PC290LC 10

SEN05644-02
HYDRAULIC PC290LC -10

EXCAVATOR
SERIAL NUMBERS 15001 and up
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
00 Index and foreword

1 00 Index and foreword
PC290LC-10 00-1
Index
Index
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-13
Important safety notice ....................................................................................................... 00-13
How to read the shop manual.............................................................................................. 00-18
Explanation of terms for maintenance standard .................................................................... 00-20
Handling of fuel system devices .......................................................................................... 00-22
Handling of intake system parts........................................................................................... 00-23
Handling of hydraulic equipment.......................................................................................... 00-24
Method of disconnecting and connecting push-pull type coupler............................................. 00-26
Handling of electrical equipment.......................................................................................... 00-29
How to read electric wire code............................................................................................. 00-37
Precautions when performing operation ............................................................................... 00-40
Standard tightening torque table.......................................................................................... 00-43
List of abbreviation ............................................................................................................. 00-47
Conversion table ................................................................................................................ 00-51
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawings.......................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-8
Table of fuel, coolant and lubricants ....................................................................................... 01-9
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
Cooling system .................................................................................................................... 10-5
Power train system ..................................................................................................................... 10-7
Power train .......................................................................................................................... 10-7
Swing circle ......................................................................................................................... 10-9
Swing machinery ............................................................................................................... 10-10
Final drive ......................................................................................................................... 10-12
Undercarriage and frame........................................................................................................... 10-14
Track frame and idler cushion ............................................................................................. 10-14
Hydraulic system ...................................................................................................................... 10-16
Hydraulic equipment layout drawing .................................................................................... 10-16
Valve control...................................................................................................................... 10-18
Hydraulic tank.................................................................................................................... 10-20
CLSS ................................................................................................................................ 10-22
Main pump ........................................................................................................................ 10-27
Control valve ..................................................................................................................... 10-51
Swing motor .................................................................................................................... 10-104
Travel motor .................................................................................................................... 10-115
PPC valve ....................................................................................................................... 10-129
Solenoid valve ................................................................................................................. 10-150
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-153
Attachment circuit selector valve (for low pressure circuit).................................................... 10-155
Center swivel joint ............................................................................................................ 10-158
Accumulator .................................................................................................................... 10-160
Work equipment ..................................................................................................................... 10-161
Work equipment............................................................................................................... 10-161
Work equipment shim....................................................................................................... 10-162
Bucket play adjustment shim............................................................................................. 10-163
Cab and its attachments .......................................................................................................... 10-164
Cab mount and cab tipping stopper ................................................................................... 10-164
ROPS cab ....................................................................................................................... 10-165
00-2 PC290LC-10
Index
Electrical system .................................................................................................................... 10-166

Electrical control system ................................................................................................... 10-166
Machine monitor system ................................................................................................... 10-209
KOMTRAX system ........................................................................................................... 10-227
Sensors .......................................................................................................................... 10-229
20 Standard value table ..................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine related parts .......................................................................... 20-3
Standard value table for chassis related parts......................................................................... 20-5
30 Testing Adjusting .......................................................................................................................... 30-1
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Checking engine speed ........................................................................................................ 30-9
Measuring boost pressure................................................................................................... 30-10
Measuring exhaust gas color............................................................................................... 30-11
Measuring and adjusting valve clearance ............................................................................. 30-13
Measuring compression pressure ........................................................................................ 30-16
Measuring blowby pressure ................................................................................................ 30-20
Measuring engine oil pressure............................................................................................. 30-21
Measuring EGR valve and KVGT oil pressure....................................................................... 30-22
Measuring fuel pressure ..................................................................................................... 30-23
Measuring fuel delivery, return and leakage .......................................................................... 30-29
Bleeding air from fuel system .............................................................................................. 30-34
Checking fuel circuit for leakage .......................................................................................... 30-36
Handling cylinder cutout mode operation.............................................................................. 30-37
Handling no injection cranking operation .............................................................................. 30-38
Checking and adjusting air conditioner compressor belt tension ............................................. 30-39
Replacing fan belt .............................................................................................................. 30-40
Power train............................................................................................................................... 30-41
Testing swing circle bearing clearance ................................................................................. 30-41
Testing and adjusting track shoe tension .............................................................................. 30-42
Releasing remaining pressure from hydraulic circuit .............................................................. 30-43
Measuring and adjusting of oil pressure in work equipment, swing, and travel circuits .............. 30-44
Measuring oil pressure in control circuit................................................................................ 30-48
Measuring and adjusting oil pressure in pump PC control circuit............................................. 30-49
Measuring and adjusting oil pressure in pump LS control circuit ............................................. 30-52
Measuring solenoid valve output pressure............................................................................ 30-57
Measuring PPC valve output pressure ................................................................................. 30-60
Adjusting play of work equipment and swing PPC valves....................................................... 30-62
Testing pump swash plate sensor ........................................................................................ 30-63
Isolating the parts causing hydraulic drift in work equipment................................................... 30-64
Measuring oil leakage......................................................................................................... 30-65
Bleeding air from hydraulic circuit ........................................................................................ 30-68
Cab and its attachments ............................................................................................................ 30-70
Checking cab tipping stopper .............................................................................................. 30-70
Adjusting mirrors ................................................................................................................ 30-71
Electrical system ...................................................................................................................... 30-73
Special functions of machine monitor ................................................................................... 30-73
Angle adjustment of rear view camera ............................................................................... 30-142
Handling voltage circuit of engine controller........................................................................ 30-144
Handling battery disconnect switch .................................................................................... 30-145
Testing diodes ................................................................................................................. 30-146
Pm clinic ................................................................................................................................ 30-147
PC290LC-10 00-3
Index
Pm clinic service .............................................................................................................. 30-147

40 Troubleshooting............................................................................................................................ 40-1
General information on troubleshooting ........................................................................................ 40-9
Instruction on troubleshooting ............................................................................................... 40-9
How to proceed troubleshooting .......................................................................................... 40-11
Testing before troubleshooting ............................................................................................ 40-12
Testing procedure before troubleshooting............................................................................. 40-14
Preparation work for troubleshooting of electrical system....................................................... 40-42
Classification and procedure for troubleshooting ................................................................... 40-46
Symptom of probable failure and troubleshooting No............................................................. 40-49
Information mentioned in troubleshooting table ..................................................................... 40-52
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-55
Connector list and layout .................................................................................................... 40-57
Connector contact identification........................................................................................... 40-68
T-branch box and T-branch adapter table ........................................................................... 40-105
Fuse list and location.........................................................................................................40-111
Precautions for cleaning and replacing KDPF (KCSF, KDOC) .............................................. 40-113
Failure codes table........................................................................................................... 40-115
Troubleshooting by failure code (Display of code) ...................................................................... 40-124
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-124
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-125
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-126
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-127
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-128
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-129
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-130
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-131
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-132
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-133
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-134
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-135
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-136
Failure code [A1U0N3] HC desorb request1 ....................................................................... 40-137
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-141
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-143
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-145
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-146
Failure code [B@BCNS] Engine Coolant Overheat ............................................................. 40-147
Failure code [B@BCZK] Radiator Coolant Level Low .......................................................... 40-148
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-150
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-151
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-152
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-154
Failure code [CA131] Throttle Sensor High Error................................................................. 40-156
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-158
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-160
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-162
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-164
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-166
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-168
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-170
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-172
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-174
Failure code [CA234] Eng Overspeed ................................................................................ 40-175
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-176
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-177
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-178
00-4 PC290LC-10
Index
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-180

Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-181
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-182
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-194
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-195
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-198
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-200
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-203
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-205
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-207
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-208
Failure code [CA442] Battery Voltage High Error................................................................. 40-210
Failure code [CA449] Rail Press Very High Error................................................................. 40-211
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-212
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-214
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-215
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-216
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-218
Failure code [CA553] Rail Press High Error ........................................................................ 40-220
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-221
Failure code [CA559] Rail Press Low Error......................................................................... 40-223
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-225
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-226
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-228
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-230
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-232
Failure code [CA697] ECM Int Temp Sensor High Error ....................................................... 40-234
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-235
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-236
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-237
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-241
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-242
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-244
Failure code [CA1695] Sensor 5 Supply Volt Low Error ....................................................... 40-246
Failure code [CA1696] Sensor 5 Supply Volt High Error....................................................... 40-248
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-250
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-252
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-254
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-256
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-258
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-261
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-268
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-269
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-270
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-271
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-272
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-273
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-275
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-278
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-279
PC290LC-10 00-5
Index
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-280
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-282
Failure code [CA2357] EGR Differential Pressure ............................................................... 40-284
Failure code [CA2373] Exh Manifold Press. Sens Volt ......................................................... 40-285
Failure code [CA2374] Exhaust Manifold Press Sens Low Error ........................................... 40-287
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-289
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-291
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-293
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-295
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-297
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-299
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-301
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-302
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-303
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-306
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-308
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-310
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-312
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-313
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-314
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-316
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-318
Failure code [CA3251] DOC Inlet Temp High Error .............................................................. 40-321
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-324
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-325
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-328
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-329
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-330
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-333
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-336
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-340
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-344
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-347
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-355
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-359
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-362
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-366
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-367
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-369
Failure code [D110KB] Battery Relay Output Voltage .......................................................... 40-370
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-372
Failure code [D811MC] KOMTRAX Error............................................................................ 40-375
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-376
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX)
......................................................................................................................... 40-377
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-379
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-380
Failure code [DA20MC] Pump Controller............................................................................ 40-381
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-382
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-384
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-387
Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con)........................................ 40-389
Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con) ........................................ 40-391
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-392
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-395
Failure code [DAF0MC] Monitor Error ................................................................................ 40-396
00-6 PC290LC-10
Index
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-397
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-399
Failure code [DAFGMC] GPS Module Error........................................................................ 40-400
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-401
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) ............................................ 40-403
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-404
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-405
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-406
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-410
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-415
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-419
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-421
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-422
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-425
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality........................................ 40-428
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-430
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-433
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality .................................. 40-436
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ..................................... 40-439
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ...................................... 40-442
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-445
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-448
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-451
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-454
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-457
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-460
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality....................................... 40-463
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ...................................... 40-466
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-469
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-473
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-475
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-477
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-479
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-482
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-485
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-487
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-489
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-491
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-493
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit...................................................... 40-495
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-497
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-499
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ................................................. 40-501
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ................................................. 40-503
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-505
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-507
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-509
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-511
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-513
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-515
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-517
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-519
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ................................................ 40-521
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ................................................ 40-523
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-525
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ................................................... 40-527
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-529
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-531
PC290LC-10 00-7
Index
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-533

Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-535
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-537
Troubleshooting of electrical system (E-mode) .......................................................................... 40-539
E-1 Engine does not start (Engine does not rotate).............................................................. 40-539
E-2 Manual preheating system does not work..................................................................... 40-545
E-3 Automatic preheating system does not work................................................................. 40-548
E-4 Preheating monitor does not light up when preheater is operated ................................... 40-550
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-552
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow.................................................................................... 40-555
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow ............................................................................ 40-556
E-8 Coolant temperature monitor lights up in white while engine is running ........................... 40-557
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-558
E-10 Charge level monitor lights up while engine is running ................................................. 40-559
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-560
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-561
E-13 Water separator monitor lights up while engine is running ............................................ 40-562
E-14 Coolant temperature monitor lights up in red while engine is running............................. 40-563
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-564
E-16 Engine oil pressure monitor lights up in red while engine is running .............................. 40-565
E-17 Fuel gauge indicate either full or empty and does not move.......................................... 40-566
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-567
E-19 Coolant temperature gauge indicate either Min or Max and does not move.................... 40-568
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor
Max) .................................................................................................................. 40-569
E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move ............. 40-570
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min
nor Max) ............................................................................................................ 40-572
E-23 Content of display on machine monitor is different from that of actual machine .............. 40-573
E-24 Machine monitor does not display some items ............................................................ 40-574
E-25 Function switch does not work................................................................................... 40-575
E-26 Automatic preheating system does not work (In cold season)....................................... 40-576
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration
switch is operated ............................................................................................... 40-577
E-28 Auto-deceleration is not actuated or canceled when lever is operated ........................... 40-578
E-29 Working mode selector screen selection screen is not diplayed when working mode
E-30 Engine or hydraulic pump setting does not change when working mode is
changed............................................................................................................. 40-581
E-31 Travel speed monitor does not change when travel speed switch is operated ................ 40-582
E-32 Travel speed does not change when travel speed is shifted ......................................... 40-583
E-33 Alarm buzzer does not stop sounding......................................................................... 40-584
E-34 When starting switch is turned to OFF position, service meter is not displayed............... 40-585
E-35 Service mode cannot be selected .............................................................................. 40-586
E-36 Any of work equipment, swing and travel does not work............................................... 40-587
E-37 Any of work equipment, swing and travel can not be locked ......................................... 40-589
E-38 Machine can not swing while swing brake cancel switch is canceled............................. 40-590
E-39 Swing brake does not operate while swing brake cancel switch is locked ...................... 40-592
E-40 One-touch power maximizing function does not work or monitor is not displayed ........... 40-594
E-41 One-touch power maximizing function cannot be released ........................................... 40-596
E-42 Travel alarm does not sound when machine travels..................................................... 40-597
E-43 Travel alarm does not stop sounding when machine stops ........................................... 40-598
E-44 Horn does not sound ................................................................................................ 40-599
E-45 Horn does not stop sounding..................................................................................... 40-601
E-46 Wiper monitor does not light up or go out when wipper switch is operated ..................... 40-602
E-47 Wiper does not operate when wipper switch is operated .............................................. 40-603
00-8 PC290LC-10
Index
E-49 BOOM LOWER indication is not displayed properly with monitoring function ................. 40-606
E-50 ARM DUMP indication is not displayed properly with monitoring function ...................... 40-607
E-51 ARM IN indication is not displayed properly with monitoring function............................. 40-608
E-52 BOOM RAISE indication is not displayed properly with monitoring function ................... 40-609
E-53 BUCKET CURL indication is not displayed properly with monitoring function ................. 40-610
E-54 BUCKET DUMP indication is not displayed properly with monitoring function ................ 40-611
E-55 SWING indication is not displayed properly with monitoring function ............................. 40-612
E-56 TRAVEL indication is not displayed properly with monitoring function............................ 40-613
E-57 Service is not displayed properly with monitoring function ............................................ 40-614
E-58 Attachment hydraulic circuit cannot be changed.......................................................... 40-617
E-59 KOMTRAX system does not work properly ................................................................. 40-618
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-619
Information mentioned in troubleshooting table (H mode) .................................................... 40-619
System chart for hydraulic system ..................................................................................... 40-620
Failure mode and cause table ........................................................................................... 40-622
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-630
H-2 Engine speed lowers significantly or engine stalls ......................................................... 40-633
H-3 Any of work equipment, swing and travel does not work ................................................ 40-635
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-636
H-5 Fine control performance or response is poor ............................................................... 40-637
H-6 Boom operation lacks speed or power ......................................................................... 40-638
H-7 Arm operation lacks speed or power ............................................................................ 40-640
H-8 Bucket operation lacks speed or power........................................................................ 40-642
H-9 Work equipment does not move in single operation....................................................... 40-643
H-10 Hydraulic drift of boom is large .................................................................................. 40-644
H-11 Hydraulic drift of arm is large ..................................................................................... 40-645
H-12 Hydraulic drift of bucket is large ................................................................................. 40-646
H-13 Time lag of work equipment is large ........................................................................... 40-647
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-649
E-15 One-touch power maximizing function does not work .................................................. 40-650
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-651
H-17 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-652
H-18 In combined operations of swing and travel, travel speed drops largely......................... 40-653
H-19 Machine does not travel straight ................................................................................ 40-654
H-20 Travel speed is too low ............................................................................................. 40-655
H-21 Machine is hard to steer or travel power is low ............................................................ 40-657
H-22 Travel speed does not change, or travel speed is too low or high.................................. 40-659
H-23 One of tracks dose not run ........................................................................................ 40-660
H-24 Upper structure does not swing to the right or left ........................................................ 40-661
H-25 Upper structure swing only to the right or left .............................................................. 40-662
H-26 Swing acceleration is poor or swing speed is low (both right and left) ............................ 40-663
H-27 Swing acceleration is poor or swing speed is low (either right or left)............................. 40-664
H-28 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-665
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-666
H-30 Shock is large when upper structure stops swinging.................................................... 40-667
H-31 Large unusual noise is heard when upper structure stops swinging .............................. 40-668
H-32 Swing drift on a slope is large while swing holding brake is applied............................... 40-669
H-33 Swing drift on a slope is large while swing holding brake is released............................. 40-670
H-34 Attachment circuit cannot be changed while attachment is installed.............................. 40-671
H-35 Oil flow in attachment circuit cannot be controlled ....................................................... 40-672
Troubleshooting of engine (S-mode)......................................................................................... 40-673
Information mentioned in troubleshooting table (S mode)..................................................... 40-673
S-1 When starting switch is turned to START position, engine does not crank ....................... 40-674
S-2 When engine cranks, smoke does not come out ........................................................... 40-675
S-3 Engine does not start while fuel is injected (Incomplete combustion)............................... 40-676
S-4 Startability is poor....................................................................................................... 40-677
PC290LC-10 00-9
Index
S-5 Engine does not pick up smoothly ............................................................................... 40-679

