Komatsu Hydraulic Excavator Pc290lc 11 Shop Manual

Full download: http://manualplace.com/download/komatsu-hydraulic-excavator-pc290lc-11-shop-manual/

SEN06507-01

HYDRAULIC
PC290LC -11
EXCAVATOR SERIAL NUMBERS 35001 and up

This is the cut pages sample. Download all 2499 page(s) at: ManualPlace.com
 00 INDEX AND FOREWORD

PC290LC-11 00-1
INDEX 00 INDEX AND FOREWORD

INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-18
HOW TO READ THE SHOP MANUAL........................................................................................... 00-18
SAFETY NOTICE FOR OPERATION............................................................................................. 00-20
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-26
ACTION IF FIRE OCCURS............................................................................................................ 00-28
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-29
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-30
PRECAUTIONS FOR AdBlue/DEF ................................................................................................ 00-31
STORE AdBlue/DEF ...................................................................................................................... 00-32
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-33
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-35
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-41
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-44
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-45
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-46
METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL TYPE COUPLER .............. 00-47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-50
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-54
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-55
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-60
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-61
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-65
LIST OF ABBREVIATION .............................................................................................................. 00-68
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-73
CONVERSION TABLE ................................................................................................................... 00-80
01 SPECIFICATION....................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
SPECIFICATIONS .................................................................................................................................. 01-3
SPECIFICATION DRAWING............................................................................................................ 01-3
WORKING RANGE DRAWINGS ..................................................................................................... 01-4
SPECIFICATIONS ........................................................................................................................... 01-5
WEIGHT TABLE .............................................................................................................................. 01-8
TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-10
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
UREA SCR SYSTEM.............................................................................................................................. 10-5
LAYOUT DRAWING OF UREA SCR SYSTEM ................................................................................ 10-5
UREA SCR SYSTEM DIAGRAM ....................................................................................................10-11
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-12
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-26
BOOT-UP SYSTEM .............................................................................................................................. 10-35
LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-35
SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-37
BATTERY DISCONNECT SWITCH ............................................................................................... 10-38
ENGINE SYSTEM ................................................................................................................................ 10-39
LAYOUT DRAWING OF ENGINE RELATED PARTS ..................................................................... 10-39
ENGINE CONTROL SYSTEM ....................................................................................................... 10-41
AUTO-DECELERATION SYSTEM ................................................................................................. 10-44
ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-46
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-48
TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-51
AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-53

00-2 PC290LC-11
00 INDEX AND FOREWORD INDEX

COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-56

COOLING SYSTEM.............................................................................................................................. 10-71
LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-71
CONTROL SYSTEM............................................................................................................................. 10-73
LAYOUT DRAWING OF ELECTRICAL CONTROL SYSTEM ........................................................ 10-73
MACHINE MONITOR SYSTEM ..................................................................................................... 10-76
KOMTRAX SYSTEM...................................................................................................................... 10-77
COMPONENT PARTS OF CONTROL SYSTEM............................................................................ 10-78
HYDRAULIC SYSTEM.........................................................................................................................10-105
LAYOUT DRAWING OF HYDRAULIC COMPONENT...................................................................10-105
CLSS ............................................................................................................................................ 10-111
ENGINE AND PUMP COMBINED CONTROL SYSTEM...............................................................10-129
PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-135
COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-138
WORK EQUIPMENT SYSTEM ............................................................................................................10-222
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-222
STRUCTURE OF VALVE CONTROL............................................................................................10-227
ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-229
MACHINE PUSH-UP SYSTEM .....................................................................................................10-231
PPC LOCK SYSTEM ....................................................................................................................10-233
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-234
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-236
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-238
SWING CONTROL SYSTEM...............................................................................................................10-256
LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-256
SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-260
COMPONENT PARTS OF SWING SYSTEM................................................................................10-264
TRAVEL SYSTEM................................................................................................................................10-278
LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-278
TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-282
COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-284
UNDERCARRIAGE AND FRAME........................................................................................................10-304
LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-304
WORK EQUIPMENT............................................................................................................................10-306
STRUCTURE OF WORK EQUIPMENT ........................................................................................10-306
FUNCTION OF WORK EQUIPMENT ...........................................................................................10-307
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-308
BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-309
CAB AND ITS ATTACHMENTS ...........................................................................................................10-310
ROPS CAB ...................................................................................................................................10-310
CAB MOUNT ................................................................................................................................10-311
CAB TIPPING STOPPER .............................................................................................................10-312
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11 ................................................................ 20-3
STANDARD VALUE TABLE FOR MACHINE........................................................................................... 20-7
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11 ............................................................. 20-7
STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-24
STANDARD VALUE TABLE FOR ELECTRICAL ............................................................................ 20-24
30 TESTING AND ADJUSTING ..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................. 30-5
TOOLS FOR TESTING AND ADJUSTING....................................................................................... 30-5
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ................................................................30-11
ENGINE AND COOLING SYSTEM....................................................................................................... 30-12
TEST ENGINE SPEED .................................................................................................................. 30-12
TEST BOOST PRESSURE............................................................................................................ 30-15

