This Complete Service Repair Workshop Manual PDF Download for the Komatsu PC290LC-8, PC290NLC-8 Hydraulic Excavator (SN: K50001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu PC290LC-8 - S/N: K50001 and up
Komatsu PC290NLC-8 - S/N: K50001 and up
Engine : SAA6D107E-1
TABLE OF CONTENTS :
00 Index and foreword
01 Specification
10 Structure, function and maintenance standard
20 Standard value table
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
90 Diagrams and drawings
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEN00001-01
Total Pages : 1050
This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
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00 Index and foreword
Index
Organization list of the shop manual
Table of contents
00 Index and foreword
Foreword and general information
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
How to read electric wire code
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
Specification and technical data
Specification and technical data
Specification dimension drawings
Working range diagram
Specifications
Weight table
Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
Engine and cooling system
Engine and cooling system
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
Power train
Power train
Power train
Final drive
Swing machinery
Swing circle
Undercarriage and frame
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system, Part 1
Hydraulic system, Part 1
Hydraulic equipment layout drawing
Hydraulic tank and filter
Hydraulic pump
Pilot oil filter
Hydraulic system, Part 2
Hydraulic system, Part 2
Control valve
CLSS
Functions and operation by valve
Hydraulic drift prevention valve
Hydraulic system, Part 3
Hydraulic system, Part 3
Swing motor
Center swivel joint
Travel motor
PPC valve
Valve control
ATT EPC Valve Assembly
Solenoid valve
PPC Accumulator
Return oil filter
Attachment circuit selector valve
Quick coupler control valve
Quick coupler control valve
Hydraulic cylinder
Work equipment
Work equipment
Dimensions of components
Cab and its attachments
Cab and its attachments
Air conditioner piping
Electrical system
Electrical system
Engine control
Electrical control system
Monitor system
Sensor
PPC Levers
KOMTRAX terminal system
20 Standard value table
Standard service value table
Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts
30 Testing and adjusting
Testing and adjusting, Part 1
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Checking and adjusting air conditioner compressor belt tension
Measuring swing circle bearing clearance
Checking and adjusting track shoe tension
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits
Measuring control circuit basic pressure
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
Measuring and adjusting quick coupler control valve output pressure
Checking parts which cause hydraulic drift of work equipment
Releasing residual pressure from hydraulic circuit
Measuring oil leakage
Bleeding air from each part
Checking cab tipping stopper
Adjusting mirrors
Testing and adjusting, Part 2
Testing and adjusting, Part 2
Special functions of machine monitor
Testing and adjusting, Part 3
Testing and adjusting, Part 3
Handling high-voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service
40 Troubleshooting
General information on troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
How to read electric wire code
Connection table for connector pin numbers
T-boxes and T-adapters table
Troubleshooting by failure code (Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1
Failure codes table
Before carrying out troubleshooting when failure code is displayed
Information in troubleshooting table
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng Oil Press. Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@HANS] Hydr Oil Overheat
Failure code [CA111] EMC Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3 (L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2 (L#2) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error
Troubleshooting by failure code (Display of code), Part 2
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA553] Rail Press High Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2555] Grid Htr Relay Volt High Error
Failure code [CA2556] Grid Htr Relay Volt Low Error
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D862KA] GPS Antenna Discon
Failure code [DA25KP] 5V Sensor 1 Power Abnormality
Failure code [DA29KQ] Model Selection Abnormality
Troubleshooting by failure code (Display of code), Part 3
Troubleshooting by failure code (Display of code), Part 3
Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Failure code [DAFGMC] GPS Module Error
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DGH2KB] Hydr Oil Sensor Short
Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)
Failure code [DW43KA] Travel Speed Sol Discon
Failure code [DW43KB] Travel Speed Sol Short
Failure code [DW45KA] Swing Brake Sol Discon
Failure code [DW45KB] Swing Brake Sol Short
Failure code [DW91KA] Travel Junction Sol Discon
Failure code [DW91KB] Travel Junction Sol Short
Failure code [DWA2KA] Service Sol Discon
Failure code [DWA2KB] Service Sol Short
Failure code [DWK0KA] 2-stage Relief Sol Discon
Failure code [DWK0KB] 2-stage Relief Sol Short
Troubleshooting by failure code (Display of code), Part 4
Troubleshooting by failure code (Display of code), Part 4
Failure code [DXA8KA] PC-EPC (F) Sol Discon
Failure code [DXA8KB] PC-EPC (F) Sol Short
Failure code [DXA9KA] PC-EPC (R) Sol Discon
Failure code [DXA9KB] PC-EPC (R) Sol Short
Failure code [DXE0KA] LS-EPC Sol Discon
Failure code [DXE0KB] LS-EPC Sol Short
Failure code [DXE4KA] Service Current EPC Discon
Failure code [DXE4KB] Service Current EPC Short