S-6 Engine stops during operation ..................................................................................... 40-680
S-7 Engine runs rough or is unstable ................................................................................. 40-682
S-8 Engine lacks power .................................................................................................... 40-683
S-9 Exhaust smoke is black (KDPF clogs up early) ............................................................. 40-685
S-10 Engine oil consumption is too much ........................................................................... 40-687
S-11 Oil becomes contaminated early ................................................................................ 40-688
S-12 Fuel consumption is excessive .................................................................................. 40-689
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-690
S-14 Engine oil pressure drops ......................................................................................... 40-691
S-15 Fuel is contaminated in engine oil .............................................................................. 40-692
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)................................. 40-693
S-17 Coolant temperature rises too high (Overheating) ....................................................... 40-694
S-18 Unusual noise is heard ............................................................................................. 40-695
S-19 Vibration is excessive ............................................................................................... 40-696
S-20 Automatic regeneration is operated frequently ............................................................ 40-697
S-21 Active regeneration is operated for long ..................................................................... 40-698
S-22 White smoke comes out in the process of active regeneration ...................................... 40-699
50 Disassembly and assembly ........................................................................................................... 50-1
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-14
Engine and cooling system ........................................................................................................ 50-17
Removal and installation of supply pump assembly............................................................... 50-17
Removal and installation of injector assembly....................................................................... 50-22
Removal and installation of cylinder head assembly.............................................................. 50-31
Removal and installation of radiator assembly ...................................................................... 50-51
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-53
Removal and installation of aftercooler assembly .................................................................. 50-56
Removal and installation of engine and main pump assembly ................................................ 50-58
Removal and installation of engine front oil seal .................................................................... 50-70
Removal and installation of engine rear oil seal..................................................................... 50-74
Removal and installation of fuel cooler assembly .................................................................. 50-77
Removal and installation of fuel tank assembly ..................................................................... 50-78
Removal and installation of engine hood assembly ............................................................... 50-81
Removal and installation of KDPF assembly......................................................................... 50-84
Disassembly and assembly of KDPF ................................................................................... 50-92
Removal and installation of KCCV assembly ...................................................................... 50-100
Removal and installation of air cleaner assembly ................................................................ 50-102
Power train system ................................................................................................................. 50-105
Removal and installation of travel motor and final drive assembly ......................................... 50-105
Disassembly and assembly of final drive ............................................................................ 50-106
Removal and installation of swing motor and swing machinery assembly .............................. 50-114
Disassembly and assembly of swing machinery.................................................................. 50-117
Removal and installation of swing circle assembly .............................................................. 50-125
Undercarriage and frame......................................................................................................... 50-126
Separation and connection of track shoe assembly ............................................................. 50-126
Removal and installation of sprocket.................................................................................. 50-128
Removal and installation of idler and idler cushion assembly ............................................... 50-129
Disassembly and assembly of idler .................................................................................... 50-130
Disassembly and assembly of idler cushion........................................................................ 50-133
Disassembly and assembly of track roller ........................................................................... 50-135
Disassembly and assembly of carrier roller......................................................................... 50-137
Removal and installation of revolving frame assembly ......................................................... 50-140
Removal and installation of counterweight assembly ........................................................... 50-142
Hydraulic system .................................................................................................................... 50-145
00-10 PC290LC-10
Index
Removal and installation of center swivel joint assembly ..................................................... 50-145

Disassembly and assembly of center swivel joint ................................................................ 50-147
Removal and installation of hydraulic tank assembly ........................................................... 50-148
Removal and installation of main pump assembly ............................................................... 50-152
Removal and installation of control valve assembly ............................................................. 50-156
Disassembly and assembly of control valve........................................................................ 50-163
Disassembly and assembly of work equipment PPC valve................................................... 50-167
Disassembly and assembly of travel PPC valve.................................................................. 50-169
Work equipment ..................................................................................................................... 50-172
Removal and installation of work equipment assembly ........................................................ 50-172
Disassembly and assembly of work equipment cylinder....................................................... 50-175
Removal and installation of operator's cab assembly........................................................... 50-181
Removal and installation of operator cab glass (adhered glass) ........................................... 50-186
Removal and installation of front window assembly ............................................................. 50-194
Removal and installation of floor frame assembly................................................................ 50-200
Removal and installation of air conditioner unit assembly..................................................... 50-206
Removal and installation of operator's seat......................................................................... 50-210
Removal and installation of seat belt .................................................................................. 50-212
Removal and installation of front wiper assembly ................................................................ 50-214
Electric system ....................................................................................................................... 50-220
Removal and installation of air conditioner compressor assembly......................................... 50-220
Removal and installation of air conditioner condenser assembly .......................................... 50-223
Removal and installation of engine controller assembly ....................................................... 50-225
Removal and installation of pump controller assembly......................................................... 50-227
Removal and installation of machine monitor assembly ....................................................... 50-230
Removal and installation of pump swash plate sensor ......................................................... 50-232
Removal and installation of Mass air flow and temperature sensor ....................................... 50-233
Removal and installation of KOMTRAX terminal assembly .................................................. 50-234
60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Swing circle ......................................................................................................................... 60-5
Swing machinery ................................................................................................................. 60-6
Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Truck frame and idler cushion ............................................................................................. 60-12
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-18
Truck shoe ........................................................................................................................ 60-19
Hydraulic tank.................................................................................................................... 60-22
Main pump ........................................................................................................................ 60-23
Control valve ..................................................................................................................... 60-24
Swing motor ...................................................................................................................... 60-32
Travel motor ...................................................................................................................... 60-34
PPC valve ......................................................................................................................... 60-37
Solenoid valve ................................................................................................................... 60-46
Attachment circuit selector valve (for high-pressure circuit) .................................................... 60-47
Attachment circuit selector valve (for low-pressure circuit) ..................................................... 60-48
Center swivel joint .............................................................................................................. 60-49
Work equipment................................................................................................................. 60-50
80 Appendix...................................................................................................................................... 80-1
PC290LC-10 00-11
Index
Air conditioner ............................................................................................................................ 80-3

Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-6
Outline of refrigeration cycle.................................................................................................. 80-7
Air conditioner unit ............................................................................................................... 80-9
Dual pressure switch .......................................................................................................... 80-15
Air conditioner controller ..................................................................................................... 80-16
Air conditioner compressor ................................................................................................. 80-17
Air conditioner condenser ................................................................................................... 80-18
Sunlight sensor .................................................................................................................. 80-20
Outside air temperature sensor ........................................................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-26
Input and output signals of the air conditioner controller ......................................................... 80-27
Parts and connectors layout................................................................................................ 80-29
Layout of air conditioner related parts and connectors ........................................................... 80-30
Testing air leakage (duct) .................................................................................................... 80-33
Testing with self-diagnosis function ...................................................................................... 80-36
How to enter air conditioner "Electrical Systems" screen in service mode of the machine
monitor................................................................................................................. 80-37
Testing vent (mode) changeover.......................................................................................... 80-39
Testing FRESH/RECIRC air changeover.............................................................................. 80-41
Testing sunlight sensor ....................................................................................................... 80-42
Testing (dual) pressure switch for refrigerant......................................................................... 80-43
Testing relays .................................................................................................................... 80-45
Troubleshooting chart 1 ...................................................................................................... 80-46
Failure code list related to air conditioner.............................................................................. 80-51
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-52
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-53
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-54
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-56
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-58
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-59
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-60
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-62
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-63
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-64
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-65
A-2 Troubleshooting of compressor system (Air is not cooled)................................................ 80-67
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-70
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-72
Troubleshooting with gauge pressure................................................................................... 80-74
Testing refrigerant pressure................................................................................................. 80-77
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-80
Handling of compressor oil.................................................................................................. 80-82
Desiccant replacement ....................................................................................................... 80-84
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electric circuit diagram........................................................................................................ 90-13
00-12 PC290LC-10
Index
Electric circuit diagram for air conditioner unit ....................................................................... 90-25

Index.................................................................................................................................................................... 1
PC290LC-10 00-13
Foreword, safety and general information

Important safety notice
(Rev. 2011/02)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
Shop Manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special precautions during the work. The work
indicated with the warning mark should be performed according to the instructions with special attention to
the precautions. Should a hazardous situation occur or be anticipated during such work, be sure to keep
safe first and take every necessary measure.
General precautions wear welding gloves, apron, shielding goggles,