PC290LC-11 00-3
INDEX 00 INDEX AND FOREWORD

TEST EXHAUST GAS COLOR ...................................................................................................... 30-17

TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-20
TEST COMPRESSION PRESSURE.............................................................................................. 30-22
TEST BLOWBY PRESSURE ......................................................................................................... 30-27
TEST ENGINE OIL PRESSURE .................................................................................................... 30-29
TEST EGR VALVE AND KVGT OIL PRESSURE ........................................................................... 30-30
TEST FUEL PRESSURE ............................................................................................................... 30-32
TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-38
BLEEDING AIR FROM FUEL SYSTEM ......................................................................................... 30-44
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-45
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-47
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-48
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-49
TEST SCR RELATED FUNCTIONS............................................................................................... 30-51
CLEAN AdBlue/DEF TANK ............................................................................................................ 30-74
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK ................................................... 30-78
POWER TRAIN..................................................................................................................................... 30-80
TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-80
UNDERCARRIAGE AND FRAME......................................................................................................... 30-81
TEST AND ADJUST TRACK TENSION......................................................................................... 30-81
HYDRAULIC SYSTEM.......................................................................................................................... 30-83
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................. 30-83
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ........
................................................................................................................................................... 30-84
TEST OIL PRESSURE OF CONTROL CIRCUIT ........................................................................... 30-94
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT .................................... 30-96
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT..................................... 30-99
TEST OUTLET PRESSURE OF SOLENOID VALVE ....................................................................30-106
TEST PPC VALVE OUTLET PRESSURE .....................................................................................30-110
ADJUST WORK EQUIPMENT AND SWING PPC VALVES ..........................................................30-112
TEST PUMP SWASH PLATE SENSOR........................................................................................30-113
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-114
TEST OIL LEAKAGE ....................................................................................................................30-116
BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-119
CAB AND ITS ATTACHMENTS ...........................................................................................................30-122
TEST CAB TIPPING STOPPER ...................................................................................................30-122
METHOD FOR ADJUSTING MIRRORS .......................................................................................30-123
ELECTRICAL SYSTEM .......................................................................................................................30-129
SET AND OPERATE MACHINE MONITOR..................................................................................30-129
METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-203
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-208
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER .....................................................30-211
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-212
TEST DIODES ..............................................................................................................................30-213
Pm CLINIC...........................................................................................................................................30-214
Pm CLINIC SERVICE ...................................................................................................................30-214
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-12
GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-12
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-13
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-26
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-28
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-30
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-32
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION ................................................. 40-54
PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-64
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-67

