —
{42.5 kg} {34 kg} deformed, replace
spring
429.9 N 336.1 N
12 Spool return spring 54.6 x 34.8 51.2 —
{43.9 kg} {34.3 kg}
393 N 314.6 N
13 Spool return spring 54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg}

10-52 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

(5/9)

1. Safety-suction valve (Arm OUT) 12. Safety-suction valve (Arm IN)

2. Suction valve (Right travel reverse) 13. LS shuttle valve (Arm)
3. Suction valve (Boom RAISE) 14. LS shuttle valve (Right travel)
4. Suction valve (Left travel reverse) 15. LS select valve
5. Safety-suction valve (Bucket DUMP) 16. LS shuttle valve (Boom)
6. Safety-suction valve (Service) 17. LS shuttle valve (Left travel)
7. Safety-suction valve (2-stage) (Service) 18. LS shuttle valve (Bucket)
8. Safety-suction valve (Bucket CURL) 19. LS shuttle valve (Service)
9. Suction valve (Left travel forward) 20. LS check valve
10. Safety-suction valve (Boom LOWER) 21. Pressure relief plug
11. Suction valve (Right travel forward)

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed If damaged or
22 Check valve spring side diameter length load length load deformed, replace
spring
1.5 N 1.2 N
11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg}

PC290-7 10-53
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

12

(6/9)

ARM CONTROL VALVE R. H. TRAVEL CONTROL VALVE

1. Unload valve 5. Safety-suction valve 12. Suction valve

2. Main relief valve 6. Spool 13. Spool
3. Safety valve (Boom 7. Pressure compensation valve 14. Pressure compensation valve
RAISE) (OUT) (Reverse)
15. LS shuttle valve
4. Lift check valve 8. LS shuttle valve
16. Pressure compensation valve (For-
9. Pressure compensation valve (IN)
ward)
10. Safety-suction valve 17. Suction valve
11. Check valve for regeneration cir-
cuit

10-54 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
18 Relief spring side diameter length load length load
430.2 N 344.2 N
34.7 x 10.4 32.3 —
{43.9 kg} {35.1 kg}
3.1 N 2.5 N
19 Valve spring 10.45 x 7 4.8 —
{0.32 kg} {0.26 kg}
70.6 N 56.4 N If damaged or
20 Unload spring 31.5 x 10.2 26.9 —
{7.2 kg} {5.8 kg} deformed, replace
spring
6.2 N 4.9 N
21 Regeneration valve spring 31.5 x 10.3 19 —
{0.6 kg} {0.5 kg}
17.5 N 14.0 N
22 Piston return spring 48.1 x 10.8 28 —
{1.8 kg} {1.4 kg}
79.4 N 63.5 N
23 Piston return spring 56.4 x 11.9 45 —
{8.1 kg} {6.5 kg}
29.4 N 23.5 N
24 Piston return spring 36.9 x 11.1 28 —
{3 kg} {2.4 kg}

PC290-7 10-55
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

(7/9)

BUCKET CONTROL VALVE SERVICE VALVE

1. Safety-suction valve 7. Safety-suction valve

2. Spool 8. Spool
3. Pressure compensation valve (DUMP) 9. Pressure compensation valve
4. LS shuttle valve 10. LS shuttle valve
5. Pressure compensation valve (CURL) 11. Pressure compensation valve
6. Safety-suction valve 12. Safety-suction valve

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
13 Piston return spring side diameter length load length load If damaged or
17.5 N 14.0 N deformed, replace
48.1 x 10.8 28 — spring
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
14 Piston return spring 36.9 x 11.1 28 —
{3 kg} {2.4 kg}

10-56 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

12

(8/9)

SWING CONTROL VALVE BOOM CONTROL VALVE L. H. TRAVEL CONTROL VALVE

1. Spool 5. Suction valve 13. Pump merge-divider valve

2. Pressure compensation valve 6. Spool (Travel junction valve)
(Left) 7. Pressure compensation valve 14. Return spring
3. LS select valve (RAISE) 15. Suction valve
4. Pressure compensation valve 8. Hydraulic drift prevention valve 16. Spool
(Right) 9. LS shuttle valve 17. Pressure compensation valve
10. Pressure compensation valve (Reverse)
(Lower) 18. LS shuttle valve
11. Safety-suction valve 19. Pressure compensation valve
12. Check valve for regeneration (Forward)
circuit 20. Suction valve

PC290-7 10-57
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
21 Regeneration valve spring side diameter length load length load
6.2 N 4.9 N
31.5 x 10.3 19 —
{0.6 kg} {0.5 kg}
17.5 N 14.0 N
22 Piston return spring 48.1 x 10.8 28 —
{1.8 kg} {1.4 kg}
29.4 N 23.5 N
23 Piston return spring 36.9 x 11.1 28 —
{3 kg} {2.4 kg} If damaged or
428.3 N 343 N deformed, replace
24 Load spring 30.4 x 16.7 27 — spring
{43.7 kg} {35.0 kg}
3.0 N 2.4 N
25 Check valve spring 13.6 x 5.5 10 —
{0.3 kg} {0.25 kg}
35.3 N 28.2 N
26 Check valve spring 33.0 x 12.0 26 —
{3.6 kg} {2.9 kg}
13.7 N 11.0 N
27 Check valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.1 kg}
50.0 N 40.0 N
28 Spool return spring 30.7 x 20.5 23 —
{5.1 kg} {4.1 kg}

10-58 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

(9/9)

1. Unload valve 9. LS bypass plug

2. Main relief valve 10. Screw
3. Pump merge-divider valve (Main) 11. Poppet
4. Return spring 12. Spring (Pressure reducing valve pilot)
5. Pump merge-divider valve (For LS) 13. Spring (Pressure reducing valve main)
6. Return spring 14. Valve (Pressure reducing valve)
7. Valve (Sequence valve) 15. Spring (Safety valve)
8. Spring (Sequence valve) 16. Ball

PC290-7 10-59
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

12
Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
17 Valve spring side diameter length load length load
3.1 N 2.5 N
10.45 x 7 4.8 —
{0.32 kg} {0.26 kg}
70.6 N 56.4 N
18 Unload spring 31.5 x 10.2 26.8 —
{7.2 kg} {5.8 kg}
1.5 N 1.2 N
19 Check valve spring 11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg} If damaged or
156.8 N 125.5 N deformed, replace
20 Spool return spring 46.6 x 21.8 3.3 — spring
{16.0 kg} {12.8 kg}
177.5 N 142.0 N
21 Spool return spring 64.5 x 32.3 63 —
{18.1 kg} {14.5 kg}
199.8 N 160.0 N
22 Sequence valve spring 70.9 x 18.0 59 —
{20.4 kg} {16.3 kg}
10.4 N 8.3 N
23 Spool return spring 29.9 x 11.0 10.7 —
{1.1 kg} {0.8 kg}
430.2 N 344.2 N
24 Relief spring 34.7 x 10.4 32.3 —
{43.9 kg) {35.1 kg}

10-60 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

Basic principle
1) Control of pump swash plate
• The pump swash plate angle (pump discharge
amount) is controlled so that LS differential
pressure ΔPLS (the difference between pump
pressure PP and control valve outlet port LS
pressure PLS) (load pressure of actuator) is
constant.
(LS pressure ΔPLS = Pump discharge pres-
sure PP – LS pressure PLS)

• If LS differential pressure ΔPLS becomes

lower than the set pressure of the LS valve
(when the actuator load pressure is high), the
pump swash plate moves towards the maxi-
mum position; if it becomes higher than the
set pressure of the LS valve (when the actua-
tor load pressure is low), the pump swash
plate moves towards the minimum position.

PC290-7 10-61
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CONTROL VALVE

• A pressure compensation valve is installed to the

outlet port side of the control valve to balance the In this way, the flow of oil from the pump is
load. divided (compensated) in proportion to the area
• When two actuators are operated together, this of opening S1 and S2 of each valve.
valve acts to make pressure difference ΔP
between the upstream (inlet port) and down-
stream (outlet port) of the spool of each valve the
same regardless of the size of the load (pres-
sure).

10-62 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

SELF PRESSURE REDUCING VALVE

FUNCTION

• This value reduces the discharge pressure of

the main pump and supplies it as control pres-
sure for the solenoid valves, PPC valves, etc.
OPERATION

1. When engine is stopped

• Poppet (11) is pressed by spring (12) against
the seat and port PR is not connected to TS.
• Valve (14) is pressed by spring (13) against
the left side and port P2 is connected to PR.
• Valve (7) is pressed by spring (8) against the
left side and port P2 is not connected to A2.

PC290-7 10-63
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

2. When in neutral or load pressure P2 is low

(When boom is lowered and arm is in IN position
and they are moving down under own weight)
Note: When load pressure A2 is lower than self-pressure
reducing valve output pressure PR.
• Valve (7) receives the force of spring (8) and PR
pressure (which is 0 MPa {0 kg/cm²} when the
engine is stopped) in the direction to close the cir-
cuit between ports P2 and A2. If the hydraulic oil
flows in port P2, the φdx P2 pressure becomes
equal to the total of the force of spring (8) and the
value of area of ∅d x PR pressure, then the area
of the pass between ports P2 and A2 is so
adjusted that the P2 pressure will be kept con-
stant above the PR pressure.
• If the PR pressure rises above the set level, pup-
pet (11) opens and the hydraulic oil flows from the
PR port through orifice "a" in spool (14) and open
part of poppet (11) to seal drain port TS.
Accordingly, differential pressure is generated
between before and after orifice "a" in spool (14)
and then spool (14) moves to close the pass
between port P2 and PR. The P2 pressure is con-
trolled constant (at the set pressure) by the area
of the oil pass at this time and supplied as the PR SXP08372B
pressure.

3. When load pressure P2 is high

• If load pressure A2 rises and the pump discharge
increases because of operation of the work
equipment, the φdx P2 pressure rises higher than
the total of the force of spring (8) and the value of
∅d x PR pressure, and then valve (7) moves to
the right stroke end.
• As a result, the area of the pass between ports
P2 and A2 increases and the pass resistance
lowers and the loss of the engine power is
reduced.
• If the PR pressure rises above the set pressure,
poppet (11) opens and the hydraulic oil flows from
the PR port through orifice "a" in spool (14) and
open part of poppet (11) to seal drain port TS.
Accordingly, differential pressure is generated
between before and after orifice "a" in spool (14)
and then spool (14) moves to close the pass
between port P2 and PR. The P2 pressure is con-
trolled constant (at the set pressure) by the area
of the oil pass at this time and supplied as the PR
pressure.

SXP08373B

10-64 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

4. When abnormally high pressure is gener-

ated
• If the PR pressure on the self-pressure reduc-
ing valve rises high abnormally, ball (16) sepa-
rates from the seat against the force of spring
(15) and the hydraulic oil flows from output
port PR to TS. Accordingly, the PR pressure
lowers. By this operation, the hydraulic
devices (PPC valves, solenoid valves, etc.)
are protected from abnormal pressure.

SXP08374B

PC290-7 10-65
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

MAIN RELIEF VALVE

1. Spring
2. Poppet

FUNCTION

• The relief valve set pressure is set to 2 stages.

When power is needed, pilot pressure P is turned ON and the pressure is set to high pressure.

OPERATION

• The relief valve set pressure is determined by the installed load of spring (1). (First stage)
• It is unnecessary to set the first and second stage individually.
The second stage is set when the first stage is set.

1. When pilot pressure P is OFF: Low-pressure setting

The set pressure is determined by the installed load of spring (1).

2. When pilot pressure P is ON: High-pressure setting

In addition to the installed load of spring (1), pilot pressure P is applied to poppet diameter d1, so the set pres-
sure becomes higher.

10-66 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

12
VARIABLE PRESSURE COMPENSATION VALVE

1. Valve Function
2. Spring • It is possible to adjust the division of the oil flow
to the service valve when the service valve (for
3. Sleeve attachment) is operated together with the main
4. Poppet control valve (boom RAISE etc.).
(Variable in proportion to surface area)
5. Spring
• The pump pressure leaving the service valve
6. Screw spool acts on the left end of valve(1), and at the
7. locknut same time passes through throttle A and enters
chamber G.
8. Plastic cap
The maximum LS pressure passes through
throttle D and enters chamber E. At the same
time, the cylinder port pressure passes through
passage C and throttle F, and goes to chamber
H.
In addition, the force of spring (2) acts on valve
(1), and the force of spring (5) acts on poppet (4).
The force of spring (5) can be adjusted with
screw(6).

PC290-7 10-67
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

12
Operation
Simultaneous operation with work equipment un-
der heavy load (boom RAISE, etc.)
1. The pump pressure and LS pressure are deter-
mined by the pressure of the other work equip-
ment, but the cylinder port pressure of the
attachment.
When the difference between the pump pres-
sure and the cylinder pressure is less than the
force of spring (5), then balance of the force act-
ing on valve (1) is as follows.
PxA1=A2++LS (A2-A1) +F
A1: Cross-sectional area of diameter D1
A2: Cross-sectional area of diameter D2
F: Force of spring

2. If the difference between pump pressure P and

the cylinder pressure becomes greater than the
force of spring (5), poppet (4) is pushed to the
right and the passage opens, so the pump pas-
sage is connected to the cylinder port through
throttle A, chamber G, and passages B and C,
and the oil flows to the cylinder port. When this
happens, a differential pressure is formed
between the upstream and downstream sides of
throttle A, and the pressure in the chamber G
goes down, so the force pushing valve (1) to the
left is reduced. In other words, the area ratio
becomes smaller, so valve (1) moves to the right
and increases the flow from the pump to the cyl-
inder.

10-68 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CLSS

12
CLSS

OUTLINE OF CLSS

FEATURES STRUCTURE

• CLSS stands for Closed centre Load Sensing • The CLSS consists of a main pump (2 pumps),
System, and has the following features. control valve, and actuators for the work equip-
ment.
1) Fine control not influenced by load • The main pump body consists of the pump itself,
2) Control enabling digging even with fine control the PC valve and LS valve.
3) Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
4) Energy saving using variable pump control

PC290-7 10-69
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR

12
SWING MOTOR
KMF125ABE-5

B : From swing lock solenoid valve SPECIFICATIONS

S : From control valve
T : To tank
MA : From control valve PC290-7
MB : From control valve
Model KMF125ABE-5

Theoretical displacement 125.0 cm³/rev

Safety valve set pressure 28.4 MPa {290 kg/cm²}

Rated revolving speed 1,694 rpm 1,879 rpm

Brake release pressure 1.9 MPa {19 kg/cm²}

10-70 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR

12

1. Brake spring 8. Housing 15. Safety valve

2. Drive shaft 9. Piston 16. Check valve
3. Spacer 10. Cylinder block 17. Check valve spring
4. Case 11. Valve plate 18. Shuttle valve
5. Disc 12. Reverse prevention valve 19. Shuttle valve spring
6. Plate 13. Centre shaft
7. Brake piston 14. Centre spring

PC290-7 10-71
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
1 Check valve spring side diameter length load length load If damaged or
3.5 N 2.8 N deformed, replace
62.5 x 20.0 35 — spring
{0.36 kg} {0.29 kg}
13.7 N 10.8 N
2 Shuttle valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.1 kg}

10-72 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR

12

Operation of swing lock

1. When swing lock solenoid valve is deactivated
When the swing lock solenoid valve is deactivated,
the pressurized oil from the main pump is shut off
and port B is connected to the tank circuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are pushed
together, and the brake is applied.

09149

2. When swing lock solenoid valve is excited

When the swing lock solenoid valve is excited, the
valve is switched and the pressure oil from the main
pump enters port B and flows to brake chamber a.
The pressure oil entering chamber a overcomes
brake spring (1) and pushes brake piston (7) up. As
a result, discs (5) and plates (6) are separated and
the brake is released.

09150

PC290-7 10-73
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SWING MOTOR

RELIEF VALVE PORTION

1) Outline
The relief portion consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief
valve (1).
2. Function
When the swing is stopped, the outlet port cir-
cuit of the motor from the control valve is
closed, but the motor continues to rotate
under inertia, so the pressure at the output
side of the motor becomes abnormally high,
and this may damage the motor.
To prevent this, the abnormally high pressure
oil is relieved to port S from the outlet port of
the motor (high-pressure side) to prevent any
damage.

3. Operation
1) When starting swing
• When the swing control lever is operated to
swing right, the pressure oil from the pump
passes through the control valve and is sup-
plied to port MA. As a result, the pressure at
port MA rises, the starting torque is generated
in the motor, and the motor starts to rotate.
The oil from the outlet port of the motor
passes from port MA through the control valve
and returns to the tank. (Fig. 1)
2) When stopping swing
• When the swing control lever is returned to
neutral, the supply of pressure oil from the
pump to port MA is stopped. With the oil from
the outlet port of the motor, the return circuit to
the tank is closed by the control valve , so the
pressure at port MB rises. As a result, rotation
resistance is generated in the motor, so the
braking effect starts.
• If the pressure at port MB becomes higher
than the pressure at port MA, it pushes shuttle
valve A (4) and chamber C becomes the
same pressure as port MB. The oil pressure
rises further until it reaches the set pressure of
relief valve (1). As a result, a high braking
torque acts on the motor and stops the motor.
(Fig.2)
• When relief valve (1) is being actuated, the
relief oil and oil from port S passes through
check valve B (3) and is supplied to port MA.
This prevents cavitation at port MA.

10-74 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE

12
REVERSE PREVENTION VALVE

Operation diagram

1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug

Explanation of effect

PC290-7 10-75
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD REVERSE PREVENTION VALVE

12

Outline
This valve reduces the swing back generation
in the swing body by the inertia of the swing
body, the backlash and rigidity of the machin-
ery system, and the compression of the
hydraulic oil when the swing is stopped. This is
effective in preventing spillage of the load and
reducing the cycle time when stopping the
swing (the positioning ability is good and it is
possible to move swiftly to the next job.

Operation
1) When brake pressure is being generated at
port MB
• Pressure MB passes through the notch and
goes to chamber d, spool (5) pushes spring
(6) according to the difference in area D1 >
D2, moves to the left, and MB is connected to
e.
When this happens, pressure MA is below the
set pressure of spring (3), so spool (2) does
not move. For this reason, the pressure oil is
closed by spool (2), and the braking force is
ensured.

2) After motor stops

• The motor is reversed by the closing pressure
generated at port MB. (1st reversal)
When this happens, reversal pressure is gen-
erated at port MA. Pressure MA goes to
chamber a, so spool (2) pushes spring (3) and
moves to the right, and MA is connected to B.
At the same time, b is connected to f through
the drill hole in spool (5), so the reversal pres-
sure at port MA is bypassed to port T to pre-
vent the 2nd reversal.

10-76 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD CENTRE SWIVEL JOINT

12
CENTRE SWIVEL JOINT

1. Cover A1. To L.H. travel motor port PB T2. To tank

2. Body A2. From control valve port A5 T1. From L.H. and R.H. travel motors port T
3. Slipper seal C1. To R.H. travel motor port PA D2. From control valve port B2
4. O-ring B2. From control valve port B5 B1. To L.H. travel motor port PA
5. Shaft D1. To R.H. travel motor port PB C2. From control valve port A2
E. To L.H. and R.H. travel motors port P
Unit: mm

No. Check Item Criteria Remedy

Clearance between rotor Standard Size Standard clearance Repair limit

6 Replace
and shaft 80 — —

PC290-7 10-77
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

TRAVEL MOTOR
HMV160ADT-2

SPECIFICATIONS
Type HMV160ADT-2

Theoretical Min. 103.5 cm³/rev

Delivery Max. 160.8 cm³/rev
Brake releasing pressure 1.2 MPa {12 kg/cm²}
Travel speed
Differential
switching pres- 0.8 MPa {8 kg/cm²}
pressure
sure

10-78 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

12

11. Plate
12. Disc
13. Regulator piston
14. Check valve spring
15. Counterbalance valve
16. Safety valve
17. Ball
18. Regulator valve
19. Spring

PC290-7 10-79
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

12
Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
20 Spool return spring side diameter length load length load
426.3 N 341 N If damaged or
58.43 x 30.0 42.0 —
{43.5 kg} {34.8 kg} deformed,
replace spring
1.27 N 1.0 N
21 Check valve spring 33.0 x 13.8 23.0 —
{0.13 kg} {0.10 kg}
398.9 N 319.5 N
22 Regulator piston spring 61.6 x 23.2 30.0 —
{40.7 kg} {32.6 kg}

10-80 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

OPERATION OF MOTOR
1) At low speed (motor swash plate angle at
maximum)

09151

SXP09151A

• The solenoid valve is deactivated, so the pilot • At the same time, the pressurized oil at regulator
pressure oil from the main pump does not flow to piston (13) passes through orifice c in regulator
port P. valve (21) and is drained to the motor case.
For this reason, regulator valve (21) is pushed to • As a result, rocker cam (3) moves in the maxi-
the right by spring (22). mum swash plate angle direction, the motor
• Because of this, it pushes slow return valve (8), capacity becomes maximum, and the system is
and the main pressure oil from the control valve set to low speed.
going to end cover (7) is shut off by regulator
valve (21).
• Fulcrum a of rocker cam (3) is eccentric to point
of force b of the combined force of the propulsion
force of cylinder (5), so the combined force of the
piston propulsion force acts as a moment to
angle rocker cam (3) in the direction of the maxi-
mum swash plate angle.

PC290-7 10-81
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

1) At high speed (motor swash plate angle at

minimum)

09152

SXP09152A

• When the solenoid valve is excited, the pilot

pressure oil from the main pump flows to port P,
and pushes regulator valve (21) to the left.
• Because of this, the main pressure oil from the
control valve passes through passage d in regu-
lator valve (21), enters regulator piston (13) at
the bottom, and pushes regulator piston (13) to
the right.
• As a result, rocker cam (3) moves in the mini-
mum swash plate angle direction, the motor
capacity becomes minimum, and the system is
set to high travel speed.

10-82 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

12

OPERATION OF PARKING BRAKE

1) When starting to travel
When the travel lever is operated, the pressu-
rized oil from the pump actuates counterbal-
ance valve spool (17), opens the circuit to the
parking brake, and flows into chamber a of the
brake piston (10).
It overcomes the force of spring (9), and
pushes piston (10) to the left in the direction of
the arrow.
When this happens, the force pushing plate
(11) and disc (12) together is lost, so plate (11) 09153
and disc (12) separate and the brake is
released.

SXP09153A

2) When stopping travel

When the travel lever is placed in neutral,
counterbalance valve spool (17) returns to the
neutral position and the circuit to the parking
brake is closed.
The pressurized oil in chamber a of brake pis-
ton (10) is drained to the case from the orifice
in the brake piston, and brake piston (10) is
pushed to the right in the direction of the arrow
by spring (9).
As a result, plate (11) and disc (12) are
pushed together, and the brake is applied. A 09154
time delay is provided by having the pressu-
rized oil pass through a throttle in slow return
valve (8) when the brake piston returns, and
this ensures that the brake is still effective
after the machine stops.

PC290-7 10-83
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

OPERATION OF BRAKE VALVE

• The brake valve consists of check valve,
counterbalance valve, and safety valve in a
circuit as shown in the diagram on the right.
(Fig. 1)
• The function and operation of each compo-
nent is as given below.

1) Counterbalance valve, check valve

Function
• When travelling downhill, the weight of the
machine makes it try to travel faster than the
speed of the motor. 09155
As a result, if the machine travels with the
engine at low speed, the motor will rotate with-
out load and the machine will run away, which
is extremely dangerous.
To prevent this these valves act to make the
machine travel according to the engine speed
(pump discharge amount).

Operation when pressure oil is supplied

• When the travel lever is operated, the pressu-
rized oil from the control valve is supplied to
port PA. It pushes open suction safety valve
(18a) and flows from motor inlet port MA to 09156
motor outlet port MB.
However, the motor outlet port is closed by
suction safety valve (18b) and spool (19), so
the pressure at the supply side rises. (Fig. 2)

• The pressurized oil at the supply side flows

from orifice E1 and E2 in spool (19) to cham-
ber S1. When the pressure in chamber S1
goes above the spool switching pressure,
spool (19) is pushed to the right in the direc-
tion of the arrow.
As a result, port MB and port PB are con-
nected, the outlet port side of the motor is 09157
opened, and the motor starts to rotate. (Fig. 3)

10-84 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

Operation of brake when travelling downhill

• If the machine tries to run away when travel-
ling downhill, the motor will turn under no load,
so the pressure at the motor inlet port will
drop, and the pressure in chamber S1 through
orifices E1 and E2 will also drop. When the
pressure in chamber S1 drops below the
spool switching pressure, spool (19) is
returned to the left, in the direction of the
arrow by spring (20), and outlet port MB is
throttled.
As a result, the pressure at the outlet port side
rises, resistance is generated to the rotation of
the motor, and this prevents the machine from
running away.
In other words, the spool moves to a position
09158
where the pressure at the outlet port MB bal-
ances the pressure at the inlet port and the
force generated by the weight of the machine.
It throttles the outlet port circuit and controls
the travel speed according to the amount of oil
discharged from the pump. (Fig. 4)
2) Safety valve (2-direction operation, 2-stage
set safety valve)
Function
• When travel is stopped (or when travelling
downhill), the circuits at the inlet and outlet
ports of the motor are closed by the counter-
balance valve. However, the motor is rotated
by inertia, so the pressure at the outlet port of
the motor will become abnormally high and
damage the motor or piping. The safety valve
acts to release this abnormal pressure and
send it to the inlet port side of the motor to
prevent damage to the equipment.
Operation in both directions
09160
1) When pressure in chamber MB has
become high (when rotating clockwise)
• When the travel is stopped (or when travelling
downhill), chamber MB in the outlet port circuit
is closed by the check valve of the counterbal-
ance valve, but the pressure at the outlet port
rises because of the inertia. (Fig. 5)
• If the pressure goes above the set pressure,
the force produced by the difference in are
between D1 and D2 [π4(D12 - D22) x pres-
sure] overcomes the force of the spring and
moves the poppet to the left, so that the oil
flows to chamber MA in the circuit on the
opposite side. (Fig. 6)

PC290-7 10-85
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

1) When pressure in chamber MA has become

high (when rotating counter clockwise)
• When the travel is stopped (or when travelling
downhill), chamber MA in the outlet port circuit is
closed by the check valve of the counterbalance
valve, but the pressure at the outlet port rises 09161
because of inertia. (Fig. 7)

• If the pressure goes above the set pressure, the

force produced by the difference in area between
D1 and D3 [π4(D32 - D12) x pressure] overcomes 09162
the force of the spring and moves the poppet to
the left, so the oil flows to chamber MB in the cir-
cuit on the opposite side. (Fig. 8)

Operation of mechanism for varying set pressure

1) When starting travel (high-pressure setting)
• When the travel lever is operated, the pressu-
rized oil from the pump actuated counterbalance
valve spool (19), and opens the pilot circuit to the
safety valve. The oil passes from chamber G to
passage H and flows into chamber J, pushes the
piston to the right, and compresses the spring to
make the set load larger. Because of this, the set
pressure of the safety valve is switched to the
high pressure setting, and a large drawbar pull is
made available.

09163

10-86 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL MOTOR

2) When stopping travel (low-pressure setting)

• When the travel lever is placed in neutral, the
pressure in chamber PA drops and counterbal-
ance valve spool (19) returns to the neutral posi-
tion. While the counterbalance valve spool is
returning to the neutral position, the pressurized
oil in chamber J passes through passage H, and
escapes to chamber PA from chamber G. The
piston moves to the left, and the set load
becomes smaller. Because of this, the set pres-
sure of the safety valve is switched to the low- 09164
pressure setting and relieves the shock when
reducing speed.

[Set pressure of safety valve]

When starting, when

When stopping: Low-
travelling: High-pres-
pressure setting
sure setting

40.2 MPa {410 kg/cm2} 27.5 MPa {280 kg/cm2}

PC290-7 10-87
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE

TRAVEL JUNCTION VALVE

Function Operation
• This valve connects both travel circuits to each other When pilot pressure is turned ON
so that the hydraulic oil will be supplied evenly to both • If the pilot pressure from the travel junction solenoid
travel motors and the machine will travel straight. valve becomes higher than the force of spring (14),
• When the machine is steered, outside pilot pressure travel junction spool (13) moves to the left stroke end
PST closes the travel junction valve to secure high and the junction circuit between port PTL (Left travel
steering performance. circuit) and PTR (Right travel circuit) is closed.

09165

10-88 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL JUNCTION VALVE

When pilot pressure is turned OFF

• If pilot pressure PST from the solenoid • If the oil flow rates in both travel motors become
valve is 0, travel junction spool (13) is different from each other, the oil flows through
pressed by the force of spring (14) the route between port PTL, travel junction
against the right side and the pass spool (13), and port PTR so that the oil flow
between ports PTL and PTR is open. rates will be equalized again.

09166

PC290-7 10-89
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE

TRAVEL PPC SHUTTLE VALVE

Function Operation
• If the boom lever is set to the "RAISE" position or 1 When travel lever is in neutral
the arm lever is set in the "IN" or "OUT" position • The oil in stroke regulation signal chamber "a" is
or the bucket lever is set in the "CURL" or drained through orifices (5) and (6) of pistons (3)
"DUMP" position while the machine is travelling and (4) in the travel spring case and the travel
up a sharp slope, the travel PPC shuttle valve PPC valve.If the boom lever is set to the "RAISE"
regulates the spool strokes of the boom, arm, position (or the arm lever is set in the "IN" or
and bucket control valves with the travel PPC "OUT" position or the bucket lever is set in the
pressure to limit the flow of the oil into the boom, "CURL" or "DUMP" position), spool (1) moves to
arm, and bucket cylinders. the left until it reaches the end of spring case (2)
• When the strokes of the boom, arm, and bucket (st0).
are regulated, the travel PPC pressure is applied
through the circuit in the control valve.

10-90 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE

2. When travel lever is operated • At this time, the right travel reverse (or forward)
• If the right travel lever is set in the reverse (or for- PPC pressure is applied through orifice (6) of
ward) direction, the right travel reverse (or for- piston (4) to the left end of piston (8) to push pis-
ward) PPC pressure pushes spool (7) to the left ton (8) to the right.
(or right). • When boom RAISE, arm IN, OUT, bucket CURL,
• Spool (7) pushes piston (3) to close orifice (5) DUMP are operated, spool (1) moves to the left,
and shut off stroke regulation signal chamber "a" but the maximum stroke of the spool is limited to
from the drain circuit of the travel PPC valve. st1, the amount of movement (st2) of piston (8).

PC290-7 10-91
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD VALVE CONTROL

VALVE CONTROL

Lever positions

1. Travel PPC valve 8. Solenoid valve (1) Hold (9) Swing "RIGHT"
2. Service PPC valve 9. Accumulator (2) Boom "RAISE" (10) Swing "LEFT"
3. Service pedal 10. Control valve (3) Boom "LOWER" (11) Neutral
4. L.H. travel lever 11. Hydraulic pump (4) Bucket "DUMP" (12) Travel "REVERSE"
5. R.H. travel lever 12. Junction box (5) Bucket "CURL" (13) Travel "FORWARD"
6. R.H. PPC valve 13. L.H. work equipment (6) Hold
7. R.H. work equipment con- control lever (7) Arm "IN"
trol lever 14. L.H. PPC valve (8) Arm "OUT"

10-92 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE

WORK EQUIPMENT • SWING PPC VALVE

P: From main pump

T: To tank

PC290-7 10-93
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE

12

1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centring spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
Centring spring
12 side diameter length load length load
(For P3 and P4)
17.6 N 13.7 N If damaged or
42.5 x 15.5 34 —
{1.8 kg} {1.4 kg} deformed,
replace spring
Centring spring 29.4 N 23.5 N
13 44.5 x 15.5 34 —
(For P3 and P4) {3.0 kg} {2.4 kg}
16.7 N 13.7 N
14 Metering spring 26.5 x 8.2 24.9 —
{1.7 kg} {1.4 kg}

10-94 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE

OPERATION
1) At neutral
Ports A and B of the control valve and ports
P1 and P2 of the PPC valve are connected to
drain chamber D through fine control hole f in
spool (1). (Fig. 1)

2) During fine control (neutral →fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is shut
off from drain chamber D, and at almost the
same time, it is connected to pump pressure
chamber PP, so pilot pressure oil from the
main pump passes through fine control hole f
and goes from port P1 to port A.
When the pressure at port P1 becomes
higher, spool (1) is pushed back and fine con-
trol hole f is shut off from pump pressure
chamber PP. At almost the same time, it is
connected to drain chamber D to release the
pressure at port P1. When this happens, spool
(1) moves up or down so that the force of
metering spring (2) is balanced with the pres-
sure at port P1. The relationship in the posi-
tion of spool (1) and body (10) (fine control
hole f is at a point midway between drain hole
D and pump pressure chamber PP) does not
change until retainer (9) contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of
the control lever, so the pressure at port P1
also rises in proportion to the travel of the con-
trol lever. In this way, the control valve spool
moves to a position where the pressure in
chamber A (the same as the pressure at port
P1) and the force of the control valve spool
return spring are balanced. (Fig. 2)

PC290-7 10-95
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE

12

3) During fine control (when control lever is

returned)
• When disc (5) starts to be returned, spool (1)
is pushed up by the force of centring spring (3)
and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure
oil at port P1 is released.
If the pressure at port P1 drops too far, spool
(1) is pushed down by metering spring (2),
and fine control hole f is shut off from drain
chamber D. At almost the same time, it is con-
nected to pump pressure chamber PP, and the
pump pressure is supplied until the pressure
at port P1 recovers to a pressure that corre-
sponds to the lever position.
When the spool of the control valve returns, oil
in drain chamber D flows in from fine control
hole f in the valve on the side that is not work-
ing. The oil passes through port P2 and enters
chamber B to fill the chamber with oil. (Fig. 3)

4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP. Therefore, the pilot pressure oil from
the main pump passes through fine control
hole f and flows to chamber A from port P1,
and pushes the control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f and flows to
drain chamber D. (Fig. 4)

10-96 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

TRAVEL PPC VALVE

P : From main pump P3 : Right reverse

T : To tank P4 : Right forward
P1 : Left reverse P5 : Travel signal
P2 : Left forward P6 : Steering signal

PC290-7 10-97
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

12

1. Plate 6. Centring spring

2. Body 7. Valve
3. Piston 8. Damper
4. Collar 9. Steering signal
5. Metering spring 10. Steering signal valve spring

10-98 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

12

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
1 Metering spring side diameter length load length load
16.7 N 13.7 N If damaged or
26.5 x 8.15 24.7 —
{1.7 kg} {1.4 kg} deformed,
replace spring
108 N 86.3 N
2 Centring spring 48.1 x 15.5 32.5 —
{11 kg} {8.8 kg}
8.8 N 7.1 N
3 Steering signal spring 12.8 x 7.3 8.5 —
{0.9 kg} {0.72 kg}

PC290-7 10-99
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

12

OPERATION
1) At neutral
Ports A and B of the control valve and ports
P1 and P2 of the PPC valve are connected to
drain chamber D through fine control hole f in
spool (1). (Fig. 1)

2) Fine control (neutral →fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2), and moves
down.
When this happens, fine control hole f is shut
off from drain chamber D. At almost the same
time, it is connected to pump pressure cham-
ber PP, and the pilot pressure of the main
pump is sent from port A through fine control
hole f to port P1.
When the pressure at port P1 rises, spool (1)
is pushed back. Fine control hole f is shut off
from pump pressure chamber PP. At almost
the same time, it is connected to drain cham-
ber D, so the pressure at port P1 escapes.
As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced
with the pressure at port P1.
The relationship of the position of spool (1)
and body (10) (fine control hole f is in the mid-
dle between drain hole D and pump pressure
chamber PP) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control lever,
so the pressure at port P1 also rises in propor-
tion to the travel of the control lever. In this
way, the spool of the control valve spool
moves to a position where the pressure of
chamber A (same as pressure at port P1) and
the force of the return spring of the control
valve spool are balanced. (Fig. 2)

10-100 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

12

3) Fine control (control lever returned)

When lever (5) starts to be returned, spool (1)
is pushed up by the force of centring spring (3)
and the pressure at port P1.
Because of this, fine control hole f is connected
to drain chamber D, and the pressurized oil at
port P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed up by metering spring (2),
so fine control hole f is shut off from drain
chamber D. At almost the same time, it is con-
nected to pump pressure chamber PP, so the
pressure at port P1 supplies the pump pres-
sure until the pressure recovers to a pressure
equivalent to the position of the lever.
When the control valve returns, oil in drain
chamber D flows in from fine control hole f of
the valve on the side that is not moving.
It passes through port P2 and goes to chamber
B to charge the oil. (Fig. 3)

4) At full stroke
Lever (5) pushes down piston (4), and retainer
(9) pushes down on spool (1). Fine control hole
f is shut off from drain chamber D, and is con-
nected to pump pressure chamber PP. There-
fore, the pilot pressure oil from the main pump
passes through fine control hole f and flows to
chamber A from port P1 to push the control
valve spool. The return oil from chamber B
passes from port P2 through fine control hole f
and flows to drain chamber D. (Fig. 4)

PC290-7 10-101
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

Any signal is not output from port P6 while the

2. Travel signal/Steering function machine is travelling straight (forward or reverse)
• Travel signal or in neutral.
If either of the travel levers is operated, the maxi- Accordingly, if the machine is being steered is
mum PPC output pressure on both sides is out- judged by the signal of port P6.
put as the travel signal. Accordingly, if the
machine is travelling is judged by the signal of Operation
port P5. 1) While in NEUTRAL
• Steering signal The signals of the output ports (P1 - P4), travel
If the operation quantities of both levers are dif- signal (Port P5), and steering signal (Port P6)
ferent from each other as in the steering opera- are not output.
tion, the higher one of the PPC output pressures
on both sides is output as the steering signal.

10-102 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

2) While travelling straight

(The following drawing shows the circuit for travelling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also
operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and right
spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal valve is kept in neu-
tral and the steering signal (Port P6) is not output.

PC290-7 10-103
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

12 In the case of the following drawing, the pressure

3) When steered or pivot-turned in left spring chamber (k) of steering signal valve
(The following drawing shows the circuit for left (j) is P2. The pressure in right spring chamber (l)
forward (slow) and right forward (fast) operation.) is P4.
If the operation quantities of both levers are dif- If (P4 - P2) x (Sectional area of spool) > Set
ferent from each other as in the steering opera- spring load, the spool is changed to the direction
tion (If the difference of the pilot pressure of the arrow and the higher one of both PPC out-
between both sides is higher than a certain put pressures (the pressure of port P4 in this
level), the pilot pressure is output as the steering drawing) is output as the steering signal to port
signal. P6.

10-104 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD TRAVEL PPC VALVE

12
4) When pivot-turned port P4 is output), only the pressure in right
(The following drawing shows the circuit for left spring chamber (l) of steering signal valve (j) is
reverse and right forward operation.) set high. Accordingly, the steering signal valve
While the left motor is operating for reverse travel moves to the left and outputs the steering signal
(the signal of port P1 is output) and the right (port P6).
motor is operating for forward travel (the signal of

PC290-7 10-105
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE

SERVICE PPC VALVE

1. Spool
2. Metering spring
3. Centring spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body

T : To tank
P : From main pump
P1 : Port
P2 : Port

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Free length x Out- Installed Installed Free Installed
9 Centring spring side diameter length load length load If damaged or
124.5 N 100 N deformed,
33.9 x 15.3 28.4 — replace spring
{12.7 kg} {10.2 kg}
16.7 N 13.7 N
10 Metering spring 22.7 x 8.1 22 —
{1.7 kg} {1.4 kg}

10-106 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE

OPERATION
At neutral
• The pressurized oil from the main pump
enters from port P and is blocked by spool (1).
• Ports A and B of the control valve and ports a
and b of the PPC valve are connected to
drain port T through fine control hole X of
spool (1).

WHEN OPERATED

• When lever (5) is moved, metering spring (2)

is pushed by piston (4) and retainer (7), and
spool (1) is pushed down by this.
• As a result, fine control portion Y is connected
with port a, and the pressurized oil from port P
flows from port a to port A of the control valve.

PC290-7 10-107
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SERVICE PPC VALVE

• When the pressure at port a becomes higher,

spool (1) is pushed back by the force acting
on the end of the spool, and fine control por-
tion Y closes.
• As a result, spool (1) moves up and down to
balance the force at port a and the force at
metering spring (2).
• Therefore, metering spring (2) is compressed
in proportion to the amount the control lever is
moved. The spring force becomes larger, so
the pressure at port a also increases in pro-
portion to the amount the control lever is
operated.
In this way, the control valve spool moves to a
position where the pressure of port A (the
same as the pressure at port a) is balanced
with the force of the return spring of the con-
trol valve spool.

10-108 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE

SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake,
merge-divider, travel junction solenoid valves

1. PPC lock solenoid valve T : To tank A6 : To main valve (2-stage relief

2. Travel junction solenoid valve A1 : To PPC valve valve)
3. Merge-divider solenoid valve A2 : To main valve (Travel junction P1 : From main pump
4. Travel speed solenoid valve valve) ACC: To accumulator
5. Swing brake solenoid valve A3 . To main valve (Merge-divider
6. 2-stage relief solenoid valve valve)
A4 : To both travel motors
A5 : To swing motor

PC290-7 10-109
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SOLENOID VALVE

12

1.Connector
2.Moving core
3.Coil
4.Spool
5.Block
6.Spring

OPERATION

WHEN SOLENOID IS TURNED OFF

• Since the signal current does not flow from the

controller, solenoid (3) is turned off.
Accordingly, spool (4) is pressed by spring (6)
against the left side.
By this operation, the pass from P to A is
closed and the hydraulic oil from the main
pump does not flow into the actuator.
At this time, the oil from the actuator is drained
through ports A and T into the tank.

WHEN SOLENOID IS TURNED ON

The signal current flows from the controller to

solenoid (3), and the latter is turned on.
Accordingly, spool (4) is pressed against to
the right side.
By this operation, the hydraulic oil from the
main pump flows through port P and spool (4)
to port A, then flows into the actuator.
At this time, port T is closed and the oil does
not flow into the tank.

10-110 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD PPC ACCUMULATOR

PPC ACCUMULATOR

1. Gas plug
2 2. Shell
3. Poppet
4. Holder
5. Bladder
3 6. Oil port

SPECIFICATIONS
4 Type of gas : Nitrogen gas
Gas capacity : 300 cc (for PPC)
Max. actuating pressure: 3.1 MPa(32 kg/cm²)
Min. actuating pressure: 1.2 MPa(12 kg/cm²)
5

SBP00290

Function
• The accumulator is installed between the PPC
control pump and the PPC valve. Even if the
engine is stopped with the work equipment
raised, pilot oil pressure is sent to the main con-
trol valve by the pressure of the nitrogen gas
compressed inside the accumulator, so it is pos-
sible to lower the work equipment under its own
weight.
Operation
• After the engine stops, when the PPC valve is at
neutral, chamber A inside the bladder is com-
pressed by oil pressure in chamber B.
• If the PPC valve is operated, the oil pressure in
chamber B becomes less than 2.9 MPa (30 kg/
cm2), so the bladder expands under the pres-
sure of the nitrogen gas in chamber A. The oil
entering chamber B is sent as the pilot pressure
to actuate the main control valve.

10-112 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD RETURN OIL FILTER

RETURN OIL FILTER

FOR BREAKER

SPECIFICATIONS

1. Drain plug Rated pressure: 6.9 MPa {70 kg/cm2}

2. Element Flow : 200 l/min.
3. Case Relief valve cracking pressure:
4. Head cover 0.34 ± 0.05 MPa
5. Relief valve {3.5 ± 0.5 kg/cm2}
Filter mesh size: 6 μm
Filtering area : 4,570 cm2

PC290-7 10-113
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION VALVE

BOOM HYDRAULIC DRIFT PREVENTION VALVE

When boom control valve is at RAISE

08900

When boom control valve is at NEUTRAL

10-114 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION VALVE

Function

• This valve prevents the oil in the boom cylinder The main hydraulic oil is shut off from the holding
bottom from leaking through spool (1) and the pressure on the boom cylinder bottom side.
boom from lowering under its weight while the • At this time, the holding pressure on the boom
boom lever is not operated. cylinder bottom side is applied toward the right to
Operation area "A" of the ring formed by the difference
between outside diameter d1 of puppet (5) and
1. When boom lever is in "RAISE" position seat diameter d2 (= Area of ∅d1 - Area of ∅d2).
If the boom lever is set in the "RAISE" position, The total of this pressure and the force of spring
the pressure of the main hydraulic oil is applied (4) closes puppet (5) to shut off the main hydrau-
toward the left to area "A" of the ring formed by lic oil from the holding pressure on the boom cyl-
the difference between outside diameter d1 of inder bottom. Accordingly, the boom is held.
puppet (5) and seat diameter d2 (= Area of ∅d1 - 3. When boom lever is in "LOWER" position
Area of ∅d2). At this time, if this pressure is If the boom lever is set in the "LOWER" position,
higher than the force of spring (4), puppet (5) pilot spool (2) is pushed by the pilot pressure
moves to the left. By this operation, the main from the PPC valve and the hydraulic oil in
hydraulic oil from the control valve flows through chamber "b" in the puppet is drained through ori-
the open part of puppet (5) to the boom cylinder fice "c".
bottom. The oil on the boom bottom side flows from ori-
2. When boom lever is in neutral fice "a" through chamber "b" and orifice "c" to the
• If the control lever is returned to the neutral posi- drain hole, and the oil pressure in chamber "b"
tion while the boom is raised, the oil in puppet (5) lowers.
which has flowed through orifice "a" is sealed by If the pressure in chamber "b" lowers below the
pilot piston (2). pressure at port B, puppet (4) opens and the
hydraulic oil from port B flows through port A to
the control valve.

PC290-7 10-115
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION VALVE

4. When abnormally high pressure is generated • If the hydraulic drift prevention valve for the arm
• If abnormally high pressure is generated in the cylinder head circuit is installed (optional), the
boom cylinder bottom circuit, the hydraulic oil in hydraulic oil in the boom cylinder bottom circuit
port B pushes check valve (6) open, then safety or that in the arm cylinder head circuit, having
valve (3) operates. higher pressure, pushes check valve (6 or 6A)
open, then safety valve (3) operates.

10-116 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD LIFT CHECK VALVE

LIFT CHECK VALVE

Function

This valve applies back pressure to the drain cir-

cuit to prevent generation of negative pressure on
the hydraulic devices for the work equipment
(motors, cylinders, etc.)

Operation

1. While engine is stopped

Any oil is not supplied from the pump to the
self-pressure reducing valve and valve (1) is
pressed by only the force of spring (2) toward
the right and drain circuit "a" of the control 09174
valve is connected through orifice "b" of valve
(1) to port T.

SXP09174A

2. While engine is running

• Output pressure PR of the self-pressure
reducing valve is applied through the control
valve to spring chamber "c" of the back pres-
sure valve.
• Output pressure PR applied to spring cham-
ber "c" is applied to the left end of valve (1)
(area of ∅d) to push valve (1) to the right.
• At this time, pressure PA of drain circuit "a" of 09175
the control valve is applied to the right end of
valve (1) (area of ∅d1) to push valve (1) to the
left.
• Valve (1) is balanced so that the back pres-
sure PA will be as follows.
PA = {(Area of ∅d) x PR + Force of spring (2)} /
(Area of ∅d1)

SXP09175A

PC290-7 10-117
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE

ATTACHMENT CIRCUIT SELECTOR VALVE

1. Spool V : To control valve

2. Spring T : To hydraulic tank
ATT: To attachment
ACC: To accumulator
P1 : From attachment circuit selector solenoid valve
TS : To hydraulic tank

Unit: mm

No. Check item Criteria Remedy

Standard size Repair limit

Replace spring if
Free length x Installed Installed Installed
Free length any damages or
3 Spool return spring Outside Dia. length load load
deformations are
833 N 666 N found
132.0 x 29 114.5 --
{85.0 Kg} {68.0 Kg}

10-118 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE

Function

When a breaker is installed, the return oil from the

breaker does not pass through the main valve, but
returns directly to the hydraulic tank. When other
attachments (crusher, etc.) are installed, the attach-
ment and the main valve are interconnected.

Operation

1. When attachment other than breaker is

installed 08901
Spool (1) is pushed fully to the left by the force of
spring (2), ATT port and port V are intercon-
nected, and ATT port and port T are shut off, so
the attachment and main valve are intercon-
nected.

2. When breaker is installed

When the pilot pressure from the attachment cir-
cuit selector solenoid valve overcomes the force
of spring (2), the spool (1) moves fully to the
right. ATT port and port V are shut off and ATT
port and port T are interconnected, so the oil 08902
returning from the breaker does not pass through
the main valve, but passes through port T and
returns directly to the hydraulic tank.

PC290-7 10-119
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CYLINDER

HYDRAULIC CYLINDER
PC290LC-7, PC290NLC-7
BOOM CYLINDER

ARM CYLINDER

BUCKET CYLINDER

10-120 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD HYDRAULIC CYLINDER

500 HOURS GREASING

Unit: mm

No. Check item Criteria Remedy

Tolerance
Standard Standard clear- Clearance
Cylinder
size Shaft Hole ance limit

-0.036 +0.257
Clearance between Boom 100 0.083 ~ 0.347 0.412
-0.090 +0.047 Replace bush-
1 piston rod and bush-
ing
ing -0.036 +0.261
Arm 110 0.083 ~ 0.351 0.412
-0.090 +0.047

-0.030 +0.257
Bucket 90 0.083 ~ 0.347 0.447
-0.076 +0.047

-0.030 +0.190
Boom 80 0.100 ~ 0.250 —
-0.060 +0.070
Clearance between
-0.030 +0.175
2 piston rod support pin Arm 80 0.105 ~ 0.251 —
-0.076 +0.075
and bushing
-0.030 +0.175
Bucket 80 0.105 ~ 0.251 —
-0.076 +0.075
Replace pin or
-0.030 +0.190 bushing
Boom 80 0.075 ~ 0.225 —
-0.060 +0.070
Clearance between
-0.036 +0.190
3 cylinder bottom sup- Arm 100 0.106 ~ 0.280 —
-0.090 +0.070
port pin and bushing
-0.030 +0.175
Bucket 80 0.105 ~ 0.251 —
-0.076 +0.075

PC290-7 10-121
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT

WORK EQUIPMENT

10-122 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD WORK EQUIPMENT

500 HOURS GREASING

Unit: mm

No. Check item Criteria Remedy

Standard Tolerance Standard clear- Clearance

Clearance between connecting pin size ance limit
Shaft Hole
1 and bushing of revolving frame and
boom -0.036 +0.168
100 0.110 ~ 0.239 1.0
-0.071 +0.079

Clearance between connecting pin -0.036 +0.166

2 90 0.110 ~ 0.237 1.0
and bushing of boom and arm -0.071 +0.074

Clearance between connecting pin -0.030 +0.158 Replace

3 70 0.108 ~ 0.178 1.0
and bushing of arm and link -0.020 +0.078

Clearance between connecting pin -0.036 +0.137

4 80 0.110 ~ 0.227 1.0
and bushing of arm and bucket -0.090 +0.074

Clearance between connecting pin -0.030 +0.166

5 80 0.1168 ~ 0.242 1.0
and bushing of link and bucket -0.076 +0.086

Clearance between connecting pin -0.036 +0.154

6 70 0.110 ~ 0.230 1.0
and bushing of link and link -0.076 +0.074

7 Bucket clearance (a) 0.5 ~ 1.0

Adjust shims
8 Bucket clearance (b) 2.0

PC290-7 10-123
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

1.DIMENSION OF ARM

10-124 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Unit: mm
Model
2000 2500 3050 3500
No.

1 80 ± 1 80 ± 1 80 ± 1 80 ± 1

2 109.3 109.3 109.3 109.3

3 310 310 310 310

4 90 ± 1 90 ± 1 90 ± 1 90 ± 1
5 465.3 ± 1 435.9± 1 429.7± 1 506.6± 1
6 200 ± 0.5 229.4± 0.5 206.1± 0.5 199.4± 0.5
7 920 ±1 968±1 918.6±1 923.3± 1
8 1993.5± 3 2489.5± 3 2997.4± 3 3493.7± 3
9 2563.2 ± 1 2554.9± 1 2562.6± 1 2553.8± 1
10 171.2± 1 465± 1 465± 1 465± 1
11 707± 0.2 707± 0.2 707± 0.2 707± 0.2
12 600 ± 0.5 600 ± 0.5 600 ± 0.5 600 ± 0.5
13 520 520 520 520
14 1562 1562 1562 1562

15 70 ± 1 70 ± 1 70 ± 1 70 ± 1
16 280 ± 0.5 280 ± 0.5 280 ± 0.5 280 ± 0.5

17 70 ± 1 70 ± 1 70 ± 1 70 ± 1

Arm as individual part 311 311 311 311

18
When pressfitting bush-
325 325 325 325
ing
Min. 2075 2075 2075 2075
19
Max. 3565 3565 3565 3565

PC290-7 10-125
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

2.DIMENSION OF BUCKET

10-126 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

Unit: mm
PC290LC-7, 290NLC-7
No.
Standard size Tolerance
1 326.5 ±1
2 10 —
3 346.5 ±1
4 35 —
5 59 —
6 105 —
7 φ140 —
8 490.5 ±1
9 60 —
10 251 —
11 520 —
+0.1
12 φ80
+0.1
13 1562 —
14 1321 —
15 270 —
16 1400 —
17 470 —
18 φ23.5 —
19 107 max —

PC290-7 10-127
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD AIR CONDITIONER

AIR CONDITIONER

AIR CONDITIONER PIPING

1. Hot water pickup piping A. Fresh air

2. Receiver tank B. Recirculated air
3. Hot water return piping C. Hot air/cold air
4. Condenser
5. Air conditioner compressor
6. Refrigerant piping
7. Air conditioner unit
8. Duct

10-128 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL

ENGINE CONTROL

transmits the drive signal to governor motor (9) to

1. Battery relay control the governor lever angle of fuel injection
2. Battery pump (8) and control the engine speed.
3. Starting switch
4. Fuel control dial
5. Linkage
6. Starting motor
7. Engine throttle and pump controller
8. Fuel injection pump
9. Governor motor

OUTLINE

• The engine can be started and stopped with only

starting switch (3).
• The engine throttle and pump controller(7)
receives the signal of fuel control dial (4) and

PC290-7 10-129
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL

12
1. OPERATION OF SYSTEM
Starting engine
• When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, and the starting motor turns
to start the engine.
When this happens, the engine throttle and
pump controller checks the signal from the 09176
fuel control dial and sets the engine speed to
the speed set by the fuel control dial.
• If the engine stop solenoid (shut-off valve) is
not driven before starting the engine, the
engine will not start.
(At the same time as the starting signal for the
starting motor is input from the controller, the
drive signal is output for 3 seconds.)

Engine speed control

• The fuel control dial sends a signal to the
engine throttle and pump controller according
to the position of the dial. The engine throttle
and pump controller calculates the angle of
the governor motor according to this signal, 09177
and sends a signal to drive the governor motor
so that it is at that angle.
When this happens, the operating angle of the
governor motor is detected by the potentiome-
ter, and feedback is sent to the engine throttle
and pump controller, so that it can observe the
operation of the governor motor.

Stopping engine
• When the engine throttle and pump controller
detects that the starting switch has been
turned to the STOP position, it drives the gov-
ernor motor so that it is set to the low idling
angle position. 09178
The engine stop solenoid signal (HOLD)
which drives directly from the ACC signal is
turned OFF and the engine stops.
• When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle and pump con-
troller itself drives the battery relay.

10-130 PC290-7
 STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL

12
1. COMPONENT
Fuel control dial

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

Function
• The fuel control dial is installed under the
monitor panel, and a potentiometer is installed
under the knob. The potentiometer shaft is
turned by turning the knob.
• As the potentiometer shaft is turned, the
resistance of the variable resistor in the poten-
tiometer changes and a throttle signal is sent
to the engine throttle and pump controller.
The hatched area in the graph shown at right
is the abnormality detection area.

PC290-7 10-131
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL

Governor motor

1. Potentiometer • A potentiometer for feedback is installed to moni-

2. Cover tor the operation of the motor.
3. Shaft • Revolution of the motor is transmitted through
4. Dust seal the gear to the potentiometer.
5. Bearing
6. Motor Operation
7. Gear While motor is stopped
8. Connector
• Electric power is applied to both phases A and B
of the motor.
Function
• The motor is turned according to the drive signal
While motor is running
from the engine throttle and pump controller to
control the governor lever of the fuel injection • The engine throttle and pump controller supplies
pump. a pulse current to phases A and B, and the motor
revolves, synchronizing to the pulse.
This motor used as the motive power source is a
stepping motor.