cap and other clothes suited for welding work.
k Inappropriate handling creates an extreme • Before starting work, warm up your body
danger. Read and understand what is thoroughly to start work under good condition.
described in the Operation and Maintenance • Avoid continuing work for long hours and take
Manual before operating the machine. In rests at proper intervals to keep your body in
addition read this manual carefully and good condition. Take rests in specified safe
understand its contents before starting work. places.
• Before performing any greasing or repairs, read Safety points
all the safety labels stuck to the machine. For 1 Good arrangement
the locations of the safety labels and detailed 2 Correct work clothes
explanation of precautions, see the Operation Following work standard
3
and Maintenance Manual.
4 Making and checking signals
• Locate a place in the repair workshop to keep
Prohibition of operation and handling by
tools and removed parts. Always keep the tools 5
unlicensed workers
and parts in their correct places. Always keep
6 Safety check before starting work
the work area clean and make sure that there is
Wearing protective goggles (for cleaning or
no dirt, water, or oil on the floor. Smoke only in 7 grinding work)
the areas provided for smoking. Never smoke
Wearing shielding goggles and protectors (for
while working. 8 welding work)
• When performing any work, always wear safety
shoes and helmet. Do not wear loose work 9 Good physical condition and preparation
clothes, or clothes with buttons missing. Precautions against work which you are not
10 used to or you are used to too much
1. Always wear the protective eyeglasses when
hitting parts with a hammer. Preparation work
2. Always wear the protective eyeglasses when • Before adding oil or making any repairs, park the
grinding parts with a grinder, etc. machine on a hard and level ground, and apply
• When performing any work with two or more the parking brake and chock the wheels or
workers, always agree on the operating tracks to prevent the machine from moving.
procedure before starting. Always inform your • Before starting work, lower the work equipment
fellow workers before starting any step of the (blade, ripper, bucket, etc.) to the ground. If this
work. During the work, hang UNDER REPAIR is not possible, insert the lock pin or use blocks
warning tag in the operator's compartment. to prevent the work equipment from falling. In
• Only qualified workers must perform the work addition, be sure to lock all the control levers
and operation which require license or and hang warning tag on them.
qualification. • When disassembling or assembling, support the
• Keep all tools in good condition. Learn the machine with blocks, jacks, or stands before
correct way to use them, and use the proper starting the work.
ones of them. Before starting work, thoroughly • Remove all mud and oil from the steps or other
check the tools, machine, forklift truck, service places used to get on and off the machine.
car, etc. Always use the handrails, ladders or steps when
• If welding repairs are needed, always have a getting on or off the machine. Never jump on or
trained and experienced welder perform the off the machine. When a scaffolding is not
work. When performing welding work, always
00-14 PC290LC-10
provided, use steps or a step ladder to secure When installing hoses and wires, be sure that
your footing. they will not be damaged by contact with other
parts when the machine is operated.
Precautions during work • When installing high pressure hoses and tubes,
• For the machine equipped with a battery make sure that they are not twisted. Damaged
disconnect switch, before starting the work, hoses and tubes are dangerous, so be
check that the system operating lamp is turned extremely careful when installing hoses and
OFF, and then turn the battery disconnect switch tubes for high-pressure circuits. In addition,
to the OFF (Q) position and pull the switch key check that connections of them are correct.
out. For machines without a battery disconnect • When assembling or installing parts, always
switch, before starting the work, remove the tighten them to the specified torques. When
cables from the battery. Always remove the installing protective parts such as guards, or
cable from the negative (–) terminal first. parts which vibrate violently or rotate at high
• Before disconnecting or removing components speeds, be particularly careful to check that they
of the oil, water, or air circuits, first release the are installed correctly.
remaining pressure completely from the circuit. • When aligning two holes, never insert your
When removing the oil filter cap, a drain plug, or fingers or hand. Be careful not to get your
an oil pressure pickup plug, loosen it slowly to fingers caught in a hole.
prevent the oil from spurting out. • When measuring hydraulic pressure, check that
• The coolant and oil in the circuits are hot when the measuring tools are correctly installed.
the engine is shut down. Be careful not to get • Take care when removing or installing the tracks
scalded. Wait for the oil and coolant to cool of track-type machines. When removing the
before performing any work on the oil or water track, the track separates suddenly, so never let
circuits. anyone stand at either end of the track.
• Before starting work, shut down the engine. • If the engine is operated for a long time in a
When working on or around a rotating part, in place which is not ventilated well, you may suffer
particular, shut down the engine. When checking from gas poisoning. Accordingly, open the
the machine without stopping the engine windows and doors to ventilate well.
(measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to get Precautions for slinging work and making
rolled or caught in rotating parts or moving parts. signals
• When raising a heavy component (heavier than • Only one appointed worker must make signals
25 kg), use a hoist or crane. Before starting work, and co-workers must communicate with each
check that the slings (wire ropes, chains, and other frequently. The appointed signaler must
hooks) are free from damage. Always use slings make specified signals clearly at a place where
which have ample capacity and install them to he (she) is well seen from the operator's seat
proper places. Operate the hoist or crane slowly and where he (she) can see the working
to prevent the component from hitting any other condition easily. The signaler must always stand
part. Do not work with any part still raised by the in front of the load and guide the operator safely.
hoist or crane. 1. Do not stand under the load.
• When removing a cover which is under internal 2. Do not step on the load.
pressure or under reaction force of a spring, • Check the slings before starting sling work.
always leave two bolts in diagonal positions. • Keep putting on gloves during sling work. (Put
Loosen those two bolts gradually and alternately on leather gloves, if available.)
to release the pressure, and then remove the • Measure the weight of the load by the eye and
cover. check its center of gravity.
• When removing components, be careful not to • Use proper sling according to the weight of the
break or damage the electrical wiring. Damaged load and method of slinging. If too thick wire
wiring may cause electrical fires. ropes are used to sling a light load, the load may
• When removing piping, stop the fuel or oil from slip and fall.
spilling out. If any fuel or oil drips onto the floor, • Do not sling a load with one wire rope alone. If it
wipe it off immediately. Fuel or oil on the floor is slung by one wire rope, It may rotate and slip
can cause you to slip and can even cause fires. out of the rope. Install two or more wire ropes
• As a general rule, do not use gasoline to wash symmetrically.
parts. Do not use it to clean electrical parts, in
particular.
• Be sure to assemble all parts again in their
original places. Replace any damaged parts and
parts which must not be reused with new parts.
PC290LC-10 00-15
k Slinging with one rope may cause turning

of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load,
which can result in a dangerous accident.
• Limit the hanging angle to 60 degrees, as a rule.
• Do not sling a heavy load (25 kg or more) with
ropes forming a wide hanging angle from the
hook.
a When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angle. The figure below
• Do not use twisted or kinked wire ropes.
shows the variation of allowable load in kN
• When lifting up a load, observe the following.
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN 1. Wind in the crane slowly until wire ropes are
{1,000 kg} vertically, at various hanging stretched. When settling the wire ropes with
angles. When the two ropes sling a load the hand, do not grasp them but press them
vertically, up to 19.6 kN {2,000 kg} of total from above. If you grasp them, your fingers
weight can be suspended. This weight is may be caught.
reduced to 9.8 kN {1,000 kg} when the two 2. After the wire ropes are stretched, stop the
ropes make a hanging angle of 120 degrees. crane and check the condition of the slung
If the two ropes sling a 19.6 kN {2,000 kg} load, wire ropes, and pads.
load at a lifting angle of 150 degrees, each 3. If the load is unstable or the wire rope or
rope is subjected to a force as large as 39.2 chains are twisted, lower the load and lift it
kN {4,000 kg}. up again.
4. Do not lift up the load at an angle.
• When lowering a load, observe the following.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane

a Read the Operation and Maintenance Manual of
• When installing wire ropes to an angular load, the crane carefully in advance and operate the
apply pads to protect the wire ropes. If the load crane safely.
is slippery, apply proper material to prevent the
wire rope from slipping. Precautions for using overhead traveling crane
• Use the specified eyebolts and fix wire ropes,
k When raising a heavy part (heavier than 25
chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle portion of the kg), use a hoist, etc. . In disassembly and
hook. assembly, the weight of a part heavier than
a Slinging near the tip of the hook may cause 25 kg is indicated after the mark of 4 .
the rope to slip off the hook during hoisting.
• Before starting work, inspect the wire ropes,
The hook has the maximum strength at the
brake, clutch, controller, rails, over wind stop
middle part.
device, ground fault circuit interrupter, crane
collision prevention device, and power
application warning lamp, and check safety.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Check the direction indicator plates (north, south,
east, and west) and the directions of the control
buttons without fail.
00-16 PC290LC-10
• Do not sling a load at an angle. Do not move the Precautions for disconnecting and connecting
crane while the slung load is swinging. hoses and tubes in air conditioner circuit
• Do not raise or lower a load while the crane is
Disconnection
moving longitudinally or laterally.
• Do not drag a sling. k Disconnection although the refrigerant
• When lifting up a load, stop it just after it leaves (refrigerant gas: R134a) used on the
the ground and check safety, and then lift it up. machine's air conditioner is less destructive
• Consider the travel route in advance and lift up a to the ozone layer for environmentally
load to a safe height. friendliness, it is not allowed to be released
• Place the control switch in a position where it will into the atmosphere as is. Whenever
not be an obstacle to work and passage. disconnecting the air conditioner gas circuit,
• After operating the hoist, do not swing the be sure to recover the refrigerant gas to
control switch. reuse it.
• Remember the position of the main switch so
that you can turn off the power immediately in an a Ask a qualified person for collection, and charge
emergency. of the refrigerant (R134a).
• If the hoist stops because of a power failure, turn a Never release the refrigerant (R134a) to the
the power switch OFF. When turning on a switch atmosphere.
which was turned OFF by the ground fault circuit
interrupter, check that the devices related to that k If refrigerant gas (R134a) gets in your eyes,
switch are not in operating condition. you may lose your sight. And if it touches
• If you find an obstacle around the hoist, stop the your skins, you may suffer from frostbite.
operation. Accordingly, put on protective eyeglasses,
• After finishing the work, stop the hoist at the gloves and working suits with long sleeves
specified position and raise the hook to at least while you are collecting or filling the
two meters above the floor. Do not leave the refrigerant (R134a).
sling attached to the hook.
• When loosening the nuts fixing air conditioner
Selecting wire ropes hoses and tubes, be sure to use two wrenches;
• Select adequate ropes depending on the weight use one wrench to fix and use the other one to
of parts to be hoisted, referring to the table loosen the nut.
below
Connection
Wire ropes (standard "Z" twist ropes without
• When installing the air conditioner hoses and
galvanizing) (JIS G3525, No. 6, Type 6x37-A)
tubes, take care to prevent any dirt, dust or
Nominal water from entering.
diameter of rope Allowable load
• When installing the air conditioner hoses and
mm kN ton tubes, check that O-rings are fitted to their joints.
10 8.8 0.9 • Once an O-ring is used, it is deformed and
12 12.7 1.3 deteriorated. Accordingly, do not reuse it.
14 17.3 1.7 • When removing O-rings, use a soft tool so that
16 22.6 2.3 the piping will not be damaged.
18 28.6 2.9 • Check that there is no defect or deterioration on
20 35.3 3.6 the O-ring.
• Apply compressor oil for refrigerant (R134a) to
25 55.3 5.6
the O-ring.
30 79.6 8.1
40 141.6 14.4 a However, do not apply oil to the threads
50 221.6 22.6 portion of a bolt, nut or union.
60 318.3 32.4 Manufacturer Part name
DENSO ND–OIL8
a The allowable load is one-sixth of the breaking
VALEO
strength of the rope to be used (Safety THERMAL ZXL100PG (equivalent to PAG46)
coefficient: 6). SYSTEMS
SANDEN SP–10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with
PC290LC-10 00-17
the other wrench to the specified torque (Use a

torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of hoses and
tubes in the air conditioner circuit.
a For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".
00-18 PC290LC-10
How to read the shop manual

(Rev. 2011/02)
• Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of
them is required, consult KOMATSU distributors.
• Materials and specifications are subject to change without notice.
• Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual

• This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
• This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of each component. It serves not only to give an
understanding for the structure of each component, but also serves as reference material for
troubleshooting.
20. Standard value table
• This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and
adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
• This section explains measuring tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are
explained in "Standard value table".
40. Troubleshooting
• This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by
failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
• This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque, and quantity
and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
• This section gives maintenance standard values of each component. The maintenance standard sub-
section explains the criteria and remedies for disassembly and service.
80. Appendix
• The section contains the equipment which can not be class, field in the other sections.
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment.
90 Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Revision and distribution

• Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
Filing method
• File pages in the correct order of the page numbers printed in the LIST OF REVISED PAGES.
• Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)
• Revisions
The revised pages are shown in the LIST OF REVISED PAGES.
PC290LC-10 00-19
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol Item Description
Safety Special safety precautions which are necessary when performing work are
k described.
Special technical precautions or other precautions for preserving
a Caution standards which are necessary when performing work are described.
Weight of parts of component or parts are indicated. Caution necessary
4 Weight when selecting hoisting wire, or when working posture is important, etc.
are described.
Tightening
3 Tightening torque of the places that requires special attention.
torque
2 Coat Places to be coated with adhesives, etc. during assembly are indicated.
5 Oil, coolant Places where oil, etc. must be added, and capacity are indicated.
Places where oil, etc. must be drained, and quantity to be drained are
6 Drain
indicated.
Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00-20 PC290LC-10
Explanation of terms for maintenance standard

(Rev. 2011/02)
• The maintenance standard chapter describes the criteria for replacing or reusing products or parts in the
machine disassembly and maintenance work. The following terms are used to describe the criteria.
Standard dimension and tolerance

• To be accurate, the finished dimension of parts
is slightly different from one to another.
• To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
• The above dimension set is called the "standard
dimension" and the range of difference from the
standard dimension is called the "tolerance".
• The tolerance with the symbols of + or is
indicated on the right side of the standard
dimension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example) 120 (–0.022/–0.126)
• Usually, the dimension of a hole and the
dimension of the shaft to be inserted into that
hole are indicated by the same standard
dimension and different tolerances of the hole
and shaft. The tightness of fit is decided by the
tolerance. Standard interference
• Indication of dimension of rotating shaft and hole • When the diameter of a hole of a part shown in
and their related drawing. the given standard dimension and tolerance
Example: table is smaller than that of the shaft to be
Standard Tolerance inserted, the difference between those
dimension Shaft Hole diameters is called the "interference".
-0.030 +0.046 • Subtract the maximum dimension of the hole
60 from the minimum dimension of the shaft and
-0.076 0
call it (A). Subtract the minimum dimension of
Standard clearance and standard value the hole from the maximum dimension of the
• The clearance made when new parts are shaft and call it (B). The range between (A) and
assembled is called the standard clearance, (B) is the "standard interference".
which is indicated by the range from the • After repairing or replacing some parts, measure
minimum clearance to the maximum clearance. the dimension of their hole and shaft and check
• When some parts are repaired, the clearance is that the interference is in the standard range.
generally adjusted to the standard clearance.
Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimension of parts changes due to the wear
"standard value", which is indicated by a range or deformation while they are used. When the
or a target value. dimension charges exceeding certain valve,
• When some parts are repaired, the value of parts can not be used any longer. This value is
performance/function is set to the standard called the "repair limit".
value. • If a part is worn to the repair limit, it must be
replaced or repaired.
PC290LC-10 00-21
• The performance and function of products

lowers while they are used. When alternative
charactaristic value of the performance and
function towers exceeding certain limit, it fluence
operation etc. This value is called the allowable
value or allowable dimension
• If a product deviates from the allowable value, it
must be checked or repaired. However, since
the allowable values are generally estimated
from various tests or experiences in most cases,
it must be judged after considering the operating
condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• If the interference between the parts exceeds
the allowable interference, they must be
replaced or repaired.
00-22 PC290LC-10
Handling of fuel system devices

(Rev. 2011/02)
• The common rail fuel injection system (CRI)
consists of more precise parts than the
conventional fuel injection pump and nozzles. If
foreign matter enters this system, it can cause a
problem. Use special care to prevent entry of
foreign matter when performing inspection and
maintenance of the fuel system.
Be careful of the work environment

• Avoid replacing filters or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.
Cleaning off dusts

• Wash the system carefully with clean fuel if
dusts enter the system.
Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzles, it
employs a high-efficiency special filter to prevent
foreign matter from entering it. If a filter other
than the genuine one is used, the fuel system
may have a trouble. Accordingly, never use such
a filter.
PC290LC-10 00-23
Handling of intake system parts

(Rev. 2011/02)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the conventional turbocharger.
If foreign matter enters this system, it can cause
a problem. Use special care to prevent entry of
foreign matter when servicing the air intake
system.