00-4 PC290LC-11
00 INDEX AND FOREWORD INDEX

INFORMATION IN TROUBLESHOOTING TABLE ......................................................................... 40-71

TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM............................................................................................................................ 40-73
CONNECTOR LIST AND LAYOUT ................................................................................................ 40-76
CONNECTOR PIN NUMBERS - CONNECTION TABLE................................................................ 40-89
T-BOXES AND T-ADAPTERS LIST ..............................................................................................40-128
FUSE LOCATION TABLE .............................................................................................................40-134
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE .....................................40-136
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135])..........................................................................................................................40-140
FAILURE CODES TABLE .............................................................................................................40-142
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-159
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit.....................40-159
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit .....................40-160
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit ................................40-161
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit ................................40-163
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit..........................................................40-165
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit..........................................................40-166
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit.....................................40-167
FAILURE CODE [879EMC] Ventilation Damper Malfunction .........................................................40-169
FAILURE CODE [879FMC] Air Mix Damper Malfunction ...............................................................40-170
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range ................................40-171
FAILURE CODE [989L00] Engine Controller Lock Caution 1 ........................................................40-173
FAILURE CODE [989M00] Engine Controller Lock Caution 2 .......................................................40-174
FAILURE CODE [989N00] Engine Controller Lock Caution 3........................................................40-175
FAILURE CODE [A1U0N3] HC Desorb Request 1 ........................................................................40-176
FAILURE CODE [A1U0N4] HC Desorb Request 2 ........................................................................40-178
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3...........................................40-180
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1...........................................40-181
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2 ..........................................40-182
FAILURE CODE [AA10NX] Air Cleaner Clogging..........................................................................40-183
FAILURE CODE [AB00KE] Charge Voltage Low...........................................................................40-185
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) ....40-188
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) ...............................40-190
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) ................................................40-192
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) ...........................................40-193
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality) ...........................................40-194
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality) ...........................................40-195
FAILURE CODE [AS00R6] Temporary Recovery of Inducement...................................................40-196
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5...........................................................40-197
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning ............................................40-198
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning ...............................40-199
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution..............................................40-200
FAILURE CODE [B@BAZG] Engine Oil Pressure Low .................................................................40-201
FAILURE CODE [B@BAZK] Eng Oil Level Low ............................................................................40-202
FAILURE CODE [B@BCNS] Eng Water Overheat ........................................................................40-204
FAILURE CODE [B@BCZK] Eng Water Level Low .......................................................................40-205
FAILURE CODE [B@HANS] Hyd Oil Overheat .............................................................................40-207
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error.........................................40-208
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error................................................40-209
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error.................................................40-211
FAILURE CODE [CA131] Throttle Sensor High Error....................................................................40-213
FAILURE CODE [CA132] Throttle Sensor Low Error.....................................................................40-215
FAILURE CODE [CA144] Coolant Temperature Sensor High Error...............................................40-217
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error................................................40-219
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error ..........................................40-221
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...........................................40-224
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error ......................................................40-226

PC290LC-11 00-5
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA221] Ambient Pressure Sensor High Error....................................................40-228

FAILURE CODE [CA222] Ambient Pressure Sensor Low Error ....................................................40-230
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error .....................................................40-232
FAILURE CODE [CA234] Engine Overspeed................................................................................40-233
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error ...............................................40-234
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error .......................................40-236
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error ....................................................40-238
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error.....................................................40-240
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error ..............................................................40-242
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error ..............................................................40-244
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error ....................40-246
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error ....................40-248
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error ....................40-250
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error ....................40-252
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error ....................40-254
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error ....................40-256
FAILURE CODE [CA343] Engine Controller Internal Failure .........................................................40-258
FAILURE CODE [CA351] Injectors Drive Circuit Error...................................................................40-259
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error ......................................................40-260
FAILURE CODE [CA356] MAF Sensor High Error ........................................................................40-262
FAILURE CODE [CA357] MAF Sensor Low Error .........................................................................40-264
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error .....................................................40-266
FAILURE CODE [CA428] Water in Fuel Sensor High Error ...........................................................40-267
FAILURE CODE [CA429] Water in Fuel Sensor Low Error............................................................40-269
FAILURE CODE [CA435] Engine Oil Pressure SW Error ..............................................................40-271
FAILURE CODE [CA441] Battery Voltage Low Error.....................................................................40-273
FAILURE CODE [CA442] Battery Voltage High Error ....................................................................40-275
FAILURE CODE [CA449] Common Rail Pressure High Error 2 ....................................................40-276
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error ...........................................40-277
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error ............................................40-279
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate........................................40-281
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error...................40-282
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error....................40-284
FAILURE CODE [CA553] Common Rail Pressure High Error 1 ....................................................40-286
FAILURE CODE [CA555] Crankcase Pressure High Error 1 .........................................................40-287
FAILURE CODE [CA556] Crankcase Pressure High Error 2 .........................................................40-288
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 .....................................................40-289
FAILURE CODE [CA595] Turbocharger Speed High Error 2.........................................................40-292
FAILURE CODE [CA687] Turbocharger Speed Low Error ............................................................40-293
FAILURE CODE [CA689] Engine NE Speed Sensor Error ............................................................40-295
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error ............................................40-298
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error.............................................40-300
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error ...................40-302
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error....................40-303
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error ..........................................40-304
FAILURE CODE [CA778] Engine Backup Speed Sensor Error .....................................................40-306
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error ............................................40-311
FAILURE CODE [CA1664] KDOC Abnormality .............................................................................40-312
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error ....................................40-314
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3 ...........................................................40-315
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error .....................................40-316
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error .....................................40-317
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error........................................................40-318
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error...........................40-320
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error ...........................40-322
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error..................................40-324
FAILURE CODE [CA1691] Defective Regeneration ......................................................................40-325
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error.............................................40-328

00-6 PC290LC-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error ...................................................40-331

FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error ....................................................40-332
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error .......................................................40-334
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error..............................40-337
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error ..........................40-339
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error ...............................40-340
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error ............................................40-341
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error .............................................40-344
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error..............................................40-347
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error...............................................40-349
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error ...................................40-352
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error ....................................40-354
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error ............................40-356
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error ...............................................40-359
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error .................................................40-361
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 ...............................................40-363
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2 ...............................................40-366
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error.......................................40-371
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error ................................................40-372
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error .........................................40-375
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error ..........................................40-376
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 ...................................................40-378
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error ...............................................40-379
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error................................................40-382
FAILURE CODE [CA2288] Turbocharger Speed High Error 1.......................................................40-385
FAILURE CODE [CA2311] lMV Solenoid Error..............................................................................40-386
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error..............................................40-387
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error ..............................................40-390
FAILURE CODE [CA2357] EGR Valve Servo Error.......................................................................40-392
FAILURE CODE [CA2381] KVGT Position Sensor High Error.......................................................40-393
FAILURE CODE [CA2382] KVGT Position Sensor Low Error .......................................................40-396
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error .....................................................40-399
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error .....................................................40-402
FAILURE CODE [CA2387] KVGT Servo Error ..............................................................................40-404
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error .........................................40-405
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error .........................................40-408
FAILURE CODE [CA2637] KDOC Face Plugging .........................................................................40-411
FAILURE CODE [CA2639] Manual Stationary Regeneration Request ..........................................40-413
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error.................................40-415
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable ..
..................................................................................................................................................40-421
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error.........................40-424
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error...........................................40-426
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error............................................40-429
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error....................................40-431
FAILURE CODE [CA3142] SCR Temperature Sensor High Error..................................................40-434
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error ..................................................40-435
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error ..........................................40-436
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error .......................................40-438
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error ........................................40-439
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error ................................40-440
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2...................................................40-442
FAILURE CODE [CA3165] SCR Outlet Temperature High Error ...................................................40-448
FAILURE CODE [CA3229] SCR Temperature High Error..............................................................40-450
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration ..............................40-452
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error ...............................40-454
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration....................40-458
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error....................................40-460

PC290LC-11 00-7
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error ....................................40-463
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error .........................................................40-466
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error ...................................................40-469
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration ...................................40-471
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1..............................................40-474
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration ....................................40-477
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 ..............................................40-480
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2 ..............................................40-482
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2 ..............................................40-484
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error ........................................40-487
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error .......................................40-489
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error ................................40-490
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error .....................................40-492
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error ....................................40-493
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error .............................40-494
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error .....................................40-496
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error ......................................40-497
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error ..............................40-499
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error..............................................40-501
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error...............................................40-503
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1 ...........................................................40-505
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2 ...........................................................40-506
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)...................40-507
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error .............................................40-513
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4 ...........................................................40-515
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error................................................40-516
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error ................................................40-518
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error...........................40-520
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error ...........................40-522
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error ............40-525
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction ........................................................40-528
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error .................................40-532
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error..................................40-534
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error .......................................40-536
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error.......................................40-538
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error..................................................40-540
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error ..................................................40-542
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1...................................................40-544
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error.............................40-550
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error.......................................40-552
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error ...........................40-554
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error ....................................40-556
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error...................................40-561
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error....................................40-567
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error ...............................40-570
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error..............................40-571
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error............................................40-572
FAILURE CODE [CA3741] Rail Press Valve Trip Error..................................................................40-575
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error .................................40-576
FAILURE CODE [CA3751] SCR Catalyst Degradation Error.........................................................40-578
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error .........................40-580
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 .............................................40-582
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1 .............................................40-585
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error...............................40-588
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error............................................................40-592
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error ...........................................40-594
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error .......................................40-598
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error ......................................40-600

00-8 PC290LC-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error.......................................40-602
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error .............................................40-604
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error ............................................40-607
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error...............................................40-609
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error ..........40-611
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error ..............................40-615
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error ..........................40-619
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error...........................40-622
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction ............................................................40-625
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error ..............40-627
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error ..................................40-628
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error ........40-629
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error .........40-632
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error 40-635
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error ............................40-637
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error .............................40-639
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error ....................40-641
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error .........................................40-643
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error .......................................40-646
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error ......................................................40-648
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error .................40-651
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error .................40-653
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error.............40-655
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error.................................40-658
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error .........40-661
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error............................................40-664
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error...........................40-667
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error ...........................40-670
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error...............................................................40-673
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error................40-677
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error ...........................40-678
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error .................................40-679
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error...........................................................40-680
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible......................................40-682
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error................................................40-685
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller) ..................40-688
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error.....................................40-690
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error....................................40-693
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error ....................................40-695
FAILURE CODE [CA5383] Ash Accumulation High Error..............................................................40-697
FAILURE CODE [D110KB] Battery Relay Output Short Circuit......................................................40-699
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit.............................40-701
FAILURE CODE [D811MC] KOMTRAX Malfunction......................................................................40-704
FAILURE CODE [D862KA] GPS Antenna Open Circuit ................................................................40-705
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)...........................40-706
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) ...........................40-708
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX) .................................40-710
FAILURE CODE [DA20MC] Pump Controller Malfunction .............................................................40-712
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error ..........................40-713
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error...............................................40-716
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller) .........................40-719
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)...................40-721
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller) ...................40-723
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller)......
..................................................................................................................................................40-725
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)......
..................................................................................................................................................40-728
FAILURE CODE [DAF0MB] Monitor ROM Abnormality.................................................................40-729

