Komatsu Excavator PC290LC-10 service & repair manual

Description Komatsu Excavator PC290LC-10 service & repair manual

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

Serial numbers:
A25001 and up
15001 and up

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

SERVICE MANUAL CONTENT:
GENERAL
SPECIFICATION DIMENSION DRAWINGS
Dimensions
Working Ranges
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
Lubrication Chart

STRUCTURE AND FUNCTION
ENGINE AND COOLING SYSTEM
Engine Related Parts
Radiator, Oil Cooler, After Cooler, and Fuel Cooler
POWER TRAIN
Swing Machinery
Swing Circle
Final Drive
UNDERCARRIAGE AND FRAME
Track Frame and Idler Cushion
HYDRAULIC SYSTEM
Hydraulic Equipment Layout
Valve Control
Hydraulic Tank
Oil Filler Cap
CLSS
Structure of CLSS
Basic Principle
Main Pump
Operation
LS Valve
PC Valve
LS(PC)-EPC Valve
Control Valve
Functions and Operation by Valve
Hydraulic Circuit Diagram and Name of Valves
Unload Valve
Introduction of LS Pressure
LS By-Pass Plug
Pressure Compensation Valve
Shuttle Valve In Pressure Compensation Valve
Boom Regeneration Circuit
Arm Regeneration Circuit
Merge-Divider Valve
LS Selector Valve
Self-Pressure Reducing Valve
Travel Junction Valve
Travel PPC Shuttle Valve
Boom Hydraulic Drift Prevention Valve
Arm Hydraulic Drift Prevention Valve (If Equipped)
Suction Safety Valve For Drift Prevention Valve
Arm Quick Return Valve
Variable Back Pressure Valve
Main Relief Valve
Suction 2-Stage Safety Valve
Swing Motor
Swing Holding Brake
Relief Valve
Swing 2-Stage Relief Valve
Swing Motor Reverse Prevention Valve
Travel Motor
Operation of Travel Motor
Operation of Parking Brake
Brake Valve
Counterbalance Valve
Suction Safety Valve
PPC Valve
Work Equipment and Swing PPC Valve
Travel PPC Valve
1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)
EPC Valve (If Equipped)
2nd-Line Attachment PPC Valve (If Equipped)
Solenoid Valve
Attachment Circuit Selector Valve (For High Pressure Circuit) (If Equipped)
Attachment Circuit Selector Valve (For Low Pressure Circuit) (If Equipped)
Center Swivel Joint
Accumulator
PPC Accumulator
WORK EQUIPMENT
Work Equipment Shim
Bucket Play Adjustment Shim
CAB AND ITS ATTACHMENTS
Cab Mount and Cab Tipping Stopper
ROPS Cab
ELECTRICAL SYSTEM
Electrical Control System
Machine Control System Diagram
Engine Control Function
Engine and Pump Combined Control Function
Pump and Valve Control Function
One-Touch Power Maximizing Function
Auto-Deceleration Function
Engine Automatic Warm-Up Function
Overheat Prevention Function
Turbocharger Protection Function
Swing Control Function
Quick Warm-Up Function
Swing 2-Stage Relief Function
Travel Control Function
PPC Lock Function
Attachment Flow Control Function
System Component Part
Engine Controller
Pump Controller
Fuel Control Dial
Resistor for PC-EPC Valve
CAN Terminating Resistor
Engine Oil Pressure Switch
PPC Oil Pressure Switch
MACHINE MONITOR SYSTEM
Machine Monitor
Input and Output Signals
Display
Gauges
Caution Monitor
Pilot Monitor
Switches
Guidance ICON and Function Switch
Operator Mode Function
Service Mode Function
KOMTRAX SYSTEM
Komtrax Terminal
Input and Output Signals
SENSORS
Ambient Pressure Sensor
Charge (Boost) Pressure and Temperature Sensor
Coolant Temperature Sensor
Ne (Crankshaft) Speed Sensor
Bkup (Camshaft) Speed Sensor
Common Rail Pressure Sensor
Exhaust Manifold Pressure Sensor
EGR Orifice Temperature Sensor
EGR Valve Lift Sensor
Turbo Speed Sensor
KVGT Position Sensor
Mass Air Flow and Temperature Sensor
KDPF Differential Pressure and Outlet Pressure Sensor
KDOC Inlet Temperature Sensor
KDOC Outlet Temperature Sensor
KDPF Outlet Temperature Sensor
Crankcase Pressure Sensor
Engine Oil Level Sensor
Fuel Level Sensor
Coolant Level Sensor
Hydraulic Oil Temperature Sensor
Front Pump Oil Pressure Sensor
Rear Pump Oil Pressure Sensor
PPC Oil Pressure Sensor
Air Cleaner Clogging Sensor
Front Pump Swash Plate Sensor
Rear Pump Swash Plate Sensor
Water-In Fuel Sensor

STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLES
Standard Value Table for Engine Related Parts
Standard Value Table for Chassis Related Parts
Engine Speed
Control Valve Spool Stroke
Control Lever Stroke
Operating Effort of Control Lever and Pedal
Hydraulic Pressure
Swing
Travel
Work Equipment
Performance in Combined Operation
Pump Swash Plate Sensor
Characteristics of PC Flow Control
Hydraulic Pump
Posture of Machine for Measuring Performance and Measurement Procedure
Control Valve: Spool Stroke
Swing 1: Swing Brake Angle, Time Taken to Start Swing, Time Taken to Swing
Swing 2: Hydraulic Drift of Swing
Travel 1: Travel Speed, Idle Running (Without Load)
Travel 2: Travel Speed (Actual Run), Travel Deviation
Travel 3: Travel Deviation
Travel 4: Hydraulic Drift of Travel
Work Equipment 1: Hydraulic Drift of Work Equipment
Work Equipment 2: Boom Speed
Work Equipment 3: Arm Speed
Work Equipment 4: Bucket Speed
Work Equipment 5: Boom Time Lag
Work Equipment 6: Arm Time Lag
Work Equipment 7: Bucket Time Lag
Work Equipment 8: PC Flow Characteristics Control

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
Testing Low-Pressure Circuit (Fuel Main Filter Inlet Side)
Testing Low-Pressure Circuit (Pressure Difference)
Testing Return Circuit
Testing Negative-Pressure Circuit
Measuring Fuel Delivery, Return and Leakage
Testing Supply Pump Delivery
Testing Supply Pump Return Rate
Testing Leakage from Pressure Limiter
Testing Injector Return Rate from Injector
Bleeding Air from Fuel System
Bleeding Air
Route for Bleeding Air from Fuel Circuit
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
Checking Oil Pressure with Sensor Adapter (Special Tool)
Measuring Solenoid Valve Output Pressure
Operating Condition
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
Upper Part of machine monitor (display portion)
Upper Part of Machine Monitor (Switch Portion)
Lower Part of Machine Monitor (Switch Portion)
Ordinary Functions and Special Functions of Machine Monitor
Operator Mode (Outline)
Service Mode
Angle Adjustment of Rear View Camera
Handling Voltage Circuit of Engine Controller
Handling Battery Disconnect Switch
Testing Diodes
PM CLINIC
PM Clinic Service
Check Items Related to Engine
Check Items Related to Oil Pressure
Check Sheet

TROUBLESHOOTING
GENERAL INFORMATION ON TROUBLESHOOTING
Points to Remember When Troubleshooting
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Testing Procedure Before Troubleshooting
Walk-Around Check
Testing in Accordance with Testing Procedure
Preparation Work for Troubleshooting of Electrical System
Preparation Work
Classification and Procedure for Troubleshooting
Classification of Troubleshooting
Procedure for Troubleshooting
Symptom of Probable Failure and Troubleshooting No
Information Mentioned in Troubleshooting Table
Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System
Connection Table for Connector Pin Numbers
T-Branch Box and T-Branch Adapter Table
Fuse List and Location
Connection Table of Fuse Box
Locations of Fusible Links
Location of Fuse Box and Fuse Numbers
Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)

DISASSEMBLY AND ASSEMBLY
Removal And Installation Of Assemblies
Special Tools
Removal
Installation
Disassembly And Assembly Of Assemblies
Special Tools
Disassembly
Assembly
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

MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Engine Mounts
Cooling System
POWER TRAIN
Swing Circle
Swing Machinery
Final Drive
Sprocket
UNDERCARRIAGE AND FRAME
Track Frame and Idler Cushion
Idler
Track Roller
Carrier Roller
Track Shoe
Triple Grouser Shoe
HYDRAULIC SYSTEM
Hydraulic Tank
Main Pump
Control Valve

AIR CONDITIONER
Precautions for Refrigerant
Air Conditioner Component
Structure and Function of Refrigeration System
Overview of Refrigeration System
Air Conditioner Unit
Function
Functions of Major Components
Evaporator
Heater core
Evaporator temperature sensor
Servomotor
Expansion valve
Dual Pressure Switch
Air Conditioner Controller
Air Conditioner Compressor
Air Conditioner Condenser
Sunlight Sensor
Outside Air Temperature Sensor
Inspection and Troubleshooting Procedure of Air Conditioner
Basic Inspection and Troubleshooting Sequence
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
Information in Troubleshooting Table
Failure Code List Related to Air Conditioner

DIAGRAMS AND SCHEMATICS
HYDRAULIC SYSTEM
Hydraulic Circuit Symbols
Hydraulic Circuit Diagram and Name of Valves
Hydraulic Circuit Diagram
ELECTRICAL SYSTEM
Electrical Circuit Symbols
Air Conditioner Electrical Circuit
Electrical Control System Diagram
Electrical Circuit Diagram
Connector List and Stereogram
Chassis
Operators Compartment
Engine Compartment

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