• Avoid repairing the machine in rain or high winds,
or at places where there is a lot of dust.
Sealing openings
• Install a cap, tape, plastic bag, etc. to the open
ends of disconnected piping to prevent entry of
foreign matter. Never leave the openings
uncovered nor plug the openings with rags.
Foreign matter will enter the system.
00-24 PC290LC-10
Handling of hydraulic equipment

(Rev. 2011/02)
• With the increase in pressure and precision of hydraulic components, the most common cause of failure is
dirt (foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding
hydraulic oil, or when disassembling or assembling hydraulic components.

• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
Disassembly and maintenance work in the field

• When disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the
Preventing intrusion of foreign materials during
performance should be checked with special refilling operations.
test equipment. • Be careful not to let any foreign materials get in
when refilling with hydraulic oil. Always keep the
oil filler and the area around it clean, and also
use clean pumps and oil containers. If an oil
cleaning device is used, it is possible to filter out
the dirt that has been collected during storage,
so this is an even more effective method.
Sealing openings
• After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any foreign materials from
entering. If the opening is exposed or is blocked
with a rag, there is a danger of foreign materials
entering or of the surrounding area being Replacing hydraulic oil while its temperature is
contaminated by leaking oil, so never do this. Do high
not simply drain oil out onto the ground, but • When hydraulic oil or other oil is warm, it flows
collect it and ask the customer to dispose of it, or easily. In addition, the sludge can also be
take it back with you for disposal. drained out easily from the circuit together with
the oil, so it is better to change the oil when it is
still warm. When changing the oil, the old
hydraulic oil must be drained out as much as
possible. (Drain the oil not only from the
hydraulic tank, but also from the filter and the
drain plug hole in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
PC290LC-10 00-25
Flushing operations
• After disassembling and assembling the
equipment, or changing the oil with new one,
use flushing oil to remove the contaminants,
sludge, and old oil from the hydraulic circuit.
Normally, flushing is performed twice. Primary
flushing is performed by use of flushing oil and
secondary flushing is performed by use of the
specified hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
00-26 PC290LC-10
Method of disconnecting and connecting push-pull type coupler

(Rev. 2011/02)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank slowly to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3), aligning them with each
other. (Fig. 4)
a The adapter can be pushed in approximately
3.5 mm. a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
a Do not hold rubber cap portion (4).
the other side perfectly, pull it back to check the
2. While hose joint (2) is pushed into adapter (3),
connecting condition (Fig. 5)
press rubber cap portion (4) against adapter (3)
until it "clicks". (Fig.2) a When the hose is pulled back, the rubber cap
3. Hold hose adapter (1) or hose (5) and pull it out. portion moves toward the hose
(Fig. 3) approximately 3.5 mm. This does not
indicate abnormality, however.
a Since some hydraulic oil flows out, prepare
an oil container.
PC290LC-10 00-27
Type 2
Disconnection
1. Hold the tightening adapter portion and push
body (7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2. While holding the condition of Step 1), turn lever
(8) to the right (clockwise). (Fig. 7)
3. While holding the condition of Steps 1) and 2),
pull out whole body (7) to disconnect it. (Fig. 8)
Connection
• Hold the tightening adapter portion and push
contacts contact surface (a) of the hexagonal
00-28 PC290LC-10
Type 3
Disconnection
1. Hold the tightening adapter portion and push
contacts contact surface (b) of the hexagonal
2. While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the male
end. (Fig. 11)
3. While holding the condition of Steps 1) and 2),
pull out whole body (9) to disconnect it. (Fig. 12)
Connection
• Hold the tightening adapter portion and push
contacts contact surface (b) of the hexagonal
PC290LC-10 00-29
Handling of electrical equipment

(Rev. 2011/02)
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For • The pins of the male and female connectors are
this reason, it is necessary to be extremely attached to wires by crimping or soldering. If
careful when handling wiring harnesses. excessive force is applied to the wire, the joint
area may become loose, which may result in a
defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective contact
between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the harness is pulled to disconnect the
occur because the male connector is not connector, or components are lifted with a crane
properly inserted into the female connector, or while the harness is still connected, or a heavy
because one or both of the connectors is object hits the harness, the crimping of the
deformed or the position is not correctly aligned, connector may separate, or the soldering may
or because there is corrosion or oxidization of be damaged, or the harness may be broken.
the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connector appoximately ten
times.
00-30 PC290LC-10
dry cloth or blow it with compressed air and

spray it with electrical contact cleaner.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier, so
remove the oil and water from the
compressed air completely before cleaning
with compressed air.
High-pressure water entering connector

• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but at the same time, if water does
enter, it is difficult to drain it. Therefore, if water
should get into the connector, the pins will be
short-circuited by the water, so if any water gets Removing, installing, and drying connectors
and wiring harnesses
in, immediately dry the connector or take other
Disconnecting connectors
appropriate action before passing electricity
through it. 1. Hold the connectors when disconnecting.
• When disconnecting the connectors, hold the
connectors. For connectors held by a screw,
loosen the screw fully, then hold the male
and female connectors in each hand and pull
them apart. For connectors which have a
lock stopper, press down the stopper with
your thumb and pull the connectors apart.
a Never pull with one hand.
Entry of water or mud or dirt when disconnecting a

connector
• If any water or mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting a connector, wipe off any
stuck water or dirt using a piece of dry cloth or
blow it with compressed air.
Oil or mud or dirt stuck to connector 2. When removing from clips
• If any oil or grease are stuck to the connector • Both of the connector and clip have stoppers,
and an oil film is formed on the mating surface of which are engaged with each other when the
the male and female pins, the oil will prevent connector is installed.
electricity from passing through, resulting in
defective contact. If any oil or grease or mud or
dirt is stuck to the connector, wipe it off with a
PC290LC-10 00-31
• Check that connector pins are free from

deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water, or dirt are stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
inside of the wiring with a dryer, but be
careful not to make it too hot as this will
cause short circuits.
• When removing a connector from a clip, pull
a If there is any damage or breakage, replace
the connector in a parallel direction to the clip
the connector.
for removing stoppers.
2. Fix the connector securely.
a If the connector is pried up and down or • Align the position of the connectors correctly
to the right or left, the housing may break. and then fit them securely. For connectors
with the lock stopper, push in the connector
until the stopper "clicks" into position.
3. Action to take after removing connectors

• After removing a connector, cover it with a
vinyl bag to prevent entry of dust, dirt, oil, or 3. Correcting protrusion of the boot and
water to the contact portion. misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness is misaligned or the clamp is
cover the connector. out of position, adjust it to its correct position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
Connecting connectors
1. Check the connector visually.
• Check that there is no oil, dirt, or water stuck
to connector pins (joint portion).
00-32 PC290LC-10
• If the connector clamp is removed, be sure to • If there is any oil or dirt on the wiring harness,
return it to its original position. Also check wipe it off with a dry cloth. Avoid washing it in
that there are no loose clamps. water or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.
1. Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is the risk that oil in
the air may cause defective contact,
remove oil and water in the air before
starting air blow.
Deutsch connector (DT8-pin, DT12-pin)

Disconnection
1. While pressing locks (a) and (b), pull out female
connector (2).
2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that hot air is used in
order to prevent the connector or related
Connection parts from becoming too hot, as this will
cause deformation or damage to the
1. Push in female connector (2) horizontally until
connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) while
moving it up and down until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins
caused by water.
Drying wiring harness
PC290LC-10 00-33
a After completely drying the connector,

blow it with contact restorer and
reassemble.
Connection
1. Insert the connector straight until it "clicks".
Slide, lock type (Type 2) (FRAMATOME-24)

Handling of connectors used on engine • 107/114/125 series
• Intermediate connector between machine wiring
a Mainly, following engines are object for following
harness and engine wiring harness
connectors.
Examples)
• 95E-5 Intermediate connector (engine wiring harness):
• 107E-1, 107E-2 OEM CONNECTION (107/114/125 series)
• 114E-3, 114E-5 Disconnection
• 125E-5, 125E-6
1. Slide down lock (red) (L1).
• 140E-5, 140E-6
• 170E-5
• 12V140E-3
Slide, lock type (Type 1) (FRAMATOME-3,
FRAMATOME-2)
• 95/107/114/125/140/170/12V140 Series
• Various pressure sensors and Ne speed sensor
Examples)
Charge (boost) pressure sensor in the air intake
manifold: PIM (125/170/12V140 series)
Oil pressure sensor: POIL (125/170/12V140
series)
Oil pressure switch (95/107/114 series)
Ne speed sensor on flywheel housing: Ne (95/ 2. While pressing lock (L2), pull out connector (1).
107/114/125/140/170/12V140 series)
Ambient pressure sensor: PAMB (125/170/
12V140 series)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a Even if lock (L2) is pressed, connector (1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A with a
small flat-head screwdriver while press lock
(L2), and then pull out connector (1) toward
you.
a Lock (L2) is located in the back of connector
(1).
00-34 PC290LC-10
Connection • 107 series

1. Insert the connector straight until it "clicks".
Pull lock type (PACKARD-2)

• 95/107/114/125/140/170/12V140 Series
• Various temperature sensors
Examples)
Charge (boost) temperature sensor in the air
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR and other.
Disconnection
1. Disconnect the connector by pulling lock (B) (on
the wiring harness side) of connector (2) a If the lock is located on the underside, use
outward. flat-head screwdriver [1] since you cannot
insert your fingers.
While pressing up lock (C) of the connector
with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
Connection
1. Insert the connector straight in until it "clicks".
Push lock type (1)

• 95/107/114 series
Connection
Examples)
Fuel pressure sensor in common rail (BOSCH-3) 1. Insert the connector straight until it "clicks".
Disconnection
Push lock type (2)
1. While pressing lock (C), pull out connector (3) in • 107/114 series
the direction of the arrow. Examples)
• 114 series Charge (boost) pressure sensor in the air intake
manifold (SUMITOMO-4)
Disconnection
1. While pressing lock (D), pull out connector (4) in
the direction of the arrow.
PC290LC-10 00-35
Connection Connection
1. Insert the connector straight in until it "clicks". 1. Insert the connector straight in until it "clicks".
Push lock type (3) Turn-housing type (Round green connector)

• 95/125/140/170/12V140 series • 140 series
Disconnection Example) Charge (boost) pressure sensor in the
1. While pressing lock (E) of the connector, pull out air intake manifold: PIM (CANNON-4), etc.
connector (5) in the direction of the arrow. Disconnection
Example) Fuel pressure sensor in common rail 1. Turn housing (H1) in the direction of the arrow.
PFUEL etc (AMP-3)
a When connector is unlocked, housing (H1)
becomes heavy to turn.
2. Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.
Example) Injection pressure control valve of

supply pump: PCV (SUMITOMO-2)
Connection
1. Insert the connector to the end, while aligning its
groove to the other.
2. Turn housing (H1) in the direction of the arrow
until it "clicks".
Example) Speed sensor of supply pump: G

(SUMITOMO-3)
a Pull the connector straight up.
00-36 PC290LC-10
connected to the controller.Fit an arc welding

ground close to the welding point.
Precautions for troubleshooting electrical

circuits
• Be sure to turn the power "OFF" before
disconnecting or connecting connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check by disconnecting and connecting the
related connectors several times.
• Be sure to connect any disconnected
connectors before going on to the next step.
Handling controller
a If the power is turned ON with the connectors
• Electronic circuits for control including
still disconnected, unnecessary warning not
microcomputers are assembled in the controller.
related to the part where an abnormality
These electronic circuits inside must be handled
occurs will be displayed.
with care since they control the machine.
• When performing troubleshooting of circuits
• Do not place objects on top of the controller.
(measuring the voltage, resistance, continuity, or
current), wag the related wiring harnesses and
connectors several times and check that the
tester reading does not change.
a If there is any value change on the tester,
there may be a defective contact in the
circuit.
• Cover the control connectors with tape or a vinyl

bag. Never touch the connector contacts with
your hand.
• During rainy weather, do not leave the controller
in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
temperature even for a short period of time.
(Place it on a suitable dry stand.)
• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all wiring harness connectors
PC290LC-10 00-37
How to read electric wire code

(Rev. 2011/02)
• In the electric circuit diagram, material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.
Type, symbol, and material

• AV and AVS are different only in thickness and outside diameter of the coating. CAVS has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Operating
Type Sym- temperature Example of use
Material
bol range (˚C)
Low-voltage Conduc- Annealed copper wire for General wiring
wire for AV tor electric appliance
automobiles (nominal No. 5 and above)
Insulator Soft polyvinyl chloride
Thin low- Conduc- Annealed copper wire for
voltage wire for tor electric appliance General wiring
automobile AVS
(nominal No. 3 and below)
Insulator Soft polyvinyl chloride -30 to +60
(type 1)
Thin low- Conduc- Annealed copper wire for
tor electric appliance For mid- to small-size
voltage wire for
automobile CAVS excavators
Insulator Soft polyvinyl chloride (nominal No. 1.25 and below)
(type 2)
Heat resistant Conduc- Annealed copper wire for General wiring in extremely cold
low-voltage tor electric appliance weather district. For wiring in a
AEX -50 to +110 place of high atmospheric
wire for Heat-resistant crosslinked
automobiles Insulator polyethylene temperature
00-38 PC290LC-10
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
Conduc- strand
tor Cross-
section 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Coating D
AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
Conduc- strand
tor Cross-
section 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
strands/ 7/Circular 11/Circular 16/Circular
– – –
Diameter of compressed compressed compressed
Conduc- strand
tor Cross-
section – 0.56 – 0.88 – 1.29
area (mm2)
d (approx.) – 0.9 – 1.1 – 1.4
Coating D
CAV- – – –
Standard 1.6 1.8 2.1
S
a "f" of nominal No. denotes "flexible".
PC290LC-10 00-39
Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
a Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of – – –
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
00-40 PC290LC-10
Precautions when performing operation