PC290LC-11 00-9
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [DAF0MC] Monitor Malfunction ..........................................................................40-730

FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit ..................................................40-731
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor).......................................40-733
FAILURE CODE [DAFGMC] GPS Module Malfunction .................................................................40-734
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) ................................40-735
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) ................................40-737
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor) ......................................40-739
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) ............................................40-740
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)....................................40-741
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller) .......................40-746
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller) .......................40-751
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit.....................................................40-756
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit .....................................................40-758
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On..............................................40-760
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit................................40-762
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault...............................40-764
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit ...............................................40-766
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen ......................................40-768
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen .............................................40-769
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function .............................40-770
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function .............................40-773
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function ............................40-776
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function ..................40-779
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function...................40-782
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function ................40-785
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function ....................40-788
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function ......................40-791
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function........................40-794
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function.................40-797
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function.........40-800
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function......40-803
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function ........40-806
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function.......40-809
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function........................40-812
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function ........................40-815
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit ...........................................................40-818
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit............................................................40-820
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit .....................................................40-822
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range ........................40-824
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range ........................40-826
FAILURE CODE [DV20KB] Travel Alarm Short Circuit ..................................................................40-828
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit .................................................40-830
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit .................................................40-832
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit...........................................40-834
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit ......................................40-836
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit .....................................40-839
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit ...............................40-842
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit ...............................................40-844
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit ..............................................40-846
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit ..............................................40-848
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit........................................40-850
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit.............40-852
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit.............40-854
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit ......40-856
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit ...............................................40-858
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit ...............................................40-860
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit .........................................40-862
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit .................................40-864

00-10 PC290LC-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit .................................40-866
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit...........................40-868
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit ..................................40-870
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit...................................40-872
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit ............................40-874
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit......................................40-876
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit ......................................40-878
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit ......................................40-880
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit.......................................40-882
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit..........................................................40-884
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit ..........................................................40-885
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit ..................40-887
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit ..................40-889
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit ............................................40-891
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit ........................................40-893
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit ........................................40-895
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit............................................40-897
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit............................................40-899
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit ...............40-901
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit ...............40-903
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit........................40-905
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit ...............40-907
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit ...............40-909
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit........................40-911
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit ...............40-913
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit ...............40-915
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit........................40-917
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit...............40-919
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit ...............40-921
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 1 Hot Short Circuit .......................40-923
FAILURE CODE [DY20KA]Wiper Motor Open Circuit ...................................................................40-925
FAILURE CODE [DY20MA] Wiper Motor Defective Function ........................................................40-927
FAILURE CODE [DY2CKB] Washer Motor Short Circuit ...............................................................40-929
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit .....................................40-932
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit....................................40-934
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...........................................................40-936
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ................................................40-936
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK..........................................................40-942
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ....................................................40-945
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.......40-947
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING..................................................................................................................................40-949
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), EN-
GINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW .............................................................40-952
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIA-
TOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW ...................................................40-953
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-954
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-955
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...
..................................................................................................................................................40-956
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................40-957
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING......................40-958
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ........40-959
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-960
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ..40-961