10-132 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL

Engine throttle and pump controller

PC290-7 10-133
12
 STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ENGINE CONTROL

Input and output signals

CN-1 CN-2 CN-3

Pin Signal name Input/ Pin Signal name Input/ Pin Signal name Input/
No. output No. output No. output
1 — 1 NC Output 1 VB (controller power) Input
2 R pump pressure sensor 2 Swing emergency switch Input 2 VIS (solenoid power) Input
3 — Input 3 NC Input 3 SOL_COM (solenoid common gnd)
4 Signal GND Input 4 232C_RxD Input 4 Battery relay drive Output
Abnormality in auto-greasing control- 5 Overload sensor (ON/OFF) Input 5 Governor motor A phase (+) Output
5 Input
ler 6 Overload alarm valid switch Input 6 LS-EPC Output
6 NC Input 7 Model selection 4 Input 7 Travel junction SOL Output
7 Overload sensor (analog) Input 8 Attachment circuit selector signal Output 8 Engine stop solenoid (Pull) Output
8 F boom pressure sensor Input 9 NC Output 9 Bucket CURL pressure SW Input
9 — 10 NC Input 10 Boom RAISE pressure SW Input
10 Signal GND Input 11 NC Output 11 VB (controller power) Input
11 Knob SW Input 12 CAN shield 12 VIS (solenoid power) Input
12 NC Input 13 Model selection 5 Input 13 SOL_COM (solenoid common gnd)
13 Governor motor FB potentiometer Input 14 232C_TxD Output 14 KEY_SIG Input
14 — 15 NC Input 15 Governor motor A phase (-) Output
15 NC Input 16 Travel steering signal pressure SW Input 16 PC-EPC Output
16 SENS_PWR Output 17 Model selection 3 Input 17 Pump merge/divider solenoid Output
17 Key Switch (Terminal C) Input 18 — 18 Heater relay drive Output
18 NC Input 19 NC Output 19 Bucket DUMP pressure switch Input
19 Throttle potentiometer Input 20 NC Input 20 Boom LOWER pressure switch Input
20 NC Input Input/ 21 GND (controller GND)
21 S_NET
21 GND (analog GND) output 22 VIS (solenoid PWR) Input
22 POT_PWR Output Input/ 23 SOL_COM (solenoid common gnd)
22 CAN0_L
23 Key switch (terminal ACC) Input output 24 KEY_SIG Input
Input/ 25 Governor motor B phase (+) Output
24 — 23 CAN1_L
output 26 Service flow adjustment EPC (1) Output
27 Travel Hi/Lo selector solenoid Output
24 —
28 2-stage relief solenoid Output
25 NC Input 29 Swing pressure switch Input
26 NC Input 30 Arm IN pressure switch Input
27 Model selection 2 Input 31 GND (controller GND)
28 NC Input 32 GND (controller GND)
29 GND (pulse GND) 33 GND (controller GND)
30 NC Input 34 NC
31 GND (S_NET GND) Input 35 Governor motor B phase (-) Output
Input/ 36 NC Output
32 CAN0_H
output 37 Swing parking brake solenoid Output
Input/ 38 NC Output
33 CAN1_H
output 39 Travel pressure switch Input
40 Arm OUT pressure switch Input
34 GND (232C GND)

35 Service valve pressure switch Input

36 NC Input
37 Model selection switch 1 Input
38 Swing lock switch Input

39 GND (pulse GND)

40 Engine speed sensor Input

PC290-7 10-135
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12
ELECTRONIC CONTROL SYSTEM

Control function 1

Engine/Pump composite control function

Pump/Valve control function

One-touch power maximizing function

Auto-deceleration function

Auto-warm-up/Overheat prevention function

Electronic control system
6

Swing control function

Travel control function

ATT flow control, circuit selector function (option)

Self-diagnosis function

★ For the self-diagnosis function, see "TROUBLE

SHOOTING".

10-136 PC290-7
 ELECTRONIC CONTROL SYSTEM
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

TOTAL SYSTEM DIAGRAM

10-138 PC290-7
 ELECTRONIC CONTROL SYSTEM
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

09179

PC290-7 10-139
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

1. Engine and Pump control function

SJP09121

OR

08908

SJP09121A

10-140 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

FUNCTION

• The operator can set the work mode switch on

the monitor panel to mode A, E, or B (or L)
and select proper engine torque and pump SJP08755
absorption torque according to the type of
work. OR
• The engine throttle and pump controller
detects the speed of the engine governor set 08909
with the fuel control dial and the actual engine
speed and controls them so that the pump will
absorb all the torque at each output point of
the engine, according to the pump absorption
torque set in each mode.
: The L mode is on the multi-monitor specification
machine only.

SJP09180

SJP08757

OR

08911

PC290-7 10-141
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

1) Control method in each mode

Mode A, Mode E
• Matching point in mode A: Rated speed

Mode A 132.4 kW/2,050 rpm {177.4 HP/2,050

(Work) rpm}

Mode A 132.4 kW/2,050 rpm {177.4 HP/2,050

(Travel) rpm}

Mode E 114 kW/1,850 rpm {152.8 HP/1,850 rpm}

• If the pump load increases and the pressure rises, the engine speed lowers.
At this time, the controller lowers the pump discharge so that the engine speed will be near the full output point.
If the pressure lowers, the controller increases the pump discharge so that the engine speed will be near the
full output point.
By repeating these operations, the controller constantly uses the engine near the full output point.

10-142 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

09181

09182

SJP08760

OR

08914

PC290-7 10-143
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

Mode B / (Mode L)

Mode Mode B Mode L

Partial output point 78% 69%

09183

103 kW/1,750 rpm

Mode B
{138 HP / 1,750 rpm}

91.9 kW/1,900 rpm

(Mode ❈L)
{126.8 HP / 1,900 rpm}

• At this time, the controller keeps the pump

absorption torque along the constant horsepower
curve and lower the engine speed by the com-
posite control of the engine and pump.
By this method, the engine is used in the low fuel 09184
consumption area.
: The L mode is on the multi-monitor specification ma-
chine only.

09185

10-144 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

2) Function to control pump during travel

• When the travel is operated in A operation, or
E or B working mode, the working mode stays
as it is, and the pump absorption torque and
engine speed rise to A travel mode.

09186

• If the machine travels in mode L, the working

mode and engine speed do not change, but
the pump absorption torque is increased.
: The L mode is on the multi-monitor specification
machine only.

3) Function to control when emergency pump

drive switch is turned ON
• Even if the controller or a sensor has a trou-
ble, the functions of the machine can be
secured with pump absorption torque almost
equivalent to mode E by turning on emer-
gency pump drive switch (10).
In this case, a constant current flows from the
battery to the EPC valve for PC and the oil
pressure is sensed by only the EPC valve for
PC.

4) Function of engine drive switch when

emergency occurs
• If there is a failure in the controller or any
problem in the chassis wiring or relays, and
the engine cannot be started because the
engine stop solenoid cannot drive, turn the
switch ON for approx. 5 seconds before the
starting signal comes ON. This makes it possi-
ble to drive the solenoid forcibly.
(However, if current flows through this sole-
noid continuously for more than 30 seconds,
there is danger that it will burn out, so cor-
rectly control the time that the current flows.)

PC290-7 10-145
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12
2. Pump/Valve control function

SJP08765

OR

08921

Function
• The machine is matched to various types of work
properly with the 2-stage relief function to
increase the digging force, etc.

10-146 PC290-7
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12

1) LS control function
• The change point (LS set differential pressure) of
the pump discharge in the LS valve is changed
by changing the output pressure from the LS-
EPC valve to the LS valve according to the oper-
ating condition of the actuator.
• By this operation, the start-up time of the pump
discharge is optimized and the composite opera-
tion and fine control performance is improved. 09187
2) Cut-off function
• When the cut-off function is turned on, the PC-
EPC current is increased to near the maximum
value.
By this operation, the flow rate in the relief state
is lowered to reduce fuel consumption.
• Operating condition for turning on cut-off function

Condition

• The average value of the front and rear pres-

sure sensors is above 27.9 MPa {285 kg/cm²}
and the one-touch power maximizing function
is not turned on

The cut-off function does not work, however, while

the machine is travelling in mode A or the arm crane
operation width swing lock switch is turned on.
1. 2-stage relief function
• The relief pressure in the normal work is 34.8
MPa {355 kg/cm²}. If the 2-stage relief function is
turned on, however, the relief pressure rises to
about 37.2 MPa {380 kg/cm²}.
By this operation, the hydraulic force is increased
further.
• Operating condition for turning on 2-stage relief
function

Condition Relief pressure

• During travel
• When swing lock switch is 34.8 MPa
turned on {355 kg/cm²}
• When boom is lowered ?
• When one-touch power maxi- 37.2 MPa
mizing function is turned on {380 kg/cm²}
• When L mode is operated

: The L mode is on the multi-monitor specifica-

tion machine only.

PC290-7 10-147
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

3. One-touch power maximizing function

09188

FUNCTION

• Power can be increased for a certain time by

operating the left knob switch.
• When the machine push-up switch is operated,
the boom pushing force is increased.

10-148 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

1) One-touch power maximizing function

• When the operator needs more digging force to
dig up a large rock, etc., if the left knob switch is
pressed, the hydraulic force is increased about
7% to increase the digging force.
• If the left knob switch is turned on in working
mode "A" or "E", each function is set automati-
cally as shown below.

?
Software cut-off function
Working Engine/Pump con- Software cut-
2-stage relief function Operation time
mode trol off function
34.8 MPa {355 kg/cm²}
Matching at rated Automatically
A, E ? Cancel
output point reset at 8.5 sec
37.2 MPa {380 kg/cm²}

PC290-7 10-149
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

4. Auto-deceleration function

SJP08767

OR

08924

FUNCTION

• If the all control levers are set in NEUTRAL while

waiting for a dump truck or work, the engine
speed is lowered to the medium level automati-
cally to reduce the fuel consumption and noise.
• If any lever is operated, the engine speed rises to
the set level instantly.

10-150 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

OPERATION

WHEN CONTROL LEVERS ARE SET IN NEUTRAL

• If all the control levers are set in NEUTRAL while

the engine speed is above the decelerator opera-
tion level (about 1,400 rpm), the engine speed
lowers instantly to the first deceleration level
about 100 rpm lower than the set speed.
• If 4 more seconds pass, the engine speed lowers
to the second deceleration level (about 1,400
rpm) and keeps at that level until any lever is
operated again.

WHEN ANY CONTROL LEVER IS OPERATED

• If any control lever is operated while the engine

speed is kept at the second deceleration level,
the engine speed rises instantly to the level set
with the fuel control dial.

PC290-7 10-151
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

5. Auto-warm-up/Overheat prevention function

SJP08768

OR

08925

FUNCTION

• After the engine is started, if the engine cooling

water temperature is low, the engine speed is
raised automatically to warm up the engine. If the
engine cooling water temperature rises too high
during work, the pump load is reduced to prevent
overheating.

10-152 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

1) Auto-warm-up function
• After the engine is started, if the engine cooling
water temperature is low, the engine speed is
raised automatically to warm up the engine.

Operating condition (All) Operated

Water temperature: Below 30°C.

Engine speed: Max. 1,200 rpm ? Engine speed: Max. 1,200 rpm

?
Resetting condition (Any one) Reset
Water temperature: Above 30°C
Auto
Auto-warm-up operation time: Min. 10 minutes ? Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec. or
Manual
longer

2) Overheat prevention function • This function is turned on when the water tem-
• If the engine cooling water temperature rises too perature rises above 95°C.
high during work, the pump load and engine
speed are reduced to prevent overheating.

Operating condition Operation/Remedy Resetting condition

Water temperature: Below 105°C
Work mode: Any mode Fuel control dial: Return to low idle
Water temperature:
Above 105°C ? Engine speed: Low idle
Monitor alarm lamp: Lights up
Alarm buzzer: Sounds
? position once.
• Under above condition, controller is
set to condition before operation of
function. (Manual reset)

Operating condition Operation/Remedy Resetting condition

Work mode: Mode A, E, OR B Water temperature: Below 102°C
Water temperature:
Above 102°C ? Engine speed: Keep as is.
Monitor alarm lamp: Lights up.
Lower pump discharge.
? • Under above condition, controller is
set to condition before operation of
function. (Automatic reset)

Operating condition Operation/Remedy Resetting condition

Water temperature: Below 100°C

? ?
Work mode: Mode A
Water temperature: • Under above condition, controller is
Engine speed: Keep as is.
Above 100°C set to condition before operation of
Lower pump discharge.
function. (Automatic reset)

Operating condition Operation/Remedy Resetting condition

Water temperature: Below 95°C

? ?
Work mode: Travel
Water temperature: • Under above condition, controller is
Engine speed: Keep as is.
Above 95°C set to condition before operation of
Lower travel speed.
function. (Automatic reset)

PC290-7 10-153
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

6. Swing control function

SJP08769

OR

08926

FUNCTION

The swing lock and swing holding brake functions

are installed.

10-154 PC290-7
 STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12
1) Swing lock and swing holding brake func-
tions
• The swing lock function (manual) is used to lock
machine from swinging at any position. The 2) Quick hydraulic oil warm-up function when
swing holding brake function (automatic) is used swing lock switch is turned on
to prevent hydraulic drift after the machine stops • If swing lock switch (4) is turned on, the pump-
swinging. cut function is cancelled and the relief pressure
• Swing lock switch and swing lock/holding brake rises from 34.8 MPa {355 kg/cm²} to 37.2 MPa
{380 kg/cm²}. If the work equipment is relieved
Lock Lock under this condition, the hydraulic oil tempera-
Function Operation ture rises quickly and the warm-up time can be
switch lamp
shortened.
If swing lever is set in neutral,
Swing swing brake operates in about 7
OFF OFF holding sec. If swing lever is operated,
brake brake is released and machine
can swing freely.

Swing lock operates and

machine is locked from swing-
Swing
ON ON ing. Even if swing lever is oper-
lock
ated, swing lock is not reset and
machine does not swing.

Operation of swing holding brake release switch

• If the controller, etc. has a problem, the swing
holding brake does not work normally, and the
machine cannot swing, the swing lock can be
reset with the swing holding brake release
switch.

Swing holding ON
OFF
brake release (When control has
(When controller is normal)
switch trouble)
Swing lock
ON OFF ON OFF
switch
Swing
Swing lock Swing lock Swing hold-
lock is
Swing brake is turned is turned ing brake is
can-
on. on. turned on.
celled.

★ Even if the swing holding brake release switch is

turned on, if the swing lock switch is turned on,
the swing brake is not released.
★ If the swing lock is reset, swinging is stopped by
only the hydraulic brake of the safety valve.
Accordingly, if swinging is stopped on a slope,
the upper structure may drift hydraulically.

PC290-7 10-155
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

7. Travel control function

SJP08770

OR

08927

FUNCTION

• The pumps are controlled and the travel speed is

changed manually or automatically, to secure
proper travel performance matched to the type of
work and jobsite during travel.

10-156 PC290-7
 STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12
1) Pump control function during travel
• If the machine travels in a work mode other than
mode A, the work mode and the engine speed
are kept as they are and the pump absorption
torque is increased.
★ For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.

1. Travel speed change function

i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo, ( Mi), and Hi, the governor/
pump controller controls the pump capacity
and motor capacity at each gear speed as
shown at right to change the travel speed.

Lo (Low ( Mi) (Mid- Hi (High

Travel speed switch
speed) dle Speed) speed)

Pump capacity (%) 86 65 100

Motor capacity Max. Max. Min.

Travel speed (km/h) 3 4.1 5.5

ii) Automatic change according to engine

speed
If the fuel control dial is used to set the
engine speed to less than 1,200 rpm:
• When travelling in Lo, it will not switch even
when set to Hi or Mi.
• When travelling in Hi or Mi, it will switch auto-
matically to Lo.
iii) Automatic changes according to pump dis-
charge pressure
When travelling with the travel speed switch
set to Hi or Mi, it the load increases, such as
when travelling uphill, and the travel pres-
sure goes above 3.23 MPa {330 kg/cm²} for
more than 0.5 sec, the travel motor capacity
will automatically change to low speed
(equivalent to Lo). (The travel speed switch
will stay at Hi or Mi.)
After continuing to travel in Lo, if the load
increases, such as when travelling on level
ground or travelling downhill, and the travel
pressure goes below 18.6 MPa {190 kg/cm²} 09189
for more than 0.5 sec, the travel motor
capacity will automatically change and will
return to Hi or Mi.
: The "Mi" mode is on the multi-monitor specification
machine only.

PC290-7 10-157
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

8. ATT flow control, circuit selector function (if

equipment)

SJP09135A

FUNCTION

This function is available only with the ATT specifica-

tion. The function acts as follows according to the
flow command and working mode from the monitor.
1) It throttles the ATT PPC pressure and controls
the flow when the pedal is depressed fully.
2) In mode B and the other modes, it switches to
ATT single acting (B) or double acting (other
modes).
: The ATT flow control adjustment function is on the
multi-monitor specification machine only.

10-158 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

9. System component parts

1) Engine revolution sensor

1. Sensor
2. Locknut
3. Wiring harness
4. Connector

FUNCTION

• The engine revolution sensor is installed to the

ring gear of the engine flywheel. It electrically
calculates the number of the gear teeth which
pass in front of it and transmits the result to the
engine throttle and pump controller.
• A magnet is used to sense the gear teeth. Each
time a gear tooth passes in front of the magnet, a
current is generated.

PC290-7 10-159
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

2) PPC oil pressure switch

1. Plug
2. Switch
3. Connector

SPECIFICATIONS

Type of contacts: Normally open contacts

Operating (ON) pressure: 0.5 ± 0.1 MPa
{5.0 ± 1.0 kg/cm²}
Resetting (OFF) Pressure: 0.3 ± 0.5 MPa
{3.0 ± 0.5 kg/cm²}

FUNCTION

• The junction block has 9 pressure switches,

which check the operating condition of each
actuator by the PPC pressure and transmit it to
the engine throttle and pump controller.

10-160 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

12

3) Pump pressure sensor

1. Sensor
2. Connector

FUNCTION

• The pump pressure sensor is installed to the inlet

circuit of the control valve. It converts the pump
discharge pressure into a voltage and transmits it
to the engine throttle and pump controller.
OPERATION

• The oil pressure applied from the pressure intake

part presses the diaphragm of the oil pressure
sensor, the diaphragm is deformed.
• The gauge layer facing the diaphragm measures
the deformation of the diaphragm by the change
of its resistance, then converts the change of the
resistance into a voltage and transmits it to the SJP08774
amplifier (voltage amplifier).
• The amplifier amplifies the received voltage and OR
transmits it to the engine throttle and pump con-
troller. 08930
• Relationship between pressure P (MPa {kg/cm²})
and output voltage (V) is as follows.
V = 0.08 [0.008] x P + 0.5

PC290-7 10-161
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

MULTI MONITOR SYSTEM

SJP08775

OR

08931

• The monitor panel also has various mode selec-

• The monitor system monitors the condition of the tor switches and functions to operate the
machine with sensors installed on various parts machine control system.
of the machine. It processes and immediately
displays the obtained information on the panel
notifying the operator of the condition of the
machine.
The panel is roughly divided as follows.
1. Monitor section to output alarms when the
machine has troubles
2. Gauge section to display the condition con-
stantly (Coolant temperature, hydraulic oil
temperature, fuel level, etc.)

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

12

1. Monitor panel

OUTLINE

• The monitor panel has the functions to display

various items and the functions to select
modes and electric parts.
The monitor panel has a CPU (Central
Processing Unit) in it to process, display, and
output the information.
The monitor display unit consists of LCD (Liq-
uid Crystal Display). The switches are flat
sheet switches.

PC290-7 10-163
 STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

Input and output signals

CN-1 CN-2 CN-3

Pin Signal name Input/ Pin Signal name Input/ Pin Signal name Input/
No. output No. output No. output
1 Key ON Input 1 Engine water temperature Input 1 NC Input
2 Key ON Input 2 Fuel level Input 2 NC Input
3 Washer motor output Output 3 Radiator water level Input 3 NC Input
4 Starting signal Input 4 (Hydraulic oil level) Input 4 NC Input
5 Limit switch (W) Input 5 Air cleaner clogging Input 5 NC Input
6 GND 6 NC Input 6 NC Input
7 GND 7 Engine oil pressure Input 7 RS230C CTS Input
8 VB + Input 8 Engine oil level Input 8 RS230C RXD Input
9 Wiper motor (+) Output Input/ Input/
9 N/W signal 9 RS230C RXD
10 Wiper motor (-) Output Output Output
11 Buzzer ON signal Input Input/ Input/
10 N/W signal 10 RS230C RXD
12 Limit switch (P) Input Output Output
11 Battery charge Input 11 BOOTSW Input
12 Hydraulic oil temperature (analog) Input 12 NC Input
13 GND (for analog signal) 13 GND
14 Buzzer drive Input 14 CAN (SHIELD) Input
15 Limit SW (window) Input 15 CAN (+) Input
16 Buzzer cancel Input 16 CAN (-) Input
17 Swing lock Input
18 Preheat Input
19 Light switch Input
20 N/W GND

10-164 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

MONITOR CONTROL, DISPLAY PORTION

MONITOR PORTION

08932

1. Wiper motor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power max. monitor
4. Engine water temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Engine oil pressure caution
6. Engine water temperature gauge 16. Battery charge caution
7. Working mode monitor 17. Radiator water level caution
8. Service monitor 18. Engine oil level caution
9. Travel speed monitor 19. Air cleaner clogging
10. Fuel gauge 20. Maintenance time warning caution

PC290-7 10-165
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

MONITOR ITEMS AND DISPLAY

Symbol Display item Display method

Swing holding brake release

Swing lock switch Swing lock monitor
switch

OFF OFF OFF

Swing lock
ON OFF ON

OFF ON Flashes

ON ON ON

Continuous set time Preheating monitor status

Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes

More than 40 sec. OFF

Power Max. switch status Power max. monitor status

Lights up but goes out after approx. 9

Power Max. Being pressed
sec. when kept pressed

Not being pressed Flashes

Engine water
temperature

Hydraulic oil See gauge display on the next page

temperature

Fuel level

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

Gauge Range Temperature, volume Indicator Buzzer sound

A1 105 Red m

A2 102 Red

Engine water temper- A3 100 Green

ature (° C) A4 80 Green

A5 60 Green

A6 30 White

B1 105 Red

B2 102 Red

Hydraulic oil tempera- B3 100 Green

ture (° C) B4 80 Green

B5 40 Green

B6 20 White

C1 417 Green

C2 347.5 Green

C3 277.5 Green
Fuel level (L)
C4 139 Green

C5 100 Green

C6 62 Red

PC290-7 10-167
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil tem-
perature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are displayed.

Check before
Symbol Display item When engine is stopped When engine is running
starting item

When abnormal, lights

Engine oil pressure l --
up and buzzer sounds

Lights up when abnor-

Battery charge l --
mal

Lights up when abnor- When abnormal, lights

Radiator water level l
mal up and buzzer sounds

Lights up when abnor-

Engine oil level l --
mal

Lights up when abnor-

Air cleaner clogging l --
mal

Lights up when there is a warning. Lights up for

Maintenance
only 30 sec. after key is turned ON, then goes out.

The problems that have occurred are displayed in order from the left.

When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is displayed.

Condition of hydraulic oil Colour of symbol

Low temperature (below B6 or equivalent) Black on white background

Normal (B6 - B2) No display

High temperature (below B2) White on red letters

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

Display category Symbol Display item Display range Display method

ON INT OFF
Displays set con-
Wiper
dition

Displays set
Working mode
mode

Monitor

Displays set
Travel speed
speed

Auto-deceler- Displays actua-

ON ⇔ OFF
ation tion status

Lights up when
Service meter
Service meter When service meter is working service meter is
indicator
working

PC290-7 10-169
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

SWITCHES

1. Working mode selector switch

2. Selector switch
3. Display brightness, contrast adjustment switch
4. Control switch
5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch

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STRUCTURE, FUNCTION, & MAINTENANCE STANDARD mULTI MONITOR SYSTEM

• Working mode selector switch

The condition of the machine changes according Switch that is Working mode status
to the switch that is pressed (A, E, L, B). It is pos- Display
pressed after setting
sible to check the condition on the working mode
monitor display. The relationship between each [A] A A mode (default)
working mode and the monitor display is shown [E] E E mode
in the table on the right.
[L] L L mode
• Selector switch [B] B B mode
This is used when making detailed settings in
each working mode. (For details, see ATTACH-
MENT FLOW CONTROL FUNCTION for modes
A and E.)

• Maintenance switch
Check the condition of the maintenance items.
(For details, see MAINTENANCE FUNCTION.)

• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically set
to ON.

• Travel speed selector switch

Each time the travel speed selector switch is
pressed, the travel speed changes. Display Setting
Lo →Mi →Hi →Lo. . . . . .
Crawler symbol + Lo Low speed (default)
Use the travel speed monitor display to check
the present condition. Crawler symbol + Mi Medium speed
The relationship between the set speed and the
Crawler symbol + Hi High speed
monitor display in the table on the right.

• Wiper switch
Each time the wiper switch is pressed, the wiper
setting changes OFF →INT →ON →OFF →. . . .
..
Wiper actuation
Use the wiper monitor display to check the Display Setting
status
present condition.
The relationship between the wiper setting and Stowing stopped
None OFF
or now stowing
the monitor display is as shown in the table on
the right. Intermittent actua-
Wiper symbol + INT INT
tion

Continuous actua-
Wiper symbol + ON ON
tion

PC290-7 10-171
 MULTI MONITOR SYSTEM
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD

• Window washer switch

While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.

• Control switch
This is used for control when using the mainte-
nance function or select function.
(For details, see each function.)

• Display brightness, contrast adjustment switch

Use this switch when adjusting the display bright-
ness and contrast.
(For details, see each function.)

10-172 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

SELECT MODE FUNCTION

• This is used when setting the flow in each work-

ing mode. It is possible to make the setting when
genuine attachment piping is installed and the
initial value setting function on the service menu
has been used to set to ATTACHMENT
INSTALLED.
• It is possible to check on the working mode mon-
itor if this function can be set.

Working mode Monitor display

A mode [A] + crusher symbol

E mode [E] + crusher symbol

B mode [B] + flow symbol

METHOD OF USE

★ Carry out the setting on the normal screen

1. A mode, E mode
1) Press select switch (1) on the monitor to
move to the adjustment screen.
2) Press control switch (2) to select the flow
level.

Control switch Actuation

Flow level bar graph

extends to the right

Flow level bar graph

retracts to the left

3) After completing the level selection, press

input confirmation switch (3).
Flow level Flow (L/min.) Remarks
The selection flow level is confirmed and the
screen moves to the normal screen. 8 430 h Default
From the moment that the flow level is
selected, the content of the selection is 7 350
reflected for the attachment flow. 6 250
★ Before the input confirmation switch is
pressed, the flow level is not confirmed, 5 170
so press return switch (4) to return to the 4 140
normal screen. This function can be
used to return to the previously set flow. 3 115
The relationship between the set flow 2 90
level and the flow value is as shown in
the table on the right. 1 30

PC290-7 10-173
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

2. B mode
1) Press select switch (1) on the monitor to
move to the screen for selecting the 3-stage
flow level.
2) Press control switch (2), or input [01] - [03]
with the numeral 10-key pad to choose one
on the three flow levels.

No. 10-key pad operation

01

02

03

3) After completing the level selection, press

input confirmation switch (3).
The selected flow level is selected.
★ Before the input confirmation switch is
pressed, the flow level is not confirmed,
so press return switch (4) to return to the
No. Flow level (L/min.) Remarks
operator screen. This function can be
used to return to the previously set flow. 01 180 h Default
4) After the flow level is confirmed, the screen 02 140
changes to the screen shown in the diagram
on the right. 03 100
With this screen, it is possible to make fine
adjustment to the flow.
5) Press control switch (2) and select the flow
level.

Control switch Actuation

Flow level bar graph

extends to the right

Flow level bar graph

retracts to the left

10-174 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

6) After completing the level selection, press

input confirmation switch (3). When When When
Flow flow is flow is flow is
The selected flow level is confirmed and the Remarks
level 100 l/ 140 l/ 180 l/
screen moves to the operator screen.
min. min. min.
From the moment that the flow level is
selected, the content of the selection is 7 130 170 210
reflected for the attachment flow.
6 120 160 200
★ Before the input confirmation switch is
pressed, the flow level is not confirmed, 5 110 150 190
se press return switch (4) to return to the
4 100 140 180 h Default
normal screen. This function can be
used to return to the previously set flow. 3 90 130 170
The relationship between the set flow
2 80 120 160
level and the flow value is as shown in
the table on the right. 1 70 110 150
7) Check the set value with the working mode
monitor.
The relationship between the display level
Display level Set value (l/min.)
and the set value is as shown in the table on
the right, and it is possible to check the level 8 200 or 210
of the flow that can be set.
7 180 or 190

6 160 or 170

5 140 or 150

4 120 or 130

3 100 or 110

2 80 or 90

1 70

PC290-7 10-175
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

MAINTENANCE FUNCTION

When the maintenance time for replacement, inspec-

tion, or filling has approached for the 10 maintenance
items, press maintenance switch (1) and the caution
display (yellow or red) appears on the monitor dis-
play for 30 seconds after the key is turned ON to
remind the operator to carry out lubrication mainte-
nance.

★ Maintenance items

Replacement
No. Item
interval (hours)

01 Engine oil 500

02 Engine oil filter 500

03 Fuel filter 500

04 Hydraulic filter 1000

05 Hydraulic tank breather 500

06 Corrosion resistor h (1000)

07 Damper case oil 1000

08 Final case oil 2000

09 Machinery case oil 1000

10 Hydraulic oil 5000

❈ Option, so not set

★ The above replacement intervals are set for each

item, and the time remaining to maintenance is
reduced as the machine is operated.
The content of the caution display differs accord-
ing to the remaining time. The relationship is as
shown in the table below.

Display Condition

Remaining time for main-

None tenance for all items is
more than 30 hours

There is one or more

Notice display (black sym-
items with less than 30
bol displayed on yellow
hours remaining time for
background)
maintenance

There is one or more

Warning display (wiper
items with less than 0
symbol displayed on red
hours remaining time for
background)
maintenance

10-176 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

METHOD OF CHECKING STATUS

MAINTENANCE ITEMS

★ Operate as follows when on the operator screen.

1. Press maintenance switch (1) and switch to the
maintenance list display screen.
★ The maintenance items are displayed as
symbols on the screen.
2. Press control switch (2), or use the 10-key pad to
input the number (01 - 10) of the maintenance
item to select the item.
★ The cursor moves and the item is high-
lighted.
★ The display method is the same as
described on the previous page (relationship
between remaining time and caution dis-
play). If the remaining time is less than 30
hours, the item is displayed in yellow, and if it
is less than 0 hours, it is displayed in red.

MAINTENANCE OPERATION

1. After completing the selection, press input confir-

mation switch (3).
The screen will change to the maintenance reset
screen.
2. Use the maintenance reset screen to check the
content, and if there is any problem, press input
confirmation switch (3) to move to the check
screen.
If the wrong item is selected, press return switch
(4) to return to the maintenance list screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen returns
to the maintenance list display screen. To check
the remaining time, or if the wrong item is
selected, press return switch (4) to return to the
maintenance list screen.
★ The check screen shows the symbol for the
maintenance item and the set time in large
letters.
★ The background colour of the symbol for the
item where the maintenance item was reset
is the same as the background of the screen,
so it is possible to check that it has been
reset.

PC290-7 10-177
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

BRIGHTNESS, CONTRAST ADJUSTMENT FUNC-

TION

This function is used to adjust the brightness and

contrast of the display.

ADJUSTMENT METHOD

★ Operate as follows when on the operator screen.

1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment screen.
★ Relationship between menu symbol and content.

No. Symbol Content

01 Return mark Return

02 Contrast

03 Brightness

2. Press control switch (2), or use the 10-key pad to

input the number (00 - 02) to select either con-
trast or brightness.
After completing the selection, press input confir-
mation switch (3) and return to the adjustment
screen.
Then press return switch (4) or use the 10-key
pas to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.

Control switch Actuation

Flow level bar graph

extends to the right

Flow level bar graph

retracts to the left
08937

10-178 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

PASSWORD FUNCTION

• If a passport is input, the engine will not start

unless the password is input correctly when
starting.
• When setting this function or when changing the
password, it is necessary to go from the normal 08941
screen to the setting screen and input the pass-
word.
This becomes possible 10 minutes after the
starting switch is turned ON and the monitor
screen has changed to the normal screen.

METHOD OF SETTING, CHANGING PASSWORD

1. Turn the starting switch ON, keep starting switch

(2) pressed, use the 10-key pad to input 7 →2 →
9 →7 →2 →9 in succession, and the screen will
change to the 8-digit numeral input screen.

2. On the input screen, use the 10-key pad to input

an 8-digit number [19210513]. When the final
digit [number 3] is input, the screen will change
to the Valid/Invalid screen for the password func-
tion.

PC290-7 10-179
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

3. Press control switch (1) or (2) to set to Valid/

Invalid.
The diagram on the right shows the screen when
control switch (1) is pressed and the screen is
set to [Valid].

If [Invalid] is selected and input confirmation

switch (3) is pressed, the password function will
be made invalid, and the screen will return to the
normal screen.
If [Valid] is selected and input confirmation switch
(3) is pressed, the password function will be
made valid, and the screen will change to the
screen for inputting the 4-digit number.

08942

4. Input a 4-digit number on the input screen (the

lock and key symbol are displayed), then press
input confirmation switch (3).
When the input confirmation switch is pressed,
you will be requested to input the same 4-digit
number again, so input the same 4-digit number,
then press input confirmation switch (3) to con-
firm the password.
Numerals 1 and 2 are displayed at the top right
corner of the screen to distinguish between the
1st input screen and the 2nd input screen.
When the password is confirmed, the screen will
return to the normal screen.
★ If the number input the second time is differ-
ent from the number input the first time, the
password will not be confirmed and the
screen will return to the first screen, so input
the same 4-digit password 2 times in succes-
sion.

10-180 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

SERVICE METER CHECK FUNCTION

• When the starting switch is at the OFF position,

keep return switch (1) and control switch (2) of
the monitor pressed at the same time, and the
service meter is shown on the display.
• This display is shown only while the two switches
are being pressed. When the switches are
released, the display goes out.
Note that it takes 3 - 5 seconds after the switches
are pressed for the service meter display to
appear.

DISPLAY LCD CHECK FUNCTION

• On the password input screen or on the normal

screen, if monitor return switch (1) and working
mode (A) switch are kept pressed at the same
time, all the LCD display will light up and the 08943
whole screen will become white, so the display
can be checked.
• If any part of the display is black, the LCD is bro-
ken.

PC290-7 10-181
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

USER CODE DISPLAY FUNCTION

• If there is any problem in operating the machine,

the user code is displayed on the monitor to
advise the operator of the steps to take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis- 08945
played on the portion for the hydraulic oil temper-
ature gauge.

• If more than one user code is generated at the

same time, the user codes are displayed in turn
for 2 seconds each to display all the user codes.

• While the user code is being displayed, if the

input confirmation switch is pressed, the service
code and failure code can be displayed.

10-182 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD MULTI MONITOR SYSTEM

• If there is more than one service code or failure

code, the display switches every 2 seconds and
displays all the service codes/failure codes that
caused the user code to be displayed.
Even if service codes/failure codes have 08946
occurred, if they did not cause the user code to
be displayed, this function does not display them.

• If the telephone number has been set using the

telephone number input on the service menu, it
is possible to switch on the service code/failure
code and display the telephone symbol and tele-
phone number.
For details of inputting and setting the telephone
number, see SPECIAL FUNCTIONS OF MONI- 08947
TOR PANEL in the TESTING AND ADJUSTING
section.

08948

PC290-7 10-183
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR

SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of contact
type is always connected to the chassis ground.

Sensor When When

Type of sensor
name normal abnormal

Engine oil ON OFF

Contact
level (Closed) (Open)

Engine oil OFF ON

Contact
pressure (Open) (Closed)

Hydraulic oil
Resistance — —
temperature

Coolant tem-
Resistance — —
perature

Fuel level Resistance — —

Air cleaner OFF ON

Contact
clogging (Closed) (Open)

10-184 PC290-7
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR

12

Engine oil level sensor

1. Connector
2. Bracket
3. Float
4. Switch

Engine oil pressure sensor (For low pressure)

1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal

Coolant temperature sensor

Hydraulic oil temperature sensor

1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector

PC290-7 10-185
STRUCTURE, FUNCTION, & MAINTENANCE STANDARD SENSOR

12

Fuel level sensor

1. Float
2. Connector
3. Cover
4. Variable resistor

Air cleaner clogging sensor

10-186 PC290-7
 20 TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ................................................................. 20- 2

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS................................................................. 20- 3
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING ................................................................................................................................ 20-201

★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.

1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.

• When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
• When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
• When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
• Be careful not to get caught in the fan, fan belt or other rotating parts.

PC290-7 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Engine SAA6D102E-2

Standard value Service limit

Item Measurement condition Unit
for new machine value

High idling 2,250±70 2,250±70

Engine speed Low idling rpm 1000±50 1000±50

Rated speed 2,100 2,100

Intake air pressure kPa Min 146 133

At rated output
(boost pressure) {mmHg.} {Min 1,100} {Max. 1,000}

At sudden acceleration Bosch Max. 1.0 Max. 2.0

Exhaust gas color
At high idling index Max. 0.5 Max. 1.5

Valve clearance Intake valve 0.25 —

mm
(Normal temperature) Exhaust valve 0.51 —

Difference
between cyinders
Oil temperature: 40–60ºC MPa Min. 2.4
Compression pressure Min. 1.0
Engine speed: 250–300rpm {kg/cm2} {Min. 24.6}
{Min. 10.3}

(Water temperature: operating range) kPa Max. 1.2 5.1

Blow-by pressure
At rated output {mmH2O} {Max. 123} {520}

(Water temperature: operating range)

At high idling 0.36–0.64 0.25
Oil pressure MPa
{4.0–6.5} {2.6}
(SAE15W-40) {kg/cm2}
At low idling Min. 0.15 0.09
{Min. 1.5} {0.9}

Oil temperature Whole speed range (inside oil pan) °C 80–110 120

Fuel injection timing Before Top Dead Center °(degree) 11.5 11.5

Deflection when pressed with finger

Fan belt tension mm 8 Min. 6, Max. 10
force of approx. 58.8 N{6 kg}

Air conditioner Deflection when pressed with finger

mm 5–8 5–8
compressor belt tension force of approx. 63.7 N{6.5 kg}

20-2 PC290-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
• Engine water temperature:
Within operation range
• Hydraulic oil temperature: Within
2 pumps at relief 2,100±100 2,100±100
operation range
• Engine at high idling
• Arm in relief condition
• Engine water temperature:
Engine speed

Within operation range

• Hydraulic oil temperature: Within
At 2-pump relief + one rpm
operation range 2,000±100 2,000±100
touch power up
• Engine at high idling
• Arm relief + One-touch power
max. switch in ON condition
• Engine at high idling
• Auto-deceleration switch in ON
Speed when auto-
condition 1,400±100 1,400±100
deceleration is operated
• All control levers in NEUTRAL
condition
Boom control valve
Spool stroke

Arm control valve

Bucket control valve mm 9.5±0.5 9.5±0.5
Swing control valve
Travel control valve
Boom control lever 85±10 85±10
Travel of control

Arm control lever • Engine stopped 85±10 85±10

Bucket control lever • At center of control lever grip 85±10 85±10
levers

• Max. reading up to stroke end mm

Swing control lever (excepting lever play in NEU- 85±10 85±10
Travel control lever TRAL position) 115±12 115±12
Play of control lever Max. 10 Max. 15
15.7±3.9 Max. 24.5
Boom control lever
{1.6±0.4} {Max. 2.5}
15.7±3.9 Max. 24.5
Arm control lever
• Hydraulic oil temperature: Within {1.6±0.4} {Max. 2.5}
of control levers
Operating force

operation range 12.7±2.9 Max. 21.6

Bucket control lever
• Engine at high idling {1.3±0.3} {Max. 2.2}
N{kg}
• At center of control lever grip 12.7±2.9 Max. 21.6
Swing control lever • At tip in case of pedal {1.3±0.3} {Max. 2.2}
• Max. reading up to stroke end
24.5±5.9 Max. 39.2
Lever
{2.5±0.6} {Max. 4.0}
Travel control lever
74.5±18.6 Max. 107.6
Papel
{7.6±1.9} {Max. 11}

PC290-7 20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
• Hydraulic oil temperature: Within opera-
tion range
• Engine at high idling 3.9±1.0 3.9±1.0
Unload pressure
• Working mode: A mode {40±10} {40±10}
• Hydraulic pump output pressure with all
control levers in NEUTRAL position
34.8± 1.0 33.3–36.8
RAISE
• Hydraulic oil tem- {355±10} {340–375}
perature: Within
Boom 37.2±1.0 36.3–39.2
operation range
LOWER

{380±10} {370–400}
• Engine at high idling
• Working mode: A 31.4±1.0
mode {320±10}
• Hydraulic pump output pressure with all 33.3–36.8
Arm
measurement circuits relieved 34.80±1.0 {340–375}
• Values inside parenthesis: Hydraulic oil
Hydraulic pressure

{35.5±10}
pressure with one-touch power max. (37.2±1.0{380±1.0}) {36.3–39.2(370–
Bucket
switch in ON mode (reference only) MPa 400)}
{kg/cm2} 30.8±1.4 28.9–32.8
Swing
{315±1.5} {295–335}
38.7±1.0 37.3–40.20
Travel
{395±1.0} {380–410}
• Hydraulic oil temperature: Within opera-
tion range
Control circuit • Engine running at high idling 3.23±0.2 2.84–3.43
source pressure • Self-reducing pressure valve output pres- {33±2} {29–35}
sure with all control levers in NEUTRAL
position
• Hydraulic oil tempera- When all con-
ture: Within operation trol levers in 3.9±1.0 3.9±1.0
range NEUTRAL {40±10} {40±10}
Self-reducing pres- • Engine at high idling position
sure valve • Working mode: A mode
• Traveling speed: Hi When traveling
2.2±0.1 2.2±0.1
• Hydraulic oil pump pres- at half stroke
{22±1} {22±1}
sure - LS pressure (without load)
Swing

deg.
Swing brake angle • Hydraulic oil temperature: Within operation Max. 110 Max. 140
(mm)
range
• Engine running at high idling
• Working mode: A mode
• Swing circle misalignment amount when
stopping after one turn

20-4 PC290-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory

90° 3.2±0.3 Max. 3.8

• Hydraulic oil tempera-
ture: Within operation
Time taken to start range sec.
swing • Engine running at high
idling
• Working mode: A mode
• Time required for passing 180° 4.7±0.5 Max. 5.9
points 90 and 180
degrees from starting
point

Time taken to
• Hydraulic oil temperature: Within opera- sec. 28.6±2.9 Max. 34.8
swing
tion range
• Engine running at high idling
• Working mode: A mode
Swing

• Time required for 5 more turns after mak-

ing initial one turn

15

BKP00103

Hydraulic drift of • Hydraulic oil temperature: Within opera-

tion range mm 0 0
swing
• Engine stopped
• Keeping upper structure transverse on
slope of 15 degrees
• Notching a mating mark on inner and
outer races of swing circle
• Mating mark misalignment amount during
5 minutes
• Hydraulic oil temperature: Within opera-
tion range
Leakage from • Engine running at high idling
¶/min Max. 5 Max. 10
swing motor • Swing lock switch: ON
• Leakage amount for one minute during
swing relief

PC290-7 20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory

Lo 58.3±5.8 52.8–68.6

BKP00104
Travel speed (1) • Hydraulic oil temperature: Within ( Mi) 42.7±4.3 38.6–51.2
operation range
• Engine running at high idling
• Working mode: A mode
• Time required for track shoes to Hi 30.2±0.5 28.9–33.9
make 5 turns after making one ini-
tial idle turn
sec.
45˚
Lo 24±2.5 21.5–27.5

BKP00105
Travel speed (2) • Hydraulic oil temperature: Within ( Mi) 17.6±2.5 15.0–21.0
operation range
• Engine running at high idling
• Working mode: A mode
Travel

• Flat ground Hi 13.1±1.0 12.1–15.1

• Time required for traveling 20 m
after 10 m trial run
45

BKP00105
• Hydraulic oil temperature: Within operation
range
• Engine at high idling
• Working mode: A mode
Travel deviation • Travel speed: Lo mm Max. 150 Max. 250
• Solid and flat ground
• Swerving amount while traveling 20 m (X)
after initial 10 m trial run
20m

10m BKP00107

: The “Mi” mode is on the multi-monitor specification machine only.

20-6 PC290-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory

12˚

BKP00108

Hydraulic drift of travel • Hydraulic oil temperature: Within mm 0 0

operation range
• Engine stopped
• Parking machine on slope of 12
Travel

degrees with sprocket facing

upslope
• Sliding distance for 5 minutes
• Hydraulic oil temperature: Within
operation range
• Engine at high idling
Leakage of travel motor • Traveling with sprocket locked ¶/min Max. 15 Max. 30
• Oil leakage amount for one
minute with traveling in relief con-
dition

Whole work equip-

ment (tooth tip fall Max. 600 Max. 900
amount)
Hydraulic drift of work equipment

BKP00110
Boom cylinder (cylin-
Work equipment

• Hydraulic oil temperature: Within Max. 18 Max. 27

der retraction amount) operation range
• Flat and level ground mm
• Work equipment in measurement
Arm cylinder (cylinder posture as illustrated above
• Bucket load: 2,160 kg Max. 160 Max. 240
extension amount)
• Engine stopped
• Work equipment control lever in
NEUTRAL position
Bucket cylinder (cylin- • Fall amount for 15 minutes as Max. 40 Max. 58
der retraction amount) measured every 5 minutes start-
ing immediately after initial setting

PC290-7 20-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory

RAISE
3.9±0.4 Max. 5.3

Boom • Hydraulic oil temperature: Within

operation range
LOWER
• Engine running at high idling
3.0±0.3 Max. 4.3
• Working mode: A mode
• Time required from raise stroke
end till bucket touches ground

3.2±0.3 Max. 4.2

IN
Work equipment speed

Arm
sec.
• Hydraulic oil temperature: Within
operation range
OUT

• Engine running at high idling 4.0±0.4 Max. 4.9

• Working mode: A mode
• Time required from dumping stroke
Work equipment

end to digging stroke end

CURL

2.3±0.2 Max. 2.9

Bucket
• Hydraulic oil temperature: Within
operation range
DUMP

• Engine running at high idling 3.0±0.3 Max. 3.9

• Working mode: A mode
• Time required from dumping stroke
end to digging stroke end
Time lag

BKP00114
Boom sec. Max. 1.0 Max. 1.2
• Hydraulic oil temperature: Within operation
range
• Engine running at low idling
• Working mode: A mode
• Time required from raise stroke end till
bucket touches ground and pushes up
machine front

20-8 PC290-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory

BKP00115

Arm • Hydraulic oil temperature: Within operation Max. 2.0 Max. 2.8
range
• Engine running at low idling
• Working mode: A mode
• Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
Time lag

again sec.
Work equipment

BKP00116
Bucket • Hydraulic oil temperature: Within operation Max. 1.0 Max. 3.6
range
• Engine running at low idling
• Working mode: A mode
• Time required from dumping stroke end till
bucket stops momentarily after control
lever is tilted to digging and starts to move
again
• Hydraulic oil temperature: Within operation
Cylinders range
leackage
Internal

• Engine running at high idling

cc/min
• Leakage amount for one minute with cylin-
Center
der or travel to be measured in relief condi-
swivel joint
tion
• Hydraulic oil temperature: Within operation
Performance in compound operation

range
• Engine at high idling
• Working mode: A mode
• Traveling speed: Lo
Swerving amount • Flat and level ground
in simultaneous • Swerving amount (X) when traveling 20 m
operation of work after initial trial run of 10 m mm Max. 200 Max. 220
equipment and 20m
travel

10m BKP00107
Performance of
hydraulic pump

Hydraulic pump
See next page ¶/min See next page
delivery

PC290-7 20-9
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC290LC,PC290NLC-7

Cate-
Item Measurement Condition Unit Standard value Permissible value
gory
Discharge amount of hydraulic pump (A mode)
Performance of hydraulic pump

• Pump speed: At 2,050 rpm, PC current 310 mA

Test pump Discharge Average Standard value Judgement

discharge pressure of pressure for discharge standard lower
Check point
pressure other pump amount Q limit Q
(MPa {kg/cm2}) (MPa {kg/cm2}) (MPa {kg/cm2}) (¶/min) (¶/min)

As desired P1 P2 P1+P2 See graph See graph

2

★ As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure
when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
★ When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the spec-
ified speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of
measurement, and use them as a base for calculating the pump discharge amount at the specified speed.

20-10 PC290-7
 TESTING AND ADJUSTING

INSPECTION AND ADJUSTMENT OF ENGINE RPM............................................................................... 20-102

MEASUREMENT OF EXHAUST GAS COLOR.......................................................................................... 20-104
ADJUSTMENT OF VALVE CLEARANCE................................................................................................... 20-105
MEASUREMENT OF COMPRESSION PRESSURE ................................................................................. 20-107
MEASUREMENT OF BLOW-BY PRESSURE............................................................................................ 20-108
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING........................................................... 20-109
MEASUREMENT OF ENGINE OIL PRESSURE........................................................................................ 20- 111
ADJUSTMENT OF ENGINE SPEED SENSOR.......................................................................................... 20- 112
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION.......................................... 20- 112
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM............................................... 20- 113
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS........................................................ 20- 114
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION ............................................................. 20- 115
INSPECTION OF WEAR ON SPROCKET ................................................................................................. 20- 115
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE
IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL .................................... 20- 116
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE......................................... 20-120
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE ....................... 20-121
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE........................ 20-124
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE .............................................................. 20-128
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE ......................................................................... 20-131
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE ......................................................... 20-132
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT................................... 20-133
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT ......................................................... 20-134
MEASUREMENT OF OIL LEAKAGE AMOUNT ......................................................................................... 20-135
AIR BLEEDING OF VARIOUS PARTS ....................................................................................................... 20-137
INSPECTION PROCEDURES FOR DIODE............................................................................................... 20-139
SPECIAL FUNCTION OF MULTI-MONITOR PANEL ................................................................................. 20-140
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM.................................................... 20-164

PC290-7 20-101
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM

INSPECTION AND ADJUSTMENT OF ENGINE RPM

★ Engine inspection and maintenance tools 3. Measure the engine RPM after setting each
measurement condition.
Mark Part No. Part Name 1) RPM at low idling:
1 799-203-8001 Multi-tachometer i) Set the fuel dial at low idling (MIN).
A
2 Adapter ii) Move all the control levers of work
equipment, swing and travel to the
NEUTRAL position.
★ Engine RPM may be detected using a monitoring
2) RPM at high idling:
function in the monitor panel (special function
i) Turn the auto-decelerator OFF.
furnished to the monitor panel).
ii) Set the fuel dial at high idling (MAX).
k Be careful not to touch the strongly heated por-
iii) Operate any of the work equipment,
tion of the engine by accident while installing a
swing and travel control levers.
measurement equipment.
★ Operate the lever lightly enough to turn
on the PPC hydraulic switch, but not to
Inspection
start the work equipment, swing or travel.
1. Open up the engine hood and take off cover (1).
3) RPM at fuel pump relief
i) Set the fuel dial at high idling (MAX)
ii) Put the arm in the digging relief position.
4) RPM when 2 pump relief and one-touch
power max. switch are set (near rated RPM)
i) Set the fuel dial at high idling (MAX).
ii) Put the arm in digging relief position and
keep the one-touch max. power switch
depressed.
★ The one-touch power max. function is
automatically released in 8.5 seconds,
even if the knob switch is kept de-
pressed. Take measurement during the
period.
2. Fit adapter A2, and connect pickup set and 5) RPM when auto-decelerator is set
meter of multi-tachometer A1. i) Turn the auto-decelerator ON.
ii) Set the fuel dial at high idling (MAX).
iii) Move all the control levers of work
equipment, swing and travel to the
NEUTRAL position.
★ Approx. 5 seconds after all the control le-
vers are moved to the NEUTRAL posi-
tion, the rpm falls automatically. That is
when the rpm with the auto-decelerator
in motion should be measured.

20-102 PC290-7
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF ENGINE RPM

4. Detach all the measurement tools after the

inspection, and make sure that the machine is
back to normal condition.

Adjustment
1. Adjustment of RPM at low idling
★ If the rpm at low idling deviates from the
standard value, make adjustment using the
adjustment function provided in the monitor
panel.
★ For the adjustment procedures, refer to the
section, "Special Function of Monitor Panel"

2. Adjustment of Governor Spring

★ If the rpm at high idling deviates from the
standard value, or it is unsteady (hunting),
adjust the governor spring securing dimen-
sions, using the adjustment function in the
monitor panel.
★ For the adjustment procedures, refer to the
section, "Special Function of Monitor Panel"

PC290-7 20-103
TESTING AND ADJUSTING MEASUREMENT OF EXHAUST GAS COLOR

MEASUREMENT OF EXHAUST GAS COLOR

★ Exhaust gas color measurement tool

Mark Part No. Part Name

1 799-201-9000 Handy Smoke Checker
B
2 Commercial product Smoke Meter

k Be careful not to touch the highly heated parts,

while fitting and detaching a measurement tool.
★ If no compressed air or power is not available in
the field, use Handy Smoke Checker B1. For re-
cording official data, use Smoke Meter B2.

1. Measurement with Handy Smoke Checker B1

1) Fit a filtering paper to Handy Smoke Checker 2) Connect the probe hose, accelerator switch
B1. outlet and air hose to the Smoke Meter B2.
2) Insert the exhaust gas intake pipe into the ★ Keep the pressure of the supplied com-
exhaust pipe. pressed air below 1.5 MPa {15 kg/cm2}.
3) Start the engine and keep it running until the 3) Connect the power cable to an outlet of
engine cooling water temperature comes AC100V.
within the operating range. ★ Confirm that the Smoke Meter power
4) Let the exhaust gas stay on the filtering switch is in the OFF position, before con-
paper by operating a handle of Handy necting the power cable to an outlet.
Smoke Checker B1, when the engine speed 4) Fit a filtering paper by loosening the suction
is suddenly accelerated or kept at high pump cap nut.
idling. ★ Fit the filtering paper securely so that air
may not leak.
5) Move the Smoke Meter B2 power switch to
the ON position.

5) Take out the filtering paper and compare it

with the attached scale for judgement.
6) Detach the measurement tool after the
measurement, and make sure the machine 6) Start the engine and keep it running until the
is back to normal condition. engine water temperature rises to the oper-
ating range.
2. Measurement with Smoke Meter B2 7) Let the exhaust gas stay on the filtering
paper by depressing the accelerator pedal
1) Insert probe of the Smoke Meter B2 into
of Smoke Meter B2, when the engine speed
the exhaust gas pipe outlet, and fasten it to
is suddenly accelerated or kept at high
the outlet with a clip.
idling.
8) Put the polluted filtering paper on non-pol-
luted filtering paper (more than 10 sheets) in
the filtering paper holder, and read the indi-
cated value.
9) Detach the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.

20-104 PC290-7
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE

ADJUSTMENT OF VALVE CLEARANCE

★ Valve clearance adjustment tools ★ After setting the No. 1 cylinder to the top
dead center, stamp a counter mark on the
Mark Part No. Part Name crank pulley and the front cover.
1 795-799-1131 Gear
C 2 Commercial product Filler Gauge
3 795-799-1900 Pin assembly

1. Open up the engine hood and remove air intake

connector (1).

2. Remove cylinder head covers (2).

5. When No. 1 cylinder is at the top dead center,

adjust valve clearances indicated with a black
bullet mark (z) in the chart below in the follow-
ing manner.

3. Take off cap (3) and fit gear C1.

1) Insert filler gauge C2 in between rocker arm

(4) and valve stem (5), and adjust the valve
clearance with adjusting screw (6).
★ For the adjustment, turn the adjusting
screw with filler gauge C2 inserted to the
extent that filler gauge C2 can be lightly
4. Turn the crankshaft clockwise (normal rotation) moved.
with gear C1,then match 1.6 TOP notch "a" of 2) Fix adjusting screw (6) and then tighten lock
the crank pulley with pointer (3), and bring up nut (7).
No. 1 cylinder to the top dead center . 3 Lock nut: 24±4 Nm{2.45±0.41kgm}
★ When No. 1 cylinder is at the top dead cent- ★ Check the valve clearance again after
er, its rocker arm can be manually moved as tightening lock nut (7).
much as the valve clearance. If it cannot be ★ Proceed to the next step, once all the meas-
moved, that means that No. 1 cylinder is not urements of valve clearance indicated with a
yet at the top dead center. In that case, ro- black bullet mark (z) have been completed.
tate it by one more turn.

PC290-7 20-105
TESTING AND ADJUSTING ADJUSTMENT OF VALVE CLEARANCE

6. Turn the crankshaft clockwise (normal rotation)

with gear C1 then match 1.6 TOP notch of the
crank pulley with pointer (3), and bring up No. 6
cylinder to the top dead center.

7. When No. 6 cylinder is at the top dead center,

adjust valve clearances indicated with a white
bullet mark ({) in the chart.
★ The adjustment procedures are the same as
introduced in Item 5 above.

8. After the adjustment, make sure that the

machine is back to normal condition.
3 Cylinder head cover securing bolt:
24±4 Nm{2.45±0.41 kgm}

20-106 PC290-7
TESTING AND ADJUSTING MEASUREMENT OF COMPRESSION PRESSURE

MEASUREMENT OF COMPRESSION PRESSURE

★ Compression pressure measurement tools

Mark Part No. Part Name

1 795-502-1205 Compression Gauge
D
2 795-502-1700 Adapter

k Be careful not to get burnt by touching the ex-

haust manifold or muffler, or get caught with a
rotating parts, while taking measurement of
compression pressure.

1. Adjust the valve clearances.

★ For the adjustment, refer to the section, "Ad-
justment of Valve Clearance". 6. Take off governor spring (2).

2. Make preparations for measuring the engine 7. Fasten governor lever (3) of the fuel injection
rpm. pump, as it is in contact with the stopper on the
★ For the preparations, refer to the section, "In- STOP side.
spection and adjustment of Engine RPM".

3. Warm up the engine until the engine oil temper-

ature rises up to 40 – 60°C.