(Rev. 2011/02)
• When performing "removal or installation", "disassembly or assembly" of units, be sure to follow the
general precautions given below.
Precautions for removal work

• If the coolant contains antifreeze, dispose of it correctly as chemicals.
• After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
• When draining oil, prepare an adequate-size container to catch the oil.
• Check the match marks showing the installation position, and put match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installation position to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When slinging component, be sure to use lifting tool strong enough.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Put the following plugs into the piping after disconnecting it during disassembly works.
Face seal type hoses and tubes
Nominal Plug (nut end) Nut (elbow end)
No.
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
Split flange type hoses and tubes
Nominal Flange (hose end) Sleeve head (tube end) Split flange
No.
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PC290LC-10 00-41
Precautions for installation work

• Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
• Install the hoses without twisting or interference and fix them with intermediate clamps, if equipped.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean and degrease the part, and coat the threaded portion with two to three
drops of adhesive.
• When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making sure
that the surface is free from dirt or damage.
• Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
• After installing the snap rings, check that the snap ring is settled in the ring groove completely.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
them securely.
• When using eyebolts, check that there is no deterioration or deformation, screw them in fully, and align the
direction of the hook.
• When installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on one
side.
a When the cylinders, hydraulic pumps and other hydraulic component are removed for repair, and then
reassembled again, be sure to bleed the air as follows before operating the hydraulic cylinders for the first
time.
1. Start and run the engine at low idle.
2. Operate the work equipment control lever to operate the hydraulic cylinder and stop at 100 mm off the
end of its stroke. Repeat this four to five times.
3. Next, operate the hydraulic cylinder three to four times to the end of its stroke.
a When using the machine for the first time after it has been repaired or after a long period of storage, follow
the same procedure.
Precautions for completing work

Refilling of coolant, oil and grease
• If the coolant is drained, close the drain valve securely, and add coolant to the specified level. Run the
engine to circulate the coolant through the system. Then add the coolant to the specified level again if
necessary.
• If the hydraulic component is removed and installed again, add engine oil to the specified level. Run the
engine to circulate the oil through the system. Then add the oil to the specified level again if necessary.
• If the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system after
reassembling the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
Check of installed condition of cylinder head and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any part is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
00-42 PC290LC-10
Check of engine piping for damage and looseness

Intake and exhaust Check the piping for damage, the mounting bolts and nuts for looseness, and the
system joints for air suction and exhaust gas leakage.
If any part is loose or damaged, retighten or repair it.
Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the
joints for water leakage.
Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the
joints for fuel leakage.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounts for a crack and damage. If any part is
damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loose, retighten it.
Check of KDPF or muffler function
• Check KDPF or muffler for unusual noise and sound different from that of a new one.
If any abnormal noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly
and assembly".
PC290LC-10 00-43
Standard tightening torque table

(Rev. 2011/02)
Table of tightening torque for bolt and nuts

a Unless otherwise specified, tighten metric bolt and nut to the torque shown in the following table.
1. The following table applies to the bolt in Fig. A.
Thread Width Tightening torque
diameter across flats
(Nm) (kgm)
(mm) (mm)
6 10 (10) 11.8 to 14.7 1.2 to 1.5
8 13 (12) 27 to 34 2.8 to 3.5
10 17 (14) 59 to 74 6.0 to 7.5
12 19 (17) 98 to 123 10.0 to 12.5
14 22 157 to 196 16 to 20
16 24 245 to 309 25 to 31.5
18 27 343 to 427 35 to 43.5
20 30 490 to 608 50 to 62
22 32 662 to 829 67.5 to 84.5
24 36 824 to 1,030 84 to 105
27 41 1,180 to 1,470 120 to 150
30 46 1,520 to 1,910 155 to 195
33 50 1,960 to 2,450 200 to 250
36 55 2,450 to 3,040 250 to 310
39 60 2,890 to 3,630 295 to 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
(Nm) (kgm)
(mm) (mm)
6 10 5.9 to 9.8 0.6 to 1.0
8 12 13.7 to 23.5 1.4 to 2.4
10 14 34.3 to 46.1 3.5 to 4.7
12 17 74.5 to 90.2 7.6 to 9.2
Fig. A Fig. B
a Values with ( ) are applied to * marked bolt (flange bolt) as the width across flats.
00-44 PC290LC-10
Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten split flanged bolt to the torque shown in the following table.
(Nm) (kgm)
(mm) (mm)
10 14 59 to 74 6.0 to 7.5
12 17 98 to 123 10.0 to 12.5
16 22 235 to 285 23.5 to 29.5
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten O-ring boss piping joint to the torque shown in the following table.
Thread Width Tightening torque (Nm {kgm})
Nominal diameter across flats
number Range Target
(mm) (mm)
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
– 18 Varies 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 depending 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 on type of 128 to 186 {13.0 to 19.0} 157 {16.0}
10, 12 33 connector. 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten O-ring boss plug to the torque shown in the following table.
Thread Width Tightening torque (Nm {kgm})
Nominal diameter across flats
number Range Target
(mm) (mm)
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 – 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 – 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 – 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
PC290LC-10 00-45
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque to when the thread is coated with engine oil (wetted).
Tightening torque (Nm {kgm}) Taper seal Face seal
Width
Nominal across Nominal No. Thread root
number Thread size – Number of diameter
flats Range Target
of hose (mm) (mm) threads, type (mm)
of thread (Reference)
34 to 54 {3.5 to 5.5} 44 {4.5} – 9/16-18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 – –
22 54 to 93 {5.5 to 9.5} 74 {7.5} – 11/16-16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 – –
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 – –
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 – –
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 – –
Table of tightening torque for face seal joints

a Tighten the face seal joint (sleeve nut type) made of plated steel pipes for low pressure service to be used
for engines etc. to the torque shown in the following table.
a Apply the following torque when the thread is coated with engine oil (wetted).
Outer Tightening torque (Nm {kgm}) Face seal

Width Nominal No. –
diameter of Thread root
across flats Number of
pipe Range Target diameter (mm)
(mm) threads, type of
(mm) (Reference)
thread
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1-14UNS 25.4
22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
Table of tightening torque for 102, 107 and 114 engine series (bolt and nut)
a Unless otherwise specified, tighten the metric bolt and nut used for the 102, 107 and 114 engine series to
the torque shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 – –
00-46 PC290LC-10
Table of tightening torque for 102, 107 and 114 engine series (eye joint)
a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series to the
torque shown in the following table.
Thread size Tightening torque
(mm) (Nm) (kgm)
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
Table of tightening torque for 102, 107 and 114 engine series (tapered screw)
a Unless otherwise specified, tighten the tapered screw with pipe thread for the 102, 107 and 114 series
engines to the torque shown in the following table.
Material In cast iron or steel In aluminum
Tightening torque Tightening torque
Thread diameter (inch)
(Nm) (kgm) (Nm) (kgm)
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC290LC-10 00-47
List of abbreviation
(Rev. 2011/02)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations that appear infrequently are marked in the text with an *.
• This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the
manual, and the second part is a list of abbreviations used in circuit diagrams.
List of abbreviations used in the shop manual

Purpose of use (major
Abbre- Full Spelling applicable machine (*), Explanation
viation or component/system)
Travel and brake With this function, when the tires skid (wheels stop
Anti-skid Brake
ABS rotating), the brakes are released, and when the
System (HD, HM) wheels start to rotate, the brakes are applied again.
Automatic Idling
AISS Engine This function automatically sets the idle speed.
Setting System
Advanced Steering Instead of a steering wheel, a lever is used to perform
AJSS Joystick Steering the steering operations as well as to shift gear and
System (WA) change direction (FORWARD or REVERSE).
Automatic If the accelerator pedal is released, when the machine
Retarder Travel and brake
ARAC is travelling downhill, this function automatically applies
Accelerator (HD, HM) the retardar with a constant braking force.
Control
If the accelerator pedal is released, when the machine
Automatic Travel and brake is travelling downhill, this function automatically applies
ARSC Retarder Speed the retardar to ensure that the machine speed does not
Control (HD, HM)
accelerate above the speed set by the operator.
Automatic Spin Travel and brake When the rear wheels spin on soft ground surfaces,
ASR Regulator this function automatically uses the optimum braking
(HD, HM)
force to drive both wheels.
A device that can be fixed onto a machine in order to
ATT Attachment Work equipment
enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil Brake bypasses part of the brake cooling oil to reduce the
BCV
control Valve (HD) load on the hydraulic pump.
Controller Area Communication and Communications standard that is standardized as
CAN
Network electronic control ISO11898.
Crankcase Indicates regulator valve which is installed to KCCV
CDR Depression Engine ventilator.It is written as CDR valve and it is not used
Regulator independently.
Closed-center System that can simultaneously actuate multiple
CLSS Load Sensing Hydraulic actuators regardless of the load (provides better ease
System of combined operation than OLSS).
Uses engine controller to perform electronic control of
Common Rail supply pump, common rail, and injector. Functions to
CRI Engine
Injection maintain optimum fuel injection amount and fuel
injection timing.
Electronic control device that uses the signals from the
Electronic Electronic control
ECM sensors on the machine to indicate to the actuators the
Control Module system
optimum actuation. (same as ECU)
Electronic Transmission Proportional electromagnetic valve that gradually
ECMV Control increases oil pressure to engage clutch and reduces
(D, HD, WA, etc.)
Modulation Valve transmission shock.
Electronically
Travel System that ensures smooth high-speed travel by
Controlled
ECSS Suspension using hydraulic spring effect of accumulator to absorb
(WA) vibration of machine during travel
System
00-48 PC290LC-10

Electronic control device that uses the signals from the
Electronic Electronic control
ECU sensors on the machine to indicate to the actuators the
Control Unit system
optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to
Exhaust Gas Engine combustion chamber in order to reduce combustion
EGR
Recirculation temperature, controls emission of Nox.
Equipment System that allows data (filter, oil replacement interval,
Management malfunctions on machine, failure code, and failure
EMMS Monitoring Machine monitor
history) from each sensor on the machine to be
System checked on monitor.
Electromagnetic Used for electromagnetic proportional control. Actuator
EPC Proportional Hydraulic in this system operate in proportion to the current
Control supplied.
Falling Object This structure protects the operator's head from falling
FOPS Protective Cab and canopy objects. (Falling Object Protective Structure)
Structure This performance is standardized as ISO 3449.
FORWARD-
F-N-R NEUTRAL- Operation FORWARD-NEUTRAL-REVERSE
REVERSE
Global Communication Global Positioning System. A satellite positioning
GPS Positioning (KOMTRAX, system that is used to determine the current location
System KOMTRAX Plus) on the earth.
Steering function that uses a combination of hydraulic
Hydrostatic Steering motor and bevel shaft to control difference in travel
HSS Steering System (D) speed of right and left tracks to turn machine without
using steering clutch.
Transmission Hydraulic transmission system that uses a combination
Hydro Static of hydraulic pump and hydraulic motor to shift gear
HST
Transmission (D, WA) steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel intake
Inlet Metering Engine
IMA amount in order to control fuel delivery of supply pump.
Actuator
Same as IMV.
Inlet Metering Engine amount in order to control fuel delivery of supply pump.
IMV
Valve Referred to as IMV (IMA).
KOMATSU This mechanism separates oil in blowby gas and
Closed Engine returns it to the intake side to afterburn it there. It
KCCV
Crankcase primarily consists of filters.
Ventilation
KOMATSU This filter is used to capture soot in exhaust gas.
KCSF Catalyzed Soot Engine
Filter It is built in to KDPF.
KOMATSU
The catalyst used for purifying exhaust gas.
KDOC Diesel Oxidation Engine
Catalyst It is built in to KDPF.
KOMATSU This component with built-in KDOC (catalyst) and
KDPF Diesel Particulate Engine KCSF (soot-capturing filter) purifies exhaust gas.
Filter It is installed in place of the currently used muffler.
KOMATSU
Variable The turbocharger on which the cross-section area of
KVGT Geometry Engine
the exhaust passage is made variable.
Turbocharger
Image display device made up of a large number of
Liquid Crystal pixels filled with liquid crystal. Liquid crystal display
LCD Display Machine monitor image display device such as monitor, mcorporatal with
liquid crystal pixels.
PC290LC-10 00-49

Light emitting diode. It refers to semiconductor element
Light Emitting Electronic parts
LED that emits light when the voltage is applied in forward
Diode
direction.
Function that senses differential pressure of pump and
LS Load Sensing Hydraulic
controls discharge amount according to load.
This indicates engine intake air flow.It is not used
MAF Mass Air Flow Engine independently but it is used as combined with sensor.
Mass air flow sensor can be called as MAF sensor.
Multimedia Service that allows transmission and reception of short
MMS Messaging Communication messages consisting of characters or voice or images
Service between cell phones.
Device actuated to open electric or hydraulic circuits
NC Normally Closed Electric and hydraulic
that are normally closed if not actuated.
Device actuated to close electric or hydraulic circuits
NO Normally Open Electric and hydraulic
that are normally open if not actuated.
Open-center
Hydraulic system that can operate multiple actuators at
OLSS Load Sensing Hydraulic
the same time, regardless of the load.
System
Pressure
PC Hydraulic A function used to correct oil pressure.
Compensation
Steering System in which a controller instantly analyses data
Palm Command
PCCS Control System from each lever, pedal, and dial, and performs optimum
(D) electronic control of the engine and transmission.
Pump Control Engine amount in order to control fuel discharge amount of
PCV
Valve supply pump.
Proportional Used for controlling proportional pressure. This system
PPC Hydraulic
Pressure Control moves actuators in proportion to the oil pressure.
Piston Pump and Hydraulic Piston pump and motor.
PPM
Motor (D, PC, etc.)
A device to take off the power of the engine and supply
PTO Power Take Off Power transmission
it to other units.
Power Tilt and Work equipment Function that performs hydraulic control of the tilt and
PTP power Pitch pitch of the bulldozer blade.
dozer (D)
If a machine tips over, this structure protects the
Roll-Over operator with the seat belt fastened from being
ROPS Protective Cab and canopy crushed. (Operator Protective Structure When Tipping)
Structure
This performance is standardized as ISO 3471.
Le System Abbreviation for the "International System of Units". It
SI International d’ Unit is universal unit system and a single unit for single
Unites quantity" is the basic principle applied.
Solenoid is a loop of wire. However, as a matter of fact
in engineering, it refers to an actuator consists of a
SOL Solenoid Electric solenoid and an iron core that is moved by the
magnetic force when the solenoid is energized. The
word solenoid also often refers to a solenoid valve.
TWV Two Way Valve Hydraulic and electric Solenoid valve that switches over direction of flow.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
00-50 PC290LC-10
Abbreviation Full Spelling

