Komatsu Excavator PC290LC-10 service & repair manual

Description Komatsu Excavator PC290LC-10 service & repair manual

Komatsu Hydraulic Excavator PC290LC-10 pdf workshop service manual + operation & maintenance manual

Serial numbers:
A25001 and up

Technical documentation, specifications, maintenance, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
SAFETY
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
PUSH PULL COUPLER
EXPLANATION OF MAINTENANCE STANDARD TERMS
HANDLING OF FUEL SYSTEM DEVICES
HANDLING OF INTAKE SYSTEM PARTS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
PRECAUTIONS FOR OPERATIONS
CONVERSION TABLES
COATING MATERIALS
LIST OF ABBREVIATIONS

GENERAL
SPECIFICATION DIMENSION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS

STRUCTURE AND FUNCTION
ENGINE AND COOLING SYSTEM
POWER TRAIN
UNDERCARRIAGE AND FRAME
HYDRAULIC SYSTEM
WORK EQUIPMENT
CAB AND ITS ATTACHMENTS
ELECTRICAL SYSTEM
MACHINE MONITOR SYSTEM
KOMTRAX SYSTEM
SENSORS

STANDARD SERVICE VALUE TABLES
Standard Value Table for Engine Related Parts
Standard Value Table for Chassis Related Parts
Posture of Machine for Measuring Performance and Measurement Procedure

TESTING AND ADJUSTING
GENERAL INFORMATION ON TESTING AND ADJUSTING
Tools for Testing, Adjusting, and Troubleshooting
Sketch of Tools for Testing and Adjusting
ENGINE AND COOLING SYSTEM
Checking Engine Speed
Measuring Boost Pressure
Measuring Exhaust Gas Color
Measuring and Adjusting Valve Clearance
Measuring Compression Pressure
Measuring Blow-By Pressure
Measuring Engine Oil Pressure
Measuring EGR Valve and KVGT Oil Pressure
Measuring Fuel Pressure
Measuring Fuel Delivery, Return and Leakage
Bleeding Air from Fuel System
Checking Fuel Circuit for Leakage
Handling Cylinder Cut-Out Mode Operation
Handling No-Injection Cranking Operation
Checking and Adjusting Air Conditioner Compressor Belt Tension
Replacing Fan Belt
POWER TRAIN
Testing Swing Circle Bearing Clearance
UNDERCARRIAGE AND FRAME
Testing and Adjusting Track Shoe Tension
HYDRAULIC SYSTEM
Releasing Remaining Pressure from Hydraulic Circuit
Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits
Measuring Oil Pressure in Control Circuit
Measuring and Adjusting Oil Pressure in Pump PC Control Circuit
Measuring and Adjusting Oil Pressure in Pump LS Control Circuit
Measuring Solenoid Valve Output Pressure
Measuring PPC Valve Output Pressure
Adjusting Play of Work Equipment and Swing PPC Valves
Testing Pump Swash Plate Sensor
Isolating the Parts Causing Hydraulic Drift in Work Equipment
Measuring Oil Leakage
Bleeding Air From Hydraulic Circuit
CAB AND ITS ATTACHMENTS
Checking Cab Tipping Stopper
Adjusting Mirrors
ELECTRICAL SYSTEM
Special Functions of Machine Monitor
Ordinary Functions and Special Functions of Machine Monitor
Angle Adjustment of Rear View Camera
Handling Voltage Circuit of Engine Controller
Handling Battery Disconnect Switch
Testing Diodes
PM CLINIC
PM Clinic Service
Check Sheet