PC290LC-11 00-11
INDEX 00 INDEX AND FOREWORD

E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .........................................................................................................................................40-962
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ...................40-963
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.................................40-965
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM...........................................................................................................................40-966
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOL-
ANT TEMPERATURE................................................................................................................40-967
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM .................................................................................................................................40-968
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEM-
PERATURE ...............................................................................................................................40-970
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ........................40-971
E-24 FUNCTION SWITCH DOES NOT OPERATE .......................................................................40-972
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)....................40-973
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF ......................................................................40-975
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ......................40-976
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED ......................................................................................................................40-977
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED ........................................................................................................................40-978
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE ...................................................................................................................................40-979
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE ...................................................................................................................................40-980
E-32 ALARM BUZZER CANNOT BE CANCELED ........................................................................40-982
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
..................................................................................................................................................40-983
E-34 SERVICE MODE CANNOT BE SELECTED .........................................................................40-984
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ......40-985
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK..........40-988
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING ......................................................................................................................................40-990
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE .................................................................................................40-993
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDI-
CATOR NOT DISPLAYED ON MONITOR .................................................................................40-995
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .............................40-998
E-41 ALARM DOES NOT SOUND DURING TRAVEL ..................................................................40-999
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..........................40-1001
E-43 HORN DOES NOT SOUND................................................................................................40-1002
E-44 HORN DOES NOT STOP SOUNDING...............................................................................40-1005
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .
................................................................................................................................................40-1007
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...40-1008
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPER-
ATE .........................................................................................................................................40-1010
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ...
................................................................................................................................................40-1011
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1012
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION..........
................................................................................................................................................40-1013
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1014
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
................................................................................................................................................40-1015

00-12 PC290LC-11
00 INDEX AND FOREWORD INDEX

E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1016
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.40-1017
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION40-1018
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..........
................................................................................................................................................40-1019
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.......................................40-1021
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1022
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1023
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1023
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ..........................................40-1024
FAILURE MODE AND CAUSE TABLE........................................................................................40-1026
H-1 All of work equipments, swing and travel operation lack speed or power. .............................40-1035
H-2 Engine speed lowers significantly or engine stalls ................................................................40-1037
H-3 Any of work equipment, swing and travel does not work.......................................................40-1039
H-4 Unusual sound is heard from around hydraulic pump ...........................................................40-1040
H-5 Fine control performance or response is poor ......................................................................40-1041
H-6 Speed or power of boom is low ............................................................................................40-1042
H-7 Speed or power of arm is low ...............................................................................................40-1046
H-8 Speed or power of bucket is low...........................................................................................40-1050
H-9 Work equipment does not move in single operation .............................................................40-1053
H-10 Hydraulic drift of boom is large ...........................................................................................40-1054
H-11 Hydraulic drift of arm is large ..............................................................................................40-1056
H-12 Hydraulic drift of bucket is large..........................................................................................40-1058
H-13 Other work equipment moves when one of work equipment is relieved ..............................40-1059
H-14 In combined operation of work equipment , equipment having heavier load moves slower. 40-1060
H-15 Time lag of work equipment is large ...................................................................................40-1061
H-16 Machine does not travel straight .........................................................................................40-1062
H-17 Machine is hard to steer or travel power is low ...................................................................40-1064
H-18 Travel speed is low.............................................................................................................40-1067
H-19 One of tracks does not run .................................................................................................40-1069
H-20 Travel speed does not change, or travel speed is too low or high.......................................40-1070
H-21 Upper structure does not swing in both right and left directions ..........................................40-1071
H-22 Upper structure does not swing in only one direction..........................................................40-1072
H-23 Swing acceleration or swing speed of upper structure is low in both right and left directions40-1073
H-24 Swing acceleration or swing speed is low in only one direction ..........................................40-1074
H-25 Overrun of upper structure is large in both right and left directions .....................................40-1075
H-26 Upper structure overruns excessively when it stops swing in only one direction .................40-1076
H-27 Shock is large when upper structure stops swinging ..........................................................40-1077
H-28 Large unusual noise is heard when upper structure stops swinging ...................................40-1078
H-29 Swing drift on a slope is large (while swing parking brake is applied) .................................40-1079
H-30 Swing drift on a slope is large (while swing parking brake is released) ...............................40-1080
H-31 Travel speed drops largely in combined operation of swing and trave ................................40-1081
H-32 In combined operation of swing and boom RAISE, boom rising speed is low .....................40-1082
H-33 One-touch power maximizing function does not work .........................................................40-1083
H-34 Attachment circuit cannot be changed................................................................................40-1084
H-35 Oil flow in attachment circuit cannot be controlled ..............................................................40-1085
TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1086
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1086
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
................................................................................................................................................40-1087
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1088
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ........................................................................................................40-1089
S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1091
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1093
S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1095
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1097

PC290LC-11 00-13
INDEX 00 INDEX AND FOREWORD

S-8 ENGINE LACKS POWER.....................................................................................................40-1098