4. Detach nozzle holder (1) of a cylinder to be

measured.

8. Crank up the engine with the engine starting

motor, and measure the compression pressure.
★ Read off the value, when the needle of the
compression gauge steadies itself.
★ When taking measurement of the compres-
sion pressure, be sure to measure the en-
gine rpm, too, so that it stays within the range
5. Fit Adapter D2 to the nozzle holder mounting, of designated measurement conditions.
and connect with gauge ass'y of compression
gauge D1. 9. Detach the measurement tools after the mea-
3 Adapter: 60±9 Nm{6.12±0.92 kgm} surement, and make sure that the machine is
back to normal condition.
2 Nozzle holder:
Seizure preventive (Molycoat 1000)
3 Nozzle holder:
60±9 Nm{6.12±0.92 kgm}

PC290-7 20-107
TESTING AND ADJUSTING MEASUREMENT OF BLOW-BY PRESSURE

MEASUREMENT OF BLOW-BY PRESSURE

★ Blow-by pressure measurement tools

Mark Part No. Part Name

1 799-201-1504 Blow-by Kit
E
2 795-790-3300 Tool (Nozzle)

1. Remove the engine under cover.

2. Fit tool E2 to blow-by hose and connect it with

gauge of blow-by kit F1.

3. Start the engine and keep it running until the

engine cooling water temperature rises to the
operating range.

4. Measure the blow-by pressure at high idling and

under the following conditions.
• Working mode: A mode
• Swing lock switch: ON (High pressure relief)
• Work equipment, swing and travel:
Arm IN relief
★ Read off the blow-by pressure value, when
the needle of the gauge steadies itself.

5. Detach the measurement tools after the mea-

surement, and make sure that the machine is
back to normal condition.

20-108 PC290-7
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

★ Fuel injection timing inspection and adjustment 4. Fix the fuel injection pump drive gear to match
tools injection timing by pushing drive gear timing pin
(3) in the direction of the front cover.
Mark Part No. Part Name ★ Injection timing requires adjustment of high
1 795-799-1131 Gear precision. Be sure to fix the drive gear with
F 2 795-799-1900 Pin Ass'y timing pin (3) so as to match injection timing.
3 795-799-1950 Lock Pin ★ Push-in depth: 8 mm
★ If timing pin (3) cannot be pushed in, turn the
crankshaft a bit fore or aft with gear F1.
Inspection ★ If it is found difficult to confirm the push-in
1. Open up the engine hood, and then detach the depth with timing pin (3) as installed in the
fan guard on the counterweight side. engine, metallic pin ass'y F2 may well be
2. Take off cover (1) and fit gear F1. used instead.

3. Turn the crankshaft clockwise with gear F1, then

5. Disconnect plug (4) of the fuel injection pump.
match 1.6 TOP notch "a" of the crank pulley with
pointer (2), and bring up No.1 cylinder to the top
6. Reverse and push in timing pin (5) of the fuel
dead center.
injection pump, and confirm its cut-out portion
★ Take off the cylinder head cover for No.1 cyl-
matches with protruding portion b inside the
inder, and confirm that its rocker arm can be
pump.
manually moved as much as the valve clear-
★ If timing pin (5) can be pushed in smoothly,
ance. If it cannot be moved, that means that
then injection timing is correct.
No.1 cylinder is not yet at the top dead cent- ★ If timing pin (5) cannot be pushed in smooth-
er. In that case, rotate it by one more turn. ly, injection timing is incorrect and requires
adjustment.
★ If it is found difficult to confirm the push-in
depth with timing pin (5) as installed in the
engine, metallic pin ass'y F3 may well be
used instead.

PC290-7 20-109
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING

7. Detach the measurement tools after the mea- 3. Reverse and push in timing pin (5) of the fuel
surement, and make sure that the machine is injection pump, then match the pin cut-out por-
back to normal condition. tion and protruding portion "b" inside the fuel
3 Cylinder head cover securing bolt: injection pump by turning the shaft.
24±4 Nm{2.45±0.45 kgm} ★ After fuel timing has been set, fix it by fitting
k Do not forget to bring driving gear timing pin plug (4).
(3) and injection pump timing pin (5) back to
the pre-inspection condition.
★ In case the adjustment follows, leave gear
F1 and timing pin (3) as they are.

Adjustment
★ If fuel injection timing is found incorrect, adjust it
in the following manner.
1. Confirm that drive gear injection timing is fixed
with driving gear timing pin (3).
★ If timing pin (3) was pulled back after the in-
spection had been completed, push it in
again following the foregoing inspection pro-
cedures.
4. Mount the fuel injection pump.
★ For mounting the pump, refer to the same
section mentioned in Item 2 above.

5. Detach the measurement tools after the adjust-

ment, and make sure that the machine is back
to normal condition.
k Before starting the engine again, check that
driving gear timing pin (3) and fuel injection
pump timing pin (5) have been brought back
to the pre-adjustment condition.

2. Dismantle the fuel injection pump.

★ For dismantling the fuel injection pump, refer
to the section, "FUEL INJECTION PUMP
ASSEMBLY" in the chapter of "DISASSEM-
BLY AND ASSEMBLY".

20-110 PC290-7
TESTING AND ADJUSTING MEASUREMENT OF ENGINE OIL PRESSURE

MEASUREMENT OF ENGINE OIL PRESSURE

★ Engine oil pressure measurement tools 4. Measure engine oil pressure at low idling as well
as at high idling.
Mark Part No. Part Name
799-101-5002 Hydraulic Tester
1 Digital type
790-261-1203
G hydraulic tester
Hydraulic Tester
2 799-401-2320
(1.0MPa{10 kg/cm2})

1. Take off engine oil pressure measurement plug

(1) on top of the engine filter.

5. Detach the measurement tools after the mea-

surement, and make sure that the machine is
back to normal condition.

2. Install fitting of the hydraulic tester G1, and

connect it to hydraulic tester G2.

3. Start the engine and keep it running until the

engine cooling water temperature rises to the
operating range.

PC290-7 20-111
 ADJUSTMENT OF ENGINE SPEED SENSOR
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION

ADJUSTMENT OF ENGINE INSPECTION AND ADJUST-

SPEED SENSOR MENT OF AIR COMPRESSOR
BELT TENSION
★ Detach engine speed sensor (1) before the ad-
justment, then check that there is no metal dust Inspection
stuck or damage at the tip and fit it again. Check belt deflection amount a when depressing the
mid point between the fan pulley and the compres-
sor with a thumb.
• Belt depressing force: Equivalent to 58.8 N{6 kg}

1. Screw in sensor (1) until its tip comes to contact

with the tip of flywheel ring gear teeth (2).
3 Threaded portion:
Gasket sealant (LG-6) Adjustment
★ If the belt deflection amount is not proper, adjust
2. Screw back sensor (1) from that position by the it in the following manner.
prescribed angle. 1. Loosen two compressor bracket securing bolts
★ Screw-back angle: 1±1/6 turn (1) (upper and lower).
★ Adjust clearance "a" between the sensor tip 2. Loosen lock nut (2), and adjust the belt tension
and gear tooth tip to be 1.25–1.75 mm. by shifting the position of compressor bracket
(1).
3. Fasten sensor (1) with nut (3). 3. Tighten lock nut (2).
3 Nut: 49.0–68.6 Nm{5–7 kgm} 4. Tighten two compressor bracket (1) securing
bolts.
★ Check the belt tension again after the adjust-
ment.

4. After the adjustment, confirm that correct engine

speed is displayed in the monitor panel, using
the special monitoring function.
★ For monitoring engine speed, refer to the
section, "Special Function of Monitor Panel".

20-112 PC290-7
 ADJUSTMENT OF ENGINE SPEED SENSOR
TESTING AND ADJUSTING EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM

EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL

SYSTEM
★ If a failure occurs on any of the engine control de- 3. Remove bolt (4), connect governor spring (3)
vices like fuel dial, governor pump controller or and fix it at the original position.
governor motor potentiometer, and the engine ★ Tilt the governor motor lever to the fuel injec-
gets out of control, first fix the engine rpm and tion pump side, but stop short of the gover-
take the following steps to avoid the immediate nor spring.
danger. ★ The governor lever of the fuel injection pump
★ The suggested steps are provisional ones. Iden- is fixed at a near-idling position.
tify the cause for the failure and carry out repairs
promptly thereafter.

1. Disconnect E11 connector (1) of the governor

motor from E10 connector (2) of the governor
potentiometer.
k If the governor motor connector is left con-
nected, the governor motor will be suddenly
activated while the engine is running, caus-
ing a mechanical damage. Be sure to dis-
connect it.

4. Start the engine again and travel the machine to

a safe place.

5. Disconnect governor spring (3) and stop the

engine.
k Operation of stopping the engine is to be
carried out while the engine is running at
high speed. Be careful not to touch the parts
of high temperature or get caught in rotating
parts.
★ If the governor spring is tilted all the way to
2. Detach governor spring (3) on the governor the fuel injection pump, the pump stops with
motor side. no more injection.
★ Hold the governor spring until the engine
comes to a complete stop. Otherwise the
fuel injection pump automatically returns to
the low idling position, and the engine does
not stop.

PC290-7 20-113
TESTING AND ADJUSTING MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS

MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS

★ Swing circle bearing clearance measurement 4. Hold the arm nearly perpendicular to the
tools ground, and lower the boom until the track
shoes will be lifted at the machine front.
Mark Part No. Part Name ★ The upper structure is raised at the front and
J Commercial Product Dial Gauge lowered at the rear at that time.

★ Follow the steps explained below, when measur- 5. Read off the value in dial gauge J in this condi-
ing clearance in the swing circle bearing in the tion.
actual machine. ★ The value indicated in dial gauge J express-
k Be careful not to put a hand or foot under the un- es clearance in the bearings.
dercarriage, while taking measurement.

1. Fasten dial gauge J to swing circle outer race

(1) or inner race (2), and contact the probe with
the end surface of inner race (2) or outer race
(1) on the opposite side.
★ Set dial gauge J at the machine front or rear.

6. Return the machine to the posture in Item 2

above, and confirm reading of dial gauge J is
zero.
★ If zero value is not indicated, repeat the
steps in Items 3 through 5.

2. Keep the work equipment in the max. reach pos-

ture and keep the height of the bucket teeth tip
level with the lower height of the revolving
frame.
★ The upper structure is lowered at the front
and raised at the rear at that time.

3. Set dial gauge J at zero point.

20-114 PC290-7
TESTING AND ADJUSTING INSPECTION OF WEAR ON SPROCKET

INSPECTION AND ADJUST- INSPECTION OF WEAR ON

MENT OF TRACK SHOE SPROCKET
TENSION
Inspection ★ Inspection tool for sprocket wear
1. Travel the machine forward by the length of
track on ground, keeping the engine at low Mark Part No. Part Name
idling, and stop the machine slowly. K 796-627-1130 Wear gauge

2. Place straight bar on the track shoe between

the idler and the 1st carrier roller.
★ L beam is recommended for bar , because
of its deflection-free nature.

3. Measure max. clearance a between bar and

the track shoe.
• Max. standard clearance a: 10–30 mm

Adjustment
★ If the track shoe tension is not proper, adjust it in
the following manner.

1. When the tension is too strong

Discharge grease by loosening valve (1).
k Do not loosen valve (1) by more than one
turn, because grease will spurt out due to its
internal high pressure.

2. When the tension is too weak

Add grease through grease fitting (2).
★ If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.

PC290-7 20-115
 INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HY-

INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRES-

SURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING
AND TRAVEL
★ Inspection and adjustment tools for hydraulic oil 2) Fit fitting J2 and connect it to oil pressure
pressure in hydraulic circuit for work equipment, gauge of hydraulic tester J1.
swing and travel ★ Use an oil pressure gauge with the ca-
pacity of 58 MPa{600 kg/cm2}.
Mark Part No. Part Name
799-101-5002 Hydraulic Tester
1 Digital Type
790-261-1203
Hydraulic Tester
J
Grease Fitting
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring

★ Hydraulic oil pressure in the hydraulic circuit for

work equipment, swing and travel (hydraulic
pump output pressure) may be also confirmed
with a monitoring function in the monitor panel
(special function of monitor panel).
3) Start the engine and keep it running until the
Measurement hydraulic oil temperature rises to the operat-
1. Pre-measurement work ing range.
k Lower the work equipment to the ground,
then release the remaining pressure in the
piping by operating the control lever several
times after stopping the engine, and release
the pressure inside the hydraulic tank by
gradually loosening the oil filler cap.
1) Remove hydraulic oil pressure measuring
plugs (1) and (2).
• Plug (1): For the circuit of front hydraulic
pump
• Plug (2): For the circuit of rear hydraulic
pump

2. Combination of pump, actuator and valve

★ You will know that when oil flow from the
pumps is divided, the front and rear pumps
work independently of each other for each
actuator, as well as that different relief valves
are activated then.
★ Oil flow from the pumps is merged in the sin-
gle pressure relief when the work equipment
swings, while it is divided in the single pres-
sure relief when the machine travels.

20-116 PC290-7
 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL

★ The actuators in the table below are ar- ★ Hydraulic oil pressure when the swing motor
ranged in the order that the control valves safety valve is relieved is displayed.
are viewed from the machine front. ★ The swing motor relief pressure is lower than
the main relief pressure.
Pump Actuator Relieve valve activated
(Unload) R unload valve 6. Measurement of travel circuit relief pressure
Service Safety valve 1) Start the engine and lock travel.
Rear Bucket R main relief valve k Put pin in between the sprocket and the
pump track frame to make sure locking travel.
Travel, left R main relief valve
RAISE: R main relief valve
Boom
LOWER: Safety valve
Swing Swing motor safety valve
Front Travel, right F main relief valve
pump Arm F main relief valve
(Unload) F unload valve

3. Measurement of Unload Pressure

1) Start the engine.
2) Measure hydraulic oil pressure, when the
engine is running at high idling and all the
control levers are moved to the NEUTRAL
position. 2) Measure hydraulic oil pressure when the
★ Hydraulic oil pressure when the unload valve engine is running at high idling and the
unloads is displayed. travel circuit is relieved.
★ Hydraulic oil pressure with the main relief
4. Measurement of work equipment relief pres- valve in relief condition is displayed. In the
sure travel circuit relief, the pressure is high pres-
1) Start the engine and move the cylinder to be sure relief all the time.
measured to its stroke end.
2) Measure hydraulic oil pressure, when the Adjustment
engine is running at high idling and the cylin- ★ The unload valve and the safety valve for boom
der is in relief condition. LOWER cannot be adjusted.
★ Hydraulic oil pressure when the main relief 1. Adjustment of main relief pressure
valve is in relief condition is displayed. (high pressure setting side)
★ If one-touch power max. switch is de- ★ If relief pressure of the high pressure in the
pressed, the oil pressure is turned to high re- work equipment and travel circuits is not nor-
lief pressure, and if released, it is turned to mal, adjust the high pressure setting side of
low relief pressure. main relief valves (3) and (4) in the following
★ Keep the swing lock switch in the ON position manner.
during the inspection. If it is moved to the OFF • Main relief valve (3): For the front hy-
position, hydraulic oil pressure is turned to draulic pump circuit
high relief pressure, as the constant 2-stage • Main relief valve (4): For the rear hydrau-
relief valve is moved to the ON position. lic pump circuit
★ The relief pressure at high pressure indi-
5. Measurement of swing relief pressure cates that when the 2- stage relief valve is
1) Start the engine and move the swing lock ON and pilot pressure is applied to the
switch to the ON position. switching port.
2) Measure hydraulic oil pressure when the
engine is running at high idling and the
swing circuit is relieved.

PC290-7 20-117
 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL

2. Adjustment of main relief pressure (low

pressure setting side)
★ When low pressure relief pressure of the
work equipment is not normal, or when ad-
justment is made of the high pressure setting
side, adjust the low pressure side of the main
relief valve, too.
★ The relief pressure at high pressure indi-
cates that when the 2-stage relief valve is
OFF and pilot pressure is not applied to the
switching port.
1) Disconnect pilot hose.
2) Loosen lock nut (7) and adjust the pressure
by turning holder (8).
1) Disconnect the pilot hose.
★ If the holder is turned to the right, the
2) Loosen lock nut (5) and adjust the pressure
pressure rises.
by turning holder (6).
If the holder is turned to the left, the pres-
★ If the holder is turned to the right, the
sure falls.
pressure rises.
★ Adjustment amount per turn of holder:
If the holder is turned to the left, the pres-
sure falls. Approx. 12.5 MPa{approx. 128 kg/cm2}
★ Adjustment amount per turn of holder: 3 Lock nut:
53.5±4.9 Nm{5.5±0.5 kgm}
Approx. 12.5 MPa{approx. 128 kg/cm2}
3 Lock nut:
53.5±4.9 Nm{5.5±0.5 kgm}

3) Check the pressure again after the adjust-

ment, following the aforementioned steps
for measurement.
3) Check the pressure again after the adjust-
ment, following the aforementioned steps
for measurement.
★ When measuring the pressure, connect
the pilot hose.
★ If high pressure setting side is adjusted,
low pressure setting side is also affect-
ed, so adjust it, too.

20-118 PC290-7
 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN
TESTING AND ADJUSTING HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL

3. Adjustment of swing relief pressure

★ If the swing relief pressure is not normal, ad-
just it with swing motor safety valve (9) in the
following manner.

1) Loosen lock nut (10) and adjust the pres-

sure by turning adjusting screw (11).
★ If the holder is turned to the right, the
pressure rises.
If the holder is turned to the left, the pres-
sure falls.
★ Adjustment amount per turn of adjusting
screw:
Approx. 6.71 MPa{approx. 68.4 kg/cm2}
3 Lock nut:
78–103 Nm{8.0–10.5 kgm}

2) Check the pressure again after the adjust-

ment, following the aforementioned steps
for measurement.

PC290-7 20-119
 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRES-
TESTING AND ADJUSTING SURE

INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL

PRESSURE
★ Control circuit oil pressure inspection and adjust- 3. Start the engine and keep it running until the
ment tools hydraulic oil temperature rises to the operating
range.
Mark Part No. Part Name
799-101-5002 Hydraulic Tester 4. Measure oil pressure with the engine running at
1 Digital Type high idling and all the control levers in the NEU-
790-261-1203
Hydraulic Tester TRAL position.
J
Grease Fitting
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring

Measurement
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the re-
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy-
draulic tank.

1. Remove oil pressure measurement plug (1).

5. Detach all the measurement tools after the mea-
surement, and make sure that the machine is
back to normal condition.

2. Fit fitting J2 and connect it to oil pressure gauge

of hydraulic tester J1.
★ Use an oil pressure gauge with the capacity
of 5.9 MPa{60 kg/cm2}.

20-120 PC290-7
TESTING AND ADJUSTING INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL

INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL

CIRCUIT OIL PRESSURE
★ Pump PC control circuit oil pressure inspection
and adjustment tools

Mark Part No. Part Name

799-101-5002 Hydraulic Tester
1 Digital Type
790-261-1203
Hydraulic Tester
J
Grease Fitting
799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring

Measurement
★ Implement measuring the pump PC control cir-
cuit oil pressure after confirming that the work 2) Fit fitting J2 and connect to oil pressure
equipment, swing and travel circuit oil pressure gauge of hydraulic tester J1.
as well as the control circuit original oil pressure ★ Use an oil pressure gauge with the ca-
are normal. pacity of 58.8 MPa{600 kg/cm2}.
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the re-
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy-
draulic tank.

1. Measurement of PC valve output pressure

(servo piston inlet pressure)
★ Measure PC valve output pressure (servo
piston inlet pressure) and pump delivery
pressure together, and compare the two
pressures.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
• Plug (1): For measuring the front pump
delivery pressure
• Plug (2): For measuring the rear pump
delivery pressure
• Plug (3): For measuring the front pump
PC valve delivery pressure
• Plug (4): For measuring the rear pump
PC valve delivery pressure

PC290-7 20-121
 INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE

3) Start the engine and keep it running until the 2. Measurement of PC-EPC output pressure
hydraulic oil temperature rises to the operat- 1) Remove oil pressure measurement plug (5).
ing range.

2) Fit fitting J2 and connect it to oil pressure

4) Measure the pump delivery pressure and gauge of hydraulic tester J1.
PC valve output pressure (servo piston inlet ★ Use an oil pressure gauge with the ca-
pressure) together with the engine running pacity of 5.9 MPa{60 kg/cm2}.
at high idling, after setting the machine at
the following conditions.
• Working mode: A mode
• Swing lock switch: ON (switched to high
pressure relief with 2-stage relief turned
ON)
• Work equipment, swing and travel cir-
cuit: Arm digging relief
★ Judgement method:
When the ratio between the pump deliv-
ery pressure and PC valve output pres-
sure (servo piston output pressure)
reaches the following values, both pres-
sures are judged normal.
3) Start the engine and keep it running until the
Pressure to be hydraulic oil pressure rises to the operating
Pressure ratio
measured range.
Pump delivery
1
pressure
PC valve outlet
Approx. 3/5
pressure

★ If there is any abnormality with PC valve

or servo piston, the PC valve output
pressure (servo piston output pressure)
equals to the pump delivery pressure, or
approximates to 0 pressure.

20-122 PC290-7
 INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE

4) Measure the hydraulic oil pressure with all 1. Loosen lock nut (8) and make adjustment, turn-
the control levers kept in the NEUTRAL ing adjusting screw (9).
position and the engine running at high ★ If the holder is turned to the right, the pump
idling and at low idling. absorption torque rises.
★ If PC-EPC valve output pressure chang- If the holder is turned to the left, the pump
es to the following values, it is judged absorption torque falls.
normal. ★ The adjustable range with the adjusting
screw is as shown below.
Engine Control Hydraulic oil • Left turn: Less than 1 turn
speed lever pressure • Right turn: Less than 1/2 turn (less than
2.9 MPa 180 degrees)
Low idling
Neutral {30 kg/cm2} 3 Lock nut:
High idling 0{0} 27.50–34.3Nm{2.8–3.5kgm}

Adjustment
★ If any of the phenomena mentioned below oc-
curs and PC valve malfunctioning is suspected,
adjust PC valves (6) and (7) in the following man-
ner.
• As workload increases, the engine rpm
sharply drops.
• While the engine rpm is normal, the work
equipment moves slowly.

2. Confirm that the PC valve output pressure

(servo piston inlet pressure) is normal after the
adjustment, following the measurement steps
explained earlier.

PC290-7 20-123
 INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE

INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL

CIRCUIT OIL PRESSURE
★ Pump LS control circuit oil pressure inspection
and adjustment tools

Mark Part No. Part Name

799-101-5002 Hydraulic Tester
1 Digital Type
790-261-1203
Hydraulic Tester
Grease Fitting
K 799-101-5220
2 (10 x 1.25 mm)
07002-11023 O-ring
Differential Pressure
3 799-401-1340
Gauge
2) Fit fitting K2 and connect it to oil pressure
Measurement gauge of hydraulic tester K1.
★ Measure pump LS control circuit oil pressure af- ★ Use an oil pressure gauge with the ca-
ter confirming that the work equipment, swing pacity of 58.5 MPa{600 kg/cm2}.
and travel circuit oil pressure as well as control
circuit original pressure are normal.
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate
the control lever several times to release the re-
maining pressure in the piping. Then loosen the
oil filler cap to release the pressure inside the hy-
draulic tank.

1. Measurement of LS valve output pressure

(servo piston inlet pressure)
★ Measure LS valve output pressure (servo
piston inlet pressure) and pump delivery
pressure together, and compare both pres-
sures thereafter.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
• Plug (1): For measuring the front pump
delivery pressure
• Plug (2): For measuring the rear pump
delivery pressure
• Plug (3): For measuring the front pump
LS valve delivery pressure
• Plug (4): For measuring the rear pump
LS valve delivery pressure

3) Start the engine and raise the track shoe to

be measured with the work equipment.
• For measuring oil pressure in front cir-
cuit: Right track shoe
• For measuring oil pressure in rear cir-
cuit: Left track shoe
k Provide a working area of sufficient space,
as the raised track shoe will be idly rotated.

20-124 PC290-7
 INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE

4) Wait until the hydraulic oil temperature rises • Plug (2): For measuring the rear pump
to the operating range. delivery pressure
• Plug (3): For measuring the front pump
LS pressure
• Plug (4): For measuring the rear pump
LS pressure

5) Measure pump delivery pressure and PC

valve output pressure (servo piston inlet
pressure) together with the machine set at
the following conditions and the engine run-
ning at high idling.
• Working mode: A mode
• All the control levers of the work equip-
ment, swing and travel are kept in the
NEUTRAL position and the travel control
lever is kept at half stroke (one side of
the track shoes idly rotates).
★ Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
★ Judgement method:
When the ratio between the pump deliv-
ery pressure and LS valve output pres-
sure (servo piston output pressure)
reaches the following values, both pres- 2) Fit fitting K2 and connect it to oil pressure
sures are judged normal. gauge of hydraulic tester K1 or differen-
tial pressure gauge K3.
Oil pressure ratio ★ When using a differential pressure
Oil pressure to be gauge:
All control levers Travel at half
measured Connect pump delivery pressure to the
in NEUTRAL stroke
Pump delivery high pressure side and LS pressure to
1 the low pressure side.
pressure Nearly equal
A differential pressure gauge requires
LS valve delivery pressure
Approx. 3/5 DC 12V power. Connect it with one bat-
pressure
tery.
★ When using an oil pressure gauge:
6) Detach all the measurement tools after the Use an oil pressure gauge with the ca-
measurement and make sure that the pacity of 58.5 MPa{600 kg/cm2}.
machine is back to normal condition. The max. differential pressure is no
more than approx. 40 MPa{3.9 kg/cm2}.
2. Measurement of LS differential pressure The same gauge may be used through-
★ LS differential pressure can be obtained by out the measurement.
measuring pump delivery pressure and LS
pressure (actuator loaded pressure) at the
same time and computing the difference of
both pressures.
1) Remove oil pressure measurement plugs
(1), (2), (3) and (4).
• Plug (1): For measuring the front pump
delivery pressure

PC290-7 20-125
 INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE

5) Measure pump delivery pressure and LS

pressure (actuator loaded pressure)
together with the machine set at the follow-
ing conditions and the engine running at
high idling.
• Working mode: A mode
• Traveling speed: Hi
• All the control levers of the work equip-
ment, swing and travel are kept in the
NEUTRAL position and the travel control
lever is kept at half stroke (one side of
the track shoes idly rotates).
★ Let the raised track shoe idly rotate, pay-
ing enough attention to the surroundings
for safety.
★ Calculation of LS differential pressure:
LS differential pressure = Pump delivery
pressure – LS pressure
★ If LS differential pressure is in the follow-
ing conditions, it is judged normal.

Control lever position LS differential pressure

All levers in Unload pressure
NEUTRAL (see standard value table)
Travel lever at Max. LS differential pressure
half stroke (see standard value table)

3) Start the engine and raise the track shoe to 6) Detach all the measurement tools after the
be measured with the work equipment. measurement, and make sure that the
• For measuring oil pressure in front cir- machine is back to normal condition.
cuit: Right track shoe
• For measuring oil pressure in rear cir- 3. Measurement of LS-EPC valve output pres-
cuit: Left track shoe sure
kProvide a working area of sufficient space, 1) Remove oil pressure measurement plug (5).
as the raised track shoe will be idly rotat-
ed.
4) Wait until the hydraulic oil temperature rises
to the operating range.

20-126 PC290-7
 INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL
TESTING AND ADJUSTING CIRCUIT OIL PRESSURE

2) Fit fitting K2 and connect it with oil pressure Adjustment

gauge of hydraulic tester K1. ★ When LS differential pressure is not normal, ad-
★ Use an oil pressure gauge with the ca- just it with LS valves (6) and (7).
pacity of 5.9 MPa{60 kg/cm2}.

1. Loosen lock nut (8) and adjust the pressure by

3) Start the engine and keep it running until the tuning adjusting screw (9).
hydraulic oil temperature rises to the operat- ★ If the adjusting screw is turned to the right,
ing range. the differential pressure rises.
If the adjusting screw is turned to the left, the
differential pressure falls.
★ Adjustment amount (LS differential pres-
sure) per turn of adjusting screw:
1.3 MPa{13.3 kg/cm2}
3 Lock nut: 49–64 Nm{5–7 kgm}

4) Measure the oil pressure when the engine is

running at high idling and the travel speed
switch and travel lever are operated.
★ If LS-EPC valve output pressure chang-
es to the following values, the pressure
is normal.
2. After the adjustment, confirm that LS differential
Travel Travel Control Hydraulic pressure is normal, following the steps for mea-
Speed Lever Pressure surement explained earlier.
Approx. 2.9 MPa
Lo Neutral
{approx. 30 kg/cm2}
Hi Fine control (Note) 0{0}
Note: Operate the travel control lever
slightly to the extent that the PPC
hydraulic oil pressure is turned ON.
(Stop the operation short of starting
the machine)
5) Detach all the measurement tools after the
measurement, and make sure that the
machine is back to normal condition.

PC290-7 20-127
 MEASUREMENT OF SOLENOID VALVE OUTPUT PRES-
TESTING AND ADJUSTING SURE

MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

★ Solenoid valve output pressure measurement
tools

Mark Part No. Part Name

799-101-5002 Hydraulic Tester
1 Digital Type
790-261-1203
Hydraulic Tester
L
Grease Fitting
799-401-2910
2 (Size 02)
07002-*1423 O-ring

★ Measure solenoid valve output pressure after

confirming that control circuit original pressure is 2. Fit fitting L2 and connect hoses (1) through (6)
normal. again.
k Lower the work equipment to the ground and
stop the engine. After the engine stops, operate 3. Fit fitting of hydraulic tester L1 and connect it
the control lever several times to release the re- to oil pressure gauge .
maining pressure in the piping. Then loosen the ★ Use an oil pressure gauge with the capacity
oil filler cap to release the pressure inside the hy- of 5.9 MPa{60 kg/cm2}.
draulic tank.

1. Disconnect the hoses of solenoid valve to be

measured at the outlet side.
No. Solenoid valve to be measured
1 PPC lock solenoid valve
2 Travel interconnection solenoid valve
3 Merge/divide solenoid valve
4 Travel speed shifting solenoid valve
5 Swing and parking brake solenoid valve
6 2-stage relief solenoid valve

★ Hose (1) is installed at the rear of operator's 4. Start the engine and keep it running until the
cab, and hoses (2) through (6) are installed hydraulic oil temperature rises to the operating
at the center of revolving frame. range.

5. Run the engine at full throttle, then turn each

solenoid valve ON or OFF by operating the con-
trol lever switch, and measure the pressure.
★ For conditions for turning each solenoid
valve ON or OFF, refer to the ensuing "Table

20-128 PC290-7
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

for Functioning Conditions" for each sole-

noid valve.
★ How each solenoid valve functions can be
confirmed with monitoring function in the
monitor panel. (Special Function of Machine
Monitor)
★ When each output pressure shows the fol-
lowing values, it is judged normal.
Solenoid Valve Output Pressure
OFF (Demagnetization) 0{0}
ON (Excitation) 3MPa{30kg/cm2}

6. Detach all the measurement tools after the mea-

surement, and make sure that the machine is
back to normal condition.

Table for Functioning Conditions - PPC lock

solenoid valve
Table for Functioning Conditions - Swing and
Functioning Condition Functioning
parking brake solenoid
Locked OFF
Safety lock lever Functioning Condition Functioning
Released ON
When all of them
Work equipment, is OFF OFF
swing, travel,
When any of them
signaling ON
is ON

Table for Functioning Conditions - Travel interconnection solenoid valve

Functioning Condition Functioning
When the travel steering signal is ON ON
If front or rear pump pressure
Traveling operation only ON
When the travel steering signal is OFF is over 24.5MPa{250kg/cm2}
In conditions other than above OFF

Table for Functioning Conditions - Travel speed shifting solenoid valve

Functioning Condition Functioning
When overheat setting of the 2nd stage is ON
When the fuel dial indicates less than 1500 rpm
When the travel speed switch is at Lo (or Mi)
OFF
The travel signal is OFF
If front or rear pump pressure is
When the travel speed switch is at Hi The travel 24.5 MPa{250 kg/cm2}
signal is ON If front or rear pump pressure is
15.3 MPa{150 kg/cm2} ON
In conditions other than above
: The "Mi" mode is on the multi-monitor specification machine only.

Table for Functioning Conditions - 2-stage relief solenoid valve

Functioning Condition Functioning
When overheat setting of the 1st stage is ON
When overheat setting of the 2nd stage is ON OFF
When all the signals for work equipment, swing and travel are OFF

PC290-7 20-129
TESTING AND ADJUSTING MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE

When swing lock switch is ON

When travel signal is ON
When working mode is L mode ON
When boom LOWER signal is ON
When working mode is A or E When left knob If signals other than swing operation only is ON
mode switch is ON If swing operation only is ON
OFF
In conditions other than above

Table for Functioning Conditions - Merge/divide solenoid valve

Functioning Condition Functioning
When working mode is B mode When service signal is ON
When working mode is L mode When boom RAISE and swing signals are ON
When travel signal only is ON ON
When compound travel marks When steering sig- If front or rear pump pressure is over 19.6
are ON nal is OFF MPa (200 kg/cm2)
When swing lock switch is ON
When working mode is A mode OFF
When swing signal is ON
When travel signal is OFF
When service and If front or rear pump
When swing signal
arm dumping pressure is over ON
is OFF
signal are ON 19.6 MPa{200 kg/cm2}
In conditions other than above OFF
: The "L" mode is on the multi-monitor specification machine only.

20-130 PC290-7
TESTING AND ADJUSTING MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

MEASUREMENT OF PPC VALVE OUTPUT PRESSURE

★ PPC valve output pressure measurement tools 2. Fit fitting of hydraulic tester M and connect oil
pressure gauge .
Mark Part No. Part Name ★ Use an oil pressure gauge with the capacity
799-101-5002 Hydraulic Tester of 5.9 MPa{60 kg/cm2}.
M Digital Type
790-261-1203
Hydraulic Tester

★ Measure PPC valve output pressure after con-

firming that control circuit original pressure is
normal.

1. Remove PPC oil pressure switches (1) through

(12) in the hydraulic circuits to be measured.
Circuit to be Circuit to be
No. No.
measured measured
1 Boom, RAISE 7 Swing, left
2 Boom, LOWER 8 Swing, right 3. Start the engine and keep it running until the
3 Arm, DIGGING 9 Travel (black) hydraulic oil temperature rises to the operating
4 Arm, DUMPING 10 Steering (red) range.
5 Bucket, DIGGING
6 Bucket, DUMPING

★ Oil pressure switches (1) through (8) are in-

stalled in the PPC relay block, and (9) and (10)
are installed at the rear of operator's cab.

4. Measure the pressure when the engine is run-

ning at high idling and the control lever of the cir-
cuit to be measured is kept in the NEUTRAL
position and at the full stroke.
★ If PPC valve output pressure is at the level
shown below, it is judged normal.
Lever Control Hydraulic Pressure
In NEUTRAL 0{0}
Nearly equal to control
At full stroke original pressure
(see standard value table)

5. Detach all the measurement tools, and make

sure that the machine is back to normal condi-
tion.

PC290-7 20-131
TESTING AND ADJUSTING ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE

ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE

★ If there is excessive play in the work equipment
or swing lever, adjust it in the following manner.

1. Remove work equipment and swing PPC valve

ass'y.

2. Take off boot (1).

3. Loosen lock nut (2) and screw in disc (3) until it

contacts the heads of four pistons (4).
★ Do not move the piston while doing this work.

4. Keep disc (3) in place and tighten lock nut (2) to

the specified tightening torque.
3 Lock nut: 98–127 Nm{10–13 kgm}

5. Install boot (1).

6. Install work equipment and swing PPC valve

ass'y.

20-132 PC290-7
TESTING AND ADJUSTINGINSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT

INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK

EQUIPMENT
★ If there is any hydraulic drift in the work equip- 2. Inspection of arm cylinder
ment (cylinders), check in the following manner 1) Operate the arm cylinder to move the arm to
to determine if the cause is in the cylinder pack- the position 100 mm before the digging
ing or in the control valve. stroke end, and stop the engine.

1. Inspection of boom and bucket cylinders

1) Set the work equipment in the same posture
as when measuring hydraulic drift, and stop
the engine.
★ Fill the bucket with earth or apply the rat-
ed load to the bucket.

2) Operate the arm control lever to move the

arm to the digging side.
• If the lowering speed increases, the cyl-
inder packing is defective.
• If there is no change, the control valve is
defective.
★ Operate the control lever with the engine
2) Operate the control lever to the RAISE posi- starting switch in the ON position.
tion or the bucket control lever to the CURL ★ If pressure in the accumulator has
position. dropped, run the engine for approx. 10
• If the lowering speed increases, the cyl- seconds to charge the accumulator again.
inder packing is defective. [Reference]If the cause of the hydraulic drift is in the
• If there is no change, the control valve is defective packing, and the above opera-
defective. tion is carried out, downward movement
★ Operate the control lever with the engine is accelerated for the following reasons.
starting switch in the ON position. 1) If the work equipment is set to the above pos-
★ If pressure in the accumulator has ture (holding pressure applied to the bottom
dropped, run the engine for approx. 10 end), the oil at the bottom end leaks to the head
seconds to charge the accumulator end. However, the volume at the head end is
again. small than the volume at the bottom end by the
volume of the rod end, so the internal pressure
at the head end increases because of the oil
flowing in from the bottom end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end also
rises in proportion to this. The balance is main-
tained at a certain pressure (this differs accord-
ing to the amount of leakage) by repeating this
procedure.
3) When the pressure is balanced, the downward
movement becomes slower. If the lever is then
operated according to the procedure given
above, the circuit at the head end is opened to
the drain circuit (the bottom end is closed by the
check valve), so the oil at the head end flows to
the drain circuit and the downward movement
becomes faster.

PC290-7 20-133
 RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIR-
TESTING AND ADJUSTING CUIT

3. Inspection of boom lock valve

1) Set the work equipment at the maximum
RELEASE OF REMAINING
reach and the boom top horizontal. Then PRESSURE IN HYDRAULIC
stop the engine. CIRCUIT
k Lock the work equipment control levers and
release the pressure inside the hydraulic k If the piping between the hydraulic cylinders or
tank. the hydraulic motor and control valves is to be
k Do not allow anyone to come under the disconnected, release the remaining pressure in
work equipment during the work. the following manner.
2) Disconnect drain hose (1) of the control ★ There is no pressure remaining in the swing mo-
valve, and install a blind plug in the hose. tor circuit and travel motor circuit, but the internal
• Part No. for the blind hose: 07376-70210 pressure in the hydraulic tank affects them. So
★ Leave the control valve end open. open the oil filler cap of the hydraulic tank.
★ If any oil leaks out from the port that is
left open, following hydraulic drift of the 1. Stop the engine, and loosen the oil filler cap
work equipment, the boom lock valve is gradually to release the pressure inside the
defective (loose contact). tank.

2. Turn the engine starting switch to the ON posi-

tion and operate the control levers several
times.
★ There must be power supply to the PPC lock
valve. Be sure to operate the control levers
with the engine starting switch in the ON po-
sition.
★ When the levers are operated 2-3 times, the
pressure stored in the accumulator is re-
moved.

3. Start the engine, run at low idling for approx. 10

seconds to accumulate pressure in the accumu-
4. Inspection of PPC valve lator, then stop the engine.
Measure the amount of hydraulic drift of the
work equipment when the accumulator is 4. Repeat the steps in Item 2 to 3 above several
charged with pressure and the safety lock lever times.
is put to the LOCK and FREE positions.
★ Operate the control lever with the engine
starting switch in the ON position.
★ If pressure in the accumulator has dropped,
run the engine for approx. 10 seconds to
charge the accumulator again.
★ If there is any difference in the hydraulic drift
between LOCK and FREE positions, the
PPC valve is defective (some internal fail-
ure).

20-134 PC290-7
 INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE AMOUNT

MEASUREMENT OF OIL LEAKAGE AMOUNT

1. Measurement of oil leakage amount from 4) Continue this condition for 30 seconds, then
boom cylinder measure the oil leakage amount for one
1) Start the engine and keep it running until the minute.
hydraulic oil temperature rises to the operat-
ing range. Then extend the boom cylinder to
the stroke end.
k Release the pressure remaining in the pip-
ing, referring to the foregoing section of
"Release of Remaining Pressure in Hydrau-
lic Circuit".
2) Disconnect hose (1) at the cylinder head
end and block the hose end with a plate.
k Be careful not to disconnect the hose at the
cylinder bottom end.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine running at high idling.
4) Continue this condition for 30 seconds, then 5) After the measurement, make sure that the
measure the oil leakage amount for one machine is back to normal condition.
minute.
3. Measurement of oil leakage amount from
bucket cylinder
1) Start the engine and keep it running until the
hydraulic oil temperature rises to the operat-
ing range. Then extend the bucket cylinder
to the digging stroke end.
k Release the pressure remaining in the pip-
ing, referring to the foregoing section of
"Release of Remaining Pressure in Hydrau-
lic Circuit".
2) Disconnect hose (3) at the cylinder head
end block the hose end with a plate.
k Be careful not to disconnect the hose at the
cylinder bottom end.
5) After the measurement, make sure that the 3) Start the engine and apply the relief pres-
machine is back to normal condition. sure to the bottom end of the cylinder with
the engine running at high idling.
2. Measurement of oil leakage amount from 4) Continue this condition for 30 seconds, then
arm cylinder measure the oil leakage amount for one
1) Start the engine and keep it running until the minute.
hydraulic oil temperature rises to the operat-
ing range. Then extend the arm cylinder to
the digging stroke end.
k Release the pressure remaining in the pip-
ing, referring to the foregoing section of
"Release of Remaining Pressure in Hydrau-
lic Circuit".
2) Disconnect hose (2) on the cylinder head
end and block the hose end with a plate.
k Be careful not to disconnect the hose at the
cylinder bottom end.
3) Start the engine and apply the relief pres-
sure to the bottom end of the cylinder with
the engine running at high idling.
5) After the measurement, make sure that the
machine is back to normal condition.

PC290-7 20-135
TESTING AND ADJUSTING MEASUREMENT OF OIL LEAKAGE AMOUNT

4. Measurement of oil leakage amount from 3) Disconnect drain hose (6) of the travel
swing motor motor and fit a blind plug in the hose end.
1) Disconnect drain hoses (4) and (5) and fit a 4) Start the engine and apply the travel relief
blind plug in the hoses. pressure with the engine running at high
2) Turn the swing lock switch to the ON posi- idling, then measure an oil leakage amount
tion. under such conditions.
3) Start the engine. Apply the swing relief pres- kIn this measurement, an erroneous opera-
sure with the engine running at high idling tion of the control lever will likely lead to
and measure an oil leakage amount under a serious accident. Make sure that all the
such conditions. signals and confirmations are followed
★ After keeping the conditions in 3) above without fail.
for 30 seconds, measure the oil leakage ★ After keeping the conditions in 4) above
amount for one minute. for 30 seconds, measure the oil leakage
★ After the first measurement, turn the up- amount for one minute.
per structure by 180 degrees and take ★ Repeat the measurement several times,
measurement again in the same way. slightly rotating the motor, i.e. shifting
the position of valve plate and cylinder,
and the position of cylinder and piston,
and take measurement several times.

4) After the measurement, make sure that the

machine is back to normal condition.

5. Measurement of oil leakage amount from 5) After the measurement, make sure that the
travel motor machine is back to normal condition.
1) Take off the travel motor cover.
2) Start the engine and lock the travel.
k Put pin in between the sprocket and the
track frame to block the travel.

20-136 PC290-7
TESTING AND ADJUSTING AIR BLEEDING OF VARIOUS PARTS

AIR BLEEDING OF VARIOUS PARTS

Steps for air bleeding
Air bleeding item
1 2 3 4 5 6
Hydraulic Cylinder Swing Travel
Engine Operation
pump air air motor air motor air
Contents of Work start start
bleeding bleeding bleeding bleeding
• Change of hydraulic oil
{ { { { { {
• Cleaning of strainer (Note) (Note)
• Replacement of return filter element { {
• Repair or replacement of
hydraulic pump { { { {
• Removing suction pipe
• Repair or replacement of control valve { { {
• Replacement of cylinder
{ { {
• Removing cylinder piping
• Replacement of swing motor
{ { {
• Removing swing motor piping
• Replacement of travel motor swivel
{ { {
• Removing travel motor swivel piping
Note: Bleed air from the swing motor and travel motor only when oil in the casing is drained.

1. Air bleeding from hydraulic pump 2. Air bleeding from hydraulic cylinder
1) Loosen air bleeding plug (1) and confirm 1) Start the engine and kept it running at low
that oil seeps out from the plug. idling for 5 minutes.
2) If the oil seepage is confirmed, tighten air 2) Raise and lower the boom 4 to 5 times with
bleeding plug (1). the engine running at low idling.
3 Air bleeding plug: ★ Be careful not to apply the relief pres-
7.8–9.8 Nm{0.8–1.0 kgm} sure, stopping the piston rod approx.
★ Precautions for starting engine 100 mm before its stroke end.
When starting the engine after the air bleed- 3) Repeat the steps in Item 2) above, but this
ing work explained above, run the engine at time with the engine running at high idling.
low idling for 10 minutes. 4) Apply the relief pressure by extending the
If the engine cooling water temperature is piston rod to its stroke end and with the
low and an automatic engine warming-up engine running at low idling.
function is relied on, use the fuel dial, when it 5) For bleeding air from the arm cylinder and
becomes necessary to cancel it. bucket cylinder, follow the same steps
explained in Item 2) through 4) above.
★ In case a cylinder is replaced with new one,
it is advised to bleed air from the new one be-
fore mounting the work equipment. It is es-
pecially so with the boom cylinder, because
its rod does not extend to the stroke end of
LOWER side, after the work equipment is
mounted.

3. Air bleeding from swing motor

1) Start the engine and run it at low idling.
2) Bleed air from the motor by swinging the
upper structure slowly.

4. Air bleeding from travel motor

1) Start the engine and run it at low idling.

PC290-7 20-137
TESTING AND ADJUSTING AIR BLEEDING OF VARIOUS PARTS

2) Loosen air bleeding plug (2) and confirm

that oil seeps out from the plug.
3) If the oil seepage is confirmed, tighten air
bleeding plug (2).
3 Air bleeding plug:
27.5–35.3 Nm{2.8–3.6 kgm}

20-138 PC290-7
TESTING AND ADJUSTING INSPECTION PROCEDURES FOR DIODE

INSPECTION PROCEDURES FOR DIODE

★ Check an assembled-type diode (8 pins) and sin- 3) Determine if a specific diode is good or no
gle diode (2 pins) in the following manner. good with the indicated value.
★ The continuity direction of an assembled-type di- • No change in the indicated value: No
ode is as shown in the diagram below. continuity (defective).
★ The continuity direction of a single diode is • Change in the indicated value: Continui-
shown on the diode surface. ty established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.

2. When using analog type circuit tester

1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the fol-
lowing connections.
i) Put the red probe (+) of the test lead to
the anode (P) and the black probe (–) to
the cathode (N) of diode.
ii) Put the red probe (+) of the test lead to
the cathode (N) and the black probe (–)
to the anode of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
1. When using digital type circuit tester • If the needle does not swing in Case i),
1) Switch the testing mode to diode range and but swings in Case ii): Normal (but the
confirm the indicated value. breadth of swing (i.e. resistance value)
★ Voltage of the battery inside is displayed will differ depending on a circuit tester
with conventional circuit testers. type or a selected measurement range)
2) Put the red probe (+) of the test lead to the • If the needle swings in either case of i)
anode (P) and the black probe (–) to the and ii): Defective (short-circuited inter-
cathode (N) of diode, and confirm the dis- nally)
played value. • If the needle does not swing in any case
of i) and ii): Defective (short-circuited in-
ternally)

PC290-7 20-139
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

SPECIAL FUNCTION OF MULTI-MONITOR PANEL

[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0

20-140 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

Monitor panel functions - conventional and special

The monitor panel is provided with conventional and special functions, and various kind of information are
shown in the multi-display. Display items consists of automatic display items that are preset in the monitor panel
and others that are shown by switch operations.

1. Conventional function: Operator's Menu

This is a function by which an operator can set or show displays by switch operations. The display contents
are those which are normally shown.

2. Special function: Service Menu

This is a function by which a service mechanic can set or show displays by special switch operations. The
display contents are those which are not normally shown. It is mainly used for inspection, adjustment, trou-
ble-shooting or special setting of machines.

Operator's Menu Service Menu

1 Function for inputting and setting password 16 Function for monitoring [01]
2 Function for showing Komatsu's logo Function for fail- Electrical system
17
Function for machine inspection before start- ure history [02] Mechanical system
3
ing day's work
18 Function for maintenance history [03]
4 Function for showing machine maintenance
19 Function for maintenance mode change [04]
5 Function for showing precaution items
20 Function for recording phone No. [05]
Function for confirming working mode and
6 Mode with key ON
travel speed
Function for ini- Language
7 Function for display of ordinary items tial value set-
21 Unit
Function for adjusting display luminance and ting and default
8 [06] Attachment installed/No
contrast
attachment installed
Function for adjusting breaker and attach-
9 Adjustment of governor
ment flow rate
lever stroke
Function for confirming maintenance informa-
10 Fuel pump absorbin torque
tion Function for
22
11 Function for showing service meter reading adjustment [07] RPM at low idling
12 Function for checking display LCD Adjustment of oil flow to
attachment
Function for showing occurrence of caution
13
item
14 Function for showing users' code No.
Function for showing service code No. and
15
failure code No.

PC290-7 20-141
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

Operation of Operator's Menu and

Display (Outline)
★ This section introduces only the outline of the op-
erator's menu. For details on the contents and
operation steps of each menu, refer to the oper-
ation and maintenance manual or the chapter of
"STRUCTURE AND FUNCTION" in this shop
manual.

1. Function for inputting and setting password

When the engine starting switch is turned ON,
the password inputting display is shown.
★ This display is shown only when a password
is registered.

2. Function for showing KOMATSU logo

When a password is inputted, or when the
engine starting switch is turned ON, KOMATSU
logo is shown for two seconds.

3. Function for machine inspection before

starting day's work
Following the KOMATSU logo, the display of
machine inspection before starting day's work is
shown for 2 seconds.

4. Function for machine maintenance

Following the display of machine inspection
before starting day's work, the maintenance
mark appears for 30 seconds, if there is an oil fil-
ter whose maintenance time is approaching or
has just passed.
★ This display appears only when the mainte-
nance function is set.

20-142 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

5. Function for showing precaution items

If there is any item of machine inspection before
starting day's work that indicates some abnor-
mality, a corresponding symbol mark is shown
after the display of machine inspection before
starting day's work.

6. Function for confirming working mode and

travel speed
After the display of machine inspection before
day's work, amplified symbol marks for working
mode and travel speed are shown for two sec-
onds to urge an operator to confirm the setting.

7. Function for display of ordinary items

The display of confirming working mode and
travel speed is switched to this display of ordi-
nary items.
★ If the working mode setting or travel speed
setting is changed, or auto-deceleration or
windshield wiper setting is activated while
this is in display, an amplified corresponding
symbol mark is shown for two seconds.
★ In this display, a symbol mark for preheat
monitor is shown only when preheating is
carried out.

8. Function for adjusting display luminance

and contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.

PC290-7 20-143
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

9. Function for adjusting breaker and attach-

ment flow rate (For machines equipped with
breaker attachment)
When a breaker or other attachments are used,
hydraulic pump flow rate can be adjusted by
operating the select switch.
★ Note that the symbol mark and contents of
display partially differ between the breaker
and the other attachments.

10. Function for confirming maintenance infor-

mation
Detailed information on maintenance items (set
time and elapse of time) can be confirmed and
resetting after the confirmation is feasible by
operating the maintenance switch.
★ Use service Menu for setting or releasing
maintenance items and setting maintenance
time.

11. Function for showing service meter reading

Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
• Switching operation: [ ] + [ ] (synchro-
nized switching operation)

12. Function for checking display LCD

Display of the Display LCD can be confirmed by
the following switching operation in the display
of inputting and setting password as well as in
the display of ordinary items
• Switching operation: [ ] + [A] (synchro-
nized switching operation)
★ All the LCD light up, turning the entire screen
white. If there is no showing in black, the dis-
play is normal.
★ This display returns to the immediately pre-
ceding one, if making any other switching
operation.

20-144 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

13. Function for showing occurrence of caution

item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for two
seconds and thereafter stays on the display as a
small symbol mark until it is dissolved.

14. Function for showing users' code No.

When a trouble occurs on the machine, the
user's code is automatically displayed depend-
ing on the magnitude of the trouble to call atten-
tion of the operator for a proper action.
★ This display turns to the display of service
code and failure code, if operating the switch
(Refer to Item No. 15)

★ Relation between User Code and Action Directed to Operator

User
Failed System Action Directed to Operator
Code
Ordinary work may be resumed by turning the emergency pump drive switch ON,
E02 PC-EPC Valve
but call for the inspection service immediately.
Release the brake after turning emergency swing and parking brake switch ON.
When applying the swing brake, operate the swing lock switch manually. The
E03 Swing Brake
swing brake may not be released depending on the nature of the trouble. In either
case, call for the inspection service immediately.
The governor control has become inoperable. Operate the governor control lever
E05 Governor manually. For fixing the lever at full throttle position, use a fixing bolt provided at
the bracket. In this case, call for the inspection service immediately.

PC290-7 20-145
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

15. Function for showing service code No. and

failure code No.
If the following switching operation is made
while the users' code No. is shown, a phone
symbol (if registered), phone numbers (if regis-
tered), service code No. and failure code No.
are shown in turn.
• Switching operation: [ ] (keep the switch
depressed)
★ The following display is repeated in turn,
while the switch is depressed.
Telephone symbol mark
Ø
Telephone No.
Ø
Service code No. and failure code No.
★ The telephone symbol mark and telephone
No. are shown only when they are registered
in the monitor panel.
For registration, correction and deletion of
telephone No., use Service Menu.
★ For details on the displayed service code No.
and failure code No., refer to the Table for
Service and Failure Code Nos.

20-146 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

Table for Service and Failure Code Nos.

Classification
Service Code Failure Code
User Code

Failure
No.

Code
Content Code No. Location Phenomenon
No.

Abnormality
– E101 Abnormal data in error history DAF0KT Failure history
in data
Short circuit in wiper motor drive, normal rota-
Windshield wiper motor (nor-
– E112 DY2DKB Short circuit
tion system mal rotation)
Short circuit in wiper motor drive, reverse rota-
Windshield wiper motor
– E113 DY2EKB Short circuit
tion system (reverse rotation)
– E114 Short circuit in windshield washer drive
DY2CKB Windshield washer motor Short circuit
– E115 Abnormality of windshield wiper in motion
DY20KA Windshield wiper motor Disconnection
– E116 Abnormality of windshield wiper in retraction
DY20MA Windshield wiper motor Malfunctioning
Travel interlocking solenoid
– E201 Short circuit in travel interconnection solenoid DW91KB Short circuit
valve
E03 E203 Short circuit in swing holding brake solenoid DW45KB Swing holding solenoid valve Short circuit
– E204 Short circuit in merge/divide solenoid DWJ0KB Merge solenoid valve Short circuit
– E205 Short circuit in 2-stage relief solenoid DWK0KB 2-stage relief solenoid valve Short circuit
Travel Hi-Lo shifting solenoid
– E206 Short circuit in travel speed shifting solenoid DW43KB Short circuit
valve
Travel interlocking solenoid
– E211 Disconnection in travel interlocking solenoid DW91KA Disconnection
valve
E03 E213 Disconnection in swing holding brake solenoid DW45KA Swing holding solenoid valve Disconnection
– E214 Disconnection in merge/divide solenoid DWJ0KA Merge solenoid valve Disconnection
– E215 Disconnection in 2-stage relief solenoid DWK0KA 2-stage relief solenoid valve Disconnection
Travel Hi-Lo shifting solenoid
– E216 Disconnection in travel speed shifting solenoid DW43KA Disconnection
Electrical system
valve
Nonconfor-
– E217 Abnormality in model code input DA2SKQ S_NET mance in model
selecting signal
– E218 Disconnection in S_NET signal DA2SKA S_NET Disconnection
– E222 Short circuit in LS-EPC solenoid DXE0KB LS-EPC solenoid valve Short circuit
– E223 Disconnection in LS-EPC solenoid DXE0KA LS-EPC solenoid valve Disconnection
– E224 Abnormality in F pump pressure sensor DHPAMA F pump pressure sensor Malfunctioning
– E225 Abnormality in R pump pressure sensor DHPBMA R pump pressure sensor Malfunctioning
Lowering in out-
– E226 Abnormality in pressure sensor power source DA25KP Governor pump controller
put voltage
– E227 Abnormality in engine revolution sensor DLE2MA Engine revolution sensor Malfunctioning
– E228 Short circuit in ATT return switching relay D196KB ATT switching relay Short circuit
E02 E232 Short circuit in PC-EPC solenoid DXA0KB TVC solenoid valve Short circuit
E02 E233 Disconnection in PC-EPC solenoid DXA0KA TVC solenoid valve Disconnection
– E238 Disconnection in ATT return switching relay D196KA ATT switching relay Disconnection
ATT flow rate throttling EPC
– E245 Short circuit in ATT flow rate adjusting EPC DXE4KB Short circuit
valve
ATT flow rate throttling EPC
– E246 Disconnection in ATT flow rate adjusting EPC DXE4KA Disconnection
valve
Abnormality in
– E256 Incorrect nonvolatile memory data DA20KT Nonvolatile memory
data
Governor motor feedback
– E306 Abnormality in governor potentiometer DK54KZ Malfunctioning
potentiometer
E05 E308 Abnormality in fuel dial DK10KZ Throttle potentiometer Malfunctioning
– E315 Short circuit in battery relay output D110KB Battery relay Short circuit
– E316 Abnormality in governor motor step-out DY10K4 Governor motor Out of control

PC290-7 20-147
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

Classification
Service Code Failure Code
User Code

Failure
No.