TROUBLESHOOTING
GENERAL INFORMATION ON TROUBLESHOOTING
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS SECTION
Removal And Installation Of Assemblies
Disassembly And Assembly Of Assemblies
Coating Materials List
SKETCHES OF SPECIAL TOOLS
CONNECTOR REPAIR PROCEDURES
Stripping Insulation
Wire Inspection
Contact Terminal Removal (HD30 Type)
Crimping Contact Terminal (HD30 Type)
Insertion Of Contact Terminal (HD30 Type)
Contact Terminal Removal (DT Type)
Crimping Contact Terminal (DT Type)
Insertion Of Contact Terminal (DT Type)
ENGINE AND COOLING SYSTEM
Removal and Installation of Supply Pump Assembly
Fuel Injector Assembly
Removal and Installation of Cylinder Head Assembly
Removal and Installation of Radiator Assembly
Removal and Installation of Hydraulic Oil Cooler Assembly
Removal and Installation of Aftercooler Assembly
Removal and Installation Engine And Main Pump Assembly
Special Tools
Removal and Installation of Engine Front Oil Seal
Removal and Installation of Engine Rear Oil Seal
Removal and Installation of Fuel Cooler Assembly
Removal and Installation of Fuel Tank Assembly
Removal and Installation of Engine Hood Assembly
Removal and Installation of KDPF Assembly
Disassembly and Assembly of KDPF
Removal and Installation of KCCV Assembly
Removal and Installation of Air Cleaner Assembly
POWER TRAIN
Removal and Installation of Travel Motor and Final Drive Assembly
Disassembly and Assembly of Final Drive
Removal and Installation of Swing Motor and Swing Machinery Assembly
Disassembly and Assembly of Swing Machinery
Removal and Installation of Swing Circle Assembly
UNDERCARRIAGE AND FRAME
Separation and Connection of Track Shoe Assembly
Removal and Installation of Sprocket
Removal and Installation of Idler and Idler Cushion Assembly
Disassembly and Assembly of Idler
Disassembly and Assembly of Idler Cushion
Disassembly and Assembly of Track Roller
Disassembly and Assembly of Carrier Roller
Removal and Installation of Revolving Frame Assembly
Removal and Installation of Counterweight Assembly
HYDRAULIC SYSTEM
Center Swivel Joint
Disassembly and Assembly of Swivel Joint
Removal and Installation of Hydraulic Tank Assembly
Removal and Installation of Main Pump Assembly
Removal and Installation of Control Valve
Disassembly and Assembly of Control Valve
Disassembly and Assembly of Work Equipment PPC Valve
Disassembly and Assembly of Travel PPC Valve
WORK EQUIPMENT
Removal and Installation of Work Equipment Assembly
CAB AND ITS ATTACHMENTS
Removal and Installation of Operator's Cab Assembly
Removal and Installation of Operator Cab Glass (Fixed Glass)
Removal and Installation of Front Window Assembly
Removal and Installation of Floor Frame Assembly
Removal and Installation of Air Conditioner Unit Assembly
Removal and Installation of Operator’s Seat
Removal and Installation of Seat Belt
Removal and Installation of Front Wiper Assembly
ELECTRICAL SYSTEM
Removal and Installation of Air Conditioner Compressor Assembly
Removal and Installation of Air Conditioner Condenser Assembly
Removal and Installation of Engine Controller Assembly
Removal and Installation of Pump Controller Assembly
Removal and Installation of Machine Monitor Assembly
Removal and Installation of Pump Swash Plate Sensor
Removal and Installation of Mass Air Flow and Temperature Sensor
Removal and Installation of KOMTRAX Terminal Assembly

MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
POWER TRAIN
UNDERCARRIAGE AND FRAME
HYDRAULIC SYSTEM
PPC VALVE
WORK EQUIPMENT

AIR CONDITIONING
AIR CONDITIONER
Precautions for Refrigerant
Air Conditioner Component
Structure and Function of Refrigeration System
Overview of Refrigeration System
Air Conditioner Unit
Functions of Major Components
Inspection and Troubleshooting Procedure of Air Conditioner
Air Conditioner Circuit Diagram and Arrangement of Connector Pins
System Diagram
Air Conditioner Controller Input and Output Signals
Parts and Connectors Layout
Layout of Air Conditioner Related Parts and Connectors
Testing Air Leakage (Duct)
Testing with Self-Diagnosis Function
How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor
Testing Vent (Mode) Changeover
Testing FRESH/RECIRC Air Changeover
Testing Sunlight Sensor
Testing (Dual) Pressure Switch for Refrigerant
Testing Relay
Troubleshooting Chart
Information Mentioned in Troubleshooting Table
Failure Code List Related to Air Conditioner
Failure Code [879AKA] A/C Inner Sensor Open Circuit
Failure Code [879AKB] A/C Inner Sensor Short Circuit
Failure Code [879BKA] A/C Outer Sensor Open Circuit
Failure Code [879BKB] A/C Outer Sensor Short Circuit
Failure Code [879CKA] Ventilating Sensor Open Circuit
Failure Code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure Code [879EMC] Ventilation Damper Abnormality
Failure Code [879FMC] Ventilation Damper Abnormality
Failure Code [879GKX] Refrigerant Abnormality
A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)
A-2 Troubleshooting of Compressor System (Air is Not Cooled)
A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)
A-4 Troubleshooting for FRESH/RECIRC Air Changeover
Troubleshooting with Gauge Pressure
Testing Refrigerant Pressure
Precautions for Disconnecting and Connecting Refrigerant Piping
Tightening Torque for Joint Portion of Refrigerant Piping
Filling Compressor Oil
Desiccant Replacement

DIAGRAMS AND SCHEMATICS
HYDRAULIC SYSTEM
Symbols in Hydraulic Circuit Diagrams
Hydraulic Circuit Diagram and Name of Valves
Hydraulic Circuit Diagram
ELECTRICAL SYSTEM
Air Conditioner Electrical Circuit
Electrical Control System Diagram
Electrical Diagram
Connector List and Stereogram

Engine SAA6D107E-2 workshop service manual