A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
PC290LC-10 00-51
Conversion table
(Rev. 2011/02)
Method of using the conversion table

• The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the examples given below.
Example: Method of using the conversion table to convert from millimeters to inches
Convert 55 mm into inches.
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore 55 mm = 2.165 in.
Convert 550 mm into inches.
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 in.
Millimeters to inches
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-52 PC290LC-10
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilograms to pounds
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
l to U.S.Gallons
l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC290LC-10 00-53
l to U.K.Gallons
1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-54 PC290LC-10
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC290LC-10 00-55
Temperature
Fahrenheit-Centigrade conversion
• A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice
versa is to refer the number in the center column of the following table.
• When converting from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
• When converting from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 deg.F
°C deg.F °C deg.F °C deg.F °C deg.F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-56 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
01 Specification
2 01 Specification
PC290LC-10 01-1
01 Specification
Table of contents
Table of contents
01 Specification................................................................................................................................. 01-1
Specifications............................................................................................................................. 01-3
Specification drawings.......................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-8
Table of fuel, coolant and lubricants ....................................................................................... 01-9
01-2 PC290LC-10
01 Specification
Specification drawings
Specifications
Specification drawings
Item Unit PC290LC-10

Machine weight kg 30,200
Bucket capacity m3 1.26
Engine model — Komatsu SAA6D107E-2 diesel engine
Engine flywheel horsepower
• Net [ISO 9249/SAE J1349] 147 {196}/2,050
kW {HP}/rpm
• Gross [SAE J1995] 159 {213}/2,050
A Overall length mm 9,860
B Overall height mm 3,205
C Overall width mm 3,390
D Shoe width mm 800
E Cab height mm 3,180
F Tail swing radius mm 2,940
G Overall length of track mm 4,955
Distance between tumbler mm 4,030
H
centers
J Height of handrail mm 3,275
Min. ground clearance mm 498
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Swing speed rpm 10.5
a The engine flywheel horsepower is indicated in the net value and gross value. Gross value is the flywheel
horsepower measured of the bear engine. While, net value is the value measured of the engine under the
same condition essentially as the condition that it is installed on the machine.
PC290LC-10 01-3
01 Specification
Working range drawings
Working range drawings
Item Unit PC290LC-10

A Max. digging reach mm 10,100
B Max. digging depth mm 6,460
C Max. digging height mm 10,000
D Max. vertical wall digging depth mm 5,650
E Max. dumping height mm 7,035
F Min. dumping height mm 2,570
Max. digging reach at ground mm 9,990
G
level
01-4 PC290LC-10
01 Specification
Specifications
Specifications
Machine model PC290LC-10
Serial number 15001 and up
Bucket capacity m3 1.26
Machine weight kg 30,200
Performance
PC290LC-10
15001 and up
Max. digging depth mm 6,460
Working ranges
Max. vertical wall digging depth mm 5,650

Max. digging reach mm 10,100
Max. digging reach at ground mm 9,990
level
Max. digging height mm 10,000
Max. dumping height mm 7,035
Max. digging force 184 {18,800}
kN {kg}
(with power maximizing function) (198 {20,200})
Swing speed rpm 10.5
Swing operation max. slope angle deg. 20
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Gradeability deg. 35
Ground pressure (standard shoe) kPa {kg/cm2} 42 {0.43}
Dimensions
PC290LC-10
15001 and up
Overall length mm 9,860
Overall width mm 3,390
Overall height (for transport) (*1) mm 3,205
Cab height mm 3,180
Height of handrail mm 3,275
Ground clearance of upper structure mm 1,215
Min. ground clearance mm 498
Tail swing radius mm 2,940
Min. swing radius of work equipment mm 3,430
Top height at min. swing radius of
mm 8,150
work equipment
Overall width of track mm 3,390
Overall length of track mm 4,955
Track gauge mm 2,590
Distance between tumbler centers mm 4,030
Cab height mm 2,380
Standard shoe width mm 800
PC290LC-10 01-5
01 Specification
Specifications
Engine
PC290LC-10
15001 and up
Model SAA6D107E–2
4-cycle, water-cooled, in-line vertical,
Type direct injection type with turbocharger
and air-cooled aftercooler
No. of cylinders - bore x stroke mm 6－107x124
Piston displacement l {cc} 6.69 {6,690}
Flywheel hosepower
• Net [ISO 9249/SAE J1349] 147 {196}/2,050
kW {HP}/rpm
• Gross [SAE J1995] 159 {231}/2,050
Performance
Max. torque Nm/rpm {kgm/rpm} 819/1,500 {83/1,500}

Max. speed with no load
• At mounted on machine 1,955 ± 30
rpm
• At bear engine 2,180 ± 30
Min. speed with no load rpm 1,050 ± 25
Min. fuel consumption ratio g/kWh {g/HPh} 218 {162}
Starting motor 24 V, 5.5 kW
Alternator 24 V, 60 A
Battery (*2) 12 V, 140 Ah x 2
Radiator core type Aluminum wave type, 4 rows
Undercarriage
PC290LC-10
15001 and up
Carrier roller 2 (each side)
Track roller 8 (each side)
Assembly type triple grouser, 48 (each
Track shoe side)
01-6 PC290LC-10
01 Specification
Specifications
Hydraulic system
PC290LC-10
15001 and up
Variable displacement piston type (HPV
Hydraulic pump
Type x number
125 + 125) x 2
Delivery l/min 245 x 2
Set pressure MPa {kg/cm2} 37.2 {380}
Type x number 7-spool type x1

Control valve
Operating method Hydraulic
Variable displacement piston type (HMV

Hydraulic motor
Travel motor 160ADT - 2) x 2

(with brake valve and parking brake)
Fixed displacement piston type
(KMF125ABE - 6) x 1
Swing motor
(with safety valve and swing holding
brake)
Type Double-acting piston
Cylinder bore mm 140
Boom (*3)
Piston rod diameter mm 100

Stroke mm 1,300
Max. distance between pins mm 3,150
Min. distance between pins mm 1,850
Hydraulic cylinder

Arm (*4)

Stroke mm 1,635
Bucket

Stroke mm 1,010
Hydraulic tank Box-shaped sealed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled type (CF40-1)
*1: Grouser height (36 mm) included.
*2: The battery capacity (Ah) is indicated in the 5-hour rate.
*3: With head side cushion.
*4: With head side cushion and bottom side cushion.
a The engine flywheel horsepower is indicated in the net value and gross value. Gross value is the flywheel
horsepower measured of the bear engine. While, net value is the value measured of the engine under the
same condition essentially as the condition that it is installed on the machine.
PC290LC-10 01-7
01 Specification
Weight table
Weight table
k This weight table is prepared for your reference when handling or transporting the components.
Unit:kg
Machine model PC290LC-10
Serial number 15001 and up
Engine assembly 886
• Engine 690
• Damper 6
• Main pump 190
Radiator and oil cooler assembly 172
Hydraulic tank and filter assembly (excluding hydraulic oil) 140
Fuel tank assembly (excluding fuel) 165
Revolving frame 2,273
Operator's cab 530
Operator seat 20
Counterweight 5,510
Swing machinery 218
Control valve 257
Swing motor 51.7
Travel motor 164 x 2
Center swivel joint 36
Track frame assembly (excluding piping) 7,770
4,322
• Track frame
487
• Swing circle
• Idler 168.8 x 2
• Idler cushion 287.5 x 2
• Carrier roller 28.1 x 4
• Track roller
• Final drive (including travel motor and sprocket) 52.2 x 16
550 x 2
Track shoe assembly
• Triple grouser shoe (600 mm {31.50 in}) 1,850 x 2
Boom assembly 1,940
Arm assembly 939
Bucket assembly 808
Boom cylinder assembly 231 x 2
Arm cylinder assembly 321
Bucket cylinder assembly 192
Bucket link (large) assembly 82
Bucket link (small) assembly 37 x 2
Boom foot pin 51
Boom cylinder bottom pin 10 x 2
Boom cylinder head pin 28
Arm cylinder bottom pin 18
Arm cylinder head pin 12
Boom and arm connecting pin 27
Bucket cylinder bottom pin 10
Bucket pin 21 x 2
Bucket link pin 17 x 2
01-8 PC290LC-10
01 Specification
Table of fuel, coolant and lubricants

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
PC290LC–10
Reservoir
Specified Refill
Engine oil pan 25.4 23.1
Swing machinery case 8.2 7.2
Final drive case (right and left respectively) 9.0 8.0
Damper case 0.65 0.65
Hydraulic system 250 132
Cooling system 36 36
Fuel tank 400 —
PC290LC-10 01-9
01 Specification
01-10 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
10 Structure and function

3 10 Structure and function
PC290LC-10 10-1
Table of contents
Table of contents
10 Structure and function ................................................................................................................... 10-1
Engine related parts ............................................................................................................. 10-3
Cooling system .................................................................................................................... 10-5
Power train .......................................................................................................................... 10-7
Swing circle ......................................................................................................................... 10-9
Swing machinery ............................................................................................................... 10-10
Final drive ......................................................................................................................... 10-12
Track frame and idler cushion ............................................................................................. 10-14
Hydraulic equipment layout drawing .................................................................................... 10-16
Valve control...................................................................................................................... 10-18
Hydraulic tank.................................................................................................................... 10-20
CLSS ................................................................................................................................ 10-22
Main pump ........................................................................................................................ 10-27
Control valve ..................................................................................................................... 10-51
Swing motor .................................................................................................................... 10-104
Travel motor .................................................................................................................... 10-115
PPC valve ....................................................................................................................... 10-129
Solenoid valve ................................................................................................................. 10-150
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-153
Attachment circuit selector valve (for low pressure circuit).................................................... 10-155
Center swivel joint ............................................................................................................ 10-158
Accumulator .................................................................................................................... 10-160
Work equipment ..................................................................................................................... 10-161
Work equipment............................................................................................................... 10-161
Work equipment shim....................................................................................................... 10-162
Bucket play adjustment shim............................................................................................. 10-163
Cab mount and cab tipping stopper ................................................................................... 10-164
ROPS cab ....................................................................................................................... 10-165
Electrical system .................................................................................................................... 10-166
Electrical control system ................................................................................................... 10-166
Machine monitor system ................................................................................................... 10-209
KOMTRAX system ........................................................................................................... 10-227
Sensors .......................................................................................................................... 10-229
10-2 PC290LC-10
Engine related parts
Engine and cooling system
1. EGR cooler (*1)
PC290LC-10 10-3
2 Engine oil filter

3. KDPF (*1)
4. KCCV ventilator (*1)
5. Vibration damper (*1)
6. Auto-tensioner
7. Air cleaner (*1)
8. KVGT (*1)
9. Damper assembly
9a. Drive plate
9b. Torsion spring
9c. Stopper pin
9d. Friction plate
10. Rear engine mount
11. Front engine mount
*1: *1: For the details, see Engine Shop Manual.
Function
• KVGT (8) is a turbocharger which can vary the cross-sectional area in the exhaust circuit.
• EGR cooler (1) is a device which cools the exhaust gas with the coolant.
• KGPF (3) is a device which has KDOC (catalyzer) and KCSF (filter to catch soot) for purification of the
exhaust gas.
• KCCV (4) is a mechanism which mainly consists of filters and separates oil from blowby gas to return the
gas to the air intake side for afterburning.
Specifications
Damper type Wet type
Oil used for damper TO30
Damper oil capacity (l) 0.65
10-4 PC290LC-10
Cooling system
Cooling system
1. Reservoir tank
2. Oil cooler
PC290LC-10 10-5
Cooling system
3. Radiator cap
4. Radiator
5. Aftercooler
6. Fuel cooler inlet
7. Fuel cooler
8. Fuel cooler outlet
9. Condenser
10. Air conditioner condenser switching bracket
11. Oil cooler inlet
12. Aftercooler outlet hose
13. Fan guard
14. Radiator inlet hose
15. Oil cooler outlet
16. Aftercooler inlet hose
17. Shroud
18. Fan
19. Radiator outlet hose
20. Radiator drain plug
Specifications
Radiator Oil cooler Aftercooler Fuel cooler
Core type Aluminum wave
CF40-1 Aluminum wave type Drawn cup
type, 4 rows
Fin pitch (mm) 3.5/2 3.5/2 4.0/2 4.0/2
Total heat
dissipation area (m2) 64.81 11.75 x 3 12.71 0.59
Pressure valve
cracking pressure 0.05 {0.5} — — —
(MPa {kg/cm2})
Vacuum valve
cracking pressure –0.005 {-0.05} — — —
(MPa {kg/cm2})
10-6 PC290LC-10
Power train
Power train system
Power train
1. Control valve
1a. Self-pressure reducing valve
1b. Merge-divider valve
1c. Travel junction valve
2. Main pump
3. Engine
4. Travel motor
5. Final drive
6. Swing motor
6a. Swing 2-stage relief valve
7. Center swivel joint
PC290LC-10 10-7
Power train
8. Idler
9. PPC lock solenoid valve
10. 2-stage relief solenoid valve
11. Swing brake solenoid valve
12. Travel speed increase solenoid valve
13. Travel junction solenoid valve
14. Swing 2-stage relief solenoid valve
15. Attachment selector solenoid valve (a machine ready for installing attachments)
16. Swing machinery
17. Swing circle
10-8 PC290LC-10
Swing circle
Swing circle
1. Swing circle pinion greasing port