Code
Content Code No. Location Phenomenon
No.

E05 E317 Disconnection in both governor motors A and B DY10KA Governor motor Disconnection
E05 E318 Short circuit in both governor motors A and B DY10KB Governor motor Short circuit

Electrical system
Error in operation
E50 E501 No setting in model selection DA2AKM Governor pump controller
or setting
Abnormality in
E50 E502 Malfunction in model selecting signal DA20KT Governor pump controller
data
Abnormality in boom angle sensor (short circuit
E50 E511 DKA0KB Boom angle sensor Short circuit
in power source)
– None Engine high idling out of rate A000N1 Engine Overrunning
Low idling out of
– None Engine low idling out of rate A000N2 Engine
rate
– None Air cleaner clogged AA10NX Air cleaner element Clogging
Insufficient

Mechanical system
– None Charging voltage abnormally low AB00KE Alternator
charging
Oil pressure low-
– None Engine oil pressure abnormally low B@BAZG Engine oil
ered
– None Engine oil level abnormally low B@BAZK Engine oil Oil level lowered
– None Engine cooling water overheated B@BCNS Engine cooling water Overheating
Cooling water
– None Radiator water level abnormally low B@BCZK Engine cooling water
level lowered
– None Hydraulic oil overheated B@HANS Hydraulic oil Overheating
Auto-lubrication system con-
– None Auto-lubrication system abnormal DA80MA Malfunction
troller

★ This table is arranged in the sequence of Service Code No.

★ In case there is no number assigned in the column of User Code No., or in case "none" is described in the
column of Code No. of Service Code, the corresponding service code or failure code is not shown in the dis-
play of ordinary items, even if some abnormality occurs. It is recorded only in the failure history (either in elec-
trical system or mechanical system) of Service Menu.
★ History Classification indicates that a specific failure is classified as belonging to either electrical system or
mechanical system, when it is recorded in Service Menu.
★ "E" at the head of Code No. of Service Code means the following status of a specific failure.
• With "E": The failure is yet to be dissolved and continues.
• Without "E": The failure has already been dissolved.

20-148 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

Operation and Display of Service Menu

Way of switching to Service Menu

★ When using Service Menu, change the display to
Service Menu display through the following spe-
cial operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
★ Changing to Service Menu cannot be made
from displays other than this.

2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] ➝ [2] ➝ [3]
(Enter a figure, depressing [ ])

3) Showing Service Menu display

The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.

No. Service Menu

00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
06 ✩✩✩✩✩ / Default
07 Adjustment
08 –

4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent display of Service Menu, do that
through any one of the following methods.
Depress [ ] switch. (This method may be
used for terminating any display)
If "Return" switch is shown, depress it.
If "Return" menu is shown, call that menu
and depress [ ] switch.

PC290-7 20-149
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

16. Function of monitoring [01]

The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Moni-
tored information can be put in display or con-
firmed on a real time basis through the following
operations.

1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.

2) Setting of monitoring item

Select or register an item to be monitored
through the following switch operation.
• [ ] switch: Selection
• [ ] switch: Selection
• [ ] switch: Registration
★ A monitoring item can be set in any number
between the min. one to the max. four. (De-
pending upon the selected item, the max.
number is less than four)
★ In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
• Keep [ ] switch depressed. (For about
3 seconds)
• Select Menu 999 and depress [ ]
switch.
★ The display automatically moves to the dis-
play of monitored information, when all of the
registrable items have been duly registered.
★ Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communica-
tion speed. If truly real time monitoring is re-
quired, reduce the selected items to the
minimum.
★ For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.

20-150 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.

4) Monitored information holding function

If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this con-
dition, information holding is released.

5) Machine setting mode switching function

If it becomes necessary to change settings
of working mode, select mode, travel speed
and auto-decel while monitoring, depress
the corresponding switch, then the mode
confirmation display is shown.
★ An illustration at right shows the display in A
mode and E mode. Symbol marks are par-
tially different in B mode.
★ When a specific setting is confirmed, de-
press [ ] switch, then the display returns to
that of monitoring.
★ In case a specific setting has been changed
while monitoring, the new setting is still
maintained when returning from Service
Menu to Operator's Menu after the monitor-
ing is finished.

PC290-7 20-151
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

Table for Monitoring Items

Code Unit (Default: ISO)
Item to be monitored Remark
No. ISO Meter Inch
000 Return (Not displayed) Termination menu
Execute
999 To Display Screen (Not displayed)
Command menu
002 Controller Model Select Figure
003 Controller Model Select Figure
010 Engine Speed r/min rpm rpm
011 F Pump Pressure MPa kg/cm 2
PSI
012 R Pump Pressure MPa kg/cm2 PSI
013 PC-EPC Sol. Curr. mA mA mA
015 LS-EPC Sol. Curr. mA mA mA
016 2nd Eng. Speed Command r/min rpm rpm
017 Service Sol. Curr. mA mA mA
Swing ON/OFF
Travel ON/OFF
Pressure Boom Lower ON/OFF
019
Switch 1 Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Pressure Bucket Dump ON/OFF
021
Switch 2 Service ON/OFF
Travel Steering ON/OFF
Lever Sw. ON/OFF
022 Switch Input 1 Swing Release Sw. ON/OFF
Swing Brake Sw. ON/OFF
Travel Junction ON/OFF
Swing Brake ON/OFF
023 Solenoid valve 1 Merge-divider ON/OFF
2-stage Relief ON/OFF
Travel Speed ON/OFF
024 Solenoid valve 2 Service Return ON/OFF
Model Select 1 ON/OFF
Model Select 2 ON/OFF
027 Switch Input 2 Model Select 3 ON/OFF
Model Select 4 ON/OFF
Model Select 5 ON/OFF
030 Fuel Dial Vol. V V V
031 Gov. Motor Potentio Vol. V V V
032 Battery Voltage V V V
033 Gov. Motor Phase A Curr. mA mA mA
034 Gov. Motor Phase B Curr. mA mA mA
035 Battery Relay O/P Vol. V V V
036 Switch Input 3 Key Switch ON/OFF
Batt. Relay Dr. ON/OFF
037 Controller Output
Engine Stop SOL. ON/OFF
041 Engine Water Temperature ºC ºC ºF
042 Fuel Lever Sensor Vol. V V V

20-152 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

Code Unit (Default: ISO)

Item to be monitored Remark
No. ISO Meter Inch
043 Battery Charge Vol. V V V
044 Hydr. Oil Temperature ºC ºC ºF
Key Switch ON/OFF
Start ON/OFF
Preheat ON/OFF
045 Monitor Input 1
Light ON/OFF
Rad. level ON/OFF
Hydr. Oil Level ON/OFF
Aircleaner ON/OFF
Eng. Oil Press. ON/OFF
046 Monitor Input 2 Eng. Oil Level. ON/OFF
Spare ON/OFF
Battery Charge ABN•NOR
Swing Brake Sw. ON/OFF
Buzzer cancel Sw. ON/OFF
049 Monitor Input 3 Window Limit Sw. ON/OFF
W Limit Sw. ON/OFF
P Limit Sw. ON/OFF
200 Monitor Prog. Version Figure
201 Controller Prog. Version Figure

★ Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When
changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu.
★ Abbreviations, ABN and NOR, stand for the following conditions.
ABN: Abnormal, NOR: Normal
★ It cannot be monitored how the machine push-up solenoid valve works.

PC290-7 20-153
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

17. Function for Abnormality Record [02]

The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.

1) Selection of menu
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.

2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical System
02 Mechanical Systems

3) Information shown in display of Abnormality

Record in the electrical system
: The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
: Service Code
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Time elapsed since the occurrence of
the first failure
: Contents of failure
★ Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.

4) Information shown in display of Failure His-

tory in the mechanical systems
: Record No.
: Contents of Abnormality
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Total number of occurrence
: Service meter reading at the initial
occurrence
★ Refer to "Table for Service Code and Ab-
normality Code" in Operator's Menu.

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TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

5) Resetting Electrical Systems

★ Resetting Electrical Systems (deletion)
is possible only with the electrical sys-
tem. The failure history in the mechani-
cal system cannot be reset.
★ For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,
call the resetting display in the display of
Electrical Systems.
•Switch operation: [ ] +[1] ➝ [2] ➝ [3]
★This is the same switch operation in
changing the display to Service Menu.
ii) Operate the switch, following the instruc-
tions shown in the resetting display.
★When resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
★When resetting all the information, a
display of any information will do.

PC290-7 20-155
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

18. Function for Maintenance Record [03]

The monitor panel records information on the
maintenance of filters and oils. The stored infor-
mation can be displayed through the following
switch operation.

1) Selection of menu
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.

2) Information to be displayed
: Name of oils and filters
: Times of replacement to date
: Service meter reading at the latest
replacement

20-156 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

19. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance dis-
play function can be changed in the following
manner.
• Turn the function effectual or ineffectual.
• Change the set interval for replacement.

1) Selection of menu
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.

2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No. Maintenance mode change item
00 Return
01 Maintenance Mode On/Off
02 Engine Oil Exch. Int.
03 Engine Oil Filter Exch. Int.
04 Fuel Filter Exch. Int.
05 Hydr. Oil Filter Exch. Int.
06 H/Tank Breather Exch. Int.
07 Corro. Resis. Exch. Int.
08 PTO Oil Service Int.
09 Final Drive Oil Exch. Int.
10 S/Machinery Oil Exch. Int.
11 Hydraulic Oil Exch. Int.
12 Use Default Values

★ 01 and 12 menus are provided for setting the

whole maintenance mode, while those from
02 through 11 are for setting individual items.

3) Contents of Maintenance Mode On/Off

• Use: The maintenance display function
of all oil and filter-related items are
turned effectual. (Irrespective of whether
"On" or "Off" set for individual items, this
setting prevails)
• Do not use: The maintenance display
function of all oil and filter-related items
are turned ineffectual. (Irrespective of
whether "On" or "Off" set for individual
items, this setting prevails)

PC290-7 20-157
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

4) Set contents of individual items

: Default: The maintenance time set in
the monitor (recommended by the man-
ufacturer and cannot be changed).
: Set: Maintenance time that can be
freely set. The maintenance mode pro-
gram functions based on this mainte-
nance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
: On: Maintenance display function with
this instruction becomes effectual.
: Off: Maintenance display with this
instruction becomes ineffectual.
★ The lowest maintenance time is 50 h.

5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.

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TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

20. Function for Phone Number Entry [05]

In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the fol-
lowing manner.
★ If there is no Phone number registered, the
display for Phone numbers does not appear.

1) Selection of menu
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.

2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
★ Even if a Phone number is already input-
ted, it is deleted, upon switching to the
Phone Number Entry display.

3) Entry and setting Phone number

Following the method explained below,
Entry a Phone number in the Phone
Number Entry display. (Entry automatically
begins with a cursor at the left end)
i) Enter a number into a cursor at the left
end with a ten-key.
ii) Depress [ ] switch when all the num-
bers have been entered.
★ Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
★ When entering a wrong number, de-
press [B] switch, then the cursor goes
back by one digit.
★ When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.

PC290-7 20-159
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

21. Function for ✩✩✩✩✩/Default [06]

It is possible to change the following settings for
the monitor panel as well as the machine. Make
a change as is required.
• Working mode when the engine starting
switch is in the ON position.
• Display language in Service Menu
• Display unit in the monitoring function
• With/Without Service Cir.

1) Selection of menu
Select 06 "✩✩✩✩✩/Default menu" in the
initial display of Service Menu, and depress
[ ] switch.

2) Selection of submenu
Select an item to change from the submenu,
and depress [ ] switch.
No. ✩✩✩✩✩/Default submenu
00 Return (termination of ✩✩✩✩✩/Default)
01 Key-on Mode
02 ✩✩/Language
03 Unit
04 With/Without Service Cir.

3) Function for Key-on Mode

When the engine starting switch is turned
ON, a working mode can be set that is
shown in the monitor panel.
• A, E, L and B Modes: If any of them is
set, the machine always ramps up with
that working mode, when turning the en-
gine starting switch ON.
• Mode at Previous Key-off: If this mode is
set, the machine ramps up with the
working mode that was last used in the
previous machine operation.
• Default Value: If this mode is set, the
machine ramps up with the default mode
(A mode) that was originally set at the
time of delivery from the factory.
★ Irrespective of this setting mode, a ma-
chine "With attachment" always ramps
up with B mode, when the engine start-
ing switch is turned ON at the subse-
quent operation, if that was the working
mode used in the last machine work.

20-160 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

4) Function for ✩✩/Language

In Service Menu, the language in use can
be changed between Japanese and Eng-
lish.
★ English is used as the language for de-
fault setting in the monitor panel.
★ If the monitor panel for spare parts is to
be used in a Japanese-speaking region
or organization, change the language
from English to Japanese, using this
function.

5) Function for unit selection

As the unit to be used in the monitoring
function display of Service Menu, three
kinds of unit are provided.
★ Unit used for default setting in the moni-
tor panel is SI, i.e. International System
of Units.

6) Function for selecting distinction of With/

Without Service Cir.
It is possible in this function to set a distinc-
tion between with or without attachment.
• With Service Circuit: When an attach-
ment is installed.
• Without Service Circuit: When no attach-
ment is installed.
★ If "With Service Circuit" setting is not
made in this display, while it is actually
installed on a specific machine, SELECT
function in Operator's Mode (attachment
oil flow rate adjustment) cannot be uti-
lized.

PC290-7 20-161
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

22. Function for Adjustment [07]

The monitor panel has a function of making vari-
ous adjustments of the machine.
1) Selection of menu
Select 07 adjustment in the initial display of
Service Menu, and depress [ ] switch.

2) Selection of submenu
Select an item to change from the submenu
and depress [ ] switch.
No. Adjustment submenu
00 Return (termination of adjustment)
01 Governor Motor Adjustment
02 Pump Absorption Torque
03 Low Idle Speed
04 Service Current Adjust.

3) Function for Governor Motor Adjustment

★ When adjusting the securing position of
governor actuator, fuel injection pump
and governor spring, call this display and
carry out the work in the following man-
ner.
i) Set the fuel dial at MAX.
★In this condition, the governor actuator
lever shifts to the full throttle. Hold
this display while in adjustment.
ii) Loosen nuts (2) and (3) of governor
spring (1).
★Nut (2) is of inverse thread (left).
iii) Turn rod (5) so that governor lever (4) of
the fuel injection pump contacts the full
stopper.
iv) Screw in rod (5) by 1 turn from this posi-
tion to reduce distance a between the
pins of governor spring (1) by 2.0 mm.
★Make adjustment while measuring dis-
tance a between the two pins.
v) Tighten nuts (2) and (3).
3 Nut:
11.8–19.6 Nm{1.2–2.0 kgm}
vi) Confirm that governor spring (1) stretches
by 2.0 mm, when the fuel dial is returned
to the MIN position and operated to the
MAX side again.

20-162 PC290-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MULTI-MONITOR PANEL

4) Function for Pump Absorption Torque

adjustment
The pump absorption torque can be
adjusted within the range shown in the table
below.
Adjustment value Torque adjustment value
220 +4.0 kgm
221 +3.0 kgm
222 +2.0 kgm
223 +1.0 kgm
224 0.0 kgm
225 –1.0 kgm
226 –2.0 kgm
227 –3.0 kgm
228 –4.0 kgm

5) Function for Low Idle Speed adjustment

The engine rotation at low idling can be
adjusted within the range shown in the table
below.
Adjustment value Low idling rotation
320 900 rpm
321 1,000 rpm
322 1,100 rpm
323 1,200 rpm

6) Function for Service Current Adjust.

When a machine is used for a compound
operation, distribution of hydraulic pump oil
flow can be adjusted within the range shown
in the table below.
Distribution of oil flow
Adjustment value
to attachment
370 0.5 Time
371 0.7 Time
372 1.0 Time
373 0.4 Time

PC290-7 20-163
 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
TESTING AND ADJUSTING

PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL

SYSTEM
★ When diagnosing electric circuits related to the 2. Governor pump controller
monitor panel and governor pump controller, first ★ The governor pump controller is installed un-
open up the connector portions in the following der a cover behind the operator's seat.
manner. 1) Remove three caps (1) and then three
securing bolts.
1. Monitor panel ★ When removing the caps, use of a thin
1) Take off cover (1). flat-head screw driver is recommended.
★ The cover is fixed with two upper and 2) Take off cover (2).
lower clips. Pull it up for the removal.
★ If a sunlight sensor is equipped for an air
conditioner, detach P15 connector at the
cover rear side.

3) Insert or connect a T-adapter for diagnosis

with C01, C02 and C03 connectors of gov-
ernor pump controller (3).
★ The connectors are fixed with screws.
2) Remove three securing screws and take Loosen the screws and detach the con-
monitor panel (2) off the mount. nectors.
★ Be careful not to let fall the securing ★ When putting the connectors back into
screws inside the console. position, tighten them to the specified
3) Insert or connect a T-adaptor for diagnosis torque.
with P01, P02 and P70 (multi-monitor only) 3 Screw: 2.82 Nm{0.288 kgm}
connectors.

20-164 PC290-7
TESTING AND ADJUSTING PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM

PC290LC,PC290NLC-7

PC290LC-7 PC290NLC-7

PC290-7 20-165
 Engine Hydraulic system

20-166
a

PC290-7
 1. Engine (PC290LC, 290NLC-7)
Condition setting Standard value
No. Working Auto One-touch po- Measurement item Unit
Fuel dial mode decelerator wer max. switch Work equipment operation New machine Failure jud

PC290-7
1 Operating travel control lever Engine rotation rpm 2,180 - 2,320 -
Full (Do not travel machine)
2 Engine oil pressure MPa{kg/cm2} 0.39 -0.64 {4.0 -6.5} 0.25 {
OFF
3 Engine rotation rpm 950 - 1,050 -
Low OFF All control levers in NEUTRAL
4 A Engine oil pressure MPa{kg/cm2} Min. 0.15 {Min. 1.5} 0.09 {
5 Engine rotation rpm 1900 - 2100 -
ON Arm (extended) relief
6 Full Blow-by pressure kPa{mmH2O} Max. 1.2 {Max.123} 5.1 {5
7 ON OFF All control levers in NEUTRAL Engine rotation rpm 1300 - 1500 -

2. Work equipment speed (PC290LC, 290NLC-7)

o
Hydraulic oil temperature (45 55 C)
Condition setting Standard value
No. Unit PC290LC-7 PC290NLC-7
Fuel dial Working Work equipment posture Measurement item
mode New model Permissible value New model Permissib
1 No load, fully extended Boom RAISE 3.5 - 4.3 Max. 5.3 3.5 - 4.3 Max.
2 A Arm DUMPING 3.6 - 4.4 Max. 4.9 3.6 - 4.4 Max.
3 2.9 - 3.5 Max. 4.2 2.9 - 3.5 Max.
Boom held level
4 E Arm DIGGING - - - -
5 ( L) - - - -
6 Boom and arm held level Bucket DIGGING 2.1 - 2.5 Max. 2.9 2.1 - 2.5 Max. 2
Right
7 Full Fully extended Swing (5 turns) Sec. 25.7 - 31.5 Max. 35 25.7 - 31.5 Max.
Left
Right
Lo 52.5 - 64.1 52.5 - 68.1 52.5 - 64.1 52.5 - 6
A Left
Track shoe raised Travel Right
8 at one side (Mi) 38.4 - 47.0 38.4 - 51.0 38.4 - 47.0 38.4 -
(5 turns) Left
Right
Hi 28.7 - 31.7 28.7 - 35.7 28.7 - 31.7 28.7 -
Left

3. Work equipment hydraulic drift amount (PC290LC, 290NLC-7)

Hydraulic oil temperature (45 55oC)
Condition setting Standard value
No. Working Measurement item Unit PC290LC-7 PC290NLC-7
Fuel dial mode Work equipment posture New model Failure judgement New model Failure jud
Boom and arm held Hydraulic drift amount at 600 600
1 Engine stop level, Bucket loaded bucket tooth tip (15 min.) mm Max. 900 Max. 9

20-167
 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
TESTING AND ADJUSTING
9
9

PC290-7 20-168
 TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................... 20-218
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-236

TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE

"MECHANICAL SYSTEM" ARE INDICATED ...................................................................................... 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) ................................. 20-601

PC290-7 20-201
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or ★ When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the ★ The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1)Start from the simple points.
problems with the machine condition before 2)Start from the most likely points.
this? 3)Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.

20-202 PC290-7
TESTING AND ADJUSTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

PC290-7 20-203
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).

1. Points to remember when handling electric

equipment

1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.

Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.

2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.

20-204 PC290-7
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.

4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will
be short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.

5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
★ When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
★ If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.

PC290-7 20-205
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

2) Removing, installing, and drying connectors

and wiring harnesses

• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
★ Never pull with one hand.

2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
★ If the connector is twisted up and down
or to the left or right, the housing may
break.

3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
★ If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.

20-206 PC290-7
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.

2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.

3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
★ If the connector cannot be corrected
easily, remove the clamp and adjust the
position.

4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.

PC290-7 20-207
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.

If water gets directly on the connector, do as fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.

2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
★ Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.

3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.

20-208 PC290-7
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.

3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.

6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.

2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably
defective contact in that circuit.

PC290-7 20-209
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

3. Points to remember when handling hydraulic

equipment

With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.

1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.

2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.

3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.

4) Do not let any dirt or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.

20-210 PC290-7
TESTING AND ADJUSTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.

6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.

7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.

PC290-7 20-211
TESTING AND ADJUSTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil,

4. Check hydraulic oil strainer — Clean, drain

coolant

5. Check swing machinery oil level — Add oil

6. Check engine oil level (oil pan oil level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
mechanical equipment

1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Hydraulic, Electrical

2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment

1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment

3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)

20-212 PC290-7
TESTING AND ADJUSTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting

Mode Content
Troubleshooting when Service Code (electrical system) and Failure Code (mechanical
Code display
system) are displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
(Engine) Troubleshooting of engine assembly (refer to the shop manual for engine in 102 series)

Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.

1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Service Code. Following displayed Ser-
vice Code for the electrical system, carry out the troubleshooting along the corresponding code display.

2. Troubleshooting steps when the electrical system Service Code or mechanical system Failure Code
is recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Service Code or mechanical sys-
tem Failure Code, using the failure history function of the monitor panel.
★ If Service Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
★ Failure Code in the mechanical system cannot be deleted.

3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.

PC290-7 20-213
TESTING AND ADJUSTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Failure-looking Phenomenon and Troubleshooting No.

Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode (Engine)
display
Action to be taken concerning Service Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
Display Service Code in electrical system after checking failure ing to
2
history dis-
Display Failure Code in mechanical system after checking failure played
3 code
history
Engine-related failure
Engine does not start up easily. (It always takes some time to start
4 S-1
up the engine)
5 Engine does not rotate E-1 S-2
6 Engine rotates, but there is no exhaust gas S-2
Engine does not start
There is exhaust gas, but engine does not
7 S-2
start
8 Engine pickup is poor. (Engine does not follow acceleration) S-3
9 Engine stops while in operation E-2 H-2 S-4
10 Engine rotation is irregular. (There is hunting) E-3 S-5
11 Engine is short of output, or lacks power H-1 S-6
12 Color of exhaust gas is too dark. (Incomplete combustion) S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue S-8
14 Premature engine oil contamination S-9
15 Excessive fuel consumption S-10
Engine cooling water is mixed with engine oil, spurts out or
16 S-11
decreases
17 Engine oil amount increases. (Water or fuel gets in) S-13
18 Abnormal noises are heard S-15
19 Excessive vibrations are caused S-16
20 Engine does not stop E-4
21 Auto-decelerator does not work E-5 H-5
22 Engine auto warming-up device does not work E-6
23 Engine preheater does not work E-7
Failure related to work equipment, swing and travel
Speeds of all work equipment, travel and swing are slow, or they
24 H-1 S-6
lack power
25 Engine rotation drops sharply or stalls H-2 S-4
26 All work equipment, travel and swing do not move E-8 H-3
27 There are abnormal noises from around hydraulic pump H-4
28 Fine control mode function works poorly, or shows slow response H-6

20-214 PC290-7
TESTING AND ADJUSTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode (Engine)
display
Work equipment-related failure
29 Boom moves slowly or lacks power E-21, 22 H-7
30 Arm moves slowly or lacks power E-23, 24 H-8
31 Bucket moves slowly or lacks power E-25, 26 H-9
32 Boom, arm or bucket does not move H-10
33 Natural drift of work equipment is too fast H-11
34 Work equipment time lag is too big H-12
Other work equipment moves, when specific work equipment is
35 H-13
relieved
36 One-touch power max. switch does not work E-9, 21–26 H-14
Compound operation-related failure
In compound operation, work equipment with larger load moves
37 H-15
slowly
38 In swing + boom RAISE operation, boom moves slowly H-16
39 In swing + travel operation, travel speed drops sharply H-17
Travel-related failure
40 Machine tends to swerve while in travel H-18
41 Travel speed is slow E-28 H-19
42 Machine is difficult to steer, or lacks power E-28, 29 H-20
43 Travel speed cannot be shifted or is slow or fast E-28 H-21
44 Track shoe does not move (only on one side) H-22
Swing-related failure
45 Machine does not swing E-27 H-23
46 Swing acceleration is poor, or swing speed is slow H-24
47 Upper structure overruns excessively, when stopping swing H-25
48 There is a big shock caused when stopping swing H-26
49 There is abnormal noise generated when stopping swing H-27
50 There is natural drift while in swing H-28
Monitor panel-related failure (Operator's Menu: ordinary display)
51 No display appears in monitor panel at all E-10
52 Part of display is missing in monitor panel E-11
53 Descriptions on monitor panel do not apply to the machine model E-12
In startup inspection, radiator water level monitor lamp lights up
54 B@BCZK
red ( )
55 In startup inspection, engine oil level monitor lamp lights up red B@BAZK
: The multi-monitor specification machine only.

PC290-7 20-215
TESTING AND ADJUSTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode (Engine)
display
Refer to Operation and Maintenance
56 In startup inspection, maintenance hour monitor lamp lights up red
Manual
While engine is running, battery charging level monitor lamp lights
57 AB00KE
up red
58 While engine is running, fuel level monitor lamp lights up red E-13
While engine is running, air cleaner clogging monitor lamp lights up
59 AA10NX
red
While engine is running, engine cooling water temperature monitor
60 B@BCNS
lamp lights up red
While engine is running, hydraulic oil temperature monitor lamp
61 B@HANS
lights up red ( )
62 Engine cooling water temperature gauge does not display correctly E-14
63 Hydraulic oil temperature gauge does not display correctly ( ) E-15
64 Fuel gauge does not display correctly E-16
65 Swing lock monitor does not display correctly E-17
66 When operating monitor switch, no display appears E-18
67 Windshield wiper does not work E-19
68 Warning buzzer cannot be stopped E-20
Monitor panel-related failure (Service Menu: Special Function Display)
In monitoring function, "Boom RAISE" cannot be displayed cor-
69 E-21
rectly
In monitoring function, "Boom LOWER" cannot be displayed cor-
70 E-22
rectly
In monitoring function, "Arm DIGGING" cannot be displayed cor-
71 E-23
rectly
In monitoring function, "Arm DUMPING" cannot be displayed cor-
72 E-24
rectly
In monitoring function, "Bucket DIGGING" cannot be displayed
73 E-25
correctly
In monitoring function, "Bucket DUMPING" cannot be displayed
74 E-26
correctly
75 In monitoring function, "Swing" cannot be displayed correctly E-27
76 In monitoring function, "Travel" cannot be displayed correctly E-28
In monitoring function, "Travel Differential Pressure" cannot be dis-
77 E-29
played correctly
78 In monitoring function, "Service" cannot be displayed correctly E-30
Other failure
79 Air conditioner does not work E-31
80 Travel alarm does not sound E-32
: The multi-monitor specification machine only.

20-216 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT

DIAGRAM BY SYSTEM
Connector table

Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A01 X 4 Intermediate connector T-1 H-6 I-5 I-8
A02 X 4 Intermediate connector T-1 H-6 I-4
A03 D 12 Intermediate connector N-1 H-6 I-2 I-8
A04 SWP 12 Intermediate connector O-1 I-7
A05 SWP 14 Intermediate connector T-1 H-5 I-6
A06 SWP 14 Intermediate connector N-1 H-5 I-5
A07 SWP 16 Intermediate connector S-1 H-3 I-1 I-4
A08 SWP 12 Intermediate connector N-2
A09 SWP 8 Intermediate connector N-2 I-3
A10 Terminal 1 Revolving frame grounding H-1 H-1 J-5 J-4
A11 Terminal 1 Revolving frame grounding H-1 I-1
A12 Terminal 1 Revolving frame grounding H-2 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-4 J-8
A14 Terminal 1 Revolving frame grounding K-2 I-1
A15 Terminal 1 Revolving frame grounding I-2 I-1 J-4
A16 Terminal 1 Revolving frame grounding I-2 I-1 J-1
A20 Terminal 1 Battery relay (E terminal) J-1 I-2 J-4
A21 Terminal 1 Battery relay (BR terminal) J-1 I-1 J-4
A22 Terminal 1 Battery relay (M terminal) J-1 J-2 K-4
A23 Terminal 1 Battery relay (B terminal) J-2 J-1 K-4
A25 Terminal 1 Heater relay (coil) L-3 K-6
A26 Terminal 1 Heater relay (contact) L-3 K-2
A27 X 2 Starter safety relay (S and R terminals) K-2 J-2
A29 Terminal 1 Starter safety relay (C terminal) L-3
A30 YAZAKI 2 Air conditioner outside air temperature sensor L-4
A31 D 2 Air cleaner clogging sensor L-4 K-4
A33 X 2 Radiator water level sensor L-4 K-5
A34 L 2 Fusible link (65A) A-4 K-6 K-5
A35 M 2 Fusible link (30A) A-5 K-6 K-4
A40 AMP 1 Alarm horn (low tone) H-1
A41 AMP 1 Alarm horn (high tone) H-1
A42 X 1 Intermediate connector I-9 J-7
A43 X 2 Travel alarm I-2 K-4
A44 M 1 Front right lamp A-6 K-7

20-218 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
A50 KES0 2 Window washer monitor (tank) K-3 K-5
A51 D 3 F pump hydraulic oil pressure sensor K-3 K-5
A52 D 3 R pump hydraulic oil pressure sensor J-9 K-5
A60 X 1 Fuel level sensor D-9 K-4
A61 D 2 Hydraulic oil temperature sensor H-9 K-5
C01 DRC 24 Governor pump controller V-9 A-3 A-8 A-8
C02 DRC 40 Governor pump controller W-9 A-3 A-7 A-7
C03 DRC 40 Governor pump controller W-9 A-2 A-4 A-4
C09 S 8 Model selection connector W-6 C-9
D01 SWP 8 Assembled type diode W-7 A-9 D-1 G-1
D02 SWP 8 Assembled type diode W-7 A-8 D-1
D03 SWP 8 Assembled type diode P-1 H-1
D04 SWP 8 Assembled type diode Q-1 A-8 F-1 I-1
Suction type air heater
E01 Terminal 1 J-9 L-2 L-6
(electrical intake air heater)
E02 Terminal 1 Engine hydraulic switch L-8 K-6
E03 D 2 Engine oil level switch L-6 K-5
E04 D 2 Engine rotation sensor K-9 K-8
E05 D 2 Engine cooling water temperature sensor J-9 K-4
E06 M 3 Fuel dial K-8
Air conditioner compressor electromagnetic
E06 X 1 O-8
switch
E08 X 1 Intermediate connector L-7 J-3 J-5
E10 D 3 Governor potentiometer J-9 K-3
E11 D 4 Governor motor K-9 K-2
E12 X 2 Alternator L-7 K-3 K-5
F02 YAZAKI 2 Revolving warning lamp AA-9
FB1 – – Fuse box W-5 I-9 C-4 F-9
G01 – – – V-2
G02 – – – V-3
G03 – – – V-3
G04 – – – V-2
G05 – – – V-3
H08 M 8 Intermediate connector W-4 K-8
H09 S 8 Intermediate connector W-4 J-8
H10 S 16 Intermediate connector T-9 D-6 I-8
H11 S 16 Intermediate connector S-9 D-5 I-8 B-9
H12 S 12 Intermediate connector S-9 D-5 I-7
H15 S090 20 Intermediate connector N-7 C-2 E-2 C-2

PC290-7 20-219
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
J01 J 20 Junction connector (black) W-8 C-9 D-9 C-9
J02 J 20 Junction connector (black) W-8 D-9 D-9 D-9
J03 J 20 Junction connector (green) W-8 D-9 D-9
J04 J 20 Junction connector (green) W-7 E-9 E-9 E-9
J05 J 20 Junction connector (pink) W-6 E-9 E-9 E-9
J06 J 20 Junction connector (orange) W-6 F-9 H-9
J07 J 20 Junction connector (orange) U-9 F-9 F-9 H-9
J08 J 20 Junction connector (pink) U-9 I-9
K19 M 2 Pump resistor (for driving emergency pump) U-2 E-3
K30 D 3 CAN terminating resistor T-9 A-2 C-1
K31 D 3 CAN terminating resistor N-4 A-4 K-7
M07 M 3 Lamp switch P-8 C-2
M09 M 1 Working lamp (front right) E-9 K-7
M13 KES0 2 Speaker (right) AC-8
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch N-7
M23 Y090 2 One-touch power max. switch T-1
M26 S 12 Air conditioner unit W-5
M27 SWP 16 Air conditioner unit W-5
M28 SWP 12 Air conditioner unit W-4
M29 040 20 Air control panel W-3
M30 040 16 Air control panel W-3
M31 M 2 Option power source (2) U-2
M32 M 2 Option power source (1) S-9
M33 M 2 Option power source (3) –
M33 SWP 8 Air conditioner unit S-9
M34 YAZAKI 2 Air conditioner inside air sensor W-8
M40 YAZAKI 2 Working lamp Z-8 K-8
M41 YAZAKI 2 Working lamp (additional) Y-7 K-8
M42 M 1 Intermediate connector K-3 J-7
M43 M 1 Working lamp (rear) – K-7
M45 D 12 Intermediate connector U-2
M46 S090 4 RS232C relaying connector U-9 B-9
M71 M 2 Room lamp Z-8
M72 M 4 DC/AC converter U-2
M73 KES0 2 Speaker (left) AD-8
M79 YAZAKI 2 12V electrical equipment socket V-9

20-220 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
P01 070 12 Monitor panel N-6 A-7 K-8
P02 040 20 Monitor panel N-5 A-6 K-8 A-9
P03 M 2 Buzzer canceling switch P-9 D-1
P05 M 2 Revolving warning lamp switch W-3
P15 Y050 2 Air conditioner sun light sensor N-6
P70 040 16 Monitor panel N-4 A-5 K-7
R10 R 5 Lamp relay O-8 E-1
R11 R 5 Engine starting motor cutting relay (PPC lock) P-8 E-1
Engine starting motor cutting relay (personal
R13 R 5 Q-9 F-1
code)
R20 R 5 Attachment circuit switching relay W-6 C-9
R21 – – – W-7
S01 X 2 Bucket digging oil pressure switch S-8 K-2
S02 X 2 Boom lowering oil pressure switch L-7 K-3
S03 X 2 Swing oil pressure switch, left L-7 K-2
S04 X 2 Arm digging oil pressure switch L-6 K-3
S05 X 2 Bucket dumping oil pressure switch L-5 K-2
S06 X 2 Boom raise oil pressure switch L-5 K-3
S07 X 2 Swing oil pressure switch, right L-5 K-2
S08 X 2 Arm dumping oil pressure switch L-4 K-3
Service oil pressure switch (intermediate con-
S09 X 2 K-3 K-1
nector)
S10 X 2 Service oil pressure switch, front – K-1
S11 X 2 Service oil pressure switch, rear – K-1
S14 M 3 Safety lever lock switch S-1 K-9 F-8
S21 Terminal 6 Pump emergency driving switch R-9 E-2
Swing and parking brake emergency releasing
S22 Terminal 6 R-9 F-2
switch
S25 S090 16 Intermediate connector Q-9 E-3
S30 X 2 Travel hydraulic switch O-1 A-1
S31 X 2 Travel steering hydraulic switch P-1 A-1
SC Terminal 1 Engine starting motor (C terminal) K-8
SSW Terminal 5 Engine starting switch N-7
T05 Terminal 1 Floor frame grounding W-3 J-8
T06 Terminal 1 Radio body grounding –
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Operator's cab grounding AD-3
T13 D 1 Engine starting motor (C terminal) L-6 J-3

PC290-7 20-221
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

Address
Connector No. of
Type Name of device Stereo M G P
No. pin
-gram circuit circuit circuit
V01 D 2 PPC hydraulic lock solenoid valve J-2 K-6
V02 D 2 Travel interlocking solenoid valve J-2 K-6
V03 D 2 Merge/divide valve solenoid valve J-2 K-6
V04 D 2 Travel speed solenoid valve J-3 K-5
V05 D 2 Swing and parking brake solenoid valve J-3 K-5
V06 D 2 2-stage relief solenoid valve K-3 K-6
V12 D 2 Attachment return switching solenoid valve I-9 K-4
V21 D 2 PC-EPC solenoid valve I-9 K-7
V22 D 2 LS-EPC solenoid valve I-9 K-7
Attachment oil flow rate adjusting EPC solenoid
V30 X 2 P-1 A-1
valve
W03 X 2 Rear limit switch (window) AB-9 L-8
W04 M 6 Windshield wiper motor Y-4 B-9
X05 M 4 Swing lock switch Q-9 D-2 C-2
Y08 – – – G-9
Y09 – – – G-1
Y10 – – – G-9
Y11 – – – A-6
Y12 – – – G-9
Y13 – – – G-1
Y16 – – – G-9

20-222 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

Connector No. Detailed information

D or DT Japanese and German makes DT type connector (08192-XXXXX)
L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
040 Product of Japan AMP 040 type connector
070 Product of Japan AMP 070 type connector
Y050 Product of Yazaki 050 type connector
S090 Product of Sumitomo 090 type connector
Y090 Product of Yazaki 090 type connector
YAZAKI Yazaki-made connector
KES0 KESO type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
*An affiliated company of Mitsubishi Cable Industries, Ltd.

PC290-7 20-223
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

CONNECTOR LOCATION STEREOGRAM

20-224 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

PC290-7 20-225
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

20-226 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

PC290-7 20-227
TESTING AND ADJUSTING CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY

20-228 PC290-7
TESTING AND ADJUSTING CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY

Monitor Panel System Circuit Diagram (M Circuit)

20-230 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

★ This circuit diagram has been compiled by extracting the monitor panel system and engine starting system
from the overall electrical circuit diagram.

PC290-7 20-231
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

Governor Control System Circuit Diagram (G Circuit) of Governor•Pump Controller

20-232 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

★ This circuit diagram has been compiled by extracting the governor•pump controller system (power source,
governor control, model selection and communication) from the overall electrical circuit diagram.

PC290-7 20-233
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

Pump Control System Circuit Diagram (P Circuit) of Governor•Pump Controller

20-234 PC290-7
 CONNECTOR LOCATION CHART AND ELECTRICAL
TESTING AND ADJUSTING CIRCUIT DIAGRAM BY SYSTEM

★ This circuit diagram has been compiled by extracting the governor•pump controller system (pump control),
PPC lock system and backup alarm system from the overall electrical circuit diagram.

PC290-7 20-235
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.

X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010

2 799-601-7020

Part No.: 08055-00282 Part No.: 08055-00292

3 799-601-7030

Part No.: 08055-00381 Part No.: 08055-00391

4 799-601-7040

Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
Terminal part No.: 79A-222-3380 Terminal part No.: 79A-222-3410
• Electric wire size: 2.0 • Electric wire size: 2.0
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-236 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

6 799-601-7050

Part No.: 08055-10681 Part No.: 08055-10691

8 799-601-7060

Part No.: 08055-10881 Part No.: 08055-10891

12 799-601-7310

Part No.: 08055-11281 Part No.: 08055-11291

14 799-601-7070

Part No.: 08055-11481 Part No.: 08055-11491

PC290-7 20-237
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP type connector

No. of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

16 799-601-7320

Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
• Electric wire size: 1.25 • Electric wire size: 1.25
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20

20-238 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080

2 799-601-7090

Part No.: 08056-00271 Part No.: 08056-00281

3 799-601-7110

Part No.: 08056-00371 Part No.: 08056-00381

4 799-601-7120

Part No.: 08056-00471 Part No.: 08056-00481

6 799-601-7130

Part No.: 08056-00671 Part No.: 08056-00681

8 799-601-7390

Part No.: 08056-00871 Part No.: 08056-00881

PC290-7 20-239
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

8 799-601-7140

Part No.: 08056-10871 Part No.: 08056-10881

10
799-601-7150
(White)

Part No.: 08056-11071 Part No.: 08056-11081

12
799-601-7350
(White)

Part No.: 08056-11271 Part No.: 08056-11281

16
799-601-7330
(White)

Part No.: 08056-11671 Part No.: 08056-11681

20-240 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

10
—
(Blue)

— —

12
799-601-7160
(Blue)

Part No.: 08056-11272 Part No.: 08056-11282

16
799-601-7170
(Blue)

Part No.: 08056-11672 Part No.: 08056-11682

PC290-7 20-241
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —

5 799-601-2710

Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)

9 799-601-2950

Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)

13 799-601-2720

Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)

20-242 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

17 799-601-2730

Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)

21 799-601-2740

Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)

PC290-7 20-243
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

8 799-601-7180

— Housing part No.: 79A-222-3430 (Q’ty: 5)

12 799-601-7190

— Housing part No.: 79A-222-3440 (Q’ty: 5)

16 799-601-7210

— Housing part No.: 79A-222-3450 (Q’ty: 5)

20 799-601-7220

— Housing part No.: 79A-222-3460 (Q’ty: 5)

★ Terminal part No.: 79A-222-3470 (No relation with number of pins)

20-244 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 type connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

10 799-601-7510

— Part No.: 08195-10210

12 799-601-7520

— Part No.: 08195-12210

14 799-601-7530

— Part No.: 08195-14210

18 799-601-7540

— Part No.: 08195-18210

20 799-601-7550

— Part No.: 08195-20210

PC290-7 20-245
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

2 —

— —

Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

9 —

— —

Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

10 799-601-3460

— —

20-246 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

2 —

Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)

3 —

Part No.:08027-10310 Part No.:08027-10360

4 —

Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)

6 —

Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)

PC290-7 20-247
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES 1 (Automobile) connector

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

8 —

Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)

Connector for relay (Socket type)

No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.

5 799-601-7360

— —

6 799-601-7370

— —

20-248 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.

4 —

— —

PC290-7 20-249
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9210

Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Pin (male terminal) Pin (female termial)

799-601-9220

Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (female terminal) Pin (male termial)

799-601-9220

Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106

20-250 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9230

18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

(3) Pin (female terminal) Pin (male termial)

799-601-9230

Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

Pin (male terminal) Pin (female termial)

799-601-9240

18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

(4) Pin (female terminal) Pin (male termial)

799-601-9240

Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102

PC290-7 20-251
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9250

24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

(5) Pin (female terminal) Pin (male termial)

799-601-9250

Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

Pin (male terminal) Pin (female termial)

799-601-9260

Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
(6) Pin (female terminal) Pin (male termial)

799-601-9260

Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106

20-252 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)

799-601-9270

Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
(7) Pin (female terminal) Pin (male termial)

799-601-9270

Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
Pin (male terminal) Pin (female termial)

799-601-9280

Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
(8) Pin (female terminal) Pin (male termial)

799-601-9280

Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106

PC290-7 20-253
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male termial) Pin (female terminal)

799-601-9290

Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
(9) Pin (female terminal) Pin (male termial)

799-601-9290

Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106

20-254 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.

2 799-601-9020

Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)

3 799-601-9030

Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)

4 799-601-9040

Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)

6 799-601-9050

Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)

PC290-7 20-255
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.

8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090

Part No.: 08192-1820… (normal type) Part No.: 08192-1810… (normal type)
08192-2820… (fine wire type) 08192-2810… (fine wire type)

12GR: 799-601-9110
12B: 799-601-9120
10
12G: 799-601-9130
12BR: 799-601-9140

Part No.: 08192-1920… (normal type) Part No.: 08192-1910… (normal type)
08192-2920… (fine wire type) 08192-2910… (fine wire type)

20-256 PC290-7
TESTING AND ADJUSTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

[The pin No. is also marked on the connector (electric wire insertion end)]

DTM Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.

799-601-9010
2

Part No.: 08192-02200 Part No.: 08192-02100

[The pin No. is also marked on the connector (electric wire insertion end)]

DTHD Series connector

No.of
pins T-adapter Part
Body (plug) Body (receptacle)
No.

2 —

Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)

PC290-7 20-257
 TROUBLESHOOTING WHEN SERVICE CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304

Service Code in Electrical System E101 (Abnormal data in Error History) ................................................ 20-306
Service Code in Electrical System E112 (Short-circuiting in normal rotation system of
windshield wiper motor drive)............................................................................................................... 20-308
Service Code in Electrical System E113 (Short-circuiting in reverse rotation system of
windshield wiper motor drive)............................................................................................................... 20-310
Service Code in Electrical System E114 (Short-circuiting in window washer drive system) ...................... 20-312
Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion) ........................................ 20-314
Service Code in Electrical System E116 (Abnormality in retracting windshield wiper) .............................. 20-316
Service Code in Electrical System E201 (Short-circuiting in travel interlocking solenoid) ......................... 20-318
Service Code in Electrical System E203 (Short-circuiting in swing and parking brake solenoid -
in governor • pump controller system).................................................................................................. 20-320
Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)................................. 20-322
Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)................................. 20-324
Service Code in Electrical System E206 (Short-circuiting in travel speed shifting solenoid) ..................... 20-326
Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)........................... 20-328
Service Code in Electrical System E213 (Disconnection in Swing Parking Brake Solenoid)..................... 20-330
Service Code in Electrical System E214 (Disconnection of merge/divide solenoid) .................................. 20-332
Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid) .................................. 20-334
Service Code in Electrical System E216 (Disconnection in travel speed shifting solenoid) ....................... 20-336
Service Code in Electrical System E217 (Abnormality in inputting model code)........................................ 20-338
Service Code in Electrical System E218 Disconnection of S-NET signal) ................................................. 20-342
Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid) ........................................ 20-344
Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system) ............................. 20-345
Service Code in Electrical System E224 (Abnormality in F pump pressure sensor).................................. 20-346
Service Code in Electrical System E225 (Abnormality in R pump pressure sensor) ................................. 20-348
Service Code in Electrical System E226 (Abnormality in Pressure sensor power source) ........................ 20-350
Service Code in Electrical System E227 (Abnormality in engine rotation sensor
in governor • pump controller system).................................................................................................. 20-352
Service Code in Electrical System E228 (Short-circuiting in attachment return switching relay) ............... 20-353
Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid ........................................ 20-354
Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)............................. 20-356
Service Code in Electrical System E238 (Disconnection in attachment return switching relay) ................ 20-358
Service Code in Electrical Equipment E245 (Short-circuiting in attachment oil flow rate adjusting EPC)
(Multi-monitor only)............................................................................................................................... 20-360
Service Code in Electrical System E246 (Disconnection in attachment oil flow rate adjusting EPC)
(Multi-monitor only)............................................................................................................................... 20-361
Service Code in Electrical System E256 (Incorrect nonvolatile memory data) .......................................... 20-362
Service Code in Electrical System E306 (Abnormality in governor potentiometer).................................... 20-364
Service Code in Electrical System E308 (Abnormality in fuel dial) ............................................................ 20-366

PC290-7 20-301
TESTING AND ADJUSTING

Service Code in Electrical System E315 (Short-circuiting in battery relay) ................................................ 20-368
Service Code in Electrical System E316 (Step-out in governor motor) ...................................................... 20-370
Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B) .................... 20-372
Service Code in Electrical System E318 (Short-circuiting in governor motor Phase A and Phase B) ....... 20-374
Service Code in Electrical System E501 ("Model Selection" function not provided yet) ............................ 20-376
Service Mode in Electrical System E502 (Model selecting signal fault) ..................................................... 20-377
Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling) .......................... 20-378
Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)............................ 20-378
Failure Code in Mechanical System AA10NX (Air cleaner clogging) ......................................................... 20-379
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage).............................. 20-380
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ........................ 20-382
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)............................... 20-383
Failure Code in Mechanical System B@BCNS (Engine cooling water overheating).................................. 20-384
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level) ........................ 20-385
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)................................................ 20-386

20-302 PC290-7
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

★ The troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-
tents fully before proceeding to actual troubleshooting work.

User Code Service Code Failure Code

Failure
Display in Display in Display in Title of failure phenomenon shown in failure history
phenomenon
monitor panel monitor panel monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
monitor panel
detect some failure.
or controller
Phenomenon
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
occurring on
controller
machine
Relative
Information on the failure occurred as well as the troubleshooting
information

Cause Standard value in normalcy and references for troubleshooting

<Content Included>
• Standard value in normalcy by which to pass "Good" or "No good" judgement over the
presumed cause
1
• Reference for passing the above "Good" or "No Good" judgement

<Phenomenon of Wiring Harness Failure>

Presumed cause and standard value in normalcy

• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness occurred.
• Defective grounding
2 A wiring harness that is not connected with a grounding circuit has a contact with the
grounding circuit.
• Short-circuiting
Cause that presumably A wiring harness that is not connected with a 24 V electric circuit has a contact with the
triggered failure in ques- electric circuit.
tion
3 (The assigned No. is for <Precaution for Troubleshooting>
filing purpose only. It 1) Connector No. display method and handling of T-adapter
does not stand for any Insert or connect T-adapters in the following manner before starting troubleshooting
priority) unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., disconnect
the connector and insert the T-adapter into both male and female sides.
4 • If there is an indication of "male" or "female" in a specific connector No., disconnect
the connector and connect the T-adepter with only one side of either "male" or "fe-
male".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the fol-
lowing manner unless otherwise instructed.
• Connect the positive (+) lead with the pin No. indicated at the front or the wiring har-
5
ness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring har-
ness.

20-304 PC290-7
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

Relative Electrical Circuit Diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred.

• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.

PC290-7 20-305
TESTING AND ADJUSTING E101

Service Code in Electrical System E101 (Abnormal data in Error History)

User Code Service Code Failure Code Failure Abnormal data in the error history
— E101 DAF0KT phenomenon (in Monitor Panel system)
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
• None in particular
Monitor Panel
Phenomenon
occurring on • A display for information on the failure history (in the electrical system) cannot be called.
machine

Cause Standard value in normalcy and references for troubleshooting

1 Fuse No. 12 defective If the fuse is blown, there is a big possibility that the circuit has a grounding fault.
Fusible link No. A35
2 If the fusible link is blown, there is a big possibility that the circuit has a grounding fault.
defective
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Presumed cause and standard value in normalcy

for the troubleshooting.

Disconnection of wiring Wiring harness from P01 (female) to J07 to FB1-17 out- Resistance
Above 1 Ω
harness let value
3
(Disconnection or Resistance
connector contact fault) Wiring harness between FB1-17 inlet and A35 (male) Above 1 Ω
value
Wiring harness between A35 (male) and A23 (B termi- Resistance
Above 1 Ω
nal) value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.

Grounding fault of wiring Between wiring harness between P01 (female) to J07 Resistance
Above 1 MΩ
harness and FB1-17 outlet and grounding value
4
(Contact with grounding Between wiring harness between FB1-17 inlet and A35 Resistance
circuit) Above 1 MΩ
(male) and grounding value
Between wiring harness between A35 (male) and A23 Resistance
Above 1 MΩ
(B terminal) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
5 Monitor Panel defective
C03 Voltage
Between and 20 – 30 V

20-306 PC290-7
TESTING AND ADJUSTING E101

Monitor Panel Power Source Electric Circuit Diagram

PC290-7 20-307
TESTING AND ADJUSTING E112

Service Code in Electrical System E112

(Short-circuiting in normal rotation system of windshield wiper motor drive)

User Code Service Code Failure Code Failure Short-circuiting in normal rotation system of wind-
— E112 DY2DKB phenomenon shield wiper motor drive (in monitor panel system)
Failure content • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stops moving.
machine

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between and Continued
Between and grounding Above 1 MΩ

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) and Resistance
circuit) Above 1 MΩ
W04 (male) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)

20-308 PC290-7
TESTING AND ADJUSTING E112

Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor

PC290-7 20-309
TESTING AND ADJUSTING E113

Service Code in Electrical System E113

(Short-circuiting in reverse rotation system of windshield wiper motor drive)

User Code Service Code Failure Code Failure Short-circuiting in reverse rotation system of wind-
— E113 DY2EKB phenomenon shield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
Failure content
windshield wiper was set in motion.
Response from
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stopped moving.
machine

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper motor for the troubleshooting.
defective W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between and Continued
Between and grounding Above 1 MΩ

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) and Resistance
circuit) Above 1 MΩ
W04 (male) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Below 3 V
Between and grounding Below 3 V⇔20 – 30 V
ON
(at constant cycle)

20-310 PC290-7
TESTING AND ADJUSTING E113

Electric Circuit Diagram for Monitor Panel Windshield Wiper Motor

PC290-7 20-311
TESTING AND ADJUSTING E114

Service Code in Electrical System E114

(Short-circuiting in window washer drive system)

User Code Service Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Window washer drive for the troubleshooting.
1 motor defective
A50 (male) Resistance value
(Internal short-circuiting)
Between and 5 – 20 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring for the troubleshooting.
harness Between wiring harness from P01 (female) to J04 to
2
(Contact with 24 V A50 (female) and grounding, or between wiring har-
circuit) Voltage Below 1 V
ness between P01 (female) and D04 (female) and
grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between and grounding
ON Below 1 V

20-312 PC290-7
TESTING AND ADJUSTING E114

Monitor Panel Window Washer Motor Electrical Circuit Diagram

PC290-7 20-313
TESTING AND ADJUSTING E115

Service Code in Electrical System E115 (Abnormal Windshield Wiper Motion)

User Code Service Code Failure Code Failure Abnormal operation of windshield wiper
— E115 DY20KA phenomenon (in Monitor Panel system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
W04 (female) Windshield wiper blade Resistance value
Presumed cause and standard value in normalcy

Windshield wiper motor

1 defective At upper end of operation
(Internal disconnection) Below 1 Ω
range
Between and
Outside upper end of
Above 1 MΩ
operation range
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Disconnection of wiring
harness Wiring harness between P01 (female) and W04 (male) Resistance
2 Below 1 Ω
(Disconnection or faulty value
contact with connector)
Resistance
Wiring harness between W04 (male) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
for the troubleshooting.
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of operation
Below 1 V
range
Between and grounding
Outside upper end of
20 – 30 V
operation range

20-314 PC290-7
TESTING AND ADJUSTING E115

Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram

PC290-7 20-315
TESTING AND ADJUSTING E116

Service Code in Electrical System E116 (Abnormality in retracting windshield wiper)

User Code Service Code Failure Code Failure Abnormal operation of retracting windshield wiper
— E116 DY20MA phenomenon (in Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No. 049: Monitor Input 3)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Presumed cause and standard value in normalcy

for the troubleshooting.