Failure code [DXE5KA] Merge-divider Main Sol Discon
Failure code [DXE5KB] Merge-divider Main Sol Short
Failure code [DXE6KA] Merge-divider LS Sol Discon
Failure code [DXE6KB] Merge-divider LS Sol Short
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKA] Washer Drive Discon
Failure code [DY2CKB] Washer Drive Short
Failure code [DY2DKB] Wiper Drive (For) Short
Failure code [DY2EKB] Wiper Drive (Rev) Short
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
Information in troubleshooting table
E-1 When starting switch turned ON, machine monitor displays nothing
E-2 When starting switch turned ON (before starting engine), basic check item lights up
E-3 Engine does not start (Engine does not turn)
E-4 Preheater does not operate
E-5 Automatic warm-up system does not operate (in cold season)
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked
E-7 Precaution lights up while engine is running
E-8 Emergency stop item lights up while engine is running
E-9 Engine coolant temperature gauge does not indicate normally
E-10 Hydraulic oil temperature gauge does not indicate normally
E-11 Fuel level gauge does not indicate normally
E-12 Contents of display by machine monitor are different from applicable machine
E-13 Machine monitor does not display some items
E-14 Function switch does not work
E-15 Auto-decelerator does not operate normally
E-16 Working mode does not change
E-17 Travel speed does not change
E-18 Alarm buzzer cannot be stopped
E-19 Windshield wiper and window washer do not operate
E-20 Power maximizing function does not operate normally
E-21 Swing holding brake does not operate normally
E-22 Travel alarm does not sound or does not stop sounding
E-23 Air conditioner does not operate normally (including air conditioner abnormality record)
E-24 When starting switch is turned OFF, service meter is not displayed
E-25 Machine monitor cannot be set in service mode
E-26 Monitoring function does not display lever control signal normally
E-27 KOMTRAX system does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
System diagram of hydraulic and mechanical system
Information in troubleshooting table
H-1 Speed or power of whole work equipment, swing, and travel is low
H-2 Engine speed lowers extremely or engine stalls
H-3 Work equipment, swing, and travel systems do not work
H-4 Abnormal sound comes out from around hydraulic pump
H-5 Auto-decelerator does not operate
H-6 Fine control performance or response is low
H-7 Speed or power of boom is low
H-8 Speed or power of arm is low
H-9 Speed or power of bucket is low
H-10 Work equipment does not move singly
H-11 Hydraulic drift of work equipment is large
H-12 Time lag of work equipment is large
H-13 When part of work equipment is relieved singly, other parts of work equipment move
H-14 Power maximizing function does not work
H-15 In compound operation of work equipment, speed of part loaded more is low
H-16 When machine swings and raises boom simultaneously, boom rising speed is low
H-17 When machine swings and travels simultaneously, travel speed lowers largely
H-18 Machine deviates during travel
H-19 Travel speed is low
H-20 Machine is not steered well or steering power is low
H-21 Travel speed does not change or travel speed is low/high
H-22 Travel system does not move (only one side)
H-23 Upper structure does not swing
H-24 Swing acceleration or swing speed is low
H-25 Upper structure overruns remarkably when it stops swinging
H-26 Large shock is made when upper structure stops swinging
H-27 Large sound is made when upper structure stops swinging
H-28 Hydraulic drift of swing is large
H-29 Attachment circuit is not changed
H-30 Oil flow in attachment circuit cannot be controlled
Quick coupler
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lack output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant/fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
50 Disassembly and assembly
General information on disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
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 of fuel cooler assembly
Removal and installation of engine and hydraulic pump assembly
Power train
Power train
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Undercarriage and frame
Disassembly and assembly of carrier roller assembly
Disassembly and assembly of track roller assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of sprocket
Expansion and installation of track shoe assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Removal and installation of hydraulic pump assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly and Assembly of Quick Coupler Valve
Work equipment
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Electrical system
Electrical system
Removal and installation of air conditioner unit assembly
Removal and installation of KOMTRAX communication modem assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly
90 Diagrams and drawings
Hydraulic diagrams and drawings
Hydraulic diagrams and drawings (For PC290-8 K50001 ~ K50104)
Hydraulic circuit diagram 1/2
Hydraulic circuit diagram 2/2
Hydraulic diagrams and drawings (For PC290-8 K50105 and up))
Hydraulic circuit diagram 1/2
Hydraulic circuit diagram 2/2
Electrical diagrams and drawings
Electrical circuit diagram (For PC290-8 K50001 ~ K50104)
Electrical circuit diagram (1/5)
Electrical circuit diagram (2/5)
Electrical circuit diagram (3/5)
Electrical circuit diagram (4/5)
Electrical circuit diagram (5/5)
Electrical diagrams and drawings (For PC290 K50105 and up)
Electrical circuit diagram (1/5)
Electrical circuit diagram (2/5)
Electrical circuit diagram (3/5)
Electrical circuit diagram (4/5)
Electrical circuit diagram (5/5)
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