S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1100
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1102
S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1103
S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1104
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
................................................................................................................................................40-1105
S-14 OIL PRESSURE DROPS ...................................................................................................40-1106
S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1108
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1109
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .................................... 40-1110
S-18 UNUSUAL NOISE IS HEARD............................................................................................. 40-1111
S-19 VIBRATION IS EXCESSIVE ............................................................................................... 40-1112
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT................................................................. 40-1113
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................ 40-1114
S-22 ACTIVE REGENERATION TAKES TIME............................................................................ 40-1116
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.............................. 40-1117
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ................................................................... 40-1118
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1120
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1121
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-7
HOW TO READ THIS MANUAL....................................................................................................... 50-7
COATING MATERIALS LIST............................................................................................................ 50-8
SPECIAL TOOLS LIST .................................................................................................................. 50-13
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-25
ENGINE AND COOLING SYSTEM....................................................................................................... 50-31
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-31
REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-38
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-51
REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................ 50-77
REMOVE AND INSTALL EGR COOLER ASSEMBLY.................................................................... 50-81
REMOVE AND INSTALL STARTER ASSEMBLY ........................................................................... 50-89
REMOVE AND INSTALL ALTERNATOR BELT .............................................................................. 50-93
REMOVE AND INSTALL RADIATOR ASSEMBLY ......................................................................... 50-97
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-101
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-107
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-110
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-130
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-137
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .................................................................50-141
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-143
REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-150
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-158
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-169
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-180
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-182
REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-184
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-188
REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-197
REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-201
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET ......................................................50-213
REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-228
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-235
REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-245
REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-249
REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-254

00-14 PC290LC-11
00 INDEX AND FOREWORD INDEX

REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-264

REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-267
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-272
POWER TRAIN....................................................................................................................................50-274
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-274
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-276
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................50-288
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-294
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-305
UNDERCARRIAGE AND FRAME........................................................................................................50-307
SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-307
REMOVE AND INSTALL SPROCKET ..........................................................................................50-312
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-314
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-316
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-321
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-324
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................50-328
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-332
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-336
HYDRAULIC SYSTEM.........................................................................................................................50-343
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-343
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-348
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-351
REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-356
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-362
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-374
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-380
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-382
WORK EQUIPMENT............................................................................................................................50-385
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-385
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY........................50-395
CAB AND ITS ATTACHMENTS ...........................................................................................................50-404
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-404
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-416
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-428
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-437
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-451
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-462
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-467
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-469
ELECTRICAL SYSTEM .......................................................................................................................50-482
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-482
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-485
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-494
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ..........................................................50-501
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-503
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-505
REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-507
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-511
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ENGINE AND COOLING SYSTEM......................................................................................................... 60-3
MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-3
MAINTENANCE STANDARD OF COOLING SYSTEM .................................................................... 60-4
POWER TRAIN....................................................................................................................................... 60-5
MAINTENANCE STANDARD OF SWING CIRCLE .......................................................................... 60-5
MAINTENANCE STANDARD OF SWING MACHINERY.................................................................. 60-6
MAINTENANCE STANDARD OF FINAL DRIVE .............................................................................. 60-8

PC290LC-11 00-15
INDEX 00 INDEX AND FOREWORD

MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-10

MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING..........60-11
UNDERCARRIAGE AND FRAME......................................................................................................... 60-13
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-13
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-15
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-17
MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-19
MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-20
MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-23
HYDRAULIC SYSTEM.......................................................................................................................... 60-24
MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-24
MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-25
MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-28
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-31
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-41
MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-44
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-47
MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-50
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRES-
SURE) ........................................................................................................................................ 60-51
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-52
WORK EQUIPMENT............................................................................................................................. 60-53
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-53
MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-62
MAINTENANCE STANDARD OF BOOM CYLINDER (FOR LARGE DIAMETER PISTON) ........... 60-63
MAINTENANCE STANDARD OF ARM CYLINDER ....................................................................... 60-64
MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-65
80 APPENDIX................................................................................................................................................ 80-1
CONTENTS ............................................................................................................................................ 80-2
AIR CONDITIONER SYSTEM ................................................................................................................ 80-4
PRECAUTIONS FOR REFRIGERANT ............................................................................................ 80-4
AIR CONDITIONER COMPONENT ................................................................................................. 80-5
SPECIFICATIONS OF AIR CONDITIONER ..................................................................................... 80-7
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................... 80-8
OUTLINE OF REFRIGERATION CYCLE ......................................................................................... 80-9
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .....................................................................80-11
AIR CONDITIONER UNIT...............................................................................................................80-11
COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-15
AIR CONDITIONER CONTROLLER .............................................................................................. 80-19
COMPRESSOR ............................................................................................................................. 80-20
CONDENSER ................................................................................................................................ 80-22
SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-24
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......
.......................................................................................................................................................... 80-26
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-28
AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-30
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-31
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
.......................................................................................................................................................... 80-33
TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-37
METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-37
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................ 80-39
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR .......................................................................................................... 80-40
TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-41
METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-41
TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-43
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-43