Windshield wiper motor
1 defective W04 (female) Windshield wiper blade Resistance value
(Internal disconnection) Retraction range Below 1 Ω
Between and
Operation range Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness between P01 (female) and W04 (male) Resistance
2 (Disconnection or defec- Below 1 Ω
value
tive contact with connec-
tor) Resistance
Between wiring harness W04 (male) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
3 Monitor panel defective P01 Windshield wiper blade Voltage
Retraction range Below 1V
Between and grounding
Operation range 20 – 30 V

20-316 PC290-7
TESTING AND ADJUSTING E116

Monitor Panel Windshield Wiper Motor Electrical Circuit Diagram

PC290-7 20-317
TESTING AND ADJUSTING E201

Service Code in Electrical System E201

(Short-circuiting in travel interlocking solenoid)

User Code Service Code Failure Code Failure Short-circuiting in travel interlocking solenoid
— E201 DW91KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
• Power supply to the travel interlocking circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on • It is difficult to steer the machine at turns.
machine
Relative • Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Travel interlocking sole- during the troubleshooting.
noid defective V02 (male) Resistance value
1
Presumed cause and standard value in normalcy

(Internal short-circuiting
or grounding fault) Between and 20 – 60 Ω
Between and grounding Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type diode during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
(Internal short-circuiting)
Between and Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of wiring during the troubleshooting.
harness Between wiring harness from C03 (female) to J06 to
3
(Contact with grounding V02 (female) and grounding, or between wiring har- Resistance
circuit) Above 1 MΩ
ness between C03 (female) and D03 (female) and value
grounding
★Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel control lever Voltage
4
controller defective
Straight forward Below 1 V
Between and grounding
Steering 20 – 30 V

20-318 PC290-7
TESTING AND ADJUSTING E201

Electrical Circuit for Travel Interlocking Solenoid in Governor • Pump Controller

PC290-7 20-319
TESTING AND ADJUSTING E203

Service Code in Electrical System E203

(Short-circuiting in swing and parking brake solenoid - in governor • pump controller
system)

User Code Service Code Failure Code Failure Short-circuiting in swing and parking brake solenoid
E03 E203 DW45KB phenomenon (in governor • pump controller system)
• Abnormal current flew to the swing and parking brake solenoid circuit, when power was supplied to the
Failure content
circuit.
• Power supply to the swing and parking brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing and steering brake does not return to normal-
controller
cy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The upper structure cannot swing.
machine
• Operation of the swing and parking brake solenoid (ON or OFF) can be checked in the monitoring func-
tion. (Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the parking brake does not work, when stopping the machine)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Swing and parking brake during the troubleshooting.
solenoid defective V05 (male) Resistance value
1
Presumed cause and standard value in normalcy

(Internal short-circuiting
Between and 20 – 60 Ω
or grounding fault)
Between and grounding Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type diode during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
(Internal short-circuiting)
Between and Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of wiring
harness Wiring harness from C03 (female) to D01 to J02 to X05
3
(Contact with grounding to J06 to V05 (female) , or between wiring harness Resistance
circuit) Above 1 MΩ
between C03 (female) and D03 (female) and value
grounding
★Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Swing control lever Voltage
4
controller defective
NEUTRAL Below 1 V
Between and grounding
Swing 20 – 30 V

20-320 PC290-7
TESTING AND ADJUSTING E203

Electrical Circuit Diagram for Swing and Parking Brake of Governor • Pump Controller

PC290-7 20-321
TESTING AND ADJUSTING E204

Service Code in Electrical System E204 (Short-circuiting in merge/divide solenoid)

User Code Service Code Failure Code Failure Short-circuiting in merge/divide solenoid
— E204 DWJ0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
• Power supply to the merge/divide solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
occurring on • In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
machine
Relative • Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Merge/divide solenoid during the troubleshooting.
defective V03 (male) Resistance value
1
Presumed cause and standard value in normalcy

(Internal short-circuiting
or grounding fault) Between and 20 – 60 Ω
Between and grounding Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type diode during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
(Internal short-circuiting)
Between and Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) to J06 to V03
(Contact with grounding Resistance
circuit) (female) , or between wiring harness between C03 Above 1 MΩ
value
(female) and D03 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel control lever Voltage
4
controller defective NEUTRAL Below 1 V
Between and grounding When operating one side
20 – 30 V
only

20-322 PC290-7
TESTING AND ADJUSTING E204

Electrical Circuit Diagram for Merge/Divide Solenoid in Governor • Pump Controller

PC290-7 20-323
TESTING AND ADJUSTING E205

Service Code in Electrical System E205 (Short-circuiting in 2-stage relief solenoid)

User Code Service Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E205 DWK0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The one-touch power max. switch does not work.
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
2-stage relief solenoid during the troubleshooting.
defective V06 (male) Resistance value
Presumed cause and standard value in normalcy

1
(Internal short-circuiting
Between and 20 – 60 Ω
or grounding fault)
Between and grounding Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type diode during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
(Internal short-circuiting)
Between and Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) to J06 to V06
(Contact with grounding Resistance
circuit) (female) , or between wiring harness between C03 Above 1 MΩ
value
(female) and D03 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C03 Working mode Voltage
4
controller defective
Other than L mode Below 1 V
Between and grounding
L mode 20 – 30 V

20-324 PC290-7
TESTING AND ADJUSTING E205

Electric Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller

PC290-7 20-325
TESTING AND ADJUSTING E206

Service Code in Electrical System E206

(Short-circuiting in travel speed shifting solenoid)

User Code Service Code Failure Code Failure Short-circuiting in travel speed shifting solenoid
— E206 DW43KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The display in the monitor panel changes correctly)
machine
Relative • Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Travel speed shifting during the troubleshooting.
solenoid defective V04 (male) Resistance value
Presumed cause and standard value in normalcy

1
(Internal short-circuiting
Between and 20 – 60 Ω
or grounding fault)
Between and grounding Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type diode during the troubleshooting.
2 D04 defective
D04 (male) Resistance value
(Internal short-circuiting)
Between and Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) to J06 to V04
(Contact with grounding Resistance
circuit) (female) , or between wiring harness between C03 Above 1 MΩ
value
(female) and D04 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Governor • pump C03 Travel speed Voltage
4
controller defective
Lo Below 1 V
Between and grounding
Hi + Travel operation 20 – 30 V

20-326 PC290-7
TESTING AND ADJUSTING E206

Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller

PC290-7 20-327
TESTING AND ADJUSTING E211

Service Code in Electrical System E211 (Disconnection in travel interlocking solenoid)

User Code Service Code Failure Code Failure Disconnection in travel interlocking solenoid
— E211 DW91KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • It is difficult to steer the machine while traveling.
machine
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E201].)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Travel interlocking during the troubleshooting.
1 solenoid defective V02 (male) Resistance value
Presumed cause and standard value in normalcy

(Internal disconnection)
Between and 20 – 60 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) to J06 to V02 Resistance
2 (Disconnection or defec- Below 1 Ω
(female) value
tive contact with connec-
tor) Resistance
Wiring harness between V02 (female) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) to J06 to V02
(Contact with 24 V cir-
cuit) (female) , or between wiring harness C03 (female) Voltage Below 1 V
and D03 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
4
controller defective C03 (female) Resistance value
Between and grounding 20 – 60 Ω

20-328 PC290-7
TESTING AND ADJUSTING E211

Electrical Circuit Diagram for Travel Interlocking Solenoid in Governor • Pump Controller

PC290-7 20-329
TESTING AND ADJUSTING E213

Service Code in Electrical System E213

(Disconnection in Swing Parking Brake Solenoid)

User Code Service Code Failure Code Failure Disconnection in swing and parking brake solenoid
E03 E213 DW45KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the swing parking brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The machine's upper structure does not swing.
machine
• Operation of the swing parking brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
★While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in the
OFF position.
★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E203].)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Swing parking brake
during the troubleshooting.
solenoid defective
1
(Internal disconnec- V05 (male) Resistance value
tion) 20 – 60 Ω
Between and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Below 1 Ω
Between and
Presumed cause and standard value in normalcy

LOCK Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type
during the troubleshooting.
diode D01 defective
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Diode mode Continued
Between and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Resistance
Disconnection of Wiring harness between C03 (female) and D01 (female) Below 1 Ω
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) to J02 to X05 (male) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) to J06 to V05 (female) Below 1 Ω
value
Resistance
Wiring harness between V05 (female) and grounding Below 1 Ω
value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) and D01
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
6 C03 (female) Disconnect D01 and con- Resistance value
controller defective
nect pins and of the
Between and grounding male side. 20 – 60 Ω

20-330 PC290-7
TESTING AND ADJUSTING E213

Electrical Circuit Diagram for Swing and Parking Brake Solenoid in Governor • Pump Controller

PC290-7 20-331
TESTING AND ADJUSTING E214

Service Code in Electrical System E214 (Disconnection of merge/divide solenoid)

User Code Service Code Failure Code Failure Disconnection in merge/divide solenoid
— E214 DWJ0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • In L mode, speeds of the work equipment and swing in its single operation are too fast
machine
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E204].)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Merge/divide solenoid during the troubleshooting.
1 defective
Presumed cause and standard value in normalcy

V03 (male) Resistance value

(Internal disconnection)
Between and 20 – 60 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) to J06 to V03 Resistance
2 (Disconnection or defec- Below 1 Ω
(female) value
tive contact with connec-
tor) Resistance
Wiring harness between V03 (female) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) to J06 to V03
(Contact with 24 V cir-
cuit) (female) , or between wiring harness between C03 Voltage Below 1 V
(female) and D03 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
4
controller defective C03 (female) Resistance value
Between and grounding 20 – 60 Ω

20-332 PC290-7
TESTING AND ADJUSTING E214

Electrical Circuit Diagram for Merge/Divide Solenoid in Governor • Pump Controller

PC290-7 20-333
TESTING AND ADJUSTING E215

Service Code in Electrical System E215 (Disconnection in 2-stage relief solenoid)

User Code Service Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E215 DWK0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The one-touch power max. switch does not work.
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E205].)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
2-stage relief solenoid during the troubleshooting.
1 defective V06 (male) Resistance value
Presumed cause and standard value in normalcy

(Internal disconnection)
Between and 20 – 60 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) to J06 to V06 Resistance
2 (Disconnection or defec- Below 1 Ω
(female) value
tive contact with connec-
tor) Resistance
Wiring harness between V06 (female) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) to J06 to V06
(Contact with 24 V cir-
cuit) (female) , or between wiring harness between C03 Voltage Below 1 V
(female) and D03 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
4 C03 (female) Resistance value
controller defective
Between and grounding 20 – 60 Ω

20-334 PC290-7
TESTING AND ADJUSTING E215

Electrical Circuit Diagram for 2-stage Relief Solenoid in Governor • Pump Controller

PC290-7 20-335
TESTING AND ADJUSTING E215

Service Code in Electrical System E216

(Disconnection in travel speed shifting solenoid)

User Code Service Code Failure Code Failure Disconnection in travel speed shifting solenoid
— E216 DW43KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The display changes normally in the monitor panel)
machine
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 023: Solenoid 1)
information ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Service Code [E206].)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Travel speed shifting during the troubleshooting.
1 solenoid defective V04 (male) Resistance value
Presumed cause and standard value in normalcy

(Internal disconnection)
Between and 20 – 60 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness from C03 (female) to J06 to V04 Resistance
2 (Disconnection or defec- Below 1 Ω
(female) value
tive contact with connec-
tor) Resistance
Wiring harness between V06 (female) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Short-circuiting of wiring during the troubleshooting.
harness
3 Wiring harness from C03 (female) to J06 to V04
(Contact with 24 V cir-
cuit) (female) , or between wiring harness between C03 Voltage Below 1 V
(female) and D04 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
4 C03 (female) Resistance value
controller defective
Between and grounding 20 – 60 Ω

20-336 PC290-7
TESTING AND ADJUSTING E215

Electrical Circuit Diagram for Travel Speed Shifting Solenoid in Governor • Pump Controller

PC290-7 20-337
TESTING AND ADJUSTING E217

Service Code in Electrical System E217 (Abnormality in inputting model code)

PC210-7
User Code Service Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in governor • pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC210).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular with PC210 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002 and 003: Controller Model Code)
information ★Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Model selecting connec- during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection
or short-circuiting) Between and Below 1 Ω
Between , , or and Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Presumed cause and standard value in normalcy

Disconnection of wiring during the troubleshooting.

harness Resistance
Wiring harness between C03 (female) and C09
2 (Disconnection or defec- Below 1 Ω
(male) value
tive contact with connec-
tor) Between wiring harness between C09 (male) and J05 Resistance
Below 1 Ω
and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C03 (female) and Resistance
Above 1 MΩ
C09 (male) and grounding value
Grounding fault of wiring
harness Between wiring harness between C03 (female) and Resistance
3 Above 1 MΩ
(Contact with grounding C09 (male) and grounding value
circuit)
Between wiring harness between C03 (female) and Resistance
Above 1 MΩ
C09 (male) and grounding value

Between wiring harness between C03 (female) and Resistance

Above 1 MΩ
C09 (male) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C03 Voltage
4
controller defective
Between , , or and grounding 20 – 30 V
Between and grounding Below 1 V

20-338 PC290-7
TESTING AND ADJUSTING E217

Electrical Circuit Diagram for Model Selecting Connector in Governor • Pump Controller
PC210-7

PC290-7 20-339
TESTING AND ADJUSTING E217

PC240-7
User Code Service Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in governor • pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC210).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular with PC210 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002 and 003: Controller Model Code)
information ★Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Model selecting connec- during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection
or short-circuiting) Between , and Below 1 Ω
Between , or and Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Presumed cause and standard value in normalcy

during the troubleshooting.

Disconnection of wiring Wiring harness between C03 (female) and C09 Resistance
harness Below 1 Ω
(male) value
2 (Disconnection or defec-
tive contact with connec- Wiring harness between C03 (female) and C09 Resistance
Below 1 Ω
tor) (male) value
Between wiring harness between C09 (male) and J05 Resistance
Below 1 Ω
and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.

Grounding fault of wiring Between wiring harness between C03 (female) and Resistance
Above 1 MΩ
harness C09 (male) and grounding value
3
(Contact with grounding Between wiring harness between C03 (female) and Resistance
circuit) Above 1 MΩ
C09 (male) and grounding value
Between wiring harness between C03 (female) and Resistance
Above 1 MΩ
C09 (male) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C03 Voltage
4
controller defective
Between , or and grounding 20 – 30 V
Between , and grounding Below 1 V

20-340 PC290-7
TESTING AND ADJUSTING E217

Electrical Circuit Diagram for Model Selecting Connector in Governor • Pump Controller
PC240-7

PC290-7 20-341
TESTING AND ADJUSTING E218

Service Code in Electrical System E218 Disconnection of S-NET signal)

User Code Service Code Failure Code Failure Disconnection in S-NET signal
— E218 DA2SKA phenomenon (in governor • pump controller system)
• A failure occurred in S-NET communication between the monitor and controller in the past.
Failure content
(The machine operation returned to normalcy, when the display was resumed)
• While the failure is still continuing, the machine operation is controlled by the following default setting.
1) Working mode: E mode
Response from 2) Travel speed: Lo
controller 3) Auto-decelerator: ON
4) Attachment oil flow rate: Minimum ( )
• When the failure cause disappears of itself, the machine operation returns to normalcy.
• The working mode cannot be changed. (The display changes normally in the monitor panel)
Phenomenon
• The travel speed cannot be shifted. (The display changes normally in the monitor panel)
occurring on
• The auto-decelerator cannot be released. (The display changes normally in the monitor panel)
machine
• The attachment oil flow rate cannot be changed. (The display changes normally in the monitor panel) ( )
• This Service Code No. is displayed to inform that there was a failure occurred in the past, when S-NET
communication between the monitor panel and the governor • pump controller is returned to normalcy.
Relative
• The communication has already returned to normalcy by the time this Service Code No. is displayed.
information
But thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a
failure in order to prevent recurrence of failures.
: The multi-monitor specification machine only.

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness Wiring harness between P02 (female) and C02 Resistance
1 (Disconnection or defec- Below 1 Ω
(female) value
tive contact with connec-
Presumed cause and standard value in normalcy

tor) Wiring harness between P02 (female) and C02 Resistance

Below 1 Ω
(female) value

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness between P02 (female) and Resistance
circuit) Above 1 MΩ
C02 (female) and grounding value

Short-circuiting of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Between wiring harness between P02 (female) and
cuit) Voltage Below 1 V
C02 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 (male) Voltage
Between and 6–9V
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump
5 C02 (male) Voltage
controller defective
Between and 6–9V

20-342 PC290-7
TESTING AND ADJUSTING E218

Electrical Circuit Diagram for S-NET Communication between Monitor Panel and Governor • Pump
Controller

PC290-7 20-343
TESTING AND ADJUSTING E222

Service Code in Electrical System E222 (Short-circuiting in LS-EPC solenoid)

User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
— E222 DXE0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the LS-EPC solenoid circuit.
• The controller reduces the output to the LS-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
• The travel speed is slow at Mi and Lo.
occurring on
• In L mode, speeds of the work equipment and swing are too fast.
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
LS-EPC solenoid defec- during the troubleshooting.
tive V22 (male) Resistance value
1
(Internal short-circuiting
Between and 7 – 14 Ω
or grounding fault)
Between and grounding Above 1 MΩ

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness between C03 (female) and Resistance
circuit) Above 1 MΩ
V22 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump C03 (female) Resistance value
3
controller defective
Between and 7 – 14 Ω
Between and grounding Above 1 MΩ

Electrical Circuit Diagram for LS-EPC Solenoid in Governor • Pump Controller

20-344 PC290-7
TESTING AND ADJUSTING E223

Service Code in Electrical System E223 (Disconnection in LS-EPC solenoid system)

User Code Service Code Failure Code Failure Disconnection in LS-EPC solenoid
— E223 DXE0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the LS-EPC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The travel speed is slow at Mi and Lo.
occurring on
• In L mode, speeds of the work equipment and swing are too fast.
machine
Relative • Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
information (Code No. 015: LS-EPC solenoid current)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
LS-EPC solenoid defec- during the troubleshooting.
1 tive
Presumed cause and standard value in normalcy

V22 (male) Resistance value

(Internal short-circuiting)
Between and 7 – 14 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness Between wiring harness between C03 (female) and Resistance
2 (Disconnection or defec- Below 1 Ω
V22 (female) and grounding value
tive contact with connec-
tor) Wiring harness between C03 (female) and V22 Resistance
Below 1 Ω
(female) value

Short-circuiting of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Between wiring harness between C03 (female) and
cuit) Voltage Below 1 V
V22 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
4 C03 (female) Resistance value
controller defective
Between and 7 – 14 Ω

Electrical Circuit Diagram for LS-EPC Solenoid in Governor • Pump Controller

PC290-7 20-345
TESTING AND ADJUSTING E224

Service Code in Electrical System E224 (Abnormality in F pump pressure sensor)

User Code Service Code Failure Code Failure Abnormality in F pump pressure sensor
— E224 DHPAMA phenomenon (in governor • pump controller system)
Failure content • Signal voltage from the F pump pressure sensor dropped below 0.3 V or exceeded 4.72 V.
Response from • The controller controls the F pump pressure at 0 MPa{0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
Relative • Input from the F pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 011: F pump pressure)

Cause Standard value in normalcy and references for troubleshooting

Sensor power source
1 If the Service Code No. [E226] is displayed, troubleshoot the failure first.
fault
★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
F pump pressure sensor
2 defective A51 Voltage
(Internal failure) Between and 4.5 – 5.5 V

Between and 0.5 – 4.5 V

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Presumed cause and standard value in normalcy

during the troubleshooting.

Disconnection of wiring Wiring harness from C01 (female) to J07 to A51 Resistance
Below 1 Ω
harness (female) value
3 (Disconnection or defec-
tive contact with connec- Wiring harness between C01 (female) and A51 Resistance
Below 1 Ω
tor) (female) value

Wiring harness between C01 (female) and A51 Resistance

Below 1 Ω
(female) value

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) and Resistance
circuit) Above 1 MΩ
A51 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Short-circuiting of wiring
harness Between wiring harness between C01 (female) , J07
5 Voltage Below 1 V
(Contact with 24 V cir- and A51 (female) and grounding
cuit)
Between wiring harness between C01 (female) and
Voltage Below 1 V
A51 (female) ang grounding
★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Governor • pump C01 Voltage
6
controller defective
Between and 4.5 – 5.5 V
Between and 0.5 – 4.5 V

20-346 PC290-7
TESTING AND ADJUSTING E224

Electrical Circuit Diagram for F Pump Pressure Sensor in Governor • Pump Controller

PC290-7 20-347
TESTING AND ADJUSTING E225

Service Code in Electrical System E225 (Abnormality in R pump pressure sensor)

User Code Service Code Failure Code Failure Abnormality in R pump pressure sensor
— E225 DHPBMA phenomenon (in governor • pump controller system)
Failure content • Signal voltage from the R pump pressure sensor dropped below 0.3 V or exceeded 4.42 V.
Response from • The controller controls the R pump pressure as 0 MPa {0 kg/cm2}.
controller • If the failure cause disappears, the sensor returns to normalcy of itself.
Phenomenon
occurring on • The travel speed does not shift automatically.
machine
Relative • Input from the R pump pressure sensor (pressure) can be confirmed in the monitor function.
information (Code No. 012: R pump pressure)

Cause Standard value in normalcy and references for troubleshooting

Sensor power source
1 If the Service Code No. [E226] is displayed, troubleshoot the failure first.
fault
★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
R pump pressure sen-
2 sor defective A52 Voltage
(Internal failure) Between and 4.5 – 5.5 V

Between and 0.5 – 4.5 V

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Presumed cause and standard value in normalcy

during the troubleshooting.

Disconnection of wiring Wiring harness from C01 (female) to J07 to A52 Resistance
Below 1 Ω
harness (female) value
3 (Disconnection or defec-
tive contact with connec- Wiring harness between C01 (female) and A52 Resistance
Below 1 Ω
tor) (female) value

Wiring harness between C01 (female) and A52 Resistance

Below 1 Ω
(female) value

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) and Resistance
circuit) Above 1 MΩ
A52 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Short-circuiting of wiring
harness Between wiring harness between C01 (female) , J07
5 Voltage Below 1 V
(Contact with 24 V cir- and A52 (female) and grounding
cuit)
Between wiring harness between C01 (female) and
Voltage Below 1 V
A52 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Governor • pump C01 Voltage
6
controller defective
Between and 4.5 – 5.5 V
Between and 0.5 – 4.5 V

20-348 PC290-7
TESTING AND ADJUSTING E225

Electrical Circuit Diagram for R Pump Pressure Sensor in Governor • Pump Controller

PC290-7 20-349
TESTING AND ADJUSTING E226

Service Code in Electrical System E226 (Abnormality in Pressure sensor power source)

User Code Service Code Failure Code Failure Abnormality in pressure sensor power source
— E226 DA25KP phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the power source circuit (5 V) for the pressure sensors and potentiometer.
• The controller turns OFF power supply to the power source circuit (5 V).
Response from
• Even when the failure cause disappears of itself, the current does not return to normalcy, unless the en-
controller
gine starting switch is once turned OFF.
Phenomenon • Signals from the pressure sensors and potentiometer are not inputted correctly.
occurring on • The Service Code of "pressure sensor abnormal" and that of "potentiometer abnormal" are displayed at
machine the same time.

Cause Standard value in normalcy and references for troubleshooting

Disconnect the following equipment one by one. Equipment that shows no service code
is defective, having an internal failure.
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
Pressure sensor or during the troubleshooting.
1 potentiometer defective Fuel dial E06 Connector
(Internal short-circuit)
Governor motor potentiometer E10 Connector
F pump pressure sensor A51 Connector
Presumed cause and standard value in normalcy

R pump pressure sensor A52 Connector

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness from C01 (female) to J07 to Resistance
Above 1 MΩ
E06 (female) and grounding [Fuel dial system] value
Between wiring harness from C01 (female) to J07 to
Resistance
E10 (female) and grounding Above 1 MΩ
value
Grounding fault of wiring [Governor potentiometer system]
harness Between wiring harness from C01 (female) to J07 to
2 Resistance
(Contact with grounding A51 (female) and grounding Above 1 MΩ
circuit) value
[F pump pressure sensor system]
Between wiring harness from C01 (female) to J07 to
Resistance
A52 (female) and grounding Above 1 MΩ
value
[R pump pressure sensor system]
Between wiring harness from C01 (female) to J07 to
Resistance
A08 (male) and grounding Above 1 MΩ
value
[Attachment system]
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump
3
controller defective C01 Voltage
Between and 4.5 – 5.5 V

20-350 PC290-7
TESTING AND ADJUSTING E226

Electrical Circuit Diagram for Sensor Power Source in Governor • Pump Controller

PC290-7 20-351
TESTING AND ADJUSTING E227

Service Code in Electrical System E227

(Abnormality in engine rotation sensor in governor • pump controller system)

User Code Service Code Failure Code Failure Abnormality in engine rotation sensor
— E227 DLE2MA phenomenon (in governor • pump controller system)
Failure content • A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from • The controller exercises a control equivalent to E mode.
controller • If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on • The machine lacks power a bit.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine RPM)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Engine rotation sensor during the troubleshooting.
fault E04 (male) Resistance value
1
(Internal short-circuiting
or disconnection) Between and 500 – 1,000 Ω
Presumed cause and standard value in normalcy

Between and grounding Above 1 MΩ

Engine rotation sensor For the inspection and adjustment, refer to the section of "Adjusting Engine Rotation
2
adjustment improper Sensor" in this manual.
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness Wiring harness between C02 (female) and E04 Resistance
3 (Disconnection or defec- Below 1 Ω
(female) value
tive contact with connec-
tor) Wiring harness between C02 (female) and E04 Resistance
Below 1 Ω
(female) value

Short-circuiting of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between C02 (female) and
cuit) Voltage Below 1 V
E04 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C02 (female) Resistance value
5
controller defective
Between and 500 – 1,000 Ω
Between and grounding Above 1 MΩ

Electrical Circuit Diagram for Monitor Panel Power Source

20-352 PC290-7
TESTING AND ADJUSTING E228

Service Code in Electrical System E228

(Short-circuiting in attachment return switching relay)

User Code Service Code Failure Code Failure Short-circuiting in attachment return switching relay
— E228 D196KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power ON).
Response from • The controller turned OFF power to the attachment return switching relay circuit.
controller • Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
occurring on • The hydraulic circuit for attachments is not switched to the single operation circuit.
machine
Relative • It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
information or OFF). (Code No. 024:Solenoid 2)

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Attachment return during the troubleshooting.
1 switching relay defective
R20 (male) Resistance value
(Internal short-circuiting)
Between and 100 – 500 Ω

Short-circuiting of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
2
(Contact with 24 V cir- Between wiring harness between C02 (female) and
cuit) Voltage Below 1 V
R20 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C03 Working mode Voltage
3
controller defective
Other than B mode 20 – 30 V
Between and grounding
B mode Below 1 V

Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid

PC290-7 20-353
TESTING AND ADJUSTING E232

Service Code in Electrical System E232 (Short-circuiting in PC-EPC Solenoid

User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E232 DXA0KB phenomenon (in governor • pump controller system)
Failure content • Abnormal current flew to the PC-EPC solenoid circuit.
• The controller reduces the output to the PC-EPC solenoid circuit to 0.
Response from
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
occurring on • As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative • If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information in a working mode equivalent to E mode by turning the emergency drive switch ON.
(At that time the monitor panel continues to display service code No. [E232], but this is not abnormal)
★Turn the emergency driving switch ON during the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
PC-EPC solenoid defec- during the troubleshooting.
tive V21 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between and 7 – 14 Ω
Between and grounding Above 1 MΩ

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to S21 to Resistance
circuit) Above 1 MΩ
V21 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump C03 (female) Resistance value
3
controller defective
Between and 7 – 14 Ω
Between and grounding Above 1 MΩ

20-354 PC290-7
TESTING AND ADJUSTING E232

Electrical Circuit Diagram for PC-EPC Solenoid in Governor • Pump Controller

PC290-7 20-355
TESTING AND ADJUSTING E233

Service Code in Electrical System E233 (Disconnection in PC-EPC solenoid system)

User Code Service Code Failure Code Failure Disconnection in PC-EPC solenoid
E02 E233 DXA0KA phenomenon (in governor • pump controller system)
Failure content • No current flows to the PC-EPC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
occurring on • As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
machine
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No. 013: PC-EPC solenoid current)
Relative
• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be operated
information
in a working mode equivalent to E mode by turning the emergency driving switch ON. (At that time the
monitor panel continues to display Service Code No. [E233], but this is not abnormal)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
PC-EPC solenoid during the troubleshooting.
1 defective
V21 (male) Resistance value
(Internal short-circuiting)
Between and 7 – 14 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
S21 Switch Resistance value
Emergency pump driving
2 switch defective OFF Below 1 Ω
Between and
Presumed cause and standard value in normalcy

(Internal disconnection) ON Above 1 MΩ

OFF Below 1 Ω
Between and
ON Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Resistance
Wiring harness between C03 (female) and S21 Below 1 Ω
Disconnection of wiring value
harness Resistance
3 (Disconnection or defec- Wiring harness between S21 and V21 (female) Below 1 Ω
value
tive contact with connec-
tor) Wiring harness between C03 (female) and S21 Resistance
Below 1 Ω
value
Resistance
Wiring harness between S21 and V21 (female) Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Short-circuiting of wiring
harness Between wiring harness between C03 (female) and
4 Voltage Below 1 V
(Contact with 24 V cir- S21 and grounding
cuit)
Between wiring harness between S21 and V21
Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
5
controller defective C03 (female) Resistance value
Between and 7 – 14 Ω

20-356 PC290-7
TESTING AND ADJUSTING E233

Electrical Circuit Diagram for PC-EPC Solenoid in Governor • Pump Controller

PC290-7 20-357
TESTING AND ADJUSTING E238

Service Code in Electrical System E238

(Disconnection in attachment return switching relay)

User Code Service Code Failure Code Failure Disconnection in attachment return switching relay
— E238 D196KA phenomenon (in governor • pump controller system)
• When the attachment switching relay circuit is disconnected from grounding (power OFF), 24 V voltage
Failure content
is not generated.
Response from • None in particular
controller • If the failure cause disappears, the governor returns to normalcy.
Phenomenon
occurring on • The hydraulic circuit for attachments cannot be switched to the single operation
machine
Relative • It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
information or OFF). (Code No. 024:Solenoid 2)

Cause Standard value in normalcy and references for troubleshooting

If the fuse has been blown, there is a big possibility that grounding fault occurred in the
1 Fuse No. 2 fault
relay circuit.
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Attachment return during the troubleshooting.
2 switching relay defective
R20 (male) Resistance value
Presumed cause and standard value in normalcy

(Internal disconnection)
Between and 100 – 500 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Emergency pump driving
Wiring harness between C02 (female) and R20 Resistance
3 switch defective Below 1 Ω
(female) value
(Internal disconnection)
Wiring harness from R20 (female) to J03 to FB1-2 Resistance
Below 1 Ω
outlet value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of wiring
harness Between wiring harness between C02 (female) and Resistance
4 Above 1 MΩ
(Contact with grounding R20 (female) and grounding value
circuit)
Between wiring harness from R20 (female) to J03 to Resistance
Above 1 MΩ
FB1-2 outlet and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C03 Working mode Voltage
5
controller defective
Other than B mode 20 – 30 V
Between and grounding
B mode Below 1 V

20-358 PC290-7
TESTING AND ADJUSTING E238

Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid in Governor • Pump
Controller

PC290-7 20-359
TESTING AND ADJUSTING E245

Service Code in Electrical Equipment E245

(Short-circuiting in attachment oil flow rate adjusting EPC) (Multi-monitor only)

User Code Service Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
— E245 DXE4KB phenomenon EPC (in governor • pump controller system)
Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
• The controller reduces to zero (0) power to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • The attachments do not move.
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Attachment oil flow rate during the troubleshooting.
adjusting EPC defective V30 (male) Resistance value
1
(Internal short-circuiting
or grounding fault) Between and 7 – 14 Ω
Between and grounding Above 1 MΩ

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness between C03 (female) and Resistance
circuit) Above 1 MΩ
V30 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump C03 (female) Resistance value
3
controller defective
Between and 7 – 14 Ω
Between and grounding Above 1 MΩ

Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump
Controller

20-360 PC290-7
TESTING AND ADJUSTING E246

Service Code in Electrical System E246

(Disconnection in attachment oil flow rate adjusting EPC) (Multi-monitor only)

User Code Service Code Failure Code Failure Disconnection in attachment oil flow rate adjusting
— E246 DXE4KA phenomenon EPC (in governor • pump controller system)
Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from • None in particular (The solenoid does not work, as there is no current flowing to it)
controller • If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
occurring on • The attachments do not move.
machine
Relative • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
information rate adjusting EPC solenoid circuit. (Code No. 017: Service solenoid current)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Attachment oil flow rate
during the troubleshooting.
adjusting EPC defective
Presumed cause and standard value in normalcy

1
(Internal short-circuiting V30 (male) Resistance value
or grounding fault) 7 – 14 Ω
Between and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness Between wiring harness between C03 (female) and Resistance
2 (Disconnection or defec- Below 1 Ω
V30 (male) and grounding value
tive contact with connec-
tor) Between wiring harness between C03 (female) Resistance
Below 1 Ω
and V30 (male) and grounding value

Short-circuiting of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
harness during the troubleshooting.
3
(Contact with 24 V cir- Between wiring harness between C03 (female) and
cuit) Voltage Below 1 V
V30 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump
4
controller defective C03 (female) Resistance value
Between and 7 – 14 Ω

Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid in Governor • Pump
Controller

PC290-7 20-361
TESTING AND ADJUSTING E256

Service Code in Electrical System E256 (Incorrect nonvolatile memory data)

User Code Service Code Failure Code Failure Incorrect nonvolatile memory data
— E256 DA20KT phenomenon (in governor • pump controller)
Failure content • The data in the nonvolatile memory in the controller cannot be updated.
• None in particular
Response from
• Even if the failure cause disappears, the nonvolatile memory does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• In some cases control parameters of the machines change, resulting in increase or decrease of the ma-
occurring on
chine's power.
machine
Relative
• Recorded in the nonvolatile memory are part of the machine control parameters
information

Presumed Cause Standard value in normalcy and references for troubleshooting

cause and As it is an internal failure, troubleshooting is impossible.
standard value Governor • pump
1 (There is no problem with continuing with use of the controller, so long as no
in normalcy controller defective
failure is visually evident)

20-362 PC290-7
TESTING AND ADJUSTING E306

Service Code in Electrical System E306 (Abnormality in governor potentiometer)

User Code Service Code Failure Code Failure Abnormality in governor potentiometer
— E306 DK54KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the governor potentiometer dropped below 0.4 V or exceeded 4.6 V.
• The controller exercises control by computing the motor position through voltage right before a failure
Response from occurred.
controller • Even if the failure cause disappears of itself, the governor potentiometer does not return to normalcy,
unless the engine starting switch is once turned OFF.
• The engine cannot attain the specified rotation at high idling. (A bit lower)
• The engine cannot attain the specified rotation at low idling (A bit higher)
Phenomenon
• The auto-decelerator or automatic warming-up function does not work.
occurring on
• There is hunting while the engine is running.
machine
• The engine stalls.
• The engine does not stop.
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: Governor potentiometer voltage)

Cause Standard value in normalcy and references for troubleshooting

Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor potentiometer E10 (male) Resistance value
2 defective Between and 4.0 – 6.0 kΩ
(Internal failure)
Between and 0.25 – 5.0 kΩ

Between and 0.25 – 5.0 kΩ

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring Wiring harness from C01 (female) to J07 to E10 Resistance
Below 1 Ω
harness (female) value
3 (Disconnection or defec-
tive contact with connec- Wiring harness between C01 (female) and E10 Resistance
Below 1 Ω
tor) (female) value
Wiring harness between C01 (female) and E10 Resistance
Below 1 Ω
(female) value

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) and Resistance
circuit) Above 1 MΩ
E10 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Short-circuiting of wiring
harness Between wiring harness from C01 (female) to J07 to
5 Voltage Below 1 V
(Contact with 24 V cir- E10 (female) and grounding
cuit)
Between wiring harness between C01 (female) and
Voltage Below 1 V
E10 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C01 Resistance value
6
controller defective
Between and 4.5 – 5.5 V
Between and 0.5 – 4.5 V

20-364 PC290-7
TESTING AND ADJUSTING E306

Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller

PC290-7 20-365
TESTING AND ADJUSTING E308

Service Code in Electrical System E308 (Abnormality in fuel dial)

User Code Service Code Failure Code Failure Abnormality in governor fuel dial
E05 E308 DK10KZ phenomenon (in governor • pump controller)
Failure content • Signal voltage from the from fuel dropped below 0.23 V or exceeded 4.77 V.
• The controller exercises control by computing the fuel dial position through voltage right before a failure
Response from
occurred.
controller
• If the failure cause disappears, the fuel dial returns to normalcy.
• If the fuel dial had been set at FULL before a failure occurred, it does not change to PARTIAL.
Phenomenon
• If the fuel dial had been set at PARTIALLY before a failure occurred, it does not change to FULL.
occurring on
• There is hunting while the engine is running.
machine
• The engine cannot attain the specified rotation at high idling and lacks power.
Relative • Input from the fuel dial (voltage) can be confirmed in the monitor function.
information (Code No. 030: Fuel dial voltage)

Cause Standard value in normalcy and references for troubleshooting

Sensor power source
1 If Service Code No. [E226] is displayed, troubleshoot the failure first.
defective
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness E06 (male) Resistance value
2 (Disconnection or defec- 4.0 – 6.0 kΩ
Between and
tive contact with connec-
tor) Between and 0.25 – 5.0 kΩ
Between and 0.25 – 5.0 kΩ
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wiring Wiring harness from C01 (female) to J07 to E06 Resistance
harness Below 1 Ω
(female) value
3 (Disconnection or defec-
tive contact with connec- Wiring harness between C01 (female) and E06 Resistance
Below 1 Ω
tor) (female) value
Wiring harness between C01 (female) and E06 Resistance
Below 1 Ω
(female) value

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
4
(Contact with grounding Between wiring harness between C01 (female) and Resistance
circuit) Above 1 MΩ
E06 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Short-circuiting of wiring
harness Between wiring harness from C01 (female) to J07 to
5 Voltage Below 1 V
(Contact with 24 V cir- E06 (female) and grounding
cuit)
Between wiring harness between C01 (female) and
Voltage Below 1 V
E06 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump C01 Resistance value
6
controller defective
Between and 4.5 – 5.5 V
Between and 0.5 – 4.5 V

20-366 PC290-7
TESTING AND ADJUSTING E308

Electrical Circuit Diagram for Fuel Dial in Governor • Pump Controller

PC290-7 20-367
TESTING AND ADJUSTING E315

Service Code in Electrical System E315 (Short-circuiting in battery relay)

User Code Service Code Failure Code Failure Short-circuiting in battery relay
— E315 D110KB phenomenon (in governor • pump controller)
Failure content • Abnormal current flew to the battery relay drive circuit, when power was supplied to the circuit.
• The controller turns OFF power to the battery drive circuit.
Response from
• Even when the failure cause disappears, the relay does not return to normalcy, unless the engine start-
controller
ing switch is once turned OFF.
Phenomenon
occurring on • The engine does not stop.
machine
Relative • It can be confirmed in the monitor function how the battery relay works (ON or OFF).
information (Code No. 037: Controller output)

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Battery relay defective Battery relay Continuity & Resistance value
1
(Internal failure) Between A21 (BR terminal) and A20 (E
Continued
terminal)
Between A21 (BR terminal) and grounding Above 1 MΩ
Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness from C03 (female) to D01 to Resistance
circuit) Above 1 MΩ
J01 to A21 (BR terminal) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
Governor • pump
3 C03 (female) Engine starting switch OFF Voltage
controller defective
20 – 30 V
Between and grounding ON →OFF
(for 4 to 7 seconds)

20-368 PC290-7
TESTING AND ADJUSTING E315

Electrical Circuit Diagram for Battery Relay in Governor • Pump Controller

PC290-7 20-369
TESTING AND ADJUSTING E316

Service Code in Electrical System E316 (Step-out in governor motor)

User Code Service Code Failure Code Failure Step-out in governor motor
— E316 DY10K4 phenomenon (in governor • pump controller)
Failure content • There is a big difference between signals from the potentiometer and the set values in the controller.
• The controller repeats the same controlling motions (step-out).
Response from
• Even when the failure cause disappears, the governor motor does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon • The engine rotation cannot be controlled.
occurring on • There is hunting in the rotation.
machine • The engine does not stop.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard

1 Fuel dial defective If Service Code [E308] is displayed, troubleshoot that failure first.
2 Governor potentiometer defective If Service Code [E306] is displayed, troubleshoot that failure first.
value in normalcy

3 Governor motor defective (disconnection) If Service Code [E317] is displayed, troubleshoot that failure first.
4 Governor motor defective (short-circuiting) If Service Code [E318] is displayed, troubleshoot that failure first.
Refer to the section of "Inspection and Adjustment - Special Func-
5 Governor lever adjustment improper
tion of Monitor Panel" in this manual.
6 Engine fuel control system defective Refer to Engine Shop Manual.
As this is an internal failure, no troubleshooting can be carried out.
7 Governor • pump controller defective (If there is none of the failures listed above, the controller is judged
as defective)

20-370 PC290-7
TESTING AND ADJUSTING E317

Service Code in Electrical System E317 (Disconnection in governor motor Phase A and B)

User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and B
E05 E317 DY10KA phenomenon (in governor • pump controller)
Failure content • No current flew to the governor motor, when power was supplied to the motor.
Response from • None in particular.
controller • If the failure cause disappears, the governor returns to normalcy.
• The engine rotation drops to low idling.
Phenomenon
• There is hunting in the rotation
occurring on
• The engine does not stop.
machine
• The governor motor steps out.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor motor defec-
1 tive E11 (male) Resistance value
Presumed cause and standard value in normalcy

(Internal disconnection) Between and 2.5 – 7.5 Ω

Between and 2.5 – 7.5 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Wiring harness between C03 (female) and E11 Resistance
Below 1 Ω
Disconnection of wiring (female) value
harness Wiring harness between C03 (female) and E11 Resistance
2 (Disconnection or defec- Below 1 Ω
(female) value
tive contact with connec-
tor) Wiring harness between C03 (female) and E11 Resistance
Below 1 Ω
(female) value
Wiring harness between C03 (female) and E11 Resistance
Below 1 Ω
(female) value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump C03 (female) Resistance value
3
controller defective
Between and 2.5 – 7.5 Ω
Between and 2.5 – 7.5 Ω

20-372 PC290-7
TESTING AND ADJUSTING E317

Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller

PC290-7 20-373
TESTING AND ADJUSTING E318

Service Code in Electrical System E318

(Short-circuiting in governor motor Phase A and Phase B)

User Code Service Code Failure Code Failure Disconnection in governor motor Phase A and
E05 E318 DY10KB phenomenon Phase B (in governor • pump controller system)
Failure content • Abnormal current flew to the governor motor, when power is supplied to the motor.
Response from • None in particular
controller • If the failure cause disappears, the governor motor returns to normalcy.
• The engine rotation cannot be controlled.
Phenomenon
• The engine rotation drops to low idling.
occurring on
• There is hunting in the rotation.
machine
• The engine does not stop.
Relative • Operation of the governor motor (current) can be confirmed in the monitor function.
information (Code No. 033: Governor motor Phase A current, Code No. 034: Governor motor Phase B current)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor motor defec- E11 (male) Resistance value
tive Between and 2.5 – 7.5 Ω
1
(Internal short-circuiting
or grounding fault) Between and 2.5 – 7.5 Ω
Between and grounding Above 1 MΩ
Presumed cause and standard value in normalcy

Between and grounding Above 1 MΩ

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness between C03 (female) and Resistance
Above 1 MΩ
Disconnection of wiring E11 (female) and grounding value
harness Between wiring harness between C03 (female) and Resistance
2 (Disconnection or defec- Above 1 MΩ
E11 (female) and grounding value
tive contact with connec-
tor) Between wiring harness between C03 (female) and Resistance
Above 1 MΩ
E11 (female) and grounding value
Between wiring harness between C03 (female) and Resistance
Above 1 MΩ
E11 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
C03 (female) Resistance value
Between and 2.5 – 7.5 Ω
Governor • pump Between and 2.5 – 7.5 Ω
3
controller defective
Between and grounding Above 1 MΩ
Between and grounding Above 1 MΩ
Between and grounding Above 1 MΩ
Between and grounding Above 1 MΩ

20-374 PC290-7
TESTING AND ADJUSTING E318

Electrical Circuit Diagram for Governor Motor in Governor • Pump Controller

PC290-7 20-375
TESTING AND ADJUSTING E501 / E502

Service Code in Electrical System E501 ("Model Selection" function not provided yet)

User Code Service Code Failure Code Failure "Model Selection" function not provided yet
— E501 DA2AKM phenomenon (in governor • pump controller system)
Failure content • Model Code is not inputted yet.
• Model data and rated load cannot be set.
Response from
• Even when the failure cause disappears, Service Code does not return to normalcy, unless the engine
controller
starting switch is once turned OFF.
Phenomenon
occurring on • The excess load alarm does not work normally.
machine
Relative • Model names that the controller recognizes (figure) can be confirmed in the monitor function.
information (Code No. 150: Model Code)

Cause Standard value in normalcy and references for troubleshooting

Refer to the section "Special Function of Monitor Panel" in this manual.
Presumed Setting work not finished ★There is a possibility that model selection operation has never been
1
cause and yet tried with that specific model from its delivery ex-works up to this mo-
standard value ment.
in normalcy As this is an internal failure, no troubleshooting can be conducted.
Governor • pump
2 (If there is no problem with the setting work above, the controller may be
controller defective
judged as defective.)

20-376 PC290-7
TESTING AND ADJUSTING E501 / E502

Service Mode in Electrical System E502 (Model selecting signal fault)

User Code Service Code Failure Code Failure Model selecting signal fault
— E502 DA20KT phenomenon (in governor • pump controller system)
Failure content • Information on the models stored in the controller have been damaged.
• Model data and rated load cannot be set.
Response from
• Even when the failure cause disappears, the signal does not return to normal, unless the engine starting
controller
switch is once turned OFF.
Phenomenon
occurring on • The excess load alarm does not work normally.
machine
Relative • (Model names that the controller recognizes (figure) can be confirmed in the monitor function.
information (Code No. 150: Model Code)

Cause Standard value in normalcy and references for troubleshooting

Presumed Setting work not finished
1 Refer to the section "Special Function of Monitor Panel" in this manual.
cause and yet
standard value As this is an internal failure, no troubleshooting can be conducted.
in normalcy Governor • pump
2 (If there is no problem with the setting work above, the controller may be
controller defective
judged as defective.)

PC290-7 20-377
TESTING AND ADJUSTING A000N1 / A000N2

Failure Code in Mechanical System A000N1 (Out-of-rate engine rotation at high idling)

User Code Service Code Failure Code Failure Engine rotation at high idling out of rate
— — A000N1 phenomenon (in mechanical system)
Failure content • Engine rotation above 2,350 rpm was detected for more than 10 seconds, while the engine was running.
Response from • None in particular
controller • If the failure cause disappears of itself, the engine rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if is used continuously without adjustment.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)

Cause Standard value in normalcy and references for troubleshooting

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idling, and troubleshoot the mechanical
cause and ical system
system of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (Unless there is any visible trouble found in the machine, use of the con-
controller defective
troller may be continued as it is)

Failure Code in Mechanical System A000N2 (Out-of-rate engine rotation at low idling)

User Code Service Code Failure Code Failure Out-of-rate engine rotation at low idling
— — A000N2 phenomenon (in mechanical system)
Failure content • Engine rotation below 500 rpm was detected for more than 10 seconds, while the engine was running.
Response from • None in particular
controller • If the failure cause disappears of itself, the rotation returns to normalcy.
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without adjustment.
machine
Relative • Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)

Cause Standard value in normalcy and references for troubleshooting

Check if there has been an internal or external factor that would cause
Presumed Failure in engine mechan-
1 the engine to overrun at high idling, and troubleshoot the mechanical
cause and ical system
system of the engine.
standard value
in normalcy As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (Unless there is any visible trouble found in the machine, use of the con-
controller defective
troller may be continued as it is)

20-378 PC290-7
TESTING AND ADJUSTING AA10NX

Failure Code in Mechanical System AA10NX (Air cleaner clogging)

User Code Service Code Failure Code Failure Air cleaner clogged
— — AA10NX phenomenon (in mechanical system)
• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
• This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative panel while the engine is running.
information • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)

Cause Standard value in normalcy and references for troubleshooting

Air cleaner clogged
1 (when the system is in ★Check the air cleaner for clogging. If it is clogged, clean or replace it with new one.
normal condition)
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Air cleaner clogging
2 switch defective A31 (male) Air cleaner Resistance value
(Internal disconnection) When in normal condition Below 1 Ω
Between and
When clogged Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it running during the
Disconnection of wiring troubleshooting.
harness
Wiring harness between P02 (female) and A31 Resistance
3 (Disconnection or defec- Below 1 Ω
(female) value
tive contact with connec-
tor) Resistance
Between wiring harness A31 (female) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective P02 Air cleaner Voltage
When in normal condition Below 1 V
Between and grounding
When clogged 20 – 30 V

Electrical Circuit for Air Cleaner Clogging Switch in Monitor Panel

PC290-7 20-379
TESTING AND ADJUSTING AB00KE

Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)

User Code Service Code Failure Code Failure Charging voltage abnormally lowered
— — AB00KE phenomenon (in mechanical system)
Failure content • Generation signal from the alternator is not inputted, while the engine is running.
Response from
• None in particular
controller
Phenomenon
• There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
• This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while the
Relative engine is running.
information • Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Presumed cause and standard value in normalcy

Alternator defective
1
(short generating output) E12 (male) Engine rotation Voltage
Between and grounding Above medium speed 27.5 – 29.5 V
Disconnection of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
2 (Disconnection or defec-
tive contact with connec- Wiring harness from P02 (female) to J02 to E12 Resistance
Below 1 Ω
tor) (female) value

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of wiring during the troubleshooting.
harness
3 Wiring harness from P02 (female) to J02 to E12
(Contact with grounding Resistance
circuit) (female) , or between P02 (female) and D01 (female) Above 1 MΩ
value
, or between P02 (female) and A27 (female)
★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective
P02 Engine rotation Voltage
Between and grounding Above medium speed 27.5 – 29.5 V

20-380 PC290-7
TESTING AND ADJUSTING AB00KE

Electrical Circuit Diagram for Engine Start, Stop and Charging in Monitor Panel

PC290-7 20-381
TESTING AND ADJUSTING B@BAZG

Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure)

User Code Service Code Failure Code Failure Engine oil pressure abnormally lowered
— — B@BAZG phenomenon (in mechanical system)
• The signal circuit in the engine oil pressure switch was closed (i.e. connected with grounding), while the
Failure content
engine was running.
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine may seize, if the engine is kept running without corrective action.
machine
• This Failure Code is recorded, if the engine oil pressure caution symbol is displayed in the monitor panel,
Relative while the engine is running.
information • Input from the engine oil pressure switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 046: Monitor input 2)

Cause Standard value in normalcy and references for troubleshooting

Engine oil pressure low-
Presumed cause and standard value in normalcy

1 ered (the system in nor- ★Check the failure cause and damage to the engine, and then make repairs.
mal condition)
★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
Engine oil pressure
2 switch defective E02 (on switch side) Engine oil pressure Resistance value
(Internal short-circuiting) Between terminal and When in normal condition Above 1 MΩ
grounding When lowered Below 1 Ω
Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
3
(Contact with grounding Between wiring harness between P02 (female) (7) and E02 Resistance
circuit) Above 1 MΩ
(terminal) and grounding value
★Turn the engine starting switch OFF for the preparations, and keep the engine running
during the troubleshooting.
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition 20 – 30 V
Between and grounding
When lowered Below 1 V

Electrical Circuit Diagram for Engine Oil Pressure Switch in Monitor Panel

20-382 PC290-7
TESTING AND ADJUSTING B@BAZK

Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)

User Code Service Code Failure Code Failure Engine oil level abnormally lowered
— — B@BAZK phenomenon (in mechanical system)
• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
Failure content
engine is stopped (with the starting switch in the ON position).
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
• This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is
Relative stopped (with the starting key in the ON position).
information • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)

Cause Standard value in normalcy and references for troubleshooting

Engine oil level lowered
★Check the engine oil level, and refill oil.
1 (System in normal condi-
Presumed cause and standard value in normalcy

(If the phenomenon occurs frequently, check the cause)

tion)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Engine oil level switch
2 defective E03 (male) Engine oil level Resistance value
(Internal disconnection) When in normal condition Below 1 Ω
Between and grounding
When lowered Above 1 MΩ
Disconnection of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
3 (Disconnection or defec-
tive contact with connec- Wiring harness between P02 (female) and E03 (female) Resistance
Below 1 Ω
tor) value

★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 Engine oil pressure Voltage
When in normal condition Below 1 V
Between and grounding
When lowered 20 – 30 V

Electrical Circuit Diagram for Engine Oil Level Switch in Monitor Panel

PC290-7 20-383
TESTING AND ADJUSTING B@BCNS

Failure Code in Mechanical System B@BCNS (Engine cooling water overheating)

User Code Service Code Failure Code Failure Engine cooling water overheated
— — B@BCNS phenomenon (in mechanical system)
Failure content • The engine cooling water sensor inputted a signal of 102°C, while the engine was running.
Response from
• Response from controller
controller
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the engine cooling water temperature gauge is displayed in the red
Relative range, when the engine is running.
information • Input from the engine cooling water temperature sensor (temperature) can be confirmed in the monitor
function. (Code No. 041: Engine cooling water temperature)

Cause Standard value in normalcy and references for troubleshooting

Engine Overheating
1 (system in normal condi- ★Check the engine for the cause and damage, and repair it.
Presumed cause and standard value in normalcy

tion)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Engine cooling water
temperature sensor Engine cooling water tem-
2 E05 (male) Resistance value
defective perature
(Internal short-circuiting) Between and 90 – 3.5kΩ
10 – 100 °C
Between and grounding Above 1 MΩ

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
3
(Contact with grounding Between wiring harness between P02 (female) and Resistance
circuit) Above 1 MΩ
E05 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.

4 Monitor panel defective P02 (female) Engine water temperature Resistance value
Between and 90 – 3.5kΩ
10 – 100 °C
Between and grounding Above 1 MΩ

Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor in Monitor Panel

20-384 PC290-7
TESTING AND ADJUSTING B@BCZK

Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level)
(Multi-monitor only)
User Code Service Code Failure Code Failure Radiator water level abnormally lowered
— — B@BCZK phenomenon (in mechanical system)
Failure content • The signal circuit in the radiator water level switch was opened (i.e. disconnected from grounding).
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the radiator water level caution symbol is displayed in the monitor panel,
Relative when the engine is running.
information • Input from the radiator water level switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 045: Monitor input 1)

Cause Standard value in normalcy and references for troubleshooting

Radiator water level low-
★Check the water level and refill cooling water.
1 ered (system in normal
(If this phenomenon occurs frequently, check the cause)
condition)
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Radiator water level
2 switch defective A33 (male) Engine cooling water level Resistance value
(Internal disconnection) When in normal condition Below 1 Ω
Between and
When lowered Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wiring during the troubleshooting.
harness
Wiring harness between P02 (female) and A33 (female) Resistance
3 (Disconnection or defec- Below 1 Ω
value
tive contact with connec-
tor) Resistance
Wiring harness between A33 (female) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
during the troubleshooting.
4 Monitor panel defective P02 Engine water temperature Resistance value
When in normal condition Below 1 V
Between and grounding
When lowered 20 – 30 V

Electrical Circuit Diagram for Radiator Water Level Switch in Monitor Panel

PC290-7 20-385
TESTING AND ADJUSTING B@HANS

Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)

(Multi-monitor only)
User Code Service Code Failure Code Failure Hydraulic oil overheated
— — B@HANS phenomenon (in mechanical system)
Failure content • The hydraulic oil temperature sensor inputted a signal of 102°C, while the engine was running.
Response from
• None in particular
controller
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the hydraulic oil temperature gauge is displayed in the red range, when
Relative the engine is running.
information • Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function.
(Code No. 044: Engine cooling water temperature)

Cause Standard value in normalcy and references for troubleshooting

Hydraulic oil overheat-
1 ing (system in normal ★Check the cause and damage to the hydraulic equipment, and repair it.
Presumed cause and standard value in normalcy

condition)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Hydraulic oil temperature
2 sensor defective A61 (male) Hydraulic oil temperature Resistance value
(Internal short-circuiting) Between and 90 – 3.5kΩ
10 – 100 °C
Between and grounding Above 1 MΩ

Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness during the troubleshooting.
3
(Contact with grounding Between wiring harness between P02 (female) and Resistance
circuit) Above 1 MΩ
A61 (female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.

4 Monitor panel defective P02 (female) Engine water temperature Resistance value
Between and 90 – 3.5kΩ
10 – 100 °C
Between and grounding Above 1 MΩ

Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor in Monitor Panel

20-386 PC290-7
 TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-502

E-1 Engine does not start (Engine does not rotate) ................................................................................ 20-503
E-2 Engine stops while in operation ........................................................................................................ 20-506
E-3 Engine speed is irregular, or there is hunting ................................................................................... 20-507
E-4 Engine does not stop ........................................................................................................................ 20-509
E-5 Auto-decelerator does not work ........................................................................................................ 20- 511
E-6 Auto engine warm-up device does not work ..................................................................................... 20-512
E-7 Preheater does not work................................................................................................................... 20-513
E-8 All work equipment, swing and travel do not move........................................................................... 20-515
E-9 One-touch Power Max Switch does not work ................................................................................... 20-517
E-10 No display in monitor panel at all ...................................................................................................... 20-518
E-11 Part of display on monitor panel is missing....................................................................................... 20-519
E-12 Monitor panel displays contents irrelevant to the model ................................................................... 20-519
E-13 Fuel level monitor red lamp lights up while engine is running........................................................... 20-520
E-14 Engine cooling water temperature gauge does not indicate correctly .............................................. 20-521
E-15 Hydraulic oil temperature gauge does not display correctly ............................................................. 20-522
E-16 Fuel gauge does not display correctly .............................................................................................. 20-523
E-17 Swing lock monitor does not display correctly .................................................................................. 20-524
E-18 When the monitor switch is operated, no display appears ............................................................... 20-526
E-19 Windshield wiper does not work ....................................................................................................... 20-527
E-20 Alarming buzzer cannot be cancelled ............................................................................................... 20-529
E-21 "Boom RAISE" is not correctly displayed in monitor function ........................................................... 20-530
E-22 "Boom LOWER" is not correctly displayed in monitor function ......................................................... 20-531
E-23 "Arm DIGGING" is not correctly displayed in monitor function ......................................................... 20-532
E-24 "Arm DUMPING" is not correctly displayed in monitor function ........................................................ 20-533
E-25 "Bucket DIGGING" is not correctly displayed in monitor function ..................................................... 20-534
E-26 "Bucket DUMPING" is not correctly displayed in monitor function.................................................... 20-535
E-27 "SWING" is not correctly displayed in monitor function .................................................................... 20-536
E-28 "TRAVEL" is not correctly displayed in monitor function................................................................... 20-538
E-29 "Travel Differential Pressure" is not correctly displayed in monitor function ..................................... 20-540
E-30 "Service" is not correctly displayed in monitor function..................................................................... 20-542
E-31 Air Conditioner does not work........................................................................................................... 20-544
E-32 Travel alarm does not sound ............................................................................................................ 20-545

PC290-7 20-501
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

★ The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.

Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information

Cause Standard value in normalcy and references for troubleshooting

<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
Presumed cause and standard value in normalcy

<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
with it.
Cause for presumed • Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V) is
(The attached No. for in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
• If there is no indication of (male) or (female) in the connector No., pull off a connec-
4
tor and insert a T-adapter into both sides of male and female.
• If there is an indication of (male9 and (female) in the connection No., pull off a con-
nector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead (–) for troubleshooting in the follow-
5 ing manner unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.

Relative Electrical Circuit Diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred.

• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.

20-502 PC290-7
TESTING AND ADJUSTING E-1

E-1 Engine does not start (Engine does not rotate)

Failure
• The engine does not start (the engine does not rotate).
information
• The following two engine start locking mechanisms are provided in the engine starting circuit.
Relative
1) Engine start locking by means of password in the monitor panel ( )
information
2) Engine start locking by means of safety lock lever
: The multi-monitor specification machine only.
Cause Standard value in normalcy and references for troubleshooting
Shortage in battery Battery voltage Battery electrolyte specific gravity
1
capacity Above 24 V Above 1.26
When a fuse or fusible link is blown, there is a big possibility that grounding fault occurred in
Fuse Nos. 3 and 18
the circuit.
2 and Fusible Link A35
If a monitor lamp does not light up in the monitor panel, check the power source circuit
fault
between the battery and the specific fuse.
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Engine starting during the troubleshooting.
switch fault H15 (male) Position Resistance value
3
(Internal
disconnection) OFF Above 1 MΩ
Between and
Start Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Safety lock switch during the troubleshooting.
fault S14 (female) Lock lever Resistance value
4
(Internal
Presumed cause and standard value in normalcy

short-circuiting) Release Below 1 Ω

Between and
LOCK Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Engine starting during the troubleshooting.
motor cut relay, R11
R11 (female) & R13 (male) Resistance value
and R13 defective
5 100 – 500 Ω
(Internal Between and
disconnection or Above 1 MΩ
Between and
short-circuiting)
Between and Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting. (If all of the power source, grounding (GND), generation signal and
engine start input are normal and yet the engine start output is not normal, the engine start-
ing motor relay is defective)
Engine start-
Engine starting Safety relay Voltage
ing switch
motor fault
Power source: Between B terminal and grounding 20 – 30 V
6 (Internal
disconnection or GND (grounding): Between E terminal and grounding Connected
short-circuiting) Generation signal: Between R terminal (A27 ) and
Below 1 V
grounding Start
Engine start input: Between C terminal and grounding 20 – 30 V
Engine start output: Between S terminal (A27 ) and
20 – 30 V
grounding
★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing the troubleshooting. (If all of the power source, grounding (GND), generation signal and
engine start input are normal and yet the engine start output is not normal, the engine start-
Engine starting
ing motor relay is defective)
motor fault
7 Engine start-
(Internal disconnec- Engine starting motor Voltage
tion or damage) ing switch
Power source: B terminal and grounding 20 – 30 V
Start
Engine start input: C terminal and grounding 20 – 30 V

PC290-7 20-503
TESTING AND ADJUSTING E-1

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the ON position or
Alternator fault running during the troubleshooting.
8 (Internal
E12 (male) Voltage
short-circuit)
Between and grounding Below 1 V
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Resistance
Wiring harness between FB1-18 outlet and H15 (female) Below 1 Ω
value
Resistance
Wiring harness from H15 (female) to J01 to R11 (female) Below 1 Ω
value
Resistance
Disconnection of wir- Wiring harness between R11 (female) and A27 (female) Below 1 Ω
value
ing harness
Wiring harness between engine starting motor relay C termi- Resistance
9 (Disconnection or Below 1 Ω
nal and engine starting motor C terminal value
defective contact
with connector) Resistance
Wiring harness between FB1-3 and S14 (female) Below 1 Ω
value
Presumed cause and standard value in normalcy

Resistance
Wiring harness between S14 (female) and R11 (female) Below 1 Ω
value
Resistance
Wiring harness between R11 (female) and R13 (female) Below 1 Ω
value
Resistance
Wiring harness from R13 (female) to J04 to grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Between wiring harness from battery relay B terminal (A23) Resistance
Above 1 MΩ
to A35 to FB1-18 and grounding value
Between wiring harness between FB1-18 outlet and H15 Resistance
Above 1 MΩ
(female) and grounding value
Between wiring harness from H15 (female) to J01 to R11 Resistance
Above 1 MΩ
(female) and grounding value
Grounding fault of
wiring harness Between wiring harness between R11 (female) and A27 Resistance
10 Above 1 MΩ
(Contact with (female) and grounding value
grounding circuit) Between wiring harness between engine starting motor relay C Resistance
Above 1 MΩ
terminal and engine starting motor C terminal and grounding value
Between wiring harness between FB1-3 and S14 (female) Resistance
Above 1 MΩ
and grounding value
Between wiring harness between S14 (female) and R11 Resistance
Above 1 MΩ
(female) and grounding value
Between wiring harness from R13 (female) to J05 to P02 Resistance
Above 1 MΩ
(female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness Wiring harness between A27 (female) and E12 (female)
11
(Contact with 24 V , or wiring harness from A27 (female) to J02 to D01
circuit) Voltage Below 1 V
(female) , or between wiring harness between A27
(female) and P02 (female) and grounding

20-504 PC290-7
TESTING AND ADJUSTING E-1

Electrical Circuit Diagram for Engine Start, Stop and Battery Charging

PC290-7 20-505
TESTING AND ADJUSTING E-2

E-2 Engine stops while in operation

Failure
• The engine suddenly stopped while in operation.
information
Relative • Input from the governor potentiometer (voltage) can be confirmed in the monitor function.
information (Code No. 031: governor potentiometer voltage)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor potentiom- E06 (male) Resistance value
Presumed cause and standard value in normalcy

1 eter fault 4.0 – 6.0 kΩ

Between and
(Internal failure)
Between and 0.25 – 5.0 kΩ
Between and 0.25 – 5.0 kΩ
Disconnection of wir- ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
2 (Disconnection or
defective contact Wiring harness between C01 (female) and E10 (female) Resistance
Below 1 Ω
with connector) value

Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3
(Contact with Between wiring harness between C01 (female) and E10 Resistance
grounding circuit) Above 1 MΩ
(female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C01 Voltage
4
controller defective
Between and 4.5 – 5.5 V
Between and 0.5 – 4.5 V

Electrical Circuit Diagram for Fuel Dial

20-506 PC290-7
TESTING AND ADJUSTING E-3

E-3 Engine speed is irregular, or there is hunting

• Engine speed is irregular at low idling.

Failure
• There is hunting.
information
• Engine speed is lower than specified at high idling.
Relative • Engine rotation can be confirmed in the monitor function.
information (Code No. 010: Engine rotation)

Cause Standard value in normalcy and references for troubleshooting

If the monitor display is not normal, proceed to Service Code [E217].
Model code signal
Monitoring Code Item Normal display
1 fault
(Internal failure) 002
Controller model code 200
Presumed cause and standard value in normalcy

003
Governor lever
2 Refer to the section "Special Function of Monitor Panel" in this manual.
improperly adjusted
If the governor motor lever moves smoothly in the following operations, it is judged as normal.
Governor motor
3 • The fuel dial is operated between low idling and high idling.
improperly working
• The engine is stopped with the fuel dial.
Engine fuel control
4 Refer to the Engine Shop Manual.
system defective
Disconnection of wir- ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
5 (Disconnection or
defective contact Wiring harness from C01 (female) to J07 to H15 (female) Resistance
Below 1 Ω
with connector) value

Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
6
(Contact with Between wiring harness between C01 (female) to J17 and Resistance
grounding circuit) Above 1 MΩ
H15 (female) and grounding value
Governor • pump As this is an internal failure, troubleshooting cannot be conducted.
7
controller defective (If there is none of the causes from Item 1 to 6 above, the controller is judged as defective)

PC290-7 20-507
TESTING AND ADJUSTING E-3

Electrical Circuit Diagram for Engine Start and Stop and Battery Charging

20-508 PC290-7
TESTING AND ADJUSTING E-4

E-4 Engine does not stop

Failure
• The engine does not stop.
information
• The Governor • pump controller drives the battery relay for the min. 4 seconds and max. 7 seconds from
Relative the moment the engine starting switch is turned OFF to the moment the engine completely stops.
information • It can be confirmed in the monitor function how the battery relay works (ON or OFF)
(Code No. 037: Controller output)

Cause Standard value in normalcy and references for troubleshooting

If operating sound is heard from the battery relay contact, when turning the engine starting
1 Battery relay fault switch, the battery relay is judged as normal.
• Starting switch OFF→ON→OFF
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type
during the troubleshooting.
diode D01 fault
2
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Diode mode Continued
Between and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Resistance
ing harness Wiring harness between C03 (female) and D01 (female) Below 1 Ω
value
3 (Disconnection or
defective contact Wiring harness from D01 (female) to J01 to battery relay Resistance
Below 1 Ω
with connector) BR terminal (A21) value
Wiring harness between battery relay E terminal (A20) and Resistance
Below 1 Ω
grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump
4 C03 Engine starting switch Voltage
controller defective
20 – 30 V
Between and grounding ON→OFF
(for 4 to 7 seconds)

PC290-7 20-509
TESTING AND ADJUSTING E-4

Electrical Circuit Diagram for Engine Start and Stop and Battery Charging

20-510 PC290-7
TESTING AND ADJUSTING E-5

E-5 Auto-decelerator does not work

Failure
• The auto-decelerator does not work.
information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
Relative
auto-decelerator does not work.
information
• Confirm the display on the monitor panel, when the engine is running.

Cause Standard value in normalcy and references for troubleshooting

If the display on the monitor panel is not normal, proceed to No. E-21 Troubleshooting.
Boom RAISE signal Monitoring code Item Normal display
1
fault Lever operation: ON
019 Boom RAISE
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-22 Troubleshooting.
Boom LOWER sig- Monitoring code Item Normal display
2
nal fault Lever operation: ON
019 Boom LOWER
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-23 Troubleshooting.
Arm DIGGING signal Monitoring code Item Normal display
3
fault Lever operation: ON
019 Arm DIGGING
Lever NEUTRAL: OFF
Presumed cause and standard value in normalcy

If the display on the monitor panel is not normal, proceed to No. E-24 Troubleshooting.
Arm DUMPING Monitoring code Item Normal display
4
signal fault Lever operation: ON
019 Arm DUMPING
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-26 Troubleshooting.
Bucket DIGGING Monitoring code Item Normal display
5
signal fault Lever operation: ON
021 Bucket DIGGING
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-27 Troubleshooting.
Bucket DUMPING Monitoring code Item Normal display
6
signal fault Lever operation: ON
021 Bucket DUMPING
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-28 Troubleshooting.
Monitoring code Item Normal display
7 Swing signal fault
Lever operation: ON
019 Swing
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-29 Troubleshooting.
Monitoring code Item Normal display
8 Travel signal fault
Lever operation: ON
019 Travel
Lever NEUTRAL: OFF
If the display on the monitor panel is not normal, proceed to No. E-30 Troubleshooting.
Attachment signal Monitoring code Item Normal display
9
fault Lever operation: ON
021 Service
Lever NEUTRAL: OFF
Governor • pump As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
10
controller defective causes listed in Item 1 through 9, the controller is judged as defective.

PC290-7 20-511
TESTING AND ADJUSTING E-6

E-6 Auto engine warm-up device does not work

Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C,
Relative and raise the engine rotation up to 1,200 rpm.
information • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard

If the display on the monitor panel is not normal, proceed to No. E-14
Troubleshooting.
value in normalcy

Engine cooling water

Monitoring code Item Normal display
1 temperature signal
fault Compare with the actual
Engine cooling water tem-
041 engine cooling water tem-
perature
perature.
As this is an internal failure, troubleshooting cannot be conducted.
Governor • pump
2 (If the fault mentioned in the above item is not found, the Governor • pump controller is
controller defective
judged as defective)

20-512 PC290-7
TESTING AND ADJUSTING E-7

E-7 Preheater does not work

Failure • Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does not
information (1) light up.
Relative • Input of the preheating signal (ON or OFF) can be confirmed in the monitor function.
information (Code No. 045: Monitor input 1)

Cause Standard value in normalcy and references for troubleshooting

Engine starting If preheating does not occur (the heater is not warmed up), refer to Failure Phenome-
Presumed cause and standard

1
switch fault non (2) below.
Disconnection of wir- ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
value in normalcy

ing harness tion during the troubleshooting.

2 (Disconnection or
defective contact Resistance
Wiring harness between P02 (female) and J02 Below 1 Ω
with connector) value

★Turn the engine starting switch OFF for the preparations.

P02 Engine starting switch Voltage
3 Monitor panel fault
OFF Below 1 V
Between and grounding
HEAT 20 – 30 V

Failure
• Even if the preheater switch is turned to the PREHEAT position, the preheater does not become warm.
information (2)
Relative • In low cooling water temperature (lower than 30°C), the governor • pump controller drives the heater
information relay for 100 seconds after the engine is started and automatically warms up the engine.

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations.
Engine starting
switch fault H15 (male) Engine starting switch Resistance value
1
(Internal disconnec- OFF Above 1 MΩ
tion) Between and
HEAT Below 1 Ω
Presumed cause and standard

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Heater relay fault
value in normalcy

2 (Internal disconnec- Heater relay Continuity and resistance value

tion) Between coil terminal and grounding Continued
Between contact terminals Above 1 MΩ
Electrical intake air ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
heater tion during the troubleshooting.
3
(Internal disconnec-
tion) Between heater terminals Normal if continuity is established.

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wir- tion during the troubleshooting.
ing harness
Wiring harness from H15 (female) to J02 to heater Resistance
4 (Disconnection or Below 1 Ω
relay terminal (A25) value
defective contact
with connector) Wiring harness between battery relay M terminal (A22) Resistance
Below 1 Ω
and heater relay terminal value

PC290-7 20-513
TESTING AND ADJUSTING E-7

Electrical Circuit Diagram for Engine Preheater

20-514 PC290-7
TESTING AND ADJUSTING E-8

E-8 All work equipment, swing and travel do not move

Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

1 Fuse No. 3 fault If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Safety switch lock during the troubleshooting.
defective S14 (female) Safety control lever Resistance value
2
(Internal disconnec-
tion) Lock Above 1 MΩ
Between and
Release Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
PPC lock solenoid during the troubleshooting.
Presumed cause and standard value in normalcy

fault
3 (Internal disconnec- V01 (male) Resistance value
tion or short-circuit- Between and 20 – 60 Ω
ing)
Between and grounding Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Assembled-type
during the troubleshooting.
diode D01 fault
4
(Internal short-cir- D01 (male) Resistance value
cuiting) Above 1 MΩ
Between and
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir- Resistance
ing harness Wiring harness between FB1-3 outlet and S14 (male) Below 1 Ω
value
5 (Disconnection or
defective contact Resistance
Wiring harness from S14 (male) to J02 to V01 (female) Below 1 Ω
with connector) value
Resistance
Wiring harness between V01 (female) and grounding Below 1 Ω
value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Grounding fault of
wiring harness Between wiring harness between FB1-3 outlet and S14 Resistance
Above 1 MΩ
6 (Contact with (male) and grounding value
grounding (GND) Wiring harness from S14 (male) to J02 to V01 (female) ,
circuit) Resistance
or between wiring harness between S14 (male) and D01 Above 1 MΩ
value
(female) and grounding

PC290-7 20-515
TESTING AND ADJUSTING E-8

Electrical Circuit Diagram for PPC Lock Solenoid

20-516 PC290-7
TESTING AND ADJUSTING E-9

E-9 One-touch Power Max Switch does not work

Failure
• The one-touch power max. switch does not work.
information
• If the one touch-power max. switch is pressed while the engine is running, the symbol mark is displayed
Relative in the monitor panel.
information • Input from the one-touch power max. switch (left knob switch) can be confirmed in the monitor function.
(Code No. 022: Switch input 1)

Cause Standard value in normalcy and references for troubleshooting

1 Fuse No. 9 fault If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
One-touch power during the troubleshooting.
max. switch fault M23 (male) One-touch power max. switch Resistance value
2
(Internal disconnec-
Presumed cause and standard value in normalcy

tion) Release Above 1 MΩ

Between and
Depress Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
3 (Disconnection or Wiring harness between FB1-9 outlet and M23 (female) Above 1 MΩ
value
defective contact
with connector) Resistance
Wiring harness between M23 (female) and C01 (female) Above 1 MΩ
value
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Grounding fault of during the troubleshooting.
wiring harness Between wiring harness between FB1-9 outlet and M23 Resistance
4 (Contact with Above 1 MΩ
(female) and grounding value
grounding (GND)
circuit) Between wiring harness between M23 (female) and C01 Resistance
Above 1 MΩ
(female) and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C01 One-touch power max. switch Voltage
5
controller defective
Release Below 1 V
Between and grounding
Depress 20 – 30 V

Electric Circuit Diagram for One-Touch Power Max. Switch

PC290-7 20-517
TESTING AND ADJUSTING E-10

E-10 No display in monitor panel at all

Failure
• When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

1 Fuse No. 12 fault If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness from P01 (female) to J07 to FB1-12 Below 1 Ω
value
defect contact with
connector) Resistance
Wiring harness between P01 (female) and grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness from P01 (female) to J07 to Resistance
Above 1 MΩ
circuit) FB1-12 outlet and grounding value

★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Voltage and resistance value
4
controller defective
Between and grounding Voltage: 20 – 30 V
Between and grounding Resistance value: Below 1 Ω

Electrical Circuit Diagram for Power Source in Monitor Panel

20-518 PC290-7
TESTING AND ADJUSTING E-11, E-12

E-11 Part of display on monitor panel is missing

Failure
• Part of the display in the monitor panel is missing.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

standard value in normalcy
Presumed cause and

If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the
Monitor panel LCD
1 following switching operation, then the monitor panel is normal.
fault
• Switching operation: [ ] + [ A ] (simultaneous switching operation)

Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)

E-12 Monitor panel displays contents irrelevant to the model

Failure
• The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

standard value in normalcy
Presumed cause and

If the display on the monitor panel is normal, proceed to Service Code [E217].
Model code signal
Monitoring code Item Normal display
1 fault
(Internal failure) 002
Controller model code 200
003

Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)

PC290-7 20-519
TESTING AND ADJUSTING E-13

E-13 Fuel level monitor red lamp lights up while engine is running

Failure
• The fuel level monitor red lamp lighted up while the engine was running.
information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
Relative
• (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
information
(Code No. 042: Fuel level sensor)

Cause Standard value in normalcy and references for troubleshooting

Fuel level lowered
1 (system in normal ★Refill fuel.
Presumed cause and standard value in normalcy

condition)
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Fuel level sensor during the troubleshooting.
fault A60 (male) Fuel level Resistance value
2
(Internal
disconnection) FULL (Upper limit) Approx. 12 Ω
Between and grounding
EMPTY (Lower limit) 85 – 110 Ω
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Wiring harness between P02 (female) and A60 (female) Resistance
Below 1 Ω
circuit) value

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump P02 (female) Fuel level Resistance value
4
controller defective
FULL (Upper limit) Approx. 12 Ω
Between and grounding
EMPTY (Lower limit) 85 – 110 Ω

Electrical Circuit Diagram for Fuel Level Sensor

20-520 PC290-7
TESTING AND ADJUSTING E-14

E-14 Engine cooling water temperature gauge does not indicate correctly

Failure • The engine cooling water rises normally, but the display does not exceed the white range (C).
information • The engine cooling water temperature remains stable, but the display rises to the red range (H).
Relative • Input from the engine cooling water temperature sensor can be confirmed in the monitor function.
information (Code No. 041: Engine cooling water temperature)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Engine cooling water during the troubleshooting.
temperature sensor
fault Engine cooling water
1 E05 Resistance value
(Internal disconnec- temperature
tion or short-circuit- Between and 90 – 3.5 kΩ
ing) 10 – 100 °C
Between and grounding Above 1 MΩ
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and E05 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between P02 (female) and E05 (female) Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) and E05 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) and E05
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.

Governor • pump Engine cooling water

5 P02 Resistance value
controller defective temperature
Between and 90 – 3.5 kΩ
10 – 100 °C
Between and grounding Above 1 MΩ

Electrical Circuit Diagram for Engine Cooling Water Temperature Sensor

PC290-7 20-521
TESTING AND ADJUSTING E-15

E-15 Hydraulic oil temperature gauge does not display correctly

(Multi-monitor only)
Failure • Hydraulic oil temperature rises normally, but the display does not exceed the white range (C).
information • Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No. 044: Hydraulic oil temperature)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Hydraulic oil temper- during the troubleshooting.
ature sensor fault Engine cooling water
1 (Internal disconnec- A61 Resistance value
temperature
tion or short-circuit-
ing) Between and 90 – 3.5 kΩ
10 – 100 °C
Between and grounding Above 1 MΩ
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and A61 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between P02 (female) and A61 (female) Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) and A61 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) and A61
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.

Governor • pump Engine cooling water

5 P02 Resistance value
controller defective temperature
Between and 90 – 3.5 kΩ
10 – 100 °C
Between and grounding Above 1 MΩ

Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor

20-522 PC290-7
TESTING AND ADJUSTING E-16

E-16 Fuel gauge does not display correctly

Failure • Though fuel was refilled, the display does not exceed the red range (E).
information • Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 042: Fuel sensor voltage)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Fuel level sensor
during the troubleshooting.
fault
1 (Internal disconnec- A60 (male) Fuel level Resistance value
tion or short-circuit- FULL (Upper limit) Approx. 12 Ω
ing) Between and grounding
Presumed cause and standard value in normalcy

EMPTY (Lower limit) 85 – 110 Ω

Disconnection of wir- ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
2 (Disconnection or
defective contact Resistance
Wiring harness between P02 (female) and A60 (female) Below 1 Ω
with connector) value

Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) and A60 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) and A60
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Governor • pump P01 Fuel level Resistance value
5
controller defective
FULL (Upper limit) Approx. 12 Ω
Between and grounding
EMPTY (Lower limit) 85 – 110 Ω

Electrical Circuit Diagram for Fuel Level Sensor

PC290-7 20-523
TESTING AND ADJUSTING E-17

E-17 Swing lock monitor does not display correctly

Failure • Though the swing lock switch was turned ON, the swing lock monitor does not light up.
information • Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Swing lock switch
during the troubleshooting.
fault
1 (Internal disconnec- X05 (female) Swing lock switch Resistance value
tion or short-circuit- OFF Above 1 MΩ
ing) Between and
ON Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness from P02 (female) to J02 to X05 (male) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) to J05 to grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness from P02 (female) to J02 to X05 Resistance
Above 1 MΩ
circuit) (male) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness from P02 (female) to J02 to X05
circuit) Voltage Below 1 V
(male) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Monitor panel P02 Swing lock switch Voltage
5
defective
OFF 20 – 30 V
Between and grounding
ON Below 1 V

20-524 PC290-7
TESTING AND ADJUSTING E-17

Electrical Circuit Diagram for Swing Lock Switch

PC290-7 20-525
TESTING AND ADJUSTING E-18

E-18 When the monitor switch is operated, no display appears

Failure
• When operating the working mode changing switch, the working mode monitor does not appear.
information (1)
Relative
—
information

Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective

Failure
• When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
information (2)
Relative
★If the auto-decelerator itself does not work, either, carry out No. E-5 Troubleshooting.
information

Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective

Failure
• When operating the travel speed shifting switch, the travel speed monitor does not appear.
information (3)
Relative
★If the travel speed does not actually change, carry out No. H-21 Troubleshooting.
information

Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective

Failure
• When operating the windshield wiper switch, the windshield wiper monitor does not appear.
information (4)
Relative
★If the windshield wiper itself does not work, either, carry out No. E-19 Troubleshooting.
information

Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective

• When operating the select switch, the adjustment display does not appear.
Failure
• When operating the LCD monitor adjusting switch, the adjustment display does not appear.
information (5)
• When operating the maintenance switch, the item display does not appear.
Relative
—
information

Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective

20-526 PC290-7
TESTING AND ADJUSTING E-19

E-19 Windshield wiper does not work

Failure
• The windshield wiper does not work.
information
Relative • Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Window rear limit
during the troubleshooting.
switch fault
1 (Internal disconnec- W03 (Switch side) Front window Resistance value
tion or short-circuit- When installed at front Above 1 MΩ
ing) Between and
When retracted at rear Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Windshield wiper during the troubleshooting.
motor fault
2 (Internal disconnec- W04 (male) Continuity and resistance value
Presumed cause and standard value in normalcy

tion or short-circuit- Between and Continued

ing)
Between and grounding Above 1 MΩ
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
3 (Disconnection or Wiring harness between P01 (female) and W04 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between P01 (female) and W04 (female) Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with
grounding (GND) cir- Between wiring harness between P02 (female) Resistance
and W03 Above 1 MΩ
cuit) value

★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Monitor panel fault
(Rear limit switch P02 Front window Voltage
system) When installed at front 20 – 30 V
Between and grounding
When retracted at rear Below 1 V
5 ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Monitor panel fault P02 Windshield wiper switch Resistance value
(Windshield wiper
motor system) OFF Below 3 V
Between and grounding
Below 3 V ⇔ 20 – 30 V
Between and grounding ON
(Constant cycle)

PC290-7 20-527
TESTING AND ADJUSTING E-19

Electrical Circuit Diagram for Windshield Wiper Motor

20-528 PC290-7
TESTING AND ADJUSTING E-20

E-20 Alarming buzzer cannot be cancelled

Failure
• The alarming buzzer cannot be cancelled.
information
Relative • Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Alarming buzzer
during the troubleshooting.
cancellation switch
fault Alarming buzzer
1 P03 (female) Resistance value
(Internal disconnec- cancellation switch
Presumed cause and standard value in normalcy

tion or short-circuit- Release Above 1 MΩ

ing) Between and
Depress Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) and P03 (male) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from P03 (male) to J05 to grounding Below 1 Ω
value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
3
(Contact with 24 V Between wiring harness between P02 (female) and P03
circuit) Voltage Below 1 V
(male) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Alarming buzzer
4 Monitor panel fault P02 Voltage
cancellation switch
Release 20 – 30 V
Between and grounding
Depress Below 1 V

Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch

PC290-7 20-529
TESTING AND ADJUSTING E-21

E-21 "Boom RAISE" is not correctly displayed in monitor function

Failure
• "Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Boom RAISE PPC
ing the troubleshooting.
hydraulic switch fault
1 (Internal disconnec- S06 (male) Boom control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
RAISE Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) and S06 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S06 (female) and grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) and S06 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) and S06
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Boom control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between and grounding
RAISE Below 1 V

Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch

20-530 PC290-7
TESTING AND ADJUSTING E-22

E-22 "Boom LOWER" is not correctly displayed in monitor function

Failure
• "Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Boom LOWER PPC
ing the troubleshooting.
hydraulic switch fault
1 (Internal disconnec- S02 (male) Boom control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
LOWER Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) and S02 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S02 (female) and grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) and S02 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) and S02
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Boom control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between and grounding
LOWER Below 1 V

Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch

PC290-7 20-531
TESTING AND ADJUSTING E-23

E-23 "Arm DIGGING" is not correctly displayed in monitor function

Failure
• "Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Arm DIGGING PPC
ing the troubleshooting.
hydraulic switch fault
1 (Internal disconnec- S04 (male) Arm control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
DIGGING Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) and S04 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S04 (female) and grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) and S04 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) and S04
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Arm control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between and grounding
DIGGING Below 1 V

Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch

20-532 PC290-7
TESTING AND ADJUSTING E-24

E-24 "Arm DUMPING" is not correctly displayed in monitor function

Failure
• "Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

Arm DUMPING PPC ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
hydraulic switch ing the troubleshooting.
defect S08 (male) Arm control lever Resistance value
1
(Internal disconnec-
tion and short-circuit- NEUTRAL Above 1 MΩ
Between and
ing) DUMPING Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) and S08 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S08 (female) and grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) and S08 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) and S08
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Arm control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between and grounding
DUMPING Below 1 V

Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch

PC290-7 20-533
TESTING AND ADJUSTING E-25

E-25 "Bucket DIGGING" is not correctly displayed in monitor function

Failure
• "Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

Bucket DIGGING ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
PPC hydraulic ing the troubleshooting.
switch fault S01 (male) Bucket control lever Resistance value
1
(Internal disconnec-
tion and short-circuit- NEUTRAL Above 1 MΩ
Between and
ing) DIGGING Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) and S01 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S01 (female) and grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) and S01 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) and S01
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Bucket control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between and grounding
DIGGING Below 1 V

Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch

20-534 PC290-7
TESTING AND ADJUSTING E-26

E-26 "Bucket DUMPING" is not correctly displayed in monitor function

Failure
• "Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

Bucket DUMPING ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
PPC hydraulic ing the troubleshooting.
switch fault S05 (male) Bucket control lever Resistance value
1
(Internal disconnec-
tion and short-circuit- NEUTRAL Above 1 MΩ
Between and
ing) DUMPING Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) and S05 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between S05 (female) and grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) and S05 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) and S05
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Bucket control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between and grounding
DUMPING Below 1 V

Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch

PC290-7 20-535
TESTING AND ADJUSTING E-27

E-27 "SWING" is not correctly displayed in monitor function

Failure
• "SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Swing PPC hydraulic
ing the troubleshooting.
switch, left, fault
1 (Internal disconnec- S03 (male) Swing control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
Left Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Swing PPC hydraulic
ing the troubleshooting.
switch, right, fault
2 (Internal disconnec- S07 (male) Swing control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
Presumed cause and standard value in normalcy

Right Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.

Disconnection of wir- Wiring harness between C03 (female) and S03 (female) , Resistance
ing harness or wiring harness between C03 (female) and S07 (female) Below 1 Ω
value
3 (Disconnection or
defective contact Resistance
with connector) Wiring harness between S03 (female) and grounding Below 1 Ω
value
Resistance
Wiring harness between S07 (female) and grounding Below 1 Ω
value

Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with Wiring harness between C03 (female) and S03 (female) ,
grounding (GND) Resistance
or wiring harness between C03 (female) and S07 (female) Above 1 MΩ
circuit) value
and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness
5 Wiring harness between C03 (female) and S03 (female) ,
(Contact with 24 V
circuit) or wiring harness between C03 (female) and S07 (female) Voltage Below 1 V
and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Swing control lever Voltage
6
controller defective
NEUTRAL 20 – 30 V
Between and grounding
Right or left Below 1 V

20-536 PC290-7
TESTING AND ADJUSTING E-27

Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches

PC290-7 20-537
TESTING AND ADJUSTING E-28

E-28 "TRAVEL" is not correctly displayed in monitor function

Failure
• "TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Travel PPC hydraulic
ing the troubleshooting.
switch fault
1 (Internal disconnec- S30 (male) Travel control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
Forward or reverse Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness from C03 (female) to J01 to S30 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from S30 (female) to J05 to grounding Below 1 Ω
value

Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with Wiring harness from C03 (female) to J01 to S30 (female)
grounding (GND) Resistance
, or between wiring harness between C03 (female) and Above 1 MΩ
circuit) value
A43 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness
4 Wiring harness from C03 (female) to J01 to S30 (female)
(Contact with 24 V
circuit) , or between wiring harness between C03 (female) and Voltage Below 1 V
A43 (female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Travel control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between and grounding
Forward or backward Below 1 V

20-538 PC290-7
TESTING AND ADJUSTING E-28

Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm

PC290-7 20-539
TESTING AND ADJUSTING E-29

E-29 "Travel Differential Pressure" is not correctly displayed in monitor function

Failure • "Travel Differential Pressure" is not correctly displayed in the monitor function (special function) on the mon-
information itor panel.
Relative • When pressure difference is created between the right and left travel PPC circuits (in steering), the travel
information differential mechanism is turned ON.

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Travel steering PPC
ing the troubleshooting.
hydraulic switch fault
1 (Internal disconnec- S31 (male) Travel control lever Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
One side of right or left only Below 1 Ω
Presumed cause and standard value in normalcy

★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) and S31 (female) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from S31 (female) to J05 to grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) and S31 Resistance
Above 1 MΩ
circuit) (female) and grounding value

Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between C03 (female) and S31
circuit) Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Travel control lever Voltage
5
controller defective
NEUTRAL 20 – 30 V
Between and grounding
One side of right or left only Below 1 V

20-540 PC290-7
TESTING AND ADJUSTING E-29

Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch

PC290-7 20-541
TESTING AND ADJUSTING E-30

E-30 "Service" is not correctly displayed in monitor function

Failure
• "Service" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Service (front) PPC
ing the troubleshooting.
hydraulic switch fault
1 (Internal disconnec- S10 (male) Service pedal Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
ing) Between and
Front Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
Service (rear) PPC
ing the troubleshooting.
hydraulic switch fault
2 (Internal disconnec- S11 (male) Service pedal Resistance value
tion or short-circuit- NEUTRAL Above 1 MΩ
Presumed cause and standard value in normalcy

ing) Between and

Rear Below 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
during the troubleshooting.
Disconnection of wir-
ing harness Wiring harness between C03 (female) and S10 (female)
Resistance
3 (Disconnection or , or wiring harness between C03 (female) and S11 Below 1 Ω
value
defective contact (female)
with connector)
Resistance
Wiring harness between S10 (female) and grounding Below 1 Ω
value

Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with Wiring harness between C03 (female) and S10 (female) ,
grounding (GND) Resistance
or between wiring harness between C03 (female) and S11 Above 1 MΩ
circuit) value
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness
5 Wiring harness between C03 (female) and S10 (female) ,
(Contact with 24 V
circuit) or between wiring harness between C03 (female) and S11 Voltage Below 1 V
(female) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Governor • pump C03 Service pedal Voltage
6
controller defective
NEUTRAL 20 – 30 V
Between and grounding
Front or rear Below 1 V

20-542 PC290-7
TESTING AND ADJUSTING E-30

Electrical Circuit Diagram for Service PPC hydraulic Switch

PC290-7 20-543
TESTING AND ADJUSTING E-31

E-31 Air Conditioner does not work

Failure
• The air conditioner does not work.
information
Relative • For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND
information FUNCTION - Air Conditioner in this manual.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

1 Fuse No. 11 fault When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness between FB1-11 outlet and M26 (male) Below 1 Ω
value
defective contact
with connector) Resistance
Wiring harness between M26 (male) and grounding Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between FB1-11 outlet and M26
Voltage Above 1 MΩ
circuit) (male) and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
ing the troubleshooting.
Air conditioner unit
4
defective M26 Voltage
Between and 20 – 30 V

Electrical Circuit Diagram for Air Conditioner

20-544 PC290-7
TESTING AND ADJUSTING E-32

E-32 Travel alarm does not sound

Failure • The travel alarm does not sound while the machine is traveling.
information • The alarm begins to sound when the machine is at a standstill.
Relative
—
information

Cause Standard value in normalcy and references for troubleshooting

1 Fuse No. 15 fault When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Presumed cause and standard value in normalcy

If the monitor display is not correct, proceed to No. E-21 Troubleshooting.

Monitoring code Item Normal display
2 Travel signal fault
Control lever operation: ON
019 Travel
Control lever NEUTRAL: OFF
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Disconnection of wir- during the troubleshooting.
ing harness
Wiring harness between FB1-15 outlet to J03 and A43 Resistance
3 (Disconnection or Below 1 Ω
(female) value
defective contact
with connector) Resistance
Wiring harness between A43 (female) and J01 Below 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
4 (Contact with
grounding (GND) Between wiring harness between FB1-15 outlet to J03 and Resistance
Above 1 MΩ
circuit) A43 (female) and grounding value

As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes
5 Travel alarm fault
listed in Item 1 through 4 above is found, the travel alarm is judged as defective)

PC290-7 20-545
TESTING AND ADJUSTING E-32

20-546 PC290-7
 TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H-MODE)

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS ...................................................... 20-602

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-604
H-1 All work equipment lack power, or travel and swing speeds are slow .............................................. 20-605
H-2 Engine speed sharply drops or engine stalls .................................................................................... 20-606
H-3 No work equipment, travel or swing move ........................................................................................ 20-607
H-4 Abnormal noise is heard from around hydraulic pump ..................................................................... 20-607
H-5 Auto-decelerator does not work ........................................................................................................ 20-608
H-6 Fine control mode does not function................................................................................................. 20-608
H-7 Boom moves slowly or lacks power .................................................................................................. 20-609
H-8 Arm moves slowly or lacks power..................................................................................................... 20-610
H-9 Bucket moves slowly or lacks power ................................................................................................ 20- 611
H-10 Work equipment does not move in its single operation .................................................................... 20- 611
H-11 Work equipment has a bit too fast hydraulic drift .............................................................................. 20-612
H-12 Work equipment has big time lag...................................................................................................... 20-613
H-13 Other work equipment moves when relieving single circuit .............................................................. 20-613
H-14 One-touch power max. switch does not operate .............................................................................. 20-613
H-15 In compound operation, work equipment with larger load moves slowly .......................................... 20-614
H-16 In swing + boom RAISE operation, boom moves slowly .................................................................. 20-614
H-17 In swing + travel, travel speed drops sharply.................................................................................... 20-615
H-18 Machine swerves in travel ................................................................................................................ 20-616
H-19 Machine travels slowly ...................................................................................................................... 20-617
H-20 Machine cannot be easily steered or lacks power ............................................................................ 20-618
H-21 Travel speed does not shift, or it is too slow or fast. ......................................................................... 20-619
H-22 Track shoe does not turn (on one side only)..................................................................................... 20-620
H-23 Machine does not swing ................................................................................................................... 20-621
H-24 Swing acceleration is poor, or swing speed is slow .......................................................................... 20-622
H-25 Excessive overrun when stopping swing .......................................................................................... 20-623
H-26 There is big shock when stopping swing .......................................................................................... 20-624
H-27 There is big abnormal noise caused when stopping swing .............................................................. 20-624
H-28 Swing natural drift is too big.............................................................................................................. 20-625

PC290-7 20-601
TESTING AND ADJUSTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS

20-602 PC290-7
TESTING AND ADJUSTING SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS

★ This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.

PC290-7 20-603
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

★ Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.

Failure information Phenomena occurring on machine

Relative information Information on occurred failures and troubleshooting

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

2
Cause for presumed
failure <Contents>
(The attached No. for • The standard values in normalcy by which to judge "good" or "no good" about
3
filing and reference presumed causes.
purpose only. It does not stand • References for making judgement of "good" or "no good"
for any priority)
4

20-604 PC290-7
TESTING AND ADJUSTING H-1

H-1 All work equipment lack power, or travel and swing speeds are slow

Failure information • All the work equipment lack power, or their travel and swing speeds are slow.
Relative information • Set the working mode at A mode for troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Control lever Unload pressure
1 Malfunctioning of unload valve
3.9 ± 1.0 MPa
All control levers in NEUTRAL
{40 ± 10kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Control lever Main relief pressure

Improper adjustment or mal- 33.3 – 36.8 MPa

2 Arm, DIGGING
functioning of main relief valve {340 – 375kg/cm2}
If the pressure does not return to normalcy even after the adjustment, malfunc-
tioning of main relief valve or its internal failure is suspected. In that case, check
the valve itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of self pressure Control lever Control circuit source pressure
3
Presumed cause and standard value in normalcy

decompression valve 2.83 – 3.43 MPa

All control levers in NEUTRAL
{29 – 35kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
4
functioning of PC valve PC valve output pressure Arm digging relief Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of PC valve or its internal failure is suspected. In that case, check the valve
itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever LS-EPC output pressure
Malfunctioning of LS-EPC
5 Approx. 2.9 MPa
valve Lo NEUTRAL
{Approx. 30 kg/cm2}
Hi Travel control lever 0{0}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure ratio
Oil pressure to be mea- Travel without load (con-
sured All control levers in
trol lever held at half
NEUTRAL
Improper adjustment or mal- stroke)
6
functioning of LS valve Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of LS valve or its internal failure is suspected. In that case, check the valve
itself.
7 Malfunctioning of servo piston Malfunctioning of servo piston is suspected. Check the piston itself.
If none of the above listed causes is detected, the piston pump is suspected of
8 Piston pump defective
deteriorated performance, malfunctioning or internal failure.

PC290-7 20-605
TESTING AND ADJUSTING H-2

H-2 Engine speed sharply drops or engine stalls

Failure information • The engine speed sharply drops or the engine stalls.
Relative information • Relative Information

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Control lever Main relief pressure

Improper adjustment or mal- 33.3 – 36.8 MPa

1 Arm, DIGGING
functioning of main relief valve {340 – 375kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of the main relief valve or its internal failure is suspected. In that case,
check the valve itself.
Presumed cause and standard value in normalcy

★Stop engine for preparations. Start troubleshooting at engine high idling.

Oil pressure to be mea-
Measurement condition Oil pressure ratio
sured
Improper adjustment or mal- Pump delivery pressure Swing lock: ON 1
2
functioning of PC valve PC valve output pressure Arm digging relief Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of the PC valve or its internal failure is suspected. In that case, check the
valve itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure ratio
Oil pressure to be mea- Travel without load
sured All control levers in
(control lever held at half
NEUTRAL
Improper adjustment or mal- stroke)
3
functioning of LS valve Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunc-
tioning of the LS valve or its internal failure is suspected. In that case, check the
valve itself.
Orifice or filter in servo equip- The orifice or filter in the pump servo equipment is suspected of clogging. Check
4
ment clogged the equipment itself.
5 Malfunction of servo piston The servo piston is suspected of malfunction. Check the piston itself.

20-606 PC290-7
TESTING AND ADJUSTING H-3, H-4

H-3 No work equipment, travel or swing move

Failure information • No work equipment nor travel and swing functions can be set in motion.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Stop engine for preparations. Start troubleshooting at engine high idling.

Safety lock lever Main relief pressure
Malfunctioning of PPC lock
1 Locked 0{0}
solenoid valve
2.84 – 3.43 MPa
Released
{29 – 35kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of self pressure Control lever Control circuit source pressure
2
decompression valve 2.83 – 3.43 MPa
All control levers in NEUTRAL position
{29 – 35kg/cm2}
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it
in the following manner.
3 Piston pump defective
• Remove the oil pressure measurement plug and crank the engine. If oil flows out,
it is in normal condition.
It is presumed that the pump shaft does not rotate due to some internal failure of
4 Damper defective
the dumper. Check the damper itself.

H-4 Abnormal noise is heard from around hydraulic pump

Failure information • An abnormal noise is heard from around the hydraulic pump.
Relative information —

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

1 Hydraulic oil level lowered Make a visual check.

2 Quality of hydraulic oil bad Air may have get mixed with the oil. Make a visual check.

Hydraulic tank cap breather It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
3
clogged causing negative pressure inside the tank. Make a visual check.

Hydraulic tank strainer It is presumed that the strainer in the hydraulic tank is clogged, thereby causing
4
clogged negative pressure in the suction circuit. Make a visual check.

5 Piston pump defective The piston pump is suspected of an internal failure. Check the pump itself.

PC290-7 20-607
TESTING AND ADJUSTING H-5, H-6

H-5 Auto-decelerator does not work

Failure information • The auto-decelerator does not work.

• This troubleshooting mode is applied when the auto-decelerator does not work, while operating
the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch
Relative information
only in the travel circuit -actually located inside PPC valve)
• Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-
dard value in normalcy

★Stop engine for preparations. Start troubleshooting at engine high idling.

Travel control lever PPC valve output pressure
Malfunctioning of NEUTRAL 0{0}
1 travel PPC valve
(shuttle valve)
Above 2.7 MPa
Operation
{Above 28 kg/cm2}

H-6 Fine control mode does not function

Failure information • The fine control mode poorly functions or its response is slow.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
LS-EPC valve output
Travel speed Travel control lever
Malfunctioning of pressure
1
LS-EPC valve Approx. 2.9 MPa
Lo NEUTRAL
{Approx. 30 kg/cm2}
Hi Travel control lever 0{0}
Presumed cause and stan-
dard value in normalcy

Orifice in LS circuit
2 The orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
clogged
★Stop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure ratio

Oil pressure to be measured Travel without load

All control levers in
(control lever held at half
Improper adjust- NEUTRAL
stroke)
3 ment or malfunction-
ing of LS valve Pump delivery pressure 1
Nearly equal oil pressure
PC valve output pressure Approx. 3/5
If the oil pressure does not return to normalcy even after the adjustment, malfunction-
ing of the LS valve or its internal failure is suspected. In that case, check the valve
itself.
Malfunctioning of
4 Malfunctioning of the servo piston is suspected. Check the piston itself.
servo piston

20-608 PC290-7
TESTING AND ADJUSTING H-7

H-7 Boom moves slowly or lacks power

Failure information • The boom moves slowly or lacks power

Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Boom lever PPC valve output pressure
Malfunctioning of right PPC
1 NEUTRAL 0{0}
valve (in boom circuit)
Above 2.7 MPa
RAISE or LOWER
{Above 28 kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Working mode Solenoid output pressure
Malfunction of merge/divide
2 A mode 0{0}
solenoid valve
2.84 – 3.43 MPa
Other than A mode
Presumed cause and standard value in normalcy

{29 – 35 kg/cm2}
Malfunctioning of merge/divide The merge/divide valve (main and LS valves) is presumed to malfunction. Check
3
valve (main and LS valves) the valve itself.
Malfunctioning of boom control The spool in the boom control valve is presumed to malfunction. Check the valve
4
valve (spool) itself.
Malfunctioning of boom control
The pressure compensation valve in the boom control valve is presumed to mal-
5 valve (pressure compensation
function. Check the valve itself.
valve)
Malfunctioning of boom control The regeneration valve in the boom control valve or the seal is presumed to mal-
6
valve (regeneration valve) function. Check the valve itself.
Malfunctioning of boom control The lock valve in the boom control valve is presumed to malfunction. Check the
7
valve (lock valve) valve itself.
Malfunctioning of safety valve The safety valve for the lock valve is presumed to malfunction, or the seal is sus-
8
for lock valve or seal defective pected to be defective. Check the valve itself.
Malfunctioning of boom control
The suction valve in the boom control valve is presumed to malfunction, or the
9 valve (suction valve) or seal
seal is suspected to be defective.
defective
Malfunctioning of boom control
The safety and suction valves in the boom control valve are presumed to mal-
10 valve (safety and suction
function, or the seal is suspected to be defective. Check those valves themselves.
valves) or seal defective
Malfunctioning of LS shuttle
LS shuttle valves in the left travel control valve, bucket control valve and service
11 valve (left travel, bucket and
control valve are presumed to malfunction. Check those valves themselves.
service valves)
★Stop engine for preparations. Start troubleshooting at engine high idling.
12 Boom cylinder defective Boom lever Amount oil leakage from cylinder
Raise relief 20 cc/min

PC290-7 20-609
TESTING AND ADJUSTING H-8

H-8 Arm moves slowly or lacks power

Failure information • The arm moves slowly, or lacks power.

Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Arm lever PPC valve output pressure
Malfunctioning of left PPC
1 NEUTRAL 0{0}
valve (arm circuit)
Above 2.7 MPa
DIGGING or DUMPING
{Above 28 kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Working mode Solenoid output pressure
Presumed cause and standard value in normalcy

Malfunctioning of merge/divide
2 A mode 0{0}
solenoid valve
2.84 – 3.43 MPa
Other than A mode
{29 – 35 kg/cm2}
Malfunctioning of merge/divide The merge/divide valve (main and LS valves) is presumed to malfunction. Check
3
valve (main and LS valves) the valve itself.
Malfunctioning of arm control The spool in the arm control valve is presumed to malfunction. Check the valve
4
valve (spool) itself.
Malfunctioning of arm control
The pressure compensation valve in the arm control valve is presumed to mal-
5 valve (pressure compensation
function. Check the valve itself.
valve)
Malfunctioning of arm control The generation valve in the arm control valve is presumed to malfunction, or the
6
valve (regeneration valve) seal is suspected to be defective. Check the valve itself.
Malfunctioning of arm control
The safety and suction valves in the arm control valve are presumed to malfunc-
7 valve (safety and suction
tion, or the seal is suspected of defect. Check those valves themselves.
valves) or seal defective
Malfunctioning of LS shuttle
LS shuttle valves in the right travel control valve, boom control valve, left travel
valve (right travel, boom, left
8 control valve, bucket control valve and service valve are presumed to malfunc-
travel, bucket and service
tion. Check those valves themselves.
valves)
★Stop engine for preparations. Start troubleshooting at engine high idling.
9 Arm cylinder defective Arm lever Amount oil leakage from cylinder
Digging relief 20 cc/min

20-610 PC290-7
TESTING AND ADJUSTING H-9, H-10

H-9 Bucket moves slowly or lacks power

Failure information • The bucket moves slowly, or lacks power.

Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Bucket lever PPC valve output pressure
Malfunctioning of right PPC
1 NEUTRAL 0{0}
valve (bucket circuit)
Above 2.7 MPa
DIGGING or DUMPING
{Above 28 kg/cm2}
Presumed cause and stan-
dard value in normalcy

Malfunctioning of bucket con- The spool in the bucket control valve is presumed to malfunction. Check the
2
trol valve (spool) valve itself.
Malfunctioning of bucket con-
The pressure compensation valve in the bucket control valve is presumed to
3 trol valve (pressure compen-
malfunction. Check the valve itself.
sation valve)
Malfunctioning of bucket con- The safety and suction valves in the bucket control valve are presumed to
4 trol valve (safety and suction malfunction, or the seal is suspected to be defective. Check those valves
valves) or seal defective themselves.
Malfunction of LS shuttle valve The LS shuttle valve in the service control valve is presumed to malfunction.
5
(service valve) Check the valve itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
6 Bucket cylinder defective Bucket lever Amount oil leakage from cylinder
Digging relief 20 cc/min

H-10 Work equipment does not move in its single operation

• The boom does not move when operated independently.

Failure information • The arm does not move when operated independently.
• The bucket does not move when operated independently.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-
dard value in normalcy

★Stop engine for preparations. Start troubleshooting at engine high idling.

Work equipment control lever PPC valve output pressure
1 Malfunctioning of PPC valve NEUTRAL 0{0}
Above 2.7 MPa
Operation
{Above 28 kg/cm2}
Malfunctioning of work equip- The spool in the work equipment control valve is presumed to malfunction.
2
ment control valve (spool) Check the valve itself.

PC290-7 20-611
TESTING AND ADJUSTING H-11

H-11 Work equipment has a bit too fast hydraulic drift

Failure information (1) • Hydraulic drift of the boom is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-
dard value in normalcy

★Stop engine for preparations. Start troubleshooting at engine high idling.

1 Boom cylinder defective Boom control lever Amount oil leakage from cylinder
Raise relief 20 cc/min
Boom control lever (lock valve) The seal at lock valve in the boom control lever is suspected to be defective.
2
seal defective Check the valve itself.
Seal at safety valve for lock The seal at the safety valve in the lock valve is suspected to be defective.
3
valve defective Check the valve itself.

Failure information (2) • Hydraulic drift of the arm is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
1 Arm cylinder defective Arm control lever Amount oil leakage from cylinder
Presumed cause and stan-

Digging relief 20 cc/min

dard value in normalcy

The seal for safety and suction valves in the arm control valve is suspected
to be defective. Check the valve itself.
Arm control valve (safety and ★Whether the seal is defective or not may well be determined by changing
2
suction valves) seal defective for other safety and suction valves. (Do not attempt to change them for the
safety and suction valves for the boom LOWER and the lock valve, be-
cause the set pressure differs)
Arm control valve (spool) seal The seal for spool in the arm control valve is suspected to be defective.
3
defective Check the seal itself.
Arm control valve (pressure
The seal for pressure compensation valve in the arm control valve is sus-
4 compensation valve) seal
pected to be defective. Check the seal itself.
defective

Failure information (3) • Hydraulic drift of the bucket is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
1 Bucket cylinder defective Bucket control lever Amount oil leakage from cylinder
Presumed cause and stan-

Digging relief 20 cc/min

dard value in normalcy

The seal for the safety and suction valves in the bucket control lever is sus-
pected to be defective. Check the seal itself.
Bucket control valve (safety
★Whether the seal is defective or not may well be determined by changing
2 and suction valves) seal
for other safety and suction valves. (Do not attempt to change them for the
defective
safety and suction valves for the boom LOWER and the lock valve, be-
cause the set pressure differs)
Bucket control valve (spool) The seal for spool in the bucket control valve is suspected to be defective.
3
seal defective Check the seal itself.
Bucket control valve (pres-
The seal for pressure compensation valve in the bucket control valve is sus-
4 sure compensation valve) seal
pected to be defective. Check the seal itself.
defective

20-612 PC290-7
TESTING AND ADJUSTING H-12, H-13, H-14

H-12 Work equipment has big time lag

Failure information • The work equipment has a big time lag.

Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
LS-EPC valve output
Travel speed Travel control lever
Malfunctioning of LS-EPC pressure
1
valve Approx. 2.9 MPa
Lo NEUTRAL
Presumed cause and stan-

{approx. 30 kg/cm2}
dard value in normalcy

Hi Operation 0{0}
Malfunctioning of control valve
The regeneration valve in the control valve is presumed to malfunction.
2 (regeneration valve) - with
Check the valve itself.
boom and arm only
The safety and suction valves of the control valve are presumed to malfunc-
tion. Check those valves themselves directly.
Malfunctioning of control ★For the arm and boom, whether they are defective or not may well be de-
3
valves (safety & suction valve) termined by changing them for other safety and suction valves. (Do not at-
tempt to change them for the safety and suction valves for the boom
LOWER and the lock valve, because each set pressure differs)
Malfunctioning of control valve
The pressure compensation valve of the control valve is presumed to mal-
4 (pressure compensation
function. Check the valve itself directly.
valve)

H-13 Other work equipment moves when relieving single circuit

Failure information • Other work equipment moves when relieving the single circuit of specific work equipment.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-
dard value in normalcy

Control valve (pressure com- The seal for pressure compression valve in the control valve is suspected to
1
pensation valve) seal defective be defective. Check the seal itself.

H-14 One-touch power max. switch does not operate

Failure information • The one-touch power max. switch does not operate.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-
dard value in normalcy

★Stop engine for preparations. Start troubleshooting at engine high idling.

Swing lock switch Solenoid valve output pressure
Malfunctioning of 2-stage sole-
1 OFF 0{0}
noid valve
2.84 – 3.43 MPa
ON
{29 – 35kg/cm2}
Malfunctioning of main relief
2 The main relief valve is presumed to malfunction. Check the valve itself.
valve

PC290-7 20-613
TESTING AND ADJUSTING H-15, H-16, H-17

H-15 In compound operation, work equipment with larger load moves slowly

Failure information • In a compound operation, work equipment with larger load tends to move slowly.
Relative information —

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-

The pressure compensation valve for the work equipment with larger load is
dard value in normalcy

presumed to malfunction. Check the valve itself.

Combination of compound operation Work equipment with larger load
Malfunctioning of pressure Boom RAISE + arm DIGGING Boom RAISE
1 compensation valve for work
Boom RAISE + arm DUMPING Arm DUMPING
equipment with larger load
Boom RAISE + bucket DIGGING Boom RAISE
Arm DUMPING + bucket DIGGING Arm DUMPING
Boom LOWER + arm DUMPING Arm DUMPING

H-16 In swing + boom RAISE operation, boom moves slowly

Failure information • In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information • If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-
dard value in normalcy

Malfunctioning of LS select The LS select valve is presumed to malfunction, or the seal is suspected to
1
valve or seal defective be defective. Check the valve and seal themselves.

20-614 PC290-7
TESTING AND ADJUSTING H-15, H-16, H-17

H-17 In sw ing + travel, travel speed drops sharply

Failure information • In a compound operation of swing + travel, the travel speed drops sharply.
Relative information • If the travel speed is slow in the single operation of travel, carry out the H-19 check first.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-
dard value in normalcy

Malfunctioning of LS shuttle The LS shuttle valve in the left travel control valve or the swing control valve
1
valve (left travel and swing) is presumed to malfunction. Check both of them directly.

PC290-7 20-615
TESTING AND ADJUSTING H-18

H-18 Machine swerves in travel

Failure information • The machine tends to swerve while traveling.

Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure
Malfunctioning of travel PPC Above 2.7 MPa
1 Forward or reverse
valve {Above 28 kg/cm2}
Differential output between right
0.4 MPa {4 kg/cm2}
and left sides
★Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of self-pressure Control lever Control circuit source pressure
2
decompression valve 2.83 – 3.43 MPa
All control levers in NEUTRAL
Presumed cause and standard value in normalcy

{29 – 35 kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Oil Pressure ratio
Oil pressure to be Travel without load
Improper adjustment or mal- measured All control levers in
3 (control lever held at half
functioning of LS valve NEUTRAL
stroke)
Pump delivery pressure 1
Nearly equal pressure
LS valve output pressure Approx. 3/5
★Stop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure
Malfunctioning of travel inter-
4 Operating one side only 0 {0}
locking solenoid valve
2.84 – 3.43 MPa
Operating both sides
{29 – 35 kg/cm2}
Malfunctioning of travel inter-
5 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
Malfunctioning of travel control The spool in the travel interlocking valve is presumed to malfunction. Check the
6
valve (spool) spool itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
Travel relief 27.2 ¬/min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
8 Final drive defective
★An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.

20-616 PC290-7
TESTING AND ADJUSTING H-19

H-19 Machine travels slowly

Failure information • The machine's travel speed is slow.

Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure
Malfunctioning of travel PPC Above 2.7 MPa
1 Forward or reverse
valve {Above 28 kg/cm2}
Output differential between right and Below 0.4 MPa
left or front and rear {Below 4 kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of self-pressure Control lever Control circuit source pressure
2
Presumed cause and standard value in normalcy

decompression valve 2.83 – 3.43 MPa

All control levers in NEUTRAL
{29 – 35kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
LS-EPC valve output
Travel speed Travel control lever
Malfunctioning of LS-EPC pressure
3
valve Approx. 2.9 MPa
Lo NEUTRAL
{approx. 30 kg/cm2}
Hi Travel control lever 0 {0}
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
4
valve (spool) itself.
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
5 valve (pressure compensation
function. Check the valve itself.
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
6
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
7
valve (bucket) Check the valve itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
7 Malfunction of travel motor Travel control lever Amount of oil leakage from travel motor
Travel relief 27.2 ¬/min
The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
8 Final drive defective
★An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.

PC290-7 20-617
TESTING AND ADJUSTING H-20

H-20 Machine cannot be easily steered or lacks power

Failure information • The machine cannot be easily steered.

Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure (steering)
Malfunctioning of travel PPC
1 NEUTRAL on both sides 0 {0}
valve (steering spool)
Above 2.7 MPa
Operating one side only
{Above 28 kg/cm2}
★Stop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever Solenoid valve output pressure
Malfunctioning of travel inter-
2 Operating both sides 0 {0}
locking solenoid valve
2.84 – 3.43 MPa
Operating one side only
{29 – 35 kg/cm2}
Malfunctioning of travel inter-
Presumed cause and standard value in normalcy

3 The travel interlocking valve is presumed to malfunction. Check the valve itself.
locking valve
★Stop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever Solenoid valve output pressure
Malfunctioning of merge/divide
4 Operating both sides 0 {0}
solenoid valve
2.84 – 3.43 MPa
Operating one side only
{29 – 35 kg/cm2}
Malfunctioning of merge/divide
5 The merge/divide valve is presumed to malfunction. Check the valve itself.
valve
Malfunction of travel control The spool in the travel control valve is presumed to malfunction. Check the spool
6
valve (spool) itself.
Malfunctioning of travel control
The pressure compensation valve in the travel control valve is presumed to mal-
7 valve (pressure compensation
function. Check the valve itself.
valve)
Malfunctioning of travel control The suction valve in the travel control valve is presumed to malfunction. Check
8
valve (suction valve) the valve itself.
Malfunctioning of LS shuttle The LS shuttle valve in the bucket control valve is presumed to malfunction.
9
valve (bucket) Check the valve itself.
Check valve seal defective at The seal in the check valve of LS oil pressure pickup port is suspected to be
10
LS oil pressure pickup port defective. Check the seal itself.
The seal in the check valve of the travel motor is suspected to be defective.
Malfunctioning of travel motor Check the seal itself.
11
(safety valve) ★Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.
The seal in the check valve of the travel motor is suspected of defect. Check the
Malfunctioning of travel motor seal itself.
12
(check valve) ★Whether the seal is defective or not may well be determined by swapping the
motors between forward and reverse, or right and left.

20-618 PC290-7
TESTING AND ADJUSTING H-21

H-21 Travel speed does not shift, or it is too slow or fast.

Failure information • Travel speed does not shift, or it is either too fast or slow.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever Monitoring [15]
Presumed cause and standard value in normalcy

Lo Fine control 810 mA

( Mi) (to the extent that the 470 mA
Hi decelerator is released) 0 mA
Malfunctioning of LS-EPC
1 ★Stop engine for preparations. Start troubleshooting at engine high idling.
valve
LS-EPC valve output
Travel speed Travel control lever
pressure
Approx. 2.9 MPa
Lo NEUTRAL
{approx. 30 kg/cm2}
Hi Operation 0 {0}
★Stop engine for preparations. Start troubleshooting at engine high idling.
LS-EPC valve output
Travel speed Travel control lever
Malfunctioning of travel speed pressure
2
solenoid valve Lo NEUTRAL 0 {0}
2.84 – 3.43 MPa
Hi Operation
{29 – 35 kg/cm2}
Malfunctioning of travel motor The travel motor is presumed to malfunction when shifting speed. Check the
3
(speed shifting) speed shifting portion directly.
: The "Mi" mode is on the multi-monitor specification machine only.

PC290-7 20-619
TESTING AND ADJUSTING H-22

H-22 Track shoe does not turn (on one side only)

Failure information • A track shoe does not turn (only on one side).
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

Travel control valve (suction The suction valve seat in the travel control valve is suspected of defect. Check
1
valve) seat defective the seat itself.
Travel motor (safety valve) The safety valve seat in the travel motor is suspected of defect. Check the seat
2
seat defective itself.
Travel motor (check valve) The check valve seat in the travel motor is suspected of defect. Check the seat
3
seat defective itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
4 Travel Motor speed reduced Travel control lever Amount of oil leakage from travel motor
Travel relief 27.2 ¬/min

The final drive is suspected of an internal failure. Check the inside of the final
drive directly.
5 Final drive defective ★A failure inside the final drive may well be determined by an abnormal noise from
within, abnormal heat generated or metal dust or chips contained in the drained
oil.

20-620 PC290-7
TESTING AND ADJUSTING H-23

H-23 Machine does not swing

Failure information (1) • The machine swings neither to the right nor to the left.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Malfunctioning of swing park- Swing Solenoid valve
1
ing brake solenoid valve NEUTRAL 0 {0}
Presumed cause and standard value in normalcy

Operation 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction.
2
(parking brake) Check it directly.
★Stop engine for preparations. Start troubleshooting at engine high idling.
Swing lock switch Swing control lever Swing relief pressure
Improper adjustment or mal- 28.9 – 32.9 MPa
3 functioning of swing motor ON Swing relief
{295 – 335 kg/cm2}
(safety valve)
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
Check the valve itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
4 Swing motor defective Swing control lever Amount of oil leakage from swing motor
Swing relief Below 10 ¬/min
The swing machinery is suspected of an internal failure. Check the inside of the
swing machinery directly.
5 Swing machinery defective ★A failure inside the swing machinery may well be determined by an abnormal
noise from within, abnormal heat generated or metal dust or chips contained in
the drained oil.

Failure information (2) • The machine does not swing in one direction.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

★Stop engine for preparations. Start troubleshooting at engine high idling.

Left control lever PPC valve output pressure
1 Malfunctioning of PPC valve
NEUTRAL 0 {0}
Swing operation Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control The spool in the swing control valve is presumed to malfunction. Check the spool
2
valve (spool) itself.
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal itself.
3
seal defective ★Whether the seal is defective or not may well be determined by swapping the
right and left suction valves and watching if there is any change.
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check valve) seal itself.
4
seal defective ★Whether the seal is defective or not may well be determined by swapping the
right and left check valves and watching the result.

PC290-7 20-621
TESTING AND ADJUSTING H-24

H-24 Swing acceleration is poor, or swing speed is slow

Failure information (1) • Swing acceleration is poor, or swing speed is slow.

Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and standard value in normalcy

Malfunctioning of LS shuttle The LS shuttle valves for all the control valves are presumed to malfunction.
1
valve (all LS shuttles) Check them directly.
Malfunctioning of swing motor The parking brake portion of the swing motor is presumed to malfunction. Check
2
(parking brake) it directly.
★Stop engine for preparations. Start troubleshooting at engine high idling.
Swing lock switch Swing control lever Swing relief pressure
Improper adjustment or mal- 28.9 – 32.9 MPa
3 functioning of swing motor ON Swing relief
{295 – 335 kg/cm2}
(safety valve)
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
Check the valve itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
4 Swing motor defective Swing control lever Amount of oil leakage from swing motor
Swing relief Below 10 ¬/min

Failure information (2) • Swing acceleration is poor only on one side, or swing speed is slow.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and standard value in normalcy

Swing control lever PPC valve output pressure

1 Malfunctioning of PPC valve
NEUTRAL 0 {0}
Left or right Above 2.7 MPa {Above 28 kg/cm2}
Malfunctioning of swing control The spool in the swing control valve is presumed to malfunction. Check the valve
2
valve (spool) itself.
Malfunctioning of swing motor
The pressure compensation valve in the swing motor is presumed to malfunction.
3 (pressure compensation
Check the valve itself.
valve)
The seal in the suction valve of the swing motor is suspected of defect. Check the
Swing motor (suction valve) seal itself.
4
seal defective ★Whether the seal is defective or not may well be determined by swapping the
right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect. Check the
Swing motor (check valve) seal itself.
5
seal defective ★Whether the seal is defective or not may well be determined by swapping the
right and left check valves and watching the result.

20-622 PC290-7
TESTING AND ADJUSTING H-25

H-25 Excessive overrun when stopping swing

Failure information (1) • The work equipment overruns excessively when stopping swing.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Presumed cause and stan-

Swing lock switch Swing control lever Swing relief pressure

dard value in normalcy

Improper adjustment or mal- 28.9 – 32.9 MPa

1 functioning of swing motor ON Swing relief
{295 – 335 kg/cm2}
(safety valve)
If the oil pressure does not return to normalcy even after the adjustment, the
safety valve is presumed to malfunction, or suspected of an internal failure.
Check the valve itself.
★Stop engine for preparations. Start troubleshooting at engine high idling.
Amount of oil leakage from swing
2 Swing motor defective Control lever
motor
Swing relief Below 10 ¬/min

Failure information (2) • Swing acceleration is poor only on one side, or swing speed is slow.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

★Stop engine for preparations. Start troubleshooting at engine high idling.
Swing control lever PPC valve output pressure
1 Malfunctioning of PPC valve
NEUTRAL 0 {0}
Left or right Above 2.7 MPa {Above 28 kg/cm2}
Presumed cause and stan-
dard value in normalcy

The PPC slow return valve is suspected of clogging. Check the valve itself.
Swing PPC slow return valve
2 ★Whether the valve is clogged or not may well be determined by swapping
clogged
the right and left valves and watching the result.
Malfunctioning of swing control The spool in the swing control valve is resumed to malfunction. Check the
3
valve (spool) valve itself.
The seal in the suction valve of the swing motor is suspected of defect.
Swing motor (suction valve) Check the seal itself.
4
seal defective ★Whether the seal is defective or not may well be determined by swapping
the right and left suction valves and watching the result.
The seal in the check valve of the swing motor is suspected of defect.
Swing motor (check valve) Check the seal itself.
5
seal defective ★Whether the seal is defective or not may well be determined by swapping
the right and left check valves and watching the result.

PC290-7 20-623
TESTING AND ADJUSTING H-26, H-27

H-26 There is big shock when stopping swing

Failure information • There is a big shock caused when stopping a swing motion.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-

★Stop engine for preparations. Start troubleshooting at engine high idling.

dard value in normalcy

Malfunctioning of swing PPC Swing control lever PPC valve output pressure
1
valve NEUTRAL 0 {0}
Left or right Above 2.7 MPa {Above 28 kg/cm2}
The swing PPC slow return valve is presumed to malfunction. Check the
Malfunctioning of swing PPC valve itself.
2
slow return valve ★Whether the valve malfunctions or not may well be determined by swap-
ping the right and left valves and watching the result.

H-27 There is big abnormal noise caused when stopping swing

Failure information • There is a big abnormal noise caused when stopping a swing motion.
Relative information • Set the working mode at A mode for the troubleshooting.

Cause Standard value in normalcy and references for troubleshooting

Malfunctioning of backpres-
1 The backpressure valve is presumed to malfunction. Check the valve itself.
sure valve
Presumed cause and stan-
dard value in normalcy

Malfunction of swing motor The safety valve in the swing motor is presumed to malfunction. Check the
2
(safety valve) valve itself.
The seal in suction valve of the swing motor is suspected of defect. Check
Malfunction of swing motor the seal itself.
3
(suction valve) ★Whether the seal is defective or not may well be determined by swapping
the right and left valves and watching the result.
The swing machinery is suspected of an internal failure. Check the inside of
the machinery itself.
4 Swing machinery defective ★A failure inside the swing machinery may well be determined by monitoring
abnormal noise, abnormal heat generated or metal dust or chips contained
in the drained oil.

20-624 PC290-7
TESTING AND ADJUSTING H-28

H-28 Swing natural drift is too big

Failure information (1) • Natural drift of the swing is too big (when the parking brake is activated).
• When the emergency swing release switch is in the OFF position (this is a normal condition), the
Relative information
swing and parking brake is activated and the swing is fixed with a disc brake.

Cause Standard value in normalcy and references for troubleshooting

Presumed cause and stan-
dard value in normalcy

★Stop engine for preparations. Start troubleshooting at engine high idling.

Swing and parking brake sole- Swing control lever Solenoid valve output pressure
1
noid valve malfunctioned NEUTRAL 0 {0}
Left or right 2.84 – 3.43 MPa {29 – 35 kg/cm2}

Swing motor (parking brake The parking portion of the swing motor is suspected of malfunctioning and
2
portion) malfunctioned interior failure. Check that portion directly.

Failure information (2) • Natural drift of the swing is too big (when the parking brake is released).
• When the emergency swing release switch is in the ON condition (this is an emergent condition),
Relative information
the swing and parking brake is released and the swing is retained only hydraulically.

Cause Standard value in normalcy and references for troubleshooting

Swing control valve (spool) The seal in the spool of the swing control valve is suspected of defect.
1
Presumed cause and stan-

malfunctioned Check the spool itself directly.

dard value in normalcy

Swing control valve (pressure

The pressure compensation valve seal in the swing control valve is sus-
2 compensation valve) malfunc-
pected of defect. Check the valve itself directly.
tioned
Swing motor (safety valve) The safety valve seal in the swing motor is suspected of defect. Check the
3
defective valve itself directly.
Swing motor (suction valve) The suction valve seal in the swing motor is suspected of defect. Check the
4
defective valve itself directly.
Swing motor (check valve) The check valve seal in the swing motor is suspected of defect. Check the
5
defective valve itself directly.

20-625 PC290-7
TESTING AND ADJUSTING H-28

20-626 PC290-7
 30 DISASSEMBLY AND ASSEMBLY

12
HOW TO READ THIS MANUAL . . . . . . . . . . 30-3 CARRIER ROLLER ASSEMBLY . . . . . . . . . . 30-49
Removal and Installation of Assemblies . 30-3 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-49
Disassembly and Assembly of Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
Assemblies . . . . . . . . . . . . . . . . . . . . . . . 30-4 TRACK ROLLER ASSEMBLY . . . . . . . . . . . . 30-50
PRECAUTIONS WHEN PERFORMING Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-50
OPERATION . . . . . . . . . . . . . . . . . . . . 30-5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
STARTING MOTOR ASSEMBLY . . . . . . . . . 30-7 IDLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-51
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 30-7 Disassembly. . . . . . . . . . . . . . . . . . . . . . . 30-51
FUEL INJECTION PUMP ASSEMBLY . . . . . . 30-8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 30-8 RECOIL SPRING ASSEMBLY . . . . . . . . . . . . 30-54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-54
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . 30-54
ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . 30-12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-12 SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-12 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-56
ENGINE REAR SEAL . . . . . . . . . . . . . . . . . . 30-14 TRACK SHOE ASSEMBLY . . . . . . . . . . . . . . 30-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Removal and Expansion (Iron). . . . . . . . 30-57
CYLINDER HEAD ASSEMBLY . . . . . . . . . . 30-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-58
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-16 Removal and Expansion of Road Liners 30-59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-19 SWING CIRCLE ASSEMBLY . . . . . . . . . . . . . 30-61
RADIATOR ASSEMBLY . . . . . . . . . . . . . . . . 30-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-61
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-23 REVOLVING FRAME ASSEMBLY . . . . . . . . 30-62
HYDRAULIC OIL COOLER ASSEMBLY . . . 30-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-63
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-25 CENTER SWIVEL JOINT ASSEMBLY . . . . . 30-64
ENGINE AND HYDRAULIC PUMP Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
ASSEMBLIES . . . . . . . . . . . . . . . . . . 30-26 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-65
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-26 DISASSEMBLY AND ASSEMBLY
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 Special Tools . . . . . . . . . . . . . . . . . . . . 30-66
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-30 Disassembly . . . . . . . . . . . . . . . . . . . . 30-66
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . 30-32 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 HYDRAULIC TANK ASSEMBLY . . . . . . . . . 30-67
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-32 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-67
DISASSEMBLY AND ASSEMBLY Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-68
Special Tools . . . . . . . . . . . . . . . . . . . . 30-33 CONTROL VALVE ASSEMBLY . . . . . . . . . . 30-69
Disassembly . . . . . . . . . . . . . . . . . . . . 30-33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-69
Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-71
SKETCHES OF SPECIAL TOOLS . . . . . . . . 30-40 DISASSEMBLY AND ASSEMBLY
SWING MOTOR AND SWING Special Tools . . . . . . . . . . . . . . . . . . . . 30-72
MACHINERY ASSEMBLY . . . . . . . . 30-41 Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41 HYDRAULIC PUMP ASSEMBLY . . . . . . . . . 30-75
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-41 Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-75
DISASSEMBLY AND ASSEMBLY Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
Special Tools . . . . . . . . . . . . . . . . . . . . 30-42 Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-77
Disassembly . . . . . . . . . . . . . . . . . . . . 30-42
Assembly . . . . . . . . . . . . . . . . . . . . . . . 30-44
PC290-7 30-1
DISASSEMBLY AND ASSEMBLY

OIL SEAL IN HYDRAULIC PUMP

INPUT SHAFT . . . . . . . . . . . . . . . . . . 30-78
Special Tools . . . . . . . . . . . . . . . . . . . . . 30-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 30-78
Installation . . . . . . . . . . . . . . . . . . . . . . . 30-78
WORK EQUIPMENT PPC VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-79
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-79
TRAVEL PPC VALVE ASSEMBLY . . . . . . . . 30-80
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-80
HYDRAULIC CYLINDER ASSEMBLY . . . . . 30-81
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-81
Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-81
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-83
WORK EQUIPMENT ASSEMBLY . . . . . . . . 30-87
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-87
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-87
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-88
AIR CONDITIONER UNIT ASSEMBLY . . . . 30-90
Special Tools . . . . . . . . . . . . . . . . . . . . . . 30-90
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-92
COUNTERWEIGHT ASSEMBLY . . . . . . . . . 30-93
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-93
OPERATOR’S CAB ASSEMBLY . . . . . . . . . 30-94
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-96
MONITOR ASSEMBLY . . . . . . . . . . . . . . . . 30-96
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-96
GOVERNOR PUMP CONTROLLER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . 30-97
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 30-97
Installation . . . . . . . . . . . . . . . . . . . . . . . . 30-97

30-2 PC290-7
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL

HOW TO READ THIS MANUAL

12

REMOVAL AND INSTALLATION OF ASSEMBLIES

SPECIAL TOOLS INSTALLATION OF PARTS

• Special tools that are deemed necessary for • Except where otherwise instructed, install
removal or installation of parts are listed. parts is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing
kind of information. parts are shown with mark in the
1) Necessity INSTALLATION Section, identifying which
■: Special tools which cannot be substi- step the instructions are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
●: Special tools which are very useful if stand for the following.
available, can be substituted with
commercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special doing the work.
tools ★ This mark gives guidance or precau-
N: Tools with new part numbers, newly tions when doing the procedure.
developed for this model.
R: Tools with upgraded part numbers, This mark stands for a specific coating
remodeled from already available agent to be used.
tools for other models. This mark indicates the specified
Blank: Tools already available for other mod- torque.
els, used without any modification.
This mark indicates an amount of oil or
3) Circle mark ({) in sketch column: water to be added.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
★ Part No. of special tools starting with 79*T
• Various special tools are illustrated for the
means that they are locally made parts and as
convenience of local manufacture.
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS

• The REMOVAL Section contains procedures,

precautions and the amount of oil or water to
be drained.
• Various symbols used in the REMOVAL Sec-
tion are explained and listed below.

This mark indicates safety-related pre-

cautions which must be followed
when doing the work.
★ This mark gives guidance or precau-
tions when doing the procedure.
This mark shows that there are instruc-
tions or precautions for installing
parts.

This mark shows oil or water to be

drained.

PC290-7 30-3
DISASSEMBLY AND ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES

SPECIAL TOOLS ASSEMBLY

• Special tools which are deemed necessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly are listed in this precautions and the know-how for the work,
section. as well as the amount of oil or water to be
• List of the special tools contains the following added.
kind of information. • Various symbols used in the ASSEMBLY Sec-
1) Necessity tion are explained and listed below.
■: Special tools which cannot be substi-
This mark indicates safety-related pre-
tuted, should always be used.
cautions which must be followed when
●: Special tools which are very useful if doing the work.
available, can be substituted with ★ This mark gives guidance or precautions
commercially available tools. when doing the procedure.
2) Distinction of new and existing special
tools This mark stands for a specific coating
N: Tools with new part numbers, newly agent to be used.
developed for this model. This mark indicates the specified torque.
R: Tools with upgraded part numbers,
remodeled from already available This mark indicates an amount of oil or
tools for other models. water to be added.
Blank: Tools already available for other mod-
els, used without any modification. SKETCHES OF SPECIAL TOOLS
3) Circle mark ({) in sketch column: 1) Various special tools are illustrated for the
A circle mark means that a sketch of the convenience of local manufacture.
special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts
and as such not interchangeable with
those made by Komatsu in Japan e.g.
79*T--- xxx --- xxxx.
DISASSEMBLY

• The DISASSEMBLY Section contains proce-

dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.

This mark indicates safety-related pre-

cautions which must be followed when
doing the work.
★ This mark gives guidance or precautions
when doing the procedure.
This mark shows that there are instruc-
tions or precautions for installing parts.

This mark shows oil or water to be

drained.

30-4 PC290-7
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION

PRECAUTIONS WHEN PERFORMING OPERATION

12

Be sure to follow the general precautions given below when performing removal or installation (disassem-
bly or assembly) of units.
1. Precautions when performing removal work
• If the engine coolant water contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from
entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
• To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force
to the wiring, hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify and show their installation position and help prevent any
mistakes when re-installing.
• Count and check the number and thickness of the shims, and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and
safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt
from entering after removal.
★ Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.

A. Hoses and tubes using sleeve nuts

Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)

B. Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

C. If the part is not under hydraulic pressure, the following corks can be used:

Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

PC290-7 30-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION

12
2. Precautions when carrying out installation work
• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with two or three drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After installing snap rings, check that the snap ring is installed securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then con-
nect securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them in fully, and
align the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydrau-
lic equipment removed for repair, bleed the air as follows:
1. Start the engine and run it at low idle.

2. Operate the work equipment control lever to operate the hydraulic cylinders, 4 - 5 times, stopping
the cylinders 100 mm from the end of their stroke.

3. Next operate the hydraulic cylinder 3 - 4 times to the end of its stroke.

4. After doing this run the engine at normal speed.

★ When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions when completing the operations

• If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the
specified level. Run the engine to circulate the coolant water through the system. Then check the
coolant water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, have been removed for repair, Bleed the air from the system
after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
related parts.

30-6 PC290-7
DISASSEMBLY AND ASSEMBLY STARTING MOTOR ASSEMBLY

12
REMOVAL AND INSTALLATION OF STARTING MOTOR
ASSEMBLY ASSEMBLY
REMOVAL
Disconnect the cable from the negative (-)
terminal of the battery.

1. Open up the engine hood.

2. Disconnect the two wires from the engine

starting motor at:
• Wire (1) and (2) from terminal B.
• Wire (3) from the T13 side of terminal C.

3. Remove two mounting bolts (4) to detach

engine starting motor assembly (5).

INSTALLATION
• Install in reverse order of removal.

Engine starting motor Terminal B

Securing nut:
17.7 to 24.5 Nm (1.8 to 2.5 kgm)

Both faces of engine starting motor

gasket: Gasket sealant (LG-1)

Engine starting motor Terminal B

Securing nut:
43 ± 6 Nm (4.38 ± 0.61 kgm)

PC290-7 30-7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY

12

REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 5. Disconnect fuel inlet hose (5) and fuel outlet
hose (6).
Part
Mark Part No.
Name
Necessity Qty Distinction* Sketch ★ When disconnecting the hoses, oil will
A 795-799-1390 Puller ■ 1
flow out. Stop the flow by inserting a
wooden plug into the hoses.
*Distinction between new and existing part.

REMOVAL

Leave the negative (-) terminal of the

battery disconnected.

1. Open up the engine hood.

2. Remove plate (1) and cover (2).

6. Disconnect tubes (7) and (8) between the fuel

filter and the fuel injection pump, then
remove fuel filter bracket (9).

3. Take off radiator fan guard (3).

4. Disconnect air intake hose (4).

7. Disconnect lubrication tube (10).

8. Disconnect six delivery tubes (11).

9. Detach E11 governor motor connector and

then detach governor spring (12) on the fuel
injection pump side.

30-8 PC290-7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY

12

12. Remove nut (15) and washer (16) from the

fuel injection pump.

★ Be careful not to drop the nut or washer

inside the case.

10. Adjust the timing gear to the injection timing,

using timing pin (13) on the timing gear side.
★ Refer to the Inspection and Adjustment of
Fuel Injection Timing Section.

13. Separate the fuel injection pump shaft and

drive gear, using tool A.

11. Unscrew cap (14) to remove it.

★ Use a filter wrench to unscrew the cap.

14. Remove two bracket mounting bolts (17) on

the lower part of the fuel injection pump.

PC290-7 30-9
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY

12

15. Remove sound absorbing material (18).

16. Remove four nuts (19) to remove fuel injec- • Install the fuel injection pump assembly in the
tion pump assembly (20). following manner.
1) Check that the timing pin is properly
adjusted to the fuel injection timing.
★ Refer to Step 10 in the previous proce-
dure, REMOVAL.
2) Remove plug (21), then reverse timing pin
(22) of the fuel injection pump and assem-
ble the plug to the pump again.
★ Check that the cutout portion on the
timing pin is engaged with protrusion
a inside the pump.
★ Refer to the Inspection and Adjust-
ment of Fuel Injection Timing section
of the TESTING AND ADJUSTING,
chapter in this manual.
INSTALLATION

• Install in reverse order of removal.

Air intake hose clamp:

5.4 - 6.4 Nm (0.55 - 0.65 kgm)

Hose clamp:
2.84 - 3.82 Nm (0.29 - 0.39 kgm)

3) Mount fuel injection pump assembly (20)

Joint bolt:
and secure it with four nuts (19).
19.6 - 29.4 Nm (2.0 - 3.0 kgm)
Nut: 9.8 ± 2 Nm (1.0 ± 0.2 kgm)

Sleeve nut:
24 ± 4 Nm (2.45 ± 0.41 kgm)

★ Adjust the governor lever stroke, refer to

the Special Function of Monitor Panel sec-
tion in the INSPECTION AND ADJUST-
MENT chapter, of this manual.

Nut: 95 ± 10 Nm (9.7 ± 1.0 kgm)

30-10 PC290-7
 DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY

12
4) Install washer (16) and tighten it with nut
(15) temporarily.
★ When installing the nut and washer,
be careful not to let them fall into the
case.

Tighten the nut temporarily to the

following specified torque. Take care
not to damage the timing pin.

Nut temporary tightening torque:

12.5 ± 2.5 Nm (1.27 ± 0.25 kgm)

5) Disengage the timing pin on the timing

gear side from protrusion a, and return
the position of the timing pin of the fuel
injection pump to the original point.
6) Tighten fuel injection pump mounting nut
(15) to the specified torque.

Nut: 95 ± 10 Nm (9.7 ± 1.01 kgm)

• Air bleeding
Bleed air from the fuel injection system.

PC290-7 30-11
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL

12

REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

SPECIAL TOOLS 5. Holding cover (6) securely and using a screw-
driver, push out oil seal (7) from the backside
Part to the front side of the cover.
Mark Part No. Necessity Qty Distinction* Sketch
Name
A 795-799-1380 Installer ● 1
*Distinction between new and existing part.

REMOVAL

1. Remove the radiator assembly, refer to the

Removal and Installation of Radiator Assem-
bly section in this manual.

2. Take off engine fan belt (1) and pulley (2),

using lever .

INSTALLATION

• Install in reverse order of removal.

Crankshaft pulley and pulsation

damper mounting bolt:
125 ± 5 Nm (12.75 ± 0.51 kgm)
★ Tighten the crankshaft pulley and pulsa-
tion damper mounting bolt temporarily,
3. Remove four mounting bolts (3), and then
then install engine fan belts and tighten
take off the crankshaft pulley and pulsation
the bolt to the specified torque.
damper (4).
★ Check both index lines on damper hub B
and on inertial material C (marked as A),
4. Remove 20 mounting bolts (5) to take off
when installing the pulsation damper. If
cover (6).
the two index lines are misaligned by
more than 1.59 mm, replace the pulsation
damper. Replace rubber material D, if it is
defective.

30-12 PC290-7
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL

12

3) Push the oil seal into cover (6) from the

★ Protrusion of the gear housing gasket inside to the outside.
from the oil pan installation face should ★ Push the oil seal in until tool B contacts
be kept less than 0.25 mm. the bottom of cover (6).
★ Coat the gasket installation face of the ★ Clean the crankshaft sealing face to pre-
cover with Three Bond 1207D or an equiv- vent oil leakage. Completely remove all
alent (with a bead diameter of 1 - 2 mm). oil and dry it thoroughly.
★ Install the gasket on the cover and mount
the cover on the engine.

Cover mounting bolt:

24 ± 4 Nm (2.45 ± 0.41 kgm)
★ Tighten the 20 cover mounting bolts in
the sequence of (1) through (20) as illus-
trated below.

4) Apply the cover seal with pilot (2) still

attached to the crankshaft, then tighten
the cover mounting bolts to the specified
torque and detach pilot (2).
Cover installing face:
Gasket sealant (LG-6)

★ Install the oil seal in the following man-

ner.
1) Install pilot (2) to oil seal (8).
2) Place the oil seal onto tool B with the dust
and lip faces turned upward.

PC290-7 30-13
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

12

REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

REMOVAL ★ Drill a hole of approx. 3 mm in diameter

on the seal carrier with a drilling machine.
1. Remove the hydraulic pump assembly, refer
to the Hydraulic Pump Assembly Removal
section in this manual.

2. Remove damper assembly (1).

3. Remove the mounting bolts from flywheel

assembly (2) and set guide bolts . Then lift it
off to remove it.

★ Attach a dent puller to a slide hammer

and insert the hammer into the drilled
hole. Then pull out seal (3) by sliding the
hammer.

4. Remove seal (3).

★ A suggested method for removing the
seal is to drill a hole approx. 3 mm in
diameter on the seal carrier, then insert a
slide hammer with a dent puller attached
into the hole and pull the seal out.
★ The seal may be removed by destroying
the seal carrier with a hammer. When
using this method, take care so the fly-
wheel seal and crankshaft wear ring are
not damaged.

30-14 PC290-7
 DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

12

INSTALLATION

• Install in reverse order of removal. 2) Push the oil seal into the flywheel by
inserting pilot (2) with oil seal (4) into the
crankshaft.
Flywheel mounting bolt:
3) Pull out pilot (2). Push the oil seal into the
137 ± 7 Nm (13.97 ± 0.71 kgm) front cover from the inside to the outside.
★ Tighten the mounting bolts in the 4) Install the oil seal on the flywheel housing
sequence illustrated below. to the proper depth. Use an alignment
tool.
★ Tap the head, bottom, right and left
sides of the alignment tool to make
sure that the seal carrier is not
twisted, when it is being pushed in.

★ Install the oil seal in the following man-

ner.
1) Attach pilot (2) to new oil seal (4).
★ Before installing the oil seal, clean the
crankshaft sealing face and the seal
lip face. Remove all oil and dry thor-
oughly to prevent oil leakage.

PC290-7 30-15
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY

12

REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEM-

ASSEMBLY BLY

SPECIAL TOOLS

Part
Mark Part No. Necessity Qty Distinction* Sketch
Name
1 795-799-1170 Installer ■ 1
C
2 790-331-1110 Wrench ■ 1
*Distinction between new and existing part.

REMOVAL

.Disconnect the cable from the negative

terminal (- ) of battery.
10. Remove heat cover (8) from the turbocharger
1. Drain engine coolant. assembly.

11. Remove exhaust muffler connector cover (9).

Engine coolant : 22.8 l

2. Close the fuel stop valve.

3. Open up the engine hood.

4. Remove clamp (1) from the engine oil level

gauge guide.
★ Put the clamp aside near the counter-
weight after removing it.

5. Disconnect air intake hose (2).

6. Disconnect tubes (3) and (4) between the fuel 12. Disconnect air cleaner suction hose (10).
filter and the fuel injection pump.

13. Disconnect air intake hose (11) between the

7. Remove bracket (5) in one piece with the fuel turbocharger and the after-cooler.
filter assembly.

14. Remove V clamp (12) from the exhaust muf-

8. Remove ribbon heater harness CN-E01 (6). fler.

9. Disconnect six delivery tubes (7). 15. Disconnect lubricant inlet tube (13) and lubri-
cant outlet tube (14).

16. Remove turbocharger assembly (15).

30-16 PC290-7
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY

12

17. Detach exhaust manifold (16). 24. Remove the four mounting bolts to detach
the fan and fan pulley (25).

★ Put the fan pulley aside near the radiator.

25. Disconnect radiator inlet hose (26) and heater

hose (27).

18. Detach air compressor wiring connector CN-

E06 (17).

19. Loosen tension on the air compressor belt,

then loosen adjusting bolt (18) to remove belt
(19).
26. Disconnect connector E12 (29) at terminal B
(28) from the alternator.
20. Remove air compressor assembly (20).
★ Remove the mounting bracket in one 27. Remove three alternator bracket mounting
piece with the air compressor assembly bolts (30) and the two alternator plate mount-
and put them aside near the counter ing bolts, and remove alternator assembly
weight. (31) in one piece with the bracket.

21. Detach radiator fan guards (21) and (22).

28. Disconnect connector E05 (32) from the

engine cooling water temperature sensor,
22. Loosen air compressor belt (23), using and remove the wiring clamp.
wrench and remove it.
Be careful not to get a finger caught in
the belt, when removing it.

23. Remove tension pulley (24).

PC290-7 30-17
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY

12

32. Remove head cover (37).

29. Remove the clamps (two places) and discon-

nect the spill tube (33).
33. Detach rocker arm assembly (38).
30. Remove six nozzle holders (34).
★ Loosen the lock nut, and unscrew the
★ If it is difficult to remove the nozzle holder adjusting screw 2 to 3 turns.
assemblies, use tool C1.
★ Be careful not to allow dust or foreign
matter to stick where the nozzle holder
assembly is installed.

34. Remove push rod (39).

31. Disconnect ribbon heater wiring (35) and

remove air intake connector (36).

35. Remove 26 mounting bolts from cylinder

head assembly (40) and lift it off for disas-
sembly.

Cylinder head assembly: 52 kg

30-18 PC290-7
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY

36. Remove cylinder head gasket (41).

★ Tighten the exhaust manifold mounting

bolts in the sequence illustrated below.

Exhaust manifold mounting bolt:

1st step: Tighten to 24 ± 4 Nm (2.45 ± 0.41 kgm)

in the sequence of (1) through (12).
2nd step: Tighten to 43 ± 6 Nm (4.38 ± 0.61 kgm)
in the sequence of (1) through (12).
3rd step: Tighten to 43 ± 6 Nm (4.38 ± 0.61 kgm)
in the sequence of (1) through (4).

INSTALLATION

• Install in reverse order of removal.

★ Coat the threads of the clamp bolt (used

for securing the engine oil level gauge
guide) with gasket sealant.

Air intake hose clamp bolt:

5.4 - 6.4 Nm (0.55 - 0.65 kgm)
★ Refer to the Inspection and Adjustment of
Air Compressor Belt Tension section in
the TESTING AND ADJUSTING chapter
Joint bolt: in this manual.
19.6 - 29.4 Nm (2.0 - 3.0 kgm)

Radiator fan and fan pulley

★ Coat the threads of only one bolt on the mounting bolt:
head cover side of the fuel filter bracket 33 ± 5 Nm (3.37 ± 0.51 kgm)
with gasket sealant.

Radiator inlet hose clamp bolt:

Sleeve nut: 8.3 - 9.3 Nm (0.85 - 0.95 kgm)
24 ± 4 Nm (2.45 ± 0.41 kgm)
Heater hose clamp bolt:
8.83 - 14.7 Nm (0.9 - 1.5 kgm)

Air cleaner suction hose clamp bolt:

5.4 - 6.4 Nm (0.55 - 0.65 kgm) Spill tube bolt:
30 ± 5 Nm (3.06 ± 0.51 kgm)

Intake air hose clamp bolt:

5.4 - 6.4 Nm (0.55 - 0.65 kgm) Nozzle holder assembly:
60 ± 9 Nm (6.12 ± 0.92 kgm)

PC290-7 30-19
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY

4) Install rocker arm assembly (38) and

tighten the bolts by hand.
Head cover mounting bolt: ★ Check that the adjusting screw ball is
24 ± 4 Nm (2.45 ± 0.41 kgm) well seated in the push rod socket.
★ Coat the threads and seat surface of
• Mount the rocker arm assembly and the cylin- mounting bolts (8 mm and 12 mm)
der head assembly in the following manner. with engine oil (15W-40).
★ Check that there is no dust or foreign mat-
ter stuck to the cylinder head installing
face or inside the cylinders.
1) Place cylinder head gasket (41) on the cyl-
inder block.
★ Check that the gasket is properly
matched with the cylinder block
holes.
2) Lift cylinder head assembly (40) and place
it on the cylinder block.

5) Tighten the cylinder head mounting bolts

in the sequence as illustrated below.
★ Coat the threads and seat surface of
the mounting bolts with engine oil
(15W-40).

Cylinder head mounting bolt:

1st step: Tighten to 90 ± 5 Nm
(9.18 ± 0.51 kgm) in the
sequence of (1) through (26).
3) Assemble push rod (39). 2nd step: Tighten to 120 ± 5 Nm
(12.24 ± 0.51 kgm) in the
★ Coat the push rod surface with engine
sequence of (3), (6), (11), (14),
oil (15W-40).
(19) and (22).

30-20 PC290-7
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY

3rd step:
i) If Tool C2 is used:
Using an angle tightening wrench
(Tool C2), tighten the bolts by turning
them 90° ± 5° in the sequence of (1)
through (26).

7) Adjust the valve clearance.

★ Refer to the Adjusting of Valve Clear-
ance section in the TESTING AND
ADJUSTING chapter of this manual.

• Refilling cooling water

Refill engine cooling water up to the specified
ii) If Tool C2 is not used: level. Let the cooling water circulate to
Put counter mark on the bolts and cyl- release any air pockets by starting the engine.
inder head with a felt-tip pen, and Check the water level again.
then tighten the bolts by turning them
to 90° ± 5°.

6) Tighten the rocker arm assembly mount-

ing bolts (8 mm).
Rocker arm assembly mounting
bolt: 24 ± 3 Nm (2.45 ± 0.31 kgm)

PC290-7 30-21
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY

12

REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

REMOVAL 7. Remove bell mouth shroud (8).

1. Drain the engine cooling water. 8. Remove the mounting clamp for heater hose
(9).
Engine cooling water: Approx. 31 l ★ After removing the clamp, keep the heater
hose away from the radiator cover.

2. Open up the engine hood.

3. Remove covers (1), (2) and (3).

9. Sling the radiator assembly with two lifting

hooks (1).

4. Disconnect reservoir tank hose (4).

★ Disconnect the hose at the radiator side.

5. Disconnect two radiator hoses (5) on the

upper and lower sides.

6. Remove radiator fan guards (6) and (7).

10. Remove the four radiator mounting bolts and

lift out the radiator assembly (10) .

Radiator assembly: 41.3 kg

30-22 PC290-7
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY

INSTALLATION

• Install in reverse order of removal.

Radiator hose clamp bolt:

8.3 - 9.3 Nm (0.85 - 0.95 kgm)

★ To maintain the heat balance, make sure

that sponge sheets are assembled in the
original position.
★ Adjust clearance a between the radiator
circumference and the bell mouth shroud,
using oblong hole b for mounting the bell
mouth shroud, so that the clearance may
be even all around the circumference.
★ Check that clearance a shows the follow-
ing value, measured at four points on the
right, left, top and bottom sides.
• Standard clearance a (on all the cir-
cumference): More than 13 mm
• Fan diameter c: ∅620
• Shroud inner diameter d: ∅650

• Refilling engine cooling water

Refill engine cooling water through the water
filler port up to the specified level. Let the
water circulate to release any air pockets by
starting the engine. Check the water level
again.

Engine cooling water: Approx. 31 l

PC290-7 30-23
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER ASSEMBLY

12

REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER

ASSEMBLY ASSEMBLY

REMOVAL 5. Detach control valve drain hose (4) and tank

return hose (5).
1. Open up the engine hood. ★ Plug the hoses to prevent oil from flowing
out.
2. Remove cover (1).

3. Remove hydraulic oil cooler drain plug (2)

and drain the hydraulic oil.
★ Before draining oil, unscrew the hydraulic
tank cap to release the pressure inside the
tank, and drain oil through the cooler
hose.
★ If a plug on top of the hydraulic oil cooler
is loosened, draining oil becomes easier.

Hydraulic oil cooler: Approx. 5.0 l

6. Remove the mounting clamp and put aside

reservoir tank hose (6).
★ When lifting out the hydraulic oil cooler,
keep it where it will not interfere with
other parts.

7. Remove the mounting clamp and disconnect

A30 air conditioner ambient temperature sen-
sor (7) from the condenser bracket.

8. Disconnect hydraulic oil cooler drain hose (8).

4. Remove cover (3).

30-24 PC290-7
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER ASSEMBLY

12

9. Remove four mounting bolts from hydraulic

oil cooler assembly (9) and lift it out.
★ If bolts for the after-cooler and condenser
mounting bracket are removed before-
hand, removing the hydraulic oil cooler
assembly becomes easier.

INSTALLATION

• Install in reverse order of removal.

• Refilling hydraulic oil (hydraulic tank)
Refill hydraulic oil through oil filler port up to
the specified level and circulate oil in the
hydraulic system by starting the engine. Then
check the oil level again.

Hydraulic oil cooler: Approx. 5.0 l

PC290-7 30-25
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES

12

REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC

PUMP ASSEMBLIES PUMP ASSEMBLIES
SPECIAL TOOLS

Part 3. Lift up engine hood (1).

Mark Part No. Necessity Qty Distinction* Sketch
Name
Oil
D 796-460-1210 ■ 1 Support the engine hood with an appropri-
Stopper
ate strap and lifting device.
*Distinction between new and existing part.

REMOVAL

Lower the work equipment to the ground

for safety and stop the engine. Disconnect
the cable from the negative terminal (- ) of
the battery.
To release the internal pressure, gradually
loosen the oil filler cap on the hydraulic
tank.

★ Attach an identification tag to each pipe. This

will avoid a possible mistake when reinstall-
ing. 4. Remove pin (2) and mounting bolt (3). Lift off
the hood and set it aside.
1. Remove the hydraulic tank strainer and stop
the flow of oil, using Tool D.
★ When not using tool D, remove the drain
plug to drain oil from the hydraulic tank
and piping.

Hydraulic tank: Approx. 247 l

5. Remove covers (4) and (5).

6. Remove radiator fan guards (6) and (7).

2. Drain engine cooling water.

Engine cooling water: Approx. 31 l

30-26 PC290-7
 DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES

7. Loosen air compressor belt tension adjusting 12. Disconnect fuel return hose (16).
bolt (8) and remove belt (9).

8. Disconnect E06 air conditioner wiring connec-

tor (10) and E01 ribbon heater wiring connec-
tor (11).

9. Displace air compressor assembly (12).

★ Remove air compressor assembly (12) in

one piece with the bracket, and set them
aside near the counter weight.

10. Disconnect air intake hose (13).

13. Disconnect engine wiring connectors at the

following five points.
• (17): E02 (Engine oil temperature switch)
• (18): E05 (Engine cooling water tempera-
ture sensor)
• (19): E04 (Engine revolution sensor)
• (20): E10 (Governor and potentiometer)
E11 (Governor and motor)

11. Disconnect fuel inlet hose (14) and fuel outlet

hose (15).

PC290-7 30-27
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES

12

14. Remove bell mouth shroud (21). 18. Remove cover (28) and plate (29).

15. Disconnect two radiator hoses (22) on the

upper and lower sides.

19. Remove covers (30) and (31).

20. Disconnect eight hoses.

16. Disconnect engine starting motor wiring (23) • (32): Front pump discharging port hose
and connectors (24), (25) and (26). • (33): Rear pump discharging port hose
• (23): Engine starting motor terminal B • (34): Pump pressure input port hose
(red)
• (35): Drain port hose
• (24): E08 (Intermediate connector)
• (36): EPC source pressure port hose
• (25): T13 (color band, yellow)
(Engine starting motor terminal C )
• (37): Load pressure input port hose
• (26): E03 (Engine oil level sensor) (color band, red)
• (38): Load pressure input port hose
• (39): Suction port hose

17. Disconnect engine ground (27).

30-28 PC290-7
 DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES

12

21. Remove clamp (40). 25. Remove cover (47).

22. Disconnect the pump wiring connectors at the 26. Remove water separator wiring clamp (48).
following three points.
• (41): A61 (Hydraulic oil temperature sensor) 27. Remove four engine mounting bolts (49) at
Color band, white the front and rear.
• (42): V21 (PC-EPC solenoid valve)
Color band, white
• (43): V22 (LS-EPC solenoid valve)
Color band, red

23. Disconnect exhaust muffler drain tube (44).

★ Check that there is no wiring or piping still

connected.

28. Lift out engine and hydraulic pump assembly

(50).
Engine and hydraulic pump assem-
24. Disconnect engine oil filter outlet hose (45) bly:
and engine oil filter inlet hose (46). 770 kg

PC290-7 30-29
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES

INSTALLATION ★ Install the hose clamp and tighten the

clamp screw as shown in the diagram
• Install in reverse order of removal. below.

★ Refer to the Inspection and Adjustment of

Air Compressor Belt Tension section in
the TESTING AND ADJUSTING chapter of
this manual.

Air intake hose clamp screw:

5.4 - 6.4 Nm (0.55 - 0.65 kgm)

Fuel inlet hose clamp screw:

29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
★ The engine mounting rubber pads differ
in shape at the front and rear. Place them
as illustrated below, and install the engine
Radiator hose clamp screw: and hydraulic pump assembly.
8.3 - 9.3 Nm (0.85 - 0.95 kgm)
Engine mounting bolt:
245 - 308.7 Nm (25 - 31.5 kgm)
★ After tightening the suction hose clamp
screw, check that the screw is in the posi-
tion as illustrated below.

Suction hose clamp screw:

8.8 ± 0.5 Nm (90 ± 5 kgm)

30-30 PC290-7
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP ASSEMBLIES

12

• Refilling engine cooling water

Refill engine cooling water through the water
filler port up to the specified level.

Engine cooling water: Approx. 22.8 l

• Refilling hydraulic oil (hydraulic tank)

Refill hydraulic oil through oil filler port up to
the specified level.

Hydraulic tank: Approx. 240 l

★ Let the water circulate to release any air pock-

ets by starting the engine. Check the water
level again.
★ Circulate oil in the hydraulic system by start-
ing the engine. Then check the oil level again.
• Air bleeding
Refer to the Air Bleeding of Various Part sec-
tion in the TESTING AND ADJUSTING chap-
ter of this manual.

PC290-7 30-31
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY

12
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
REMOVAL 4. Remove the 21 mounting bolts from final
drive assembly (6) and lift it off to remove.
1. Remove the sprocket, refer to the Removing
Sprocket section in this manual.
★ Be careful. Do not damage the face of the
Lower the work equipment to the ground fitting seal at the base of the hose.
for safety. Stop the engine and loosen the
★ When lifting off the final drive assembly,
oil filler cap on the hydraulic tank to release
do not use a tapped hole for lifting the
pressure inside.
cover.

2. Remove cover (1). Final drive assembly: 500 kg

3. Disconnect drain hose (2), travel speed shift-

ing hose (3) and travel motor hoses (4) and
(5). INSTALLATION

• Install in reverse order of removal.

Final drive assembly mounting bolt:

490 - 608 Nm {50 - 62 kgm}

• Refilling hydraulic oil

Refill hydraulic oil through the oil filler port to
the specified level, and let the oil circulate in
the hydraulic system by starting the engine.
Then check the oil level again.
• Air bleeding
Refer to the Air Bleeding of Various Part sec-
tion in the TESTING AND ADJUSTING chap-
ter of this manual.

30-32 PC290-7
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE

ASSEMBLY
SPECIAL TOOLS

Part
Mark Part No. Necessity Qty Distinction* Sketch
Name
Wrench
796-627-1610 ■ 1 N
assembly
1 796-627-1620 • Wrench 1 N
796-427-1140 • Pin 3
01314-20612 • Screw 3
796T-627-1630 Push tool ■ 1 N {
790-101-2510 Block ■ 1
D
791-830-1320 Rod ■ 2
01580-11613 Nut ■ 2
2
790-101-2570 Washer ■ 2
01643-31645 Washer ■ 2
3. Spacer
Remove spacer (2).
790-105-2100 Jack ass’y ■ 1
790-101-1102 Pump ■ 1
3 791-508-1510 Installer ■ 1
*Distinction between new and existing part.

DISASSEMBLY

1. Draining Oil
Remove drain plug and drain oil from final
drive case.

Final drive case: Approx. 8.5 l

2. Cover 4. No. 1 carrier assembly

1) Remove mounting bolts, then use forcing 1) Remove No. 1 carrier assembly (3).
screws to disconnect cover (1).

2) Disassemble No. 1 carrier assembly as

follows.
2) Use eyebolts to remove cover (1). i) Push in pin (4) and pull out shaft (5)
from carrier (6).
★ After removing the shaft (5),
remove pin (4).

PC290-7 30-33
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

ii) Remove thrust washer (7), gear (8),

bearing (9), and thrust washer (10).
8. Ring gear
Using eyebolts d, remove ring gear (14).

5. No. 1 sun gear shaft

Remove No. 1 sun gear shaft (11).
9. No. 2 carrier assembly
6. No. 2 sun gear
1) Remove No. 2 carrier assembly (15)
Remove No. 2 sun gear (12).

2) Disassemble No. 2 carrier assembly as

7. Thrust washer follows.
Remove thrust washer (13). i) Push in pin (16) and pull out shaft (17)
from carrier (18).
★ After removing the shaft, remove
pin (16).
ii) Remove thrust washer (19), gear (20),
bearing (21), and thrust washer (22).

30-34 PC290-7
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

PC290-7 30-35
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

12
10. Nut
1) Remove lock plate (23).
2) Disassemble hub assembly as follows.
i) Remove floating seal (26).

2) Use tool D1 and remove nut (24).

ii) Remove bearings (27) and (28) from

hub (29).

11. Hub assembly

3) Remove floating seal (30) from travel
1) Using eyebolts e, remove hub assembly
motor (31).
(25) from travel motor.

30-36 PC290-7
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

ASSEMBLY

★ Clean all parts and check for dirt or damage.

3) Using tool D3, install floating seal (30)
Coat the sliding surfaces of all parts with
onto travel motor (31).
engine oil before installing.
★ The procedure for installation is the
1. Hub assembly same as in the previous Step 2).

1) Assemble hub assembly as follows.

Using push tool, press fit bearings (27)
and (28) to hub (29).

4) Using eyebolts e, set hub assembly (25)

onto the travel motor. Use the push tool
and tap to press fit the bearing.

2) Using tool D3, install floating seal (26).

★ Remove all oil and grease from the O-
ring and O-ring contact surface. Dry
the parts before installing the floating
seal.
★ After installing the floating seal, check
that the angle of the floating seal is
within 1 mm.
★ After installing the floating seal, coat
the sliding surface thinly with engine
oil.
2. Nut
1) Install nut as follows.
i) Using tool D2, push bearing inner
race (27).
★ Pushing force:
12.7 - 16.7 kN {1.3 - 1.7
tons}
★ Rotate the hub 2 - 3 times before
applying the pushing force to the
bearing inner race.

PC290-7 30-37
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

12o not ii)

coatMeasure
the tap portion of the anut
dimension inwith
the thread tightener
condition vii) Install lock plate (23).
in Step 1) above.

★ Install the lock plate as shown in the dia-

iii) Measure thickness b of the nut (24) as gram below.
an individual part. Thread of mounting bolt:
iv) Calculate a - b = c. Thread tightener (LT-2)
v) Tighten nut (24) with tool D1 until
dimension c is obtained. ★ Do no coat the threaded portion of the
nut with thread tightener (LT-2).

Mounting bolt: 49 - 74 Nm
{6 - 7.5 kgm}

vi) Using push-pull scale f, measure

tangential force in the direction of
rotation of the hub in relation to the
motor case.
★ Tangential force: Max. 490 N
{50 kg}
★ The tangential force is the maxi-
mum force when starting rotation.

30-38 PC290-7
 DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

3. No. 2 carrier assembly

1) Assemble No. 2 carrier assembly as fol-
lows.
★ Replace thrust washers (19), (22) and
pin (16) with new ones.
★ There are remains of caulking when
the pin is inserted at the end face of
hole e at the side of the carrier.
Remove the caulked metal from the
inside diameter of the hole before
starting to assemble.
i) Assemble bearing (21) to gear (20), fit
top and bottom thrust washers (19)
and (22), and set gear assembly in
carrier (18). ★ After inserting the pin, caulk the pin
portion of the carrier.
★ After assembling the carrier assem-
bly, check that gear (20) rotates
smoothly.

ii) Align the position of pin holes on the

shaft and carrier, then tap with a plas-
tic hammer to install shaft (17).
★ When installing the shaft, rotate 2) Install No. 2 carrier assembly (15).
the planetary gear. Be careful not ★ Align the three tips of the gear shafts
to damage the thrust washer. of the carrier assembly (15) to enter
iii) Insert pin (16). the three hollows in the end face of
★ Insert the pin in such a way that any the motor case, then install.
of the three claws (f portions) on the
periphery will not fall on the slender
(g) portion of the carrier. Take note,
however, that depending on the
actual carriers, this slender portion is
on the opposite side. Hence when
inserting the pin, check them carefully
to see on which side of the carrier a
thin portion is, and insert the pin the
way its claw does not come to the thin
portion. If there is a groove, mean-
while, avoid it.

PC290-7 30-39
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

4. Ring gear 7. No. 1 carrier assembly

Install O-ring on hub end. Use eyebolts d to 1) Assemble No. 1 carrier assembly as fol-
install ring gear (14). lows.
★ Remove all grease and oil from the mat- ★ Replace thrust washers (7) and (10),
ing surface of the ring gear and hub. and pin (4) with new ones.
★ Do not put any gasket sealant on the mat- ★ There are remains of caulking when
ing surface of the ring gear and hub under the pin is inserted at the end face of
any circumstances. hole h at the side of the carrier.
Remove the caulked metal from the
inside diameter of the hole before
starting to assemble.
i) Assemble bearing (9) to gear (8), fit
top and bottom thrust washers (7) and
(10), and set gear assembly in carrier
(6).

5. Thrust washer
Install thrust washer (13).

6. No. 2 sun gear

Install No. 2 sun gear (12).

ii) Align the position of pin holes on the

shaft and carrier, then tap with a plas-
tic hammer to install shaft (5).
★ When installing the shaft, rotate
the planetary gear. Be careful not
to damage the thrust washer.

30-40 PC290-7
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

12

iii) Insert pin (4). 2) Install No. 1 carrier assembly (3).

★ Insert the pin in such a way that any
of the three claws (f portions) on the
periphery will not fall on the slender
(g) portion of the carrier. Take note,
however, that depending on the
actual carriers, this slender portion is
on the opposite side. Hence when
inserting the pin, check them carefully
to see on which side of the carrier a
thin portion is, and insert the pin the
way its claw does not come to the thin
portion. If there is a groove, mean-
while, avoid it.

8. No. 1 sun gear shaft

Install No. 1 sun gear shaft (11).

★ After inserting the pin, caulk the pin

portion of the carrier.
★ After assembling the carrier assem-
bly, check that gear (8) rotates
smoothly.
9. Spacer
Install spacer (2).
★ Take measurement of dimension "i" after
installing the spacer. If "i" dimension
exceeds 15 mm, the spacer is not installed
correctly. In that case, check it again and if
necessary, try to install it correctly once
more.

PC290-7 30-41
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

30-42 PC290-7
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

12 11. Refilling with oil

★ Tighten drain plug and add engine oil
through oil filler.

Final drive case: Approx. 8.5 l

★ Do a final check of the oil level at the

determined position after installing the
final drive assembly to the chassis.

10. Cover
Using eyebolts , lift and install cover (1),
then tighten mounting bolts with angle tight-
ening wrench .
Mounting surface of cover:
Gasket sealant (LG-6)

Mounting bolt:
Initial torque: 98.1 Nm {10 kgm}
Additional tightening angle: Turn 100 - 110°

PC290-7 30-43
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY

SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.

D2 Push Tool

30-44 PC290-7
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY

REMOVAL AND INSTALLATION OF

SWING MOTOR AND SWING MACHINERY ASSEMBLY
REMOVAL

Release the residual pressure in the hydrau- 4. Lift off swing motor and swing machinery
lic circuit. Refer to the Release of Remaining assembly (9) to remove.
Pressure in Hydraulic Circuit section in the ★ When lifting off the swing motor and
TESTING AND ADJUSTING chapter of this swing machinery assembly for removal,
manual. do so slowly so that the hoses and other
Lower the work equipment to the ground for
safety. After stopping the engine, loosen parts may not be damaged.
the oil filler cap on the fuel tank to release Swing motor and swing machin-
the residual pressure inside the tank and ery assembly: 230 kg
move the safety lock lever to the LOCK posi-
tion.