2. Inner race (Number of teeth: 90)
3. Ball
4. Outer race
5. Seal
a. Inner race soft zone "S" position
b. Outer race soft zone "S" position
Specifications
Reduction ratio –90 ／11 ＝ –8.182
Grease G2-LI
Grease quantity (l) 33
PC290LC-10 10-9
Swing machinery
Swing machinery
1. Swing pinion (number of teeth: 11)

2. No. 2 planetary carrier
3. No. 2 sun gear (number of teeth: 14)
10-10 PC290LC-10
Swing machinery
4. No. 2 planetary gear (number of teeth: 21)

7. Swing motor
8. Breather
9. Oil level gauge doubling oil filler port cap
11. Ring gear (number of teeth: 58)
12. Swing machinery case
13. Drain plug
Specifications
Reduction ratio ((17 + 58)/17) x ((14 + 58)/14) = 22.689
Swing reduction ratio 22.689 x (90/11) = 185.637
Swing speed
10.5
(rpm)
PC290LC-10 10-11
Final drive
Final drive
1. Level plug
3. Drain plug
10-12 PC290LC-10
Final drive
4. No. 1 sun gear shaft (number of teeth: 11)

7. Cover
8. Ring gear (number of teeth: 97)
10. Lock nut
11. Hub
12. Sprocket
13. Floating seal
14. Travel motor
Specifications
Reduction ratio -((11 + 106)/11) x ((19 + 97)/19) + 1 = -63.938
PC290LC-10 10-13
Track frame and idler cushion
Undercarriage and frame
1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Idler cushion
9. Front guard
Specifications
• Number of track rollers
10-14 PC290LC-10
Model Quantity (each side)

PC290LC–10 8
• Standard shoe
Model PC290LC-10
Shoe width (mm) 800
Link pitch (mm) 216
Number of shoes (each side) 48
PC290LC-10 10-15
Hydraulic equipment layout drawing
Hydraulic system
1. Bucket cylinder
10-16 PC290LC-10
2. Arm cylinder
3. R.H. PPC valve for work equipment
4. Swing motor
5. Hydraulic tank
6. Main pump
7. Control valve
8. Accumulator (for PPC circuit)
9. Oil cooler
10. Travel motor
11. Solenoid valve
12. L.H. PPC valve for work equipment
13. Attachment 2 PPC valve (*1)
14. Travel PPC valve
*1: Machine ready for installation of attachment
PC290LC-10 10-17
Valve control
Valve control
1. Attachment 1 control pedal (*1)

2. Travel lever
3. R.H. PPC valve for work equipment
4. R.H. work equipment control lever (for boom and bucket control)
5. Control valve
6. Junction block
7. Accumulator (for PPC circuit)
8. Solenoid valve
9. L.H. work equipment control lever (for arm and swing control)
10. L.H. PPC valve for work equipment
11. Lock lever
12. Attachment 2 control pedal (*1)
14. Travel PPC valve
10-18 PC290LC-10
Valve control
15. Travel pedal

17. Lock pin (*1)
*1: Machine ready for installation of attachment
PC290LC-10 10-19
Hydraulic tank
Hydraulic tank
1. Main pump
2. Hydraulic tank
3. Filler cap
4. Sight gauge
5. Drain plug
6. Bypass valve
7. Strainer
8. Filter element
9. Suction strainer
Specifications
Hydraulic tank capacity (l) 190
Amount of oil in hydraulic tank (l) 132
Bypass valve set pressure (MPa {kg/cm2}) 0.15 ± 0.03 {1.5 ± 0.3}
Oil filler cap
10-20 PC290LC-10
Hydraulic tank
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
Prevention of negative pressure in tank

• The hydraulic tank is sealed and pressurized. When the oil level in the hydraulic tank drops, negative
pressure is generated in the tank.To prevent this negative pressure generation, seam valve (4) is opened
to draw the atmosphere to the tank.
(Intake valve set pressure: 0 - 0.49 kPa {0 - 0.005 kg/cm2})
Prevention of pressure rise in tank

• When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic
cylinders operate, and the oil level and temperature increase in the tank.If the pressure in the tank rises
above the set value, bottom plate (2) is pushed up to release the pressure in the tank.
(Exhaust valve set pressure: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2 })
PC290LC-10 10-21
CLSS
CLSS
CLSS: Abbreviation for Closed center Load Sensing System
Structure of CLSS
CLSS: Abbreviation for Closed center Load Sensing System
Features
• Fine control not influenced by load
• Control performance that allows digging even when fine control operation is turned on
• Ease of combined operation enabled by the flow divider function that is determined by the opening areas
of spools during combined operations
• Energy saving by variable pump control
Configuration
• CLSS consists of variable capacity piston pump, control valve, and actuators.
• The main pump consists of pump itself, PC valve and LS valve.
10-22 PC290LC-10
CLSS
Basic principle
Pump swash plate angle control

• The pump swash plate angle (pump delivery) is controlled so that LS differential pressure (dPLS), which is
the difference between pump delivery pressure (PP) and LS pressure (PLS)) (load pressure of actuator) at
control valve outlet, is constant.
• [LS differential pressure (dPLS) = Pump delivery pressure (PP) - LS pressure (PLS)]
• The pump swash plate angle shifts toward the maximum position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate
angle shifts toward the minimum position.
PC290LC-10 10-23
CLSS
LS differential pressure (d
d PLS) and pump swash plate angle
a See "Main pump(PAGE 10-27)" for the explanation of the operation.
Pressure compensation control
10-24 PC290LC-10
CLSS
• A pressure compensation valve is installed to the outlet port side of each control valve to balance the load
pressure.
• When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the
load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
System diagram
a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.
1. Front pump
2. Rear pump
3. Main relief valve
4. Unload valve
5. Merge-divider valve
6. Control valve
PC290LC-10 10-25
CLSS
7. Actuator
8. Pump circuit
9. LS circuit
10. Tank circuit
11. Valve
12. Spring
13. LS bypass plug
14. LS valve
15. PC valve
10-26 PC290LC-10
Main pump
Main pump
Model: HPV125 + 125
IMF: Front pump PC mode selector current

IMR: Rear pump PC mode selector current
PC290LC-10 10-27
Main pump
ISIG: LS set pressure selector current

PAF: Front pump delivery port
PAR: Rear pump delivery port
PBF: Front pump pressure input port
PD3R: Air bleeder
PD1R: Case drain port
PD2F: Drain plug
PD2R: Drain plug
PENF: Front pump control pressure pickup port
PENR: Rear pump control pressure pickup port
PEPC: EPC source pressure input port
PEPB: EPC source pressure pickup port
PFC: Front pump delivery pressure pickup port
PLSF: Front pump load pressure input port
PLSFC: Front pump load pressure pickup port
PLSR: Rear pump load pressure input port
PLSRC: Rear pump load pressure pickup port
PMF: Front pump PC mode selector pressure pickup port
PMR: Rear pump PC mode selector pressure pickup port
PRC: Rear pump delivery pressure pickup port
PS: Pump suction port
PSIG: LS set selector pressure pickup port
1. Front pump
2. Rear pump
3. LS - EPC valve
4. Front pump PC - EPC valve
5. Rear pump PC - EPC valve
6. Rear pump PC valve
7. Rear pump swash plate sensor
8. Rear pump LS valve
9: Front pump LS valve
10. Front pump swash plate sensor
11: Front pump PC valve
10-28 PC290LC-10
Main pump
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. PC valve
13. Servo piston
14. Slider
15. Spline
PC290LC-10 10-29
Main pump
16. Bearing
17. LS valve
Outline
• This pump consists of two variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve,
and swash plate sensor.
Function
• The pump converts the engine speed and torque transmitted to its shaft (1) into oil pressure and delivers
pressurized oil corresponding to the load.
• It is possible to change the delivery by changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by spline (15).
• Shaft (1) is supported by each bearing (16) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and is crimped together with shoe (5).
• Piston (6) and shoe (5) constitute a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) transmits high pressure oil to cylindrical surface (B) with cradle (2), which is secured to the
case, and forms a static pressure bearing when it slides.
• Piston (6) performs reciprocal motion in the axial direction inside each cylinder chamber of cylinder block
(7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation.
• The oil pressure balance on the valve plate is maintained properly.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Operation
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• If swash plate angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7),
plane (A) functions as a cam against shoe (5).
• Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Each piston (6) sucks and discharges oil by (F) - (E).
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• The volume of chamber (F) grows larger and, in this process, the oil is sucked.
10-30 PC290LC-10
Main pump
• As center line (X) of rocker cam (4) matches the axis of cylinder block (7) (swash plate angle = 0), the
difference between volumes (E) and (F) inside cylinder block (7) equals 0.
• Suction and discharge of pressurized oil is not carried out in this state. Namely pumping action is not
performed. (Actually, however, the swash plate angle is not set to 0 deg.)
Control of discharge
• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and pump
delivery (Q) increases.
• Swash plate angle (a) is changed by servo piston (12).
• Servo piston (13) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• This linear reciprocating movement is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• Output pressure (PEN) of the LS valve is transmitted to the pressure chamber of the large diameter piston
side.
• The areas receiving the pressure on the right and left sides of servo piston (13) are different from each
other, and delivery pressure (self pressure) (PP) of the main pump is constantly transmitted to the
pressure chamber of the small diameter piston side.
• The movement of servo piston (13) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter piston side (PEN) and by the ratio of the areas receiving the pressure
of the small diameter piston and large diameter piston.
PC290LC-10 10-31
Main pump
LS valve
LS: Abbreviation for Load Sensing
10-32 PC290LC-10
Main pump
PA: Pump port

PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: LS mode selector pilot port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut
Function
• The LS (load sensing) valve detects the load and controls the pump delivery.
• This valve controls main pump delivery (Q) according to differential pressure (dPLS) [= PP - PLS], called
the LS differential pressure (the difference between main pump delivery pressure (PP) and control valve
outlet port pressure (PLS)).
• This valve receives main pump delivery pressure (PP), pressure (PLS) (called the LS pressure) coming
from the control valve output, and pressure (PSIG) (called the LS set selector pressure) from the
proportional solenoid valve.
• The relation between the pump delivery (Q) and the differential pressure (dPLS) [= (PP) - (PLS)] between
the main pump pressure (PP) and LS pressure (PLS) is changed by the LS set pressure selector current
(ISIG) of the LS-EPC valve as shown in the figure below.
• When the (ISIG) changes from 0 A to 1 A, the spring setting force will change accordingly, to let the center
of the standard value range of the pump delivery selector point vary within the range from 0.27 MPa {2.78
kg/cm2} to 1.7 MPa {17.75 kg/cm2}.
PC290LC-10 10-33
Main pump
Operation
When control valve is in “NEUTRAL“ position
• The LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) on the outlet of
control valve is transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port
(H) of sleeve (8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery
pressure (self pressure) (PP) determine the position of spool (6).
10-34 PC290LC-10
Main pump
• However, magnitude of the output pressure (PSIG) (called the LS set selector pressure) of the EPC valve
for the LS valve entering port (G) also changes the position of spool (6).(Setting force of the spring is
changed)
• Before the engine is started, servo piston (12) is pushed to the left.(See the following figure)
• If the control lever is at the neutral position when the engine is started, LS pressure (PLS) is set to 0 MPa
{0 kg/cm2}. (It is connected to the drain circuit through the control valve spool.)
• Spool (6) is pushed to the right, and port (C) and port (D) is connected.
• Pump delivery pressure (PP) is transmitted to the larger diameter end of the pump from the port (K).
• The same pump delivery pressure (PP) is transmitted to the smaller diameter end at the port (J).
• According to the area difference of servo piston (12), the servo piston is moved to the right, in the direction
which makes the swash plate angle minimum. (See the previous figure.)
PC290LC-10 10-35
Main pump
When pump delivery is increased
• When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) decreases (for example, when the control valve opening area increases and
pump delivery pressure (PP) decreases), the combined force exerted by LS pressure (PLS) and spring (4)
pushes spool (6) to the left.
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve and drain port are connected, the pressure between ports (D) and (K) becomes drain
pressure (PT). (PC valve operation will be explained later.)
• The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and
pump pressure (PP) is constantly transmitted to port (J) on the small diameter end. Accordingly, servo
piston (12) is pushed to the left and the swash plate is moved to increase the delivery.
• At this time, when the output pressure from the EPC valve for the LS valve is transmitted to port (G), a
force is applied on piston (7) to move the piston to the right.
• If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential
pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6)
are connected.
10-36 PC290LC-10
Main pump
When pump delivery is decreased
• When servo piston (12) moves to the right (the direction that reduces pump delivery) and LS differential
pressure (dPLS) increases (for example, when the control valve opening area decreases and pump
delivery pressure (PP) increases), the force exerted by pump delivery pressure (PP) pushes spool (6) to
the right.
• The movement of spool (6) transmits pump delivery pressure (PP) to the large diameter end of the piston
through port (C) , port (D) and port (K).
• Pump delivery pressure (PP) is also transmitted to port (J) of the small diameter end of the piston, but
because of the difference in area between the large diameter end and the small diameter end on servo
piston (12), it is pushed to the right. As the result, the servo piston (12) moves into the direction of reducing
the swash plate angle.
• When the LS set selector pressure (PSIG) is transmitted to port (G), the spring (4) setting force is
weakened.
PC290LC-10 10-37
Main pump
When servo piston is balanced
• The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of
the piston, the area receiving the pressure at the small diameter end and the pressure transmitted to the
large diameter end of the piston, respectively.
• When the force exerted by main pump pressure (PP) of the LS valve is balanced with the combined force
exerted by LS pressure (PLS) and spring (4), and the relationship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (12) stops in that position.
• The swash plate of the pump is held at the intermediate position.[The swash plate stops at a position
where the openings from port (D) to port (E) and from port (C) to port (D) of spool (6) are approximately
equal]
• The relationship between the area receiving the pressure at both ends of servo piston (12) is (A0):(A1) =
3:5, and the pressures transmitted to both ends of the piston when the piston is balanced is (PP):(PEN) C
5:3.
• The force of spring (4) is adjusted so that spool (6) can be balanced at the specified center when (PP) -
(PLS) = 1.7 MPa {17.75 kg/cm2}.
• When (PSIG) [LS-EPC valve output pressure, 0 to 2.9 MPa {0 to 30 kg/cm 2}] is transmitted to port (G), the
balanced position changes in proportion to the (PSIG) pressure within a range of (PP) - (PLS) = 1.7 MPa
{17.75 kg/cm2} to 0.27 MPa {2.78 kg/cm2}.
PC valve
PC: Abbreviation for Pressure Compensation
10-38 PC290LC-10
Main pump
PA: Pump port

PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
Function
• The PC valve limits the oil flow to a certain level (depends on the delivery pressure) even if the travel of
the control valve is increased extremely. This is to ensure the horsepower absorbed by the pump not to
exceed the engine horsepower, when pump delivery pressures (PP1) (self pressure) and (PP2) (other
pump's pressure) are high.
• If the pump delivery pressure (PP) increases due to increased load during work, this valve decreases the
pump delivery.
• And if the pump delivery pressure goes low, it increases the pump delivery.
• The relation between the average delivery pressure of front and rear pumps [(PP1)+(PP2)]/2 and pump
delivery (Q) is as shown in the following figure, as a parameter for each current (X) value applied to the
PC-EPC valve solenoid.
• The controller continues counting the actual engine speed.
• If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to
recover the speed.
• When the load increases and the engine speed decreases below a preset value, the controller increases
the command current to the PC-EPC valve solenoid depending on the amount of engine speed decrease,
to decrease the swash plate angle.
PC290LC-10 10-39
Main pump
Operation
When the pump controller is normal
When load on the actuator is small and pump pressures (PP1) and (PP2) are low
Actuation of PC-EPC valve solenoid (1)

• Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
10-40 PC290LC-10
Main pump
• Spool (3) stops at a position where the combined force exerted by springs (4) and (6) is equalized to the
combined force exerted by pump pressure (PP1) (self pressure) and pump pressure (PP2) (other pump's
pressure) acting on spool (3).
• Depending on this position, the pressure output from the PC valve [port (C) pressure] varies.
• The amperage of the command current (X) depends on the type of work (lever operation), work mode
selection, engine speed setting, and the actual engine speed.
a Other pump's pressure denotes the pressure of the pump situated on the opposite side.
For the front pump pressure, the other pump's pressure is that of the rear pump. And for the rear pump
pressure, the other pump's pressure is that of the front pump.
Action of spring
• The spring force of springs (4) and (6) in the PC valve depends on the position of the swash plate.
• When servo piston (9) moves to the right, spring (6) is compressed.
• When the piston moves further to the right, the piston comes in contact with seat (5) and spring (6) is fixed.
• Then, only spring (4) operates.
• When servo piston (9) compresses or decompresses springs (4) and (6), the spring force varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring forces of springs (4) and (6) are also varied by the PC-EPC valve solenoid command current
(X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Self pressure (PP1) is transmitted to the small diameter end of servo piston and (9) port (B), and other
pump's pressure (PP2) is transmitted to port (A).
• When pressures (PP1) and (PP2) are low, spool (3) is on the left.
PC290LC-10 10-41
Main pump
• Port (C) and port (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter end of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump delivery goes to increase.
• Springs (4) and (6) extends according to the movement of servo piston (9), and the reaction force of spring
decreases.
• When the reaction force of spring decreases, spool (3) moves to the right. Ports (C) is disconnected from
port (D), and pump delivery pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
• Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the
force exerted by pressures (PP1) and (PP2), the thrust generated by the PC-EPC valve solenoid, and the
force exerted by springs (4) and (6) acting on the spool (3) are balanced.
When load on the actuator is large and pump pressures (PP1) and (PP2) are high
Outline
• When the load is large and the pump delivery pressures (PP1) and (PP2) are high, the thrust moving
spool (3) to the right increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP2), because
a part of the pressure from port (B) flows through the LS valve and port (C) to port (D), as shown above.
• When spool (3) moves to the left, the opening of ports (C) and (D) widens.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
10-42 PC290LC-10
Main pump
• Servo piston (9) stops at a position further to the right than the position when pump pressures (PP1) and
(PP2) are low.
Operation
• When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
• When pump pressure (PP2) increases more and spool (3) moves further to the right, pump pressure (PP1)
flows to port (C) to minimize the pump delivery.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed, and spool (3) is pushed
back.
• The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their
positions can be represented by the polygonal line in the figure because springs (4) and (6) form the 2-
stage springs.
• The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q)
becomes as shown below.
• If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
average pump pressure (PP1 + PP2)/2 and pump delivery (Q) is shifted parallel in proportion to the thrust
of PC-EPC valve solenoid.
• Namely, the thrust of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the
pump pressure transmitted to the spool (3) , so the relationship between the average pump pressure (PP1
+ PP2)/2 and the pump delivery (Q) moves from (A) to (B) as the command current (X) is increased.
PC290LC-10 10-43
Main pump
When the pump controller malfunctions and the emergency pump drive switch is at “ON“ position
When load on the main pump is small
• If the pump controller fails, turn the emergency pump drive switch to "ON" position to select the resistor
side.
• In this case, power is taken directly from the battery, however, the current is too high as is, a resistor is
needed to control the current supplied to PC-EPC valve solenoid (1).
• Since the current is constant, the thrust applied to piston (2) is constant.
• When main pump pressures (PP1) and (PP2) are low, the combined force exerted by PC-EPC valve
solenoid (1) thrust and the pump pressure is smaller than the combined force exerted by the springs.
Spool (3) stays balanced at the left.
• Port (C) is connected to port (D) at drain pressure, and the pressure at the large diameter end of servo
piston (9) comes to drain pressure (PT) through the LS valve.
• Since the pressure at the small diameter end of the piston is large, servo piston (9) moves in the direction
to increase the delivery.
10-44 PC290LC-10
Main pump
When load on the main pump is large
• As mentioned before, when the emergency pump drive switch is turned to "ON" position, the command
current (X) sent to PC-EPC valve solenoid (1) is constant.
• Therefore, the thrust applied by piston (2) to spool (3) comes to constant.
• When main pump pressures (PP1) and (PP2) increase, spool (3) moves to a position further to the right
than when the main pump load is small, and stays balanced as shown above.
• Since the pressure from port (B) flows into port (C), servo piston (9) moves to the right (delivery
decreases), and stops at a position further to the right than when the pump load is small.
• When the emergency pump drive switch is turned to "ON" position, the curve indicating the relation
between the pump delivery pressure (PP) and delivery (Q) is plotted in accordance with the current
supplied through the resistor to the PC-EPC valve solenoid.
• When the emergency pump drive switch is turned to "ON" position, the curve is plotted as (B), which is
shifted toward the left than curve (A) for a normal pump controller.
PC290LC-10 10-45
Main pump
LS(PC)-EPC valve
EPC: Abbreviation for Electromagnetic Proportional Control
10-46 PC290LC-10
Main pump
C: To LS (PC) valve
P: From self-pressure reducing valve
T: To hydraulic tank
1. Connector
2. Coil
3. Valve body
4. Spring
5. Spool
6. Rod
7. Plunger
Function
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
• When the EPC valve receives signal current (i) from the controller, it develops EPC output pressure
proportional to the amperage of the current and supplies the pressure to the control valve.
PC290LC-10 10-47
Main pump
Operation
When signal current is zero amp. (coil is de-energized)
• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
• Port (P) is closed, and the pressurized oil from the self-pressure reducing valve does not flow to the LS
(PC) valve.
• The pressurized oil from the LS (PC) valve is drained to the tank through port (C) and then port (T).
10-48 PC290LC-10
Main pump
When signal current is minute (coil is energized)
• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
reaction force exerted by spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and port (P) is shut off from port (C).
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the force
exerted by pressure at port (C) and the reaction force exerted by spring (4).
• The circuit pressure between the EPC valve and LS (PC) valve is controlled in proportion to the amperage
of signal current.
PC290LC-10 10-49
Main pump
When signal current is maximum (coil is energized)
• Coil (2) is energized when signal current is supplied to coil (2).

• As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and LS (PC) valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.
10-50 PC290LC-10
Control valve
Control valve
a In this section, only the 7-spool valve (6-spool valve + service valve) is shown.
A1: To bucket cylinder head

A2: To L.H. travel motor
PC290LC-10 10-51
Control valve
A3: To boom cylinder bottom

A4: To swing motor
A5: To R.H. travel motor
A6: To arm cylinder head
A-1: To attachment
ATT: From attachment
B1: To bucket cylinder bottom
B2: To L.H. travel motor
B3: To boom cylinder head
B4: To swing motor
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To attachment
BP1: From LS select solenoid valve
BP5: From attachment selector solenoid valve
C: To oil cooler
P1: From R.H. work equipment PPC valve (bucket DUMP)
P2: From R.H. work equipment PPC valve (bucket CURL)
P3: From travel PPC valve (L.H. travel REVERSE)
P4: From travel PPC valve (L.H. travel FORWARD)
P5: From R.H. work equipment PPC valve (boom RAISE)
P6: From R.H. work equipment PPC valve (boom LOWER)
P7: From L.H. work equipment PPC valve (swing RIGHT)
P8: From L.H. work equipment PPC valve (swing LEFT)
P9: From travel PPC valve (R.H. travel REVERSE)
P10: From travel PPC valve (R.H. travel FORWARD)
P11: From L.H. work equipment PPC valve (arm OUT)
P12: From L.H. work equipment PPC valve (arm IN)
P-1: From R.H. attachment PPC valve
P-2: From R.H. attachment PPC valve
PLS1: To rear pump LS valve
PLS2: To front pump LS valve
PLSC: LS pressure pickup port
PP1: From rear pump
PP2: From front pump
PP1S: Front pump oil pressure sensor mounting port
PPC: Pilot source pressure pickup port
PP2S: Rear pump oil pressure sensor mounting port
PPS2: To front pump LS valve
PR: To solenoid valve, PPC valve, and EPC valve
PST: From travel junction solenoid valve
PX1: From 2-stage relief solenoid valve
PX2: From 2-stage relief solenoid valve
T1: To hydraulic tank
TS: To hydraulic tank
TSW: From swing motor
10-52 PC290LC-10
Control valve
IS1: Pump merge-divider EPC valve (for main spool) drive signal
IS2: Pump merge-divider EPC valve (for LS spool) drive signal
IS3: Variable back pressure solenoid valve drive signal
1. Variable back pressure valve
2: Variable back pressure solenoid valve
3. Pump merge-divider EPC valve (for LS spool)
4. Pump merge-divider EPC valve (for main spool)
5. Arm hydraulic drift prevention valve (if equipped)
6. Boom hydraulic drift prevention valve
7. Service valve
8. Cover A
9. 7-spool valve
10. Arm quick return valve
11. Cover B
PC290LC-10 10-53
Control valve
1. Pressure compensation valve (arm OUT)

2. Pressure compensation valve (R.H. travel REVERSE)
3. Pressure compensation valve (swing RIGHT)
4. Pressure compensation valve (boom RAISE)
10-54 PC290LC-10
Control valve
5. Pressure compensation valve (L.H. travel REVERSE)

6. Pressure compensation valve (bucket DUMP)
7. Pressure compensation valve (service)
8. Pressure compensation valve (bucket CURL)
9. Pressure compensation valve (L.H. travel FORWARD)
10. Pressure compensation valve (boom LOWER)
11. Pressure compensation valve (swing LEFT)
12. Pressure compensation valve (R.H. travel FORWARD)
13. Pressure compensation valve (arm IN)
15. Unload valve
17. Spool (service)
18. Spool (bucket)
19. Spool (L.H. travel)
20. Spool (boom)
21. Spool (swing)
22. Spool (R.H. travel)
23. Spool (arm)
PC290LC-10 10-55
Control valve
1. Suction valve (arm OUT)

2. Suction valve (R.H. travel REVERSE)
3. Suction valve (boom RAISE)
4. Suction valve (L.H. travel REVERSE)
5. Suction safety valve (bucket DUMP)
6. Suction safety valve (service)
7. Suction 2-stage safety valve (service)
8. Suction safety valve (bucket CURL)
9. Suction valve (L.H. travel FORWARD)
10-56 PC290LC-10
Control valve
10. Suction safety valve (boom LOWER)

11. Suction valve (R.H. travel FORWARD)
12. Suction safety valve (arm IN)
13. LS shuttle valve (arm)
14. LS shuttle valve (R.H. travel)
15. LS selector valve
16. LS shuttle valve (boom)
17. LS shuttle valve (L.H. travel)
18. LS shuttle valve (bucket)
19. LS shuttle valve (service)
20. LS check valve
PC290LC-10 10-57
Control valve
1. Unload valve
2. Suction safety valve for hydraulic drift prevention valve (boom “RAISE“ and arm “OUT“)
Arm valve
6. LS shuttle valve
8. Pressure compensation valve (IN)
10-58 PC290LC-10
Control valve
9. Spool
10. Suction safety valve (IN)
11. Cooler check valve
12. Regeneration circuit check valve
13. Suction valve (OUT)
14. Pressure compensation valve (OUT)
R.H. travel valve

15. LS shuttle valve
16. Pressure compensation valve (FORWARD)
17. Spool
18. Suction valve (FORWARD)
19. Suction valve (REVERSE)