00-16 PC290LC-11
00 INDEX AND FOREWORD INDEX

TEST SUNLIGHT SENSOR.................................................................................................................. 80-44

METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-44
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.................................................................. 80-45
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................ 80-45
TEST RELAYS...................................................................................................................................... 80-46
METHOD FOR TESTING RELAYS ................................................................................................ 80-46
AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-47
AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-49
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-52
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit............................. 80-54
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit ............................. 80-55
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit ........................................ 80-56
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit ........................................ 80-58
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit.................................................................. 80-60
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit.................................................................. 80-61
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit............................................. 80-62
FAILURE CODE [879EMC] Ventilation Damper Malfunction ................................................................. 80-64
FAILURE CODE [879FMC] Air Mix Damper Malfunction....................................................................... 80-65
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range ........................................ 80-66
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).
.......................................................................................................................................................... 80-68
A-2 TROUBLESHOOTING OF COMPRESSOR SYSTEM (AIR IS NOT COOLED) .............................. 80-70
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) ..................................................................................................................................... 80-73
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-75
TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-77
CONNECTION OF SERVICE TOOL ..................................................................................................... 80-79
METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-79
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS...................................................................................................................................... 80-81
HANDLE COMPRESSOR OIL .............................................................................................................. 80-83
METHOD FOR REPLACING DESICCANT ........................................................................................... 80-85
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-3
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-3
HYDRAULIC CIRCUIT DIAGRAM (1/2) ........................................................................................... 90-7
HYDRAULIC CIRCUIT DIAGRAM (2/2) ........................................................................................... 90-9
ELECTRICAL CIRCUIT DIAGRAM ........................................................................................................90-11
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM................................................................90-11
ELECTRICAL CIRCUIT DIAGRAM (1/7)........................................................................................ 90-15
ELECTRICAL CIRCUIT DIAGRAM (2/7)........................................................................................ 90-17
ELECTRICAL CIRCUIT DIAGRAM (3/7)........................................................................................ 90-19
ELECTRICAL CIRCUIT DIAGRAM (4/7)........................................................................................ 90-21
ELECTRICAL CIRCUIT DIAGRAM (5/7)........................................................................................ 90-23
ELECTRICAL CIRCUIT DIAGRAM (6/7)........................................................................................ 90-25
ELECTRICAL CIRCUIT DIAGRAM (7/7)........................................................................................ 90-27
INDEX..................................................................................................................................................................1

PC290LC-11 00-17
Komatsu Hydraulic Excavator Pc290lc 11 Shop Manual
Full download: http://manualplace.com/download/komatsu-hydraulic-excavator-pc290lc-11-shop-manual/
HOW TO READ THE SHOP MANUAL 00 INDEX AND FOREWORD

FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE SHOP MANUAL
REMARK
• Some of the attachments and options described in this Shop Manual may not be available in some districts.
If they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without advance notice.
• Shop Manuals are available for "Machine part" and "Engine part". For the engine unit, see the Shop Manual
for the same model of the engine as the one which is mounted on the machine.
Composition of Shop Manual
This Shop Manual contains technical information necessary for services performed in workshops. It is divided
into the following chapters for the easy of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component by system. "Structure and function" is
helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE
The standard values for new machine and failure criterion are described for testing and adjusting, and trouble-
shooting. Use the standard values table to check the standard values for testing and adjusting, and judge trou-
bles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes measuring tools and measuring methods for testing and adjusting, as well as the adjust-
ing method of each part. The standard values and repair limit for "Testing and adjusting" are described in
"Standard value table".
40 TROUBLESHOOTING
Troubleshooting of failure part and its remedy method on the occurrence of the failure are described. Trouble-
shooting is sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torque and quantity and
weight of the coating material, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
In this section, the maintenance standard value of each component is described. The maintenance standard
shows the criteria and remedies for disassembly and assembly.
80 APPENDIX
The structure and function, testing and adjusting, and troubleshooting for all of the other components or equip-
ment which cannot be separately classified are described together in the appendix.
90 CIRCUIT DIAGRAMS
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
Symbol
Important safety and quality portions are marked with the following symbols so that Shop Manual is used effec-
tively.

00-18 PC290LC-11

This is the cut pages sample. Download all 2499 page(s) at: ManualPlace.com