1. Remove the mounting bracket for hose clamp

(1).
★ Keep the removed mounting bracket
away from the swing motor and swing
machinery assembly.

2. Disconnect six swing motor hoses (2) through

(7).
• (2): Between the swing motor and control
valve (MA port)
• (3): Between the swing motor and control
valve (MB port)
• (4): Suction hose (S port) INSTALLATION
• (5): Pilot hose for relieving swing brake
(B port) • Install in reverse order of removal.
• (6): Between the drain hose and swing
motor, and swivel joint (T port)
• (7): Between drain hose and swing motor, Swing motor and swing machinery
and hydraulic tank (T port) assembly mounting bolt:
490 - 608 Nm (50 - 62 kgm)
3. Remove 12 mounting bolts (8).
• Refilling hydraulic oil
Refill hydraulic oil through the oil filler port to
the specified level. Let the oil circulate in the
hydraulic system by starting the engine. Then
check the oil level again.
• Air bleeding
Refer to the Air Bleeding of Various Parts sec-
tion in the TESTING AND ADJUSTING chap-
ter of this manual.

PC290-7 30-45
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND

SWING MACHINERY ASSEMBLY SWING MACHINERY
ASSEMBLY
SPECIAL TOOLS 3. No. 1 Sun gear
1) Remove No. 1 sun gear (2).
Part
Mark Part No. Necessity Qty Distinction* Sketch
Name
1 796-426-1120 Push tool ■ 1
Push tool
790-101-5401 ■ 1
kit
G
2 • 790-101-5471 • Plate 1
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
*Distinction between new and existing part.

DISASSEMBLY

1. Draining oil
Loosen the drain plug and drain oil from the
swing machinery case.
4. No. 1 carrier assembly
1) Disassemble No. 1 carrier assembly (3).
Swing machinery case: Approx. 6.6 l

2. Swing motor assembly

1) Place swing motor and swing machinery
assembly on block (1).
2) Remove the six mounting bolts to discon-
nect swing motor assembly (1).

Swing motor assembly: 70 kg

2) Disassemble the No. 1 carrier assembly in

the following manner.
Remove snap ring (4) first and then
remove shaft (5), gear (6), bearing (7),
thrust washer (8) and plate (9).

30-46 PC290-7
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY

5. Ring gear 7. Bolt

Remove the mounting bolts and remove ring Remove the holder mounting bolt (12).
gear (10).
8. No. 2 carrier assembly
1) Remove No. 1 carrier assembly (13).

6. No. 2 sun gear

Remove No. 2 sun gear (11).
2) Disassemble the No. 2 carrier assembly
by hand in the following manner.
i) Insert pin (14) and drive shaft (15) out
of carrier (16).
★ Pull out pin (14) after removing the
shaft.
ii) Remove thrust washer (17), gear (18),
bearing (19) and thrust washer (20).
iii) Remove plate (21).

PC290-7 30-47
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY

12

9. Shaft assembly ASSEMBLY

1) Set the shaft case assembly to a press, ★ Clean all related parts and check that there is
and push shaft assembly (22) out of shaft no dust or damage on the surface. Coat slid-
case assembly (23), using push tool . ing surfaces with engine oil and then assem-
ble the parts.

1. Bearing
1) Fill the hatched area (Part a) with grease
(G2-LI).
Injected grease amount:
Approx. 115 - 190 g
2) Press-fit bearing (24) into case (29), using
push tool G1.

2) Disassemble the shaft assembly in the fol-

lowing manner.
Detach bearing (24) and plate (25) from
shaft (26), using push tool d.

2. Oil seal
Press-fit oil seal (28), using tool G2.
Oil seal circumference:
Gasket sealant (LG-6)
★ When press-fitting, take care so that gas-
ket sealant (LG-6) will not stick to the lip
10. Bearing surface of the oil seal.
Take bearing (27) and oil seal (28) out of case
(29), using a push tool. Oil seal lip surface: Grease (G2-LI)

30-48 PC290-7
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY

3. Case assembly ii) Assemble bearing (19) in gear (18),

1) Set plate (25) onto shaft (26). then fit upper and lower thrust wash-
ers (17) and (20) to the gear and set
2) Set case assembly (23) onto shaft (26), the gear assembly to carrier (16).
and press-fit the bearing inner rail por-
tion, using push tool e.

iii) Align both pin holes of the shaft and

the gear, and install shaft (15), tapping
it with a plastic hammer.
4. Bearing ★ Install the shaft, rotating the planetary
Press-fit bearing (27), using tool f. gear. Take care so the thrust washer is
★ When press-fitting the bearing, press both not damaged.
inner and outer races of the bearing at the iv) Insert pin (14).
same time. Avoid pressing the inner race
only.
★ After the bearing is press-fitted, check
that the case will turn freely.

★ When inserting the pin, take care so

that any of the three pawls provided
on the circumference (Portion a) will
not come to the slender side of the
carrier (Portion b). Take note, how-
5. No. 2 carrier assembly ever, that the slender side is likely to
1) Reassemble the No. 2 carrier assembly in be on the opposite side of the carrier,
the following manner. depending on actual individual items.
Pay attention so that a pin pawl will
★ There are traces of expansion on the
not come to the slender side of the
end surface of carrier side hole h
carrier any way.
which were originally caused when
the pin was inserted. Make such the
end surfaces are smooth enough
before reassembly.
i) Assemble plate (21) in carrier (16).

PC290-7 30-49
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY

12

8. Ring gear
Fit an O-ring to case (29) and install ring gear
(10), using an eyebolt (M10 x 1.5).

★ Expand the pin of the carrier after

inserting.
2) Assemble No. 2 carrier assembly (13).

6. Bolt ★ Bring a counter mark on the ring gear

(Portion c) and a convex portion on the
Tighten bolt (12).
case flange (Portion d) to the positions
Mounting bolt thread: illustrated at right, and install the ring
Adhesive compound (LT-2) gear.

Mounting bolt:
157 - 196 Nm (16 - 20 kgm)

7. No. 2 sun gear

Install No. 2 sun gear (11).

★ Degrease the mating faces of ring gear

(10) and case (29)

30-50 PC290-7
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY

12

★ Never allow gasket sealant to stick to the 2) Install No. 1 carrier assembly (3).
mating faces of ring gear (10) and case
(29).

Ring gear mounting bolt:

157 - 196 Nm (16 - 20 kgm)

★ Do not install a washer.

9. No. 1 carrier assembly

1) Assemble the No. 1 carrier in the follow-
ing manner.
i) Press-fit shaft (5) into the carrier in the
direction of the arrow until the snap
ring groove can be seen.
ii) After installing snap ring (4), push it 10. No. 1 sun gear assembly
back from the opposite side until it Install No. 1 sun gear (2).
comes to contact p face on the carrier.
Take care not to push it back exces-
sively.

★ When installing the No. 1 sun gear, be

careful not to install it upside down.
★ Install the No. 1 sun gear with the tooth
iii) After installing plate (9), install thrust portion (Portion e) facing down.
washer (8), bearing (7), gear (6) and
snap ring (5).

PC290-7 30-51
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY

12

11. Swing motor assembly

After installing an O-ring to ring gear (10),
mount the swing motor assembly (1).

Swing motor assembly: 70 kg

★ Align the motor port position (Portion f)

and the case convex portion (Portion g) as
illustrated at right.

★ Degrease both mating surfaces of swing

motor assembly (1) and ring gear (10).
★ Never allow gasket sealant to stick to the
mating surfaces of swing motor assembly
(1) and ring gear (10).

Swing motor mounting bolt:

59 - 74 Nm (6 - 7.5 kgm)

12. Refilling hydraulic oil

Screw in the drain plug and refill hydraulic oil
through the oil filler port to the specified
level.

Swing machinery case: Approx. 6.6 l

30-52 PC290-7
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEM-

ASSEMBLY BLY
★ This section deals only with precautions to be
followed when reassembling the carrier roller
assembly.
SPECIAL TOOLS • Carrier roller
★ Check the amount of air leakage from the
Part seal with tool F by applying the standard
Mark Part No. Necessity Qty Distinction* Sketch
Name pressure to the oil filler port.
791-601-1000 Installer ■ 1 ★ Check that the gauge needle does not go
F
791-430-3230 Oil pump ■ 1 down, when the below standard pressure
*Distinction between new and existing part. is applied for 10 seconds.
Standard pressure: 0.1 MPa (1 kg/cm²)
ASSEMBLY

• Floating seal
★ Before installing a floating seal, com-
pletely degrease both contact surfaces of
the O-ring and the floating seal (hatched
area in the illustration). Furthermore, take
care so that no dust or dirt sticks to the
contact surface of the floating seal.
★ After inserting the floating seal, check that
the inclination of the seal is less than 1
mm and that protrusion a of the seal
remains within the range of 5 - 7 mm.

★ Fill the carrier roller assembly with oil,

using tool F, and screw in the plug.

Carrier roller: 145 - 155 cc (E030-CD)

PC290-7 30-53
DISASSEMBLY AND ASSEMBLY TRACK ROLLER ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEM-

ASSEMBLY BLY
★ This chapter deals only with precautions to be • Track roller cover mounting bolt.
followed when reassembling the Track Roller
Assembly. Track roller cover mounting bolt:
44.12 - 53.93 Nm (4.5 - 5.5 kgm)
SPECIAL TOOLS
• Track roller
Part
Mark Part No. Necessity Qty Distinction* Sketch ★ Using tool G, apply the specified air pres-
Name
796-670-1010 Installer ■ 1 sure to the oil filler port to check air leak-
G
791-601-1000 Oil Pump ■ 1
age from the seal.
*Distinction between new and existing part. ★ Keep applying the following specified air
pressure for 10 seconds to check that the
ASSEMBLY gauge needle does not go down.
Specified air pressure:
• Floating seal 0.1 MPa (1 kg/cm²)
★ Before installing a floating seal, com-
pletely degrease both contact surfaces of
the O-ring and the floating seal (hatched
area in the illustration). Furthermore, take
care so that no dust or dirt sticks to the
contact surface of the floating seal.
★ After inserting the floating seal, check that
inclination of the seal is less than 1 mm
and that protrusion a of the seal remains
within the range of 7 - 11 mm.

★ Fill the track roller assembly with hydrau-

lic oil. Use tool G and screw in the plug.

Track roller: 250 - 280 cc (E030-CD)

Plug: 10 - 20 Nm (1 - 2 kgm)

30-54 PC290-7
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY

SPECIAL TOOLS 3. Detach idler (4) from shaft (5) and support
assembly (7).
Part ★ The idler contains 230 ± 10 cc of oil. Drain
Mark Part No. Necessity Qty Distinction* Sketch
Name
the oil at this stage of disassembly. Take
796-570-1020 Installer ■ 1 care and spread a cloth on the floor to
H
791-601-1000 Oil pump ■ 1 prevent smearing the floor with flushing
*Distinction between new and existing part. oil.

DISASSEMBLY 4. Remove floating seal (6) on the opposite side

of idler (4), shaft (5) and support assembly (7).

5. Remove dowel pin (8) to detach support (7)

from shaft (5).

6. Remove bushings (9) and (10) from idler (4).

1. Remove dowel pin (1) and then support (2).

2. Remove floating seal (3) from support (2) and

idler (4).

PC290-7 30-55
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY

12
ASSEMBLY
★ Before installing the floating seal, com-
1. Press fit bushing (9) and (10) to idler (4). pletely degrease both contact surfaces of
the O-ring and the floating seal (hatched
2. Fit O-ring and install support (7) to shaft (5) area in the illustration). Furthermore, take
with dowel pin (8). care so that no dust or dirt sticks to the
contact surface of the floating seal.
★ After inserting the floating seal, check that
inclination of the seal is less than 1 mm
and that protrusion a of the seal remains
within the range of 5 - 7 mm.

★ Install the shaft with UP mark facing

upward.

3. Using tool H, install floating seal (6) to idler

(4), shaft (5) and support (7) assembly.

4. Assemble shaft (5) and support (7) assembly

to idler (4).

30-56 PC290-7
DISASSEMBLY AND ASSEMBLY IDLER ASSEMBLY

12

5. Using tool H, install floating seal (3) to idler 6. Install O-ring, then install support (2) with
(4) and support (2). dowel pin (1).

7. Add oil and tighten plug.

Oil: Approx. 230 ± 10 cc (EO 30-CD)

Plug: 130 - 180 Nm {13 - 18 kgm}

★ Coat the sliding surface of the floating seal

with oil, and be careful not to let any dirt or
dust get stuck to it.
★ Remove all grease and oil from the contact
surface of the O-ring and the floating seal.

PC290-7 30-57
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEM-

ASSEMBLY BLY
SPECIAL TOOLS

Mark Part No. Part Name Necessity Qty Distinction* Sketch 1. Remove piston assembly (2) from recoil
791-685-8006 Compressor ■ 1 spring assembly (1).
791-635-3160 Extension ■ 1
1 Cylinder 2. Disassembly of recoil spring assembly
790-101-1600 ■ 1
686 kN {70 T}
790-101-1102 Pump ■ 1
1) Set tool J1 to recoil spring assembly (1).
J
790-201-1500 Push tool kit ■ 1 The recoil spring is under large
• 790-201-1620 • Plate 1 installed load, so be very sure to set
2 the tool properly.
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1 Failure to do this is dangerous.
*Distinction between new and existing part.
★ Installed load of spring: 208.6 kN
{21,280 kg}
DISASSEMBLY

2) Apply hydraulic pressure slowly to com-

press the spring. Remove lock plate (3).
Then remove nut (4).
★ Compress the spring to a point where
the nut becomes loose.
★ Release the hydraulic pressure slowly
to decompress the spring.
★ Free length of spring: 814 mm
3) Remove yoke (6), cylinder (7), collar (8),
and dust seal (9) from spring (5).

3. Dissassembly of piston assembly

1) Remove lock plate (11) from piston (10),
then remove valve (12).
2) Remove snap ring (13), then remove U-
packing (14) and ring (15).

30-58 PC290-7
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY

12

ASSEMBLY 2. Assembly of recoil spring assembly

1) Using tool J2, install dust seal (9) to cylin-
der (7).

2) Assemble cylinder (7) collar (8), and yoke

(6) to spring (5), and place in tool J1.
Sliding portion of cylinder:
Grease (G2-L1)

1. Assembly of piston assembly

1) Assemble ring (15) and U-packing (14) to
piston (10) and secure with snap ring (13).
2) Tighten valve (12) temporarily, and
secure with lock plate (11).

3) Apply hydraulic pressure slowly to com-

press the spring and tighten nut (4) so
that the installed length of the spring is
dimension a, then secure it with lock plate
(3).
★ Installed length a of spring:
655 mm

PC290-7 30-59
DISASSEMBLY AND ASSEMBLY RECOIL SPRING ASSEMBLY

REMOVAL AND
INSTALLATION OF SPROCKET
REMOVAL

1. Remove track shoe assembly. For details, see

TRACK SHOE ASSEMBLY, REMOVAL.

2. Swing work equipment 90°, push up chassis

with work equipment and place block
between track frame and track shoe.
4) Remove recoil spring assembly (1) from
tool J1.

3. Assemble piston assembly (2) to recoil spring

assembly (1).
Sliding portion of wear ring:
Grease (G2-L1)
★ Install the piston assembly so the valve
installing position is on the outside.
★ Fill the inside of the cylinder with 180 cc
of grease (G2-L1), then bleed the air and
check that grease comes out of the grease
hole. 3. Remove mounting bolts and lift off sprocket
(1).

Sprocket: 65 kg

INSTALLATION
• Install in reverse order of removal.

Thread of sprocket mounting bolt:

Gasket sealant (LG-6)

Sprocket mounting bolt:

640 - 785 Nm {65 - 80 kgm}

30-60 PC290-7
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY

12

REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY

SPECIAL TOOLS

Mark Part No. Part Name Necessity Qty Distinction* Sketch

Remover
791-630-3000 & ■ 1
Installer
K
Cylinder
790-101-1300 ■ 1
980 kN {100 T}
790-101-1102 Pump ■ 1
*Distinction between new and existing part.

EXPANSION OF TRACK SHOE

1. Set master pin at the position for expanding.
★ Start the engine and bring the master pin 4. Pull out master pin (2).
in front of the idler.
★ Put block under the track shoe in front of
the idler.

2. Lower the work equipment, then loosen lubri-

cator (1), and relieve track tension.

The adjustment cylinder is under extremely

high pressure. Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine backwards
and forwards.

5. Travel machine backward to expand track

shoe.

3. Disassemble track shoe (3) above master pin

(2).

PC290-7 30-61
DISASSEMBLY AND ASSEMBLY TRACK SHOE ASSEMBLY

12
ASSEMBLY

• Assemble in reverse order of expansion.

★ Refer to the Inspection and Adjustment of

Track Shoe Tension section in the TEST-
ING AND ADJUSTING chapter of this
manual.

Mounting bolt:
Anti-seizure compound
(equivalent to Maruzen Molymax No. 2)

Mounting bolt: 393 ± 39 Nm

(40 ± 4 kgm)

★ Press-fit the master pin with a proper tool

until dimension a, master pin protrusion
amount, is obtained.
Master pin protrusion amount a:
4.2 ± 2 mm

30-62 PC290-7
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY

12
REMOVAL AND INSTALLATION OF SWING CIRCLE
ASSEMBLY
REMOVAL INSTALLATION

1. Remove revolving frame assembly. Refer to • Install in reverse order of removal.

the Removal and Installation of Revolving
Frame Assembly section in this manual.
Thread of swing circle mounting bolt:
2. Sling swing circle assembly (1) at three Thread tightener (LT-2)
points. Remove the mounting bolts and lift off
the swing circle assembly. Swing circle mounting bolt:
926.7 ± 103 Nm (94.5 ± 10.5 kgm)
★ Install the inner race to the track frame
with the S mark of its inner soft zone spot
Swing circle assembly: 500 kg
facing the right side of machine as shown
in the figure below.
Grease bath fill:
Grease (G2-L1) 33 l

PC290-7 30-63
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY

REMOVAL AND INSTALLATION OF REVOLVING FRAME

ASSEMBLY ASSEMBLY
REMOVAL

. Extend the arm and bucket fully, then lower

the work equipment to the ground and move
the safety lock lever to the LOCK position.

1. Disassemble the work equipment assembly,

refer to the Disassembling Work Equipment
Assembly section in this manual.

2. Remove the counter weight assembly, refer

to the Removal of Counterweight Assembly
section in this manual.
6. Remove plate (5), air intake hose (6) and fan
3. Disconnect four boom cylinder hoses (1). guard (7).
★ Plug the hose to stop oil flow-out.
★ Remove other parts which may interfere
with a sling, when removing the revolving
frame.

4. Sling boom cylinder assembly (2).

7. Disconnect the six hoses above the swivel

joint assembly at the swivel joint side.
(8): Center swivel joint (D port) -
Swing motor (T port)
(9): Center swivel joint (E port) -
Solenoid valve
(10): Center swivel joint (B port) -
Travel control valve, left (A2 port)
(11): Center swivel joint (D port) -
Travel control valve, right (B5 port)
(12): Center swivel joint (A port) -
Travel control valve, left (B2 port)
5. Remove plate (3) and pin (4) and lift off boom
(13): Center swivel joint (C port) -
cylinder assembly (2) to remove it.
Travel control valve, right (A5 port)
★ Remove the boom cylinder assembly on
the opposite side in the same manner.

Boom cylinder assembly: 180 kg

30-64 PC290-7
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY

12

8. Pull out pin (14) to detach jam plate (15) from INSTALLATION
the swivel joint.
• Install in reverse order of removal.

Air intake hose clamp screw:

5.4 - 6.4 Nm (0.55 - 0.65 kgm)

Swivel circle mating surface:

Gasket sealant (LG-1)
Threads of revolving frame mounting
bolt: Adhesive compound (LT-2)

Revolving frame mounting bolt

9. Remove the 32 revolving frame mounting
1st step: 294.2 ± 29.4 Nm (30 ± 3 kgm)
bolts and remove revolving frame assembly
2nd step: Retightening by 60° or
(16) by lifting it off.
588 - 677 Nm (60 - 69 kgm)
★ Attain fore and aft balance and right and
left balance of the revolving frame assem- • Refilling hydraulic oil
bly without two mounting bolts at the Refill hydraulic oil through the oil filler port to
front and rear being removed and using a the specified level, and let the oil circulate in
lever block. Only when the right balance the hydraulic system by starting the engine.
is obtained, remove the remaining two Then check the level again.
bolts. • Air bleeding
Bleed air from the travel motor, refer to the
When removing the revolving frame Air Bleeding of Various Parts section in the
assembly, take care so that it does not TESTING AND ADJUSTING chapter of this
hit the swivel joint assembly. manual.

Revolving frame assembly

Revolving frame only

Assembly
(Reference value)

PC200-7 5,050 kg 1,729 kg

PC290-7 30-65
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT ASSEMBLY

12

REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT

ASSEMBLY ASSEMBLY
REMOVAL • (10): Center swivel joint (E port) -
Solenoid valve
Release the remaining pressure in the • (11): Center swivel joint (B port) -
hydraulic circuit. For details, see TESTING Travel control valve, left (A2 port)
AND ADJUSTING, release of remaining • (12): Center swivel joint (D port) -
pressure in hydraulic circuit. Travel control valve, right (B5
port)
★ Mark all the piping with tags to prevent mis-
• (13): Center swivel joint (A port) -
takes in the mounting position when install-
Travel control valve, left (B2 port)
ing.
• (14): Center swivel joint (C port) -
1. Disconnect six hoses (1) through (6) from the Travel control valve, right (A5 port)
travel motor center swivel joint.
3. Pull out pin (15) on the side of center swivel
• (1): Center swivel joint (T port) -
joint and remove the jam plate from the cen-
Travel motor, left (T port)
ter swivel joint.
• (2): Center swivel joint (T port) -
Travel motor, right (T port)
• (3): Center swivel joint (B port) -
Travel motor, left (PA port)
• (4): Center swivel joint (D port) -
Travel motor, right (PB port)
• (5): Center swivel joint (A port) -
Travel motor, left (PB port)
• (6): Center swivel joint (C port) -
Travel motor, right (PA port)

4. Remove four mounting bolts (16).

2. Disconnect eight hoses (7) through (14).

• (7): Center swivel joint (E port) -
Travel motor, left (P port)
• (8): Center swivel joint (E port) -
Travel motor, right (P port)
• (9): Center swivel joint (D port) -
Swing motor (T port)

30-66 PC290-7
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT ASSEMBLY

12

5. Remove center swivel joint assembly (17).

Center swivel joint assembly: 40 kg

INSTALLATION

• Install in reverse order of removal.

Install the center swivel joint facing in the

direction shown in the diagram.
(The diagram shows the machine as seen
from above)

• Refilling with oil (hydraulic tank)

★ Add oil through the oil filter to the speci-
fied level. Run the engine to circulate the
oil through the system. Then check the oil
level again.
• Bleeding air
★ Bleed the air from the travel motor. For
details see TESTING AND ADJUSTING,
Air Bleeding of Various Parts.

PC290-7 30-67
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 3. Using tool E. pull out swivel rotor (4) and ring
(3) from swivel shaft (5).
Mark Part No. Part Name Necessity Qty Distinction* Sketch

790-101-2501 Push puller

●
1
4. Remove seal (6) from swivel shaft (5).

• 790-101-2510 • Block 1 5. Remove O-ring (7) and slipper seal (8) from
• 790-101-2520 • Screw 1 swivel rotor (4).
• 791-112-1180 • Nut 1
E
• 790-101-2540 • Washer 1
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
*Distinction between new and existing part.

DISASSEMBLY

ASSEMBLY

1. Assemble slipper seal (8) and O-ring (7) to

swivel rotor (4).

2. Assemble seal (6) in swivel shaft (5).

3. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic ham-
mer to install.
Contact surface of rotor, shaft:
Grease (G2-L1)
★ When installing the rotor, be extremely
careful not to damage the slipper seal and
the O-ring.

4. Install ring (3) and secure with snap ring (2).

5. Fit O-ring and install cover (1).

Mounting bolt: 31.4 ± 2.9 Nm

{3.2 ± 0.3 kgm)
1. Remove cover (1).

2. Remove snap ring (2).

30-68 PC290-7
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY

12

REMOVAL AND INSTALLATION OF HYDRAULIC TANK

ASSEMBLY ASSEMBLY
REMOVAL 6. Remove hydraulic tank side cover (8).
★ Remove two cover (8) mounting bolts at
1. Drain oil from hydraulic tank the front after removing cover (9) and
(10).

Hydraulic oil: 240 l

2. Open up the engine hood.

3. Remove engine hood (1), hydraulic pump

upper cover (2) and control valve cover (3).

4. Remove cover mounting frame (4) and

engine partition plate (5).

7. Disconnect the seven hoses.

• (11): Hydraulic oil return hose
• (12): Swing motor drain hose
• (13): Pump drain hose
• (14): PPC drain hose
• (15): Solenoid valve drain hose
• (16): Main valve drain hose
• (17): Pump suction hose
★ Disconnect suction hose (17) after discon-
5. Remove engine partition plate (6) and parti- necting the sump suction tube.
tion bracket mounting bolts (7) on the hydrau- ★ Attach a tag to the hoses for identifica-
lic tank side. tion.
★ Protect the fitting and the tapered seal
portion of the elbow with a sleeve nut so
that they may not be damaged.

8. Remove hose clamp (18).

PC290-7 30-69
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY

12

9. Sling the hydraulic tank assembly and

remove six mounting bolts (19).

★ Install the hose clamp and tighten the

clamp screw as shown in the diagram
below.
10. Lift off hydraulic tank assembly (20) to
remove it.

Hydraulic tank assembly: 130 kg

Hose clamp screw:

245.2 - 308.9 Nm
{25 - 31.5 kgm}

INSTALLATION • Refilling with oil (hydraulic tank)

★ Add oil through the oil filler to the speci-
• Install in reverse order of removal. fied level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
Hydraulic tank drain plug:
58.8 - 78.5 Nm Hydraulic tank: Approx. 240 l
{6.0 - 8.0 kgm}
• Bleeding air
★ Bleed the air.
★ After tightening the suction hose clamp For details, see TESTING AND ADJUST-
screw, check that the screw is located ING. Air Bleeding of Various Parts.
within the range shown in the diagram.

Hose clamp screw:

8.8 ± 0.5 Nm {90 ± 5 kgm}

30-70 PC290-7
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY

12

REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEM-

ASSEMBLY BLY
REMOVAL • (9): Swing LS separator valve hose
• (10): Left swing hose (Hose band, red)
Lower the work equipment to the ground for
• (11): Travel right front and reverse hose
safety and stop the engine. Unscrew the oil
(Hose band, blue)
filler cap on the hydraulic tank slowly to
release pressure inside the tank. Then move • (12): Arm dump hose (Hose band, yellow)
the safety lock lever to the LOCK position.

★ Attach an identification tag to each piping to

avoid a mistake in the position of installation
later.

1. Open up engine hood (1).

2. Remove control valve upper cover (2).

5. Disconnect the seven PPC hoses at right.

• (13): PPC hoses from the top to bottom
Bucket digging (Hose band, white)
Travel left front and reverse
(Hose band, red)
Boom lower (Hose band, brown)
Right swing
Travel right front (Hose band, green)
Arm digging (Hose band, blue)
3. Remove engine partition cover (3) and control • (14): Divide/merge valve hose (Hose
valve partition cover (4). band, yellow blue)

4. Disconnect the eight PPC hoses at left.

• (5): Relief valve hose
• (6): Bucket dump hose (Hose band, black)
• (7): Travel left front and reverse hose
• (8): Boom raise hose (Hose band, green)

PC290-7 30-71
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY

12

6. Disconnect four boom hoses (15). • (21): From top to bottom

B1 port hose (Bucket bottom side)
7. Remove boom tube mounting clamps (16) B2 port hose (Swivel joint A port)
and (17). B3 port tube (Boom head side)
B4 port hose (Swing motor MB port)
B5 port hose (Swivel joint B port)
B6 port hose (Arm bottom side)
• (22): Drain hose (TS port)

9. Disconnect hose (23) between the control

valve and the swing motor as well as hose
(24) between the control valve and the sole-
noid.

8. Disconnect the 13 control valve hoses and

two tubes.
• (18): PLS1 Hose
• (19): PLS2 hose (hose band, red)
• (20): From top to bottom
A1 Port hose (Bucket head side)
A2 Port hose (Swivel joint B port)
A3 port tube (Boom bottom side)
A4 port hose (Swing motor MA port)
A5 port hose (Swivel joint C port)
A6 port hose (Arm head side)

30-72 PC290-7
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY

12

10. Disconnect the seven hoses.

• (25): PP1 port hose (Rear pump) (Hose
band, yellow)
• (26): PP2 port hose (Front pump)
• (27): PEPC port hose (Pump)
• (28): P1 port hose (Solenoid)
• (29): PPS2 port hose (Front pump)
• (30): PST port hose (Solenoid) (Hose
band, brown)
• (31): T port hose (Oil cooler)

12. Remove the three mounting bolts for control

valve assembly (34) and lift it off for removal.

Control Valve Assembly: 220 kg

11. Disconnect the control valve wiring connec-

tors at two points.
• (32): CAN-A51 (Front pump pressure sen-
sor)

INSTALLATION

• Install in reverse order of removal.

• Refilling with oil (hydraulic tank)
★ Add oil through the oil filler to the speci-
fied level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
• Bleeding air
• (33): CN-A52 (Rear pump pressure sensor) ★ Bleed the air from the circuit between the
valve and the hydraulic cylinder.
For details, see TESTING AND ADJUST-
ING, Air Bleeding of Various Parts.

PC290-7 30-73
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEM-

ASSEMBLY BLY
★ This chapter deals with only precautions to be Procedures for replacing pressure compensation
followed when disassembling and reassem- valve seal
bling the control valve assembly.
1. Remove the seal from pressure compensa-
SPECIAL TOOLS tion valve.
★ Clean the pressure compensation valve
Distinc- thoroughly, and then assemble the seal,
Mark Part No. Part Name Necessity Qty Sketch
tion*
using a tool, as indicated in the diagram.
796-946-1310 Guide
1
(For 723-46-40100)
2. Fit an O-ring to piston (1).
796-946-1610 Guide
1
(For 723-46-41100)
3. Set tool P1 to piston (1) and push it in slowly
796-946-1810 Guide
1 1 by hand so that seal (2) may spread out
(For 723-46-43100 & 723-46-43400)
evenly.
796-946-2210 Guide
1 ★ The seal may be also fitted by pushing it
(For 723-46-45100)
down to the flat surface of the tool and
796-946-1910 Guide
1 then pushing it in with the tool fitted to
(For 723-46-46101 & 723-46-46300)
the piston.
796-946-1320 Guide
1
(For 723-46-40100)
796-946-1620 Guide
1
(For 723-46-41100)
796-946-1520 Guide
1
(For 723-46-42700)
2
796-946-1820 Guide
P 1
(For 723-46-43100 & 723-46-43400)
796-946-2220 Guide
1
(For 723-46-45100)
796-946-1920 Guide
1
(For 723-46-46101 & 723-46-46300)
796-946-1330 Sleeve
1
(For 723-46-40100)
796-946-1630 Sleeve
1 4. Likewise, set tool P2 to piston (1) in the same
(For 723-46-41100)
796-946-1430 Sleeve direction and push it slowly by hand so that
1 another seal (3) may be spread out evenly.
(For 723-46-42700)
3
796-946-1830 Sleeve ★ The seal may be also fitted by pushing it
1
(For 723-46-43100 & 723-46-43400) down to the flat surface of the tool and
796-946-2230 Sleeve then pushing it in with the tool fitted to
1
(For 723-46-45100) the piston.
796-946-1930 Sleeve
1
(For 723-46-46101 & 723-46-46300)
*Distinction between new and existing part.

30-74 PC290-7
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY

12

5. Keep compensation tool P3 fitted to piston (1) ASSEMBLY

for about one minute so that seal (2) and (3) • Coat the sliding surface with engine oil and
will become well adapted. then reassemble the control valve assembly.
★ Check that there is no protrusion or cut on • Upper and lower control valve covers
the seal.
Mating surfaces of upper and lower
control covers:
Sealant 242 or equivalent
• Tighten the mounting bolts for the upper and
lower control covers in the sequence illus-
trated at right.

Mounting bolt for upper and lower

control covers:
156.9 - 176.5 Nm (16 - 18 kgm)

6. Assemble the piston in the sleeve.

★ If its found difficult to install the sleeve,
do not attempt to push it in forcibly, but
try it again after repeating the same pro-
cess in the Item 5. above and confirming
the seals are well adapted.
★ After the installation, push the piston by
hand and check that the piston reacts only
with spring force.

• Merge-divider valve
Mating surfaces of merge-divider
valve: Sealant 242 or equivalent
• Tighten the mounting bolts for the merge-
divider valve in the same sequence as that for
the control valve cover mounting bolts.

Merge-divider valve mounting bolt:

156.9 - 176.5 Nm (16 - 18 kgm)

• A filter for the valve assembly is to be assem-

bled in the direction shown in the illustration
at right.

PC290-7 30-75
DISASSEMBLY AND ASSEMBLY CONTROL VALVE ASSEMBLY

12

• Tighten the boom lock valve mounting bolts

and the back pressure valve mounting bolts
in the same sequence as that for the control
valve cover mounting bolts.

Mounting bolts for boom lock valve

and back pressure valve:
58.8 - 73.6 Nm (6 - 7 kgm)

• Pressure compensation valve

★ Install each pressure compensation valve,
paying attention to the counter mark that
was put when removing it.
• Main relief valve assembly
After assembling the main relief valve assem-
bly in the control valve, refer to the section of
Inspection and Adjustment of Hydraulic Oil
Pressure in Hydraulic Circuit for Work Equip-
ment, Swing and Travel in the chapter, TEST-
ING AND ADJUSTING, in this manual.

30-76 PC290-7
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY

12

REMOVAL AND INSTALLATION OF HYDRAULIC PUMP

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 3. Sling engine hood (1).

Mark Part No. Part Name Necessity Qty Distinction* Sketch

D 796-460-1210 Oil stopper ■ 1

*Distinction between new and existing part.

REMOVAL

Disconnect the negative terminal (-) of the

battery before starting with the work.
Lower the work equipment to the ground
and stop the engine. Then loosen the oil
filler cap on the hydraulic tank slowly to
release pressure inside the tank.

★ Attach identification tags to all piping to avoid 4. Remove pin (2) and mounting bolt (3). Then
mistakes when installing. lift off the engine hood to remove it.

1. Remove hydraulic tank strainer and stop oil

flow-out using tool D.
★ If tool D is not used, remove the drain
plug and drain oil from the hydraulic tank
and piping.

Hydraulic tank: Approx. 240 l

5. Remove cover (3) and plate (4).

2. Drain oil from the damper case.

PC290-7 30-77
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY

12

6. Remove covers (5) and (6). 9. Disconnect the following connectors at three
points.
7. Disconnect the following eight hoses. • (16): A61 (Hydraulic oil temperature sen-
sor) (Color band, white)
• (7): Front pump discharging port hose
• (17): V21 (PC-EPC solenoid valve)
• (8): Rear pump discharging port hose
(Color band, white)
• (9): Pump pressure input port hose
• (18): V22 (LS-EPC solenoid valve)
• (10): Drain port hose (Color band, red)
• (11): EPC source pressure port hose
(Color band, yellow) 10. Disconnect exhaust muffler drain tube (19).
• (12): Load pressure input port hose
(Color band, red)
• (13): Load pressure input port hose
• (14): Suction port hose

11. Lift off hydraulic pump assembly (20) to

remove it.

Hydraulic pump assembly: 170 kg

8. Remove clamp (15).

30-78 PC290-7
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY

12
INSTALLATION
• Refilling hydraulic oil (Damper case)
• Install in reverse order of removal. Refill hydraulic oil through the oil filler port to
the specified level.

★ After tightening the hose clamp screw,

Damper hydraulic oil : Approx. 0.75 l
check that the screw is in the position
shown in the diagram at right.
• Refilling hydraulic oil (hydraulic tank)
Suction hose clamp screw: Refill hydraulic oil through the oil filler port to
8.8 ± 0.5 Nm (90 ± 5 kgm) the specified level, and let the oil circulate in
the hydraulic system by starting the engine.
Then check the oil level again.

Hydraulic tank : Approx. 240 l

• Air bleeding
Refer to the Air Bleeding of Various Parts sec-
tion in the TESTING AND ADJUSTING chap-
ter in this manual.

★ Install the hose clamp and tighten the

clamp screw as shown in the diagram
below.

Hydraulic pump involute spline:

Anti-friction compound (LM-G)
Hydraulic pump case mating surface:
Gasket sealant (LG-6)

PC290-7 30-79
DISASSEMBLY AND ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT

12

REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC

PUMP INPUT SHAFT PUMP INPUT SHAFT
SPECIAL TOOLS INSTALLATION

Mark Part No. Part Name Necessity Qty Distinction* Sketch • Install in reverse order of removal.
791-463-1141 Push tool ■ 1
N
790-201-2740 Spacer ■ 1

*Distinction between new and existing part. Oil seal lip portion: Grease (G2-LI)

REMOVAL Oil seal outer circumference:

Grease (G2-LI)
1. Remove the hydraulic pump assembly, refer-
★ Coat the oil seal outer circumference
ring to the section of Removing Hydraulic
thinly with grease.
Pump Assembly.
★ Press-fit oil seal (3), using tool N.
2. Remove snap ring (1) and then remove
spacer (2).

3. Pry off oil seal (3) with a screwdriver.

★ When attempting to pry off the seal, do

not damage the shaft.

30-80 PC290-7
 DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VALVE ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC

VALVE ASSEMBLY VALVE ASSEMBLY
★ This section deals with only precautions to be ★ When assembling piston (8), coat the piston
followed when reassembling the PPC valve outer periphery and body hole inner periph-
assembly for work equipment. ery with grease.

Plate (5) mounting bolt:

11.8 - 14.7 Nm (1.2 -1.5 kgm)

Joint (4) sliding surface:

Grease 2 - 4 cc (G2-LI)
Body female screw portion:
Adhesive compound (LT-2)
★ Coat the female screw body with Loctite at
two spots as shown in the diagram below.
Each spot is to be coated with a drop (approx.
0.02 g).

Joint (4): 39 - 49 Nm (4 - 5 kgm)

★ Strictly follow the specified torque for the

joint.

ASSEMBLY

• Reassembling work equipment PPC valve

reassembly
★ Install spring (11) so that the end surface
of smaller end coil diameter (inner diame-
ter) will face the shim (12) side. Contact surfaces of piston and disc (2):
★ Springs (10) in use differ in the number of Grease 0.3 - 0.8 cc (G2-LI)
turns according to hydraulic ports as clas-
sified in the table below. Hence take care Nut (1): 98 - 127 Nm (10 - 13 kgm)
when installing one.
★ After assembling the disc, refer to the Adjust-
Port location Spring free length ment of Work Equipment and Swing PPC
P1, P2 44.4 mm Valve section of the TESTING AND ADJUST-
ING chapter of this manual.
P3, P4 42.4 mm
★ The location of each port is stamped in
the lower part of the valve body.

Piston (8): Grease (G2-LI)

PC290-7 30-81
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE

ASSEMBLY ASSEMBLY
★ This chapter deals with only precautions to be ASSEMBLY
followed when reassembling the travel PPC
valve assembly. • Travel PPC valve assembly
★ Before fitting a shim, check its required
number and thickness, then fit it to the
same position as confirmed when remov-
ing it.
Thickness of standard shim: 0.3 mm
★ The spring is symmetrical between the
upper and lower sides, so fit it with the
side of smaller end coil diameter (inner
diameter) facing the shim side.
Piston outer periphery and body
hole inner periphery:
Grease (G2-LI)
Shaft sliding portion and connect-
ing portion of piston and lever:
Grease (G2-LI)

30-82 PC290-7
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY

12

DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 3) Pull out piston rod assembly (2).
★ Place a container under the cylinder to
Distinc- catch the oil.
Mark Part No. Part Name Necessity Qty Sketch
tion*
Cylinder repair
790-502-1003
stand
● 1
1
790-101-1102 Pump ●
790-102-4300 Wrench Assembly ■ 1
2
790-102-4310 Pin ■ 2

3 790-720-1000 Expander ● 1
Rubber Band
796-720-1670
(for boom and arm)
● 1

07281-01279 Clamp ● 1
4
Rubber band
796-720-1660
(for bucket)
● 1

07281-01159 Clamp ● 1

790-201-1702 Push tool kit ■ 1

Push tool 4) Disassemble piston rod assembly as fol-
• 790-201-1830 1
(for bucket) lows.
Q
• 790-201-1930
Push tool
11 i) Set piston rod assembly (2) in tool Q1.
5 (for arm)
Push tool
• 790-201-1940 1
(for boom)
• 790-101-5021 Grip 1

• 01010-50816 Bolt 1
Push tool kit
790-201-1500
(for bucket)
● 1

• 790-201-1640 Push tool 1

• 790-101-5021 Grip 1

• 01010-50816 bolt 1
6
790-201-1980 Plate (for boom) ● 1

790-201-1990 Plate (for arm) ● 1

790-101-5021 Grip ● 1

01010-50816 Bolt ● 1
ii) Remove stopper screw (3) of piston
*Distinction between new and existing part. assembly.
★ Common screw size for boom,
DISASSEMBLY
arm, and bucket cylinder: M12 x Pitch
1.75.
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts and disconnect
head assembly (1).

PC290-7 30-83
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY

12

★ If the caulking of screw (3) is too

strong and it cannot be removed,
tighten the screw fully, then fit a tap to
the thread and remove the screw.

vii) Remove cap (8), and pull 12 balls (9),

then remove plunger (10).
• Arm cylinder only

iii) Using tool Q2, remove piston assem-

bly (4).
• When not using tool Q2, use the
drill holes (∅ 10, 4 places) and loosen
the piston assembly.

2. Disassembly of piston assembly

1) Remove rings (11).
2) Remove wear rings (12).
3) Remove piston ring (13).

iv) Remove plunger (5). 4) Remove O-ring and backup ring (14).
• Boom and arm cylinder only
v) Remove collar (6).
• Boom and arm cylinder only
vi) Remove head assembly (7).

30-84 PC290-7
 DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY

12

3. Disassembly of cylinder head assembly 4) Using tool Q6, install dust seal (17), and
1) Remove O-ring and backup ring (15). secure with snap ring (16).
2) Remove snap ring (16), then remove dust 5) Install backup ring and O-ring (15).
seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove busing (20).

2. Assembly of piston assembly

1) Using tool Q3, expand piston ring (13).
★ Set the piston ring on tool Q3, and
turn the handle 8 - 10 times to expand
ASSEMBLY the ring.
2) Set tool Q4 in position, and compress pis-
★ Be careful not to damage the packing, dust
ton ring (13).
seals, and O-rings.
★ Clean each part, then cover the piping ports
and pin-inserting hole to prevent dust from
entering them.
★ Do not try to force the backup ring into posi-
tion.
Warm it in warm water (50 - 60°C) before
installing it.

1. Assembly of head assembly

1) Using tool Q5, press fit bushing (20).
2) Assemble buffer ring (19).
3) Assemble rod packing (18).

PC290-7 30-85
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY

12
3) Install backup ring and O-ring (14). 2) Assemble head assembly (7).
4) Assemble wear ring (12). 3) Fit O-ring and backup ring to collar (6),
5) Assemble ring (11). then assemble.
★ Be careful not to open the end gap of • Boom and arm cylinder only
the ring too wide. 4) Assemble plunger (5).
• Boom and arm cylinder only
Ring grove: Grease (G2-L1)

5) Set cushion plunger (10) to piston rod,

then assemble 12 balls (9) and secure
with cap (8).
3. Piston rod assembly
★ Check that there is a small amount of
1) Set piston rod assembly (2) to tool Q1. play at the tip of the plunger.
• Arm cylinder only

30-86 PC290-7
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY

12
6) Assemble piston assembly (4) as follows. • When using a new part for either or both of
• When using rod piston (2) again: rod piston assembly (2)
★ Wash thoroughly and remove all ★ For the rod with bottom cushion, mark the
metal particles and dirt. cushion plug position on the end of the
rod.
i) Screw in piston assembly (4), then
use tool Q2 to tighten piston • Arm cylinder only
assembly (2) so the position of the i) Screw in until piston assembly (4) con-
screw thread hole matches tacts end face of rod, then use tool to
✭ Remove all burrs and flashes tighten.
with a file.
Piston assembly: 294 ± 29.4 Nm
{30 ± 3.0 kgm)

★ After tightening the piston, check that

there is play in plunger (5).
• Boom, arm cylinder only

ii) Tighten screw (3).

Screw thread: Loctite No.
262

Screw: 58.9 - 73.6 Nm

{6 - 7.5 kgm}
ii) Machine one of the holes used to install
iii) Caulk thread at 2 places with screw (3).
punch. ★ Align a drill horizontal with the V-
groove of the thread of rod (2) and
piston (4), then carry out machining.
★ For the cylinder with bottom cushion
(arm cylinder), avoid the cushion plug
position when machining.
• Screw machining dimension (mm)
Drill Bottom
Tap used Tap depth
diameter hole depth

10.3 27 12 x 1.75 20

PC290-7 30-87
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER ASSEMBLY

12
iii) After machining, wash thoroughly to 7) Assemble piston rod assembly (2).
remove all metal particles and dust. ★ Set the end gap of the ring horizontally (at
the side position), align axial center of cyl-
inder tube, then insert.
★ After inserting, check that the ring is not
broken and has not come out, then push
in fully.

iv) Tighten screw (3).

Screw: 58.9 - 73.6 Nm {6 - 7 kgm}

v) Caulk thread at 4 places with punch.

8) Tighten head assembly (1) with mounting

bolts.

Mounting bolt:

Cylinder Tightening torque

Bucket 270 ± 39 Nm {27.5 ± 4.0 kgm}

Arm 373 ± 54 Nm {38.0 ± 5.5 kgm}

Boom 270 ± 39 Nm {27.5 ± 4.0 kgm}

9) Install piping.

30-88 PC290-7
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY

12

REMOVAL AND INSTALLATION OF WORK EQUIPMENT

ASSEMBLY ASSEMBLY
SPECIAL TOOLS ★ Remove the boom cylinder on the other
side in the same manner.
Distinc-
Mark Part No. Part Name Necessity Qty Sketch
tion* 5. Disconnect bucket cylinder hoses (6) and arm
796-900-1200 Remover ■ 1 cylinder hoses (7), two for each.
790-101-4000
Puller
■ 1 ★ Plug the hoses to prevent oil flow-out,
R (490 kN 50-T-long)
and fasten them on the valve side.
Pump
790-101-1102
(294 kN 30 T) ■ 1

*Distinction between new and existing part. 6. Disconnect intermediate connector CN-A42
(8) for a working lamp.
REMOVAL
Extend the arm and bucket fully. Lower the
work equipment to the ground and set the
safety lock lever to the lock position.
Release the residual pressure in the hydrau-
lic circuit. Refer to the Release of Remaining
Pressure in Hydraulic Circuit section in the
TESTING AND ADJUSTING chapter of this
manual.

1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (2), and

remove lock bolt (3). 7. Lift off the work equipment and remove plate
(9) and then pin (10) at the foot.
3. Remove plate (4), then remove head pin (5).

★ There are shims installed, so check the

number and thickness, and keep them in a
safe place.

• When removing them, first remove plate

(9) and then remove pin (10) at the foot,
using Tool R.
★ Shims are installed, so do not forget to
check their number and each location of
installation.
4. Start the engine and retract the piston rod.
★ Fasten the piston rod with wire so that it
will not slip out and lower the cylinder
onto a stand, or place a support under the
bottom of the cylinder to support it. In the
latter case, remove the grease fitting on
the bottom side first.

PC290-7 30-89
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY

12
INSTALLATION

• Install in reverse order of removal.

★ When tightening the locknut, tighten so

that clearance a between the plate and
nut is 0.5 - 1.5 mm.

8. Lift off work equipment assembly (11) and

disassemble it.

Work equipment assembly:

3,300 kg

Inside surface of bushing when

assembling pin:
Anti-friction compound (LM-P)
Grease after assembling pin:
Grease (LM-G)

When aligning the position of the pin

hole, never insert your fingers into the
pin hole.

★ Adjust the shim thickness so that clear-

ance a between cylinder rod (12) and
plate (4) is below 1 mm.
★ Standard shim thickness: 1.0 mm and
2.0 mm.

30-90 PC290-7
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY

12

Inside surface of bushing when

assembling pin:
Anti-friction compound (LM-P)
Grease after assembling pin:
Grease (LM-G)

When aligning the position of the pin

hole, never insert your fingers into the
pin hole.

• Bleeding air
★ Bleed the air from the cylinder. For
details, see TESTING AND ADJUSTING,
Air Bleeding of Various Parts.
• Refilling with oil (hydraulic tank)
★ Add oil through the oil filler to the speci-
fied level. Run the engine to circulate the
oil through the system. Then check the oil
level again.

PC290-7 30-91
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY

12

REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT

ASSEMBLY ASSEMBLY
SPECIAL TOOLS 4. Pull down outside air filter cover opening-
closing lever (2).
Distinc-
Mark Part No. Part Name Necessity Qty Sketch
tion*
799-703-1200 Service tool kit ■ 1
Vacuum Pump
799-703-1100
(100 V)
■ 1

Vacuum Pump
S 799-703-1110
(220 V) ■ 1

Vacuum Pump
799-703-1120
(240 V)
■ 1

799-703-1400 Gas leak tester ■ 1

*Distinction between new and existing part.

REMOVAL
First, disconnect the cable from the nega-
tive terminal (- ) of the battery.
5. Remove outside air filter (3).
1. Drain cooling water.

Cooling water: Approx. 22.8 l

2. Bleed gas from the air conditioner, using tool

S.

6. Remove monitor panel lower covers (4) and

(5).
★ When removing cover (4), first remove
the M19 wiring for cigarette lighter.

3. Remove floor mat (1).

30-92 PC290-7
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY

12

7. Remove duct (6) on the right side. 12. Remove cover (15).

8. Remove rear covers (7), (8) and (9). 13. Disconnect cab intermediate connectors (18)
at the following two points.
• H09: Upper side
• H08: Lower side

14. Disconnect radio antenna (19).

15. Remove plate (20) and then remove cover

(21).

9. Remove rear duct (10).

10. Remove plate (11) and then remove duct (12).

11. Remove plate (13) and right duct (14).

PC290-7 30-93
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT ASSEMBLY

12

16. Remove duct (22).

17. Disconnect connectors at the following seven

points.
• (23): D01
(Assembled-type diode connector)
• (24): D02
(Assembled-type diode connector)
• (25): C09 (Model selection switch connec-
tor)
• (26): Air conditioner unit connector
From top to bottom, M26, M27, M28
and M33 option power source con-
nector
INSTALLATION
18. Remove the mounting clamp and disconnect
air conditioner wiring connector (27). • Install in reverse order of removal.
★ Install hoses in the air conditioner circuit with
19. Remove the four mounting bolts and remove care so that dirt, dust, water, etc. may not
governor pump control assembly (28). enter them.
★ Put the governor pump control assembly ★ Install air conditioner hoses only after check-
aside. ing that an O-ring is in place at the connecting
part.
20. Remove cover (29). ★ Check that there is no damage on O-rings, or
that they have not deteriorated.

★ Coat the threads of the refrigerant piping

at the connecting part with compressor
oil (ND-OIL8), and then tighten the piping
with a double-ended spanner.

Hose clamp screw:

8.83 - 14.7 Nm (0.9 - 1.5 kgm)

Hose screw M16 x 1.5:

11.8 - 14.7 Nm (1.2 - 1.5 kgm)

21. Disconnect air conditioner hoses (30) and (31) Hose screw M24 x 1.5:
as well as air conditioner tubes (32) and (33). 29.4 - 34.3 Nm (3.0 - 3.5 kgm)

22. Remove the eight mounting bolts and • Filling air conditioner gas
remove air conditioner unit assembly (34). Fill the air conditioner circuit with air condi-
tioner gas (R134a), using tool S.
★ When removing the air conditioner unit
assembly, do not forget to disconnect the
two air conditioner hoses connected to
the bottom.

30-94 PC290-7
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT ASSEMBLY

12

REMOVAL AND INSTALLATION OF COUNTERWEIGHT

ASSEMBLY ASSEMBLY
REMOVAL INSTALLATION

1. Attach eyebolts to counterweight assembly • Install in reverse order of removal.

(1), and sling.

2. Remove 4 mounting bolts (2) Thread of counterweight mounting

bolt: Thread tightener (LT-2)

3. Lift off counterweight (1) horizontally with Counterweight mounting bolt:

wire or chain block. 1,180 - 1,470 Nm {120 - 150 kgm}
★ Be careful not to it the engine, radiator or
cooler.
★ Installing and adjusting counterweight
Counterweight assembly: 3,750 kg 1) Sling counterweight with crane and
place in position on the frame.
2) Push counterweight, install mounting
bolts, and adjust to the following
dimensions.
• Clearance from revolving frame:
10 ± 5 mm (left and right)
• Clearance from bodywork door:
10 ± 5 mm (left and right)
• Stepped difference b from revolv-
ing frame in left-to right direction:
Max. 5 mm
• Stepped difference a from body-
work door in left-to right direction:
10 ± 4
• Stepped difference c from body-
work top cover in up-down right
direction: Max. 5 mm

PC290-7 30-95
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY

12

REMOVAL AND INSTALLATION OF OPERATOR’S CAB

ASSEMBLY ASSEMBLY
REMOVAL 4. Disconnect cab wiring intermediate connec-
tors H10 (7), H11 (8) and H12 (9).
First, disconnect the cable from the nega-
tive terminal (- ) of the battery. 5. Remove duct (10) on the right side and rear
duct (11).
1. Remove floor mat (1).
6. Remove left plates (12) and (13).

2. Remove covers (2) and (3) under the monitor

panel. 7. Pull down outside air filter cover opening-
closing lever (14).
★ When removing cover (2), first disconnect
the CN-M19 wiring for cigarette lighter.

8. Remove outside air filter (15).

3. Remove rear covers (4), (5) and (6).

9. Remove duct (16).

30-96 PC290-7
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY

12

10. Remove cover (17). 13. Remove duct (22) on the right side.

14. Remove window washer hose (23).

11. Disconnect cab wiring intermediate connec-

tors (20) at the following two points.
• H09: Upper side
• H08: Lower side 15. Remove step plate (24).

12. Disconnect radio antenna (21). 16. Remove five mounting bolts (25) and four
mounting nuts (26).
★ Check the bolt length beforehand.

PC290-7 30-97
DISASSEMBLY AND ASSEMBLY MONITOR ASSEMBLY

17. Lift off operator's cab assembly (27) to

remove it.

Operator's cab assembly: 290 kg

INSTALLATION

• Install in reverse order of removal.

MONITOR ASSEMBLY

30-98 PC290-7
DISASSEMBLY AND ASSEMBLY MONITOR ASSEMBLY

REMOVAL AND INSTALLA-

TION OF MONITOR ASSEM-
BLY
REMOVAL

First, disconnect the cable from the nega-

tive terminal (- ) of the battery.

1. Remove cover (1) and then disconnect the

wiring connector P15 for air conditioner sun-
light sensor (2).
★ Lift the cover up to remove it.

2. Remove the three mounting screws and

remove monitor assembly (3).
★ Disconnect monitor panel wiring connec-
tors P01, P02 and P03 at the three points,
and then remove the monitor assembly.

INSTALLATION

• Install in reverse order of removal.

PC290-7 30-99
DISASSEMBLY AND ASSEMBLY GOVERNOR PUMP CONTROLLER ASSEMBLY

12
REMOVAL AND INSTALLATION OF GOVERNOR PUMP
CONTROLLER ASSEMBLY CONTROLLER ASSEMBLY
REMOVAL

First, disconnect the cable from the nega-

tive terminal (- ) of the battery.

1. Remove cover (1).

2. Disconnect governor pump controller wiring

connectors C01 (2), C02 (3) and C03 (4).

3. Remove the four mounting bolts and remove

governor pump controller assembly (5).

INSTALLATION

• Install in reverse order of removal.

30-100 PC290-7
 90 OTHERS

Hydraulic Circuit Diagram . . . . . . . . . 90-3

Electrical Circuit Diagram (1/4). . . . . . 90-5
Electrical Circuit Diagram (2/4). . . . . . 90-7
Electrical Circuit Diagram (3/4). . . . . . 90-9
Electrical Circuit Diagram (4/4). . . . . 90-11

PC290-7 90-1
OTHERS HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM

PC290-7 90-3
OTHERS ELECTRICAL CIRCUIT DIAGRAM (1/4)

ELECTRICAL CIRCUIT DIAGRAM (1/4)

FOR MULTI MONITOR

PC290-7 90-5
OTHERS ELECTRICAL CIRCUIT DIAGRAM (2/4)

ELECTRICAL CIRCUIT DIAGRAM (2/4)

FOR MULTI MONITOR

PC290-7 90-7
OTHERS ELECTRICAL CIRCUIT DIAGRAM (3/4)

ELECTRICAL CIRCUIT DIAGRAM (3/4)

FOR MULTI MONITOR

PC290-7 90-9
OTHERS ELECTRICAL CIRCUIT DIAGRAM (4/4)

ELECTRICAL CIRCUIT DIAGRAM (4/4)

FOR MULTI MONITOR

PC290-7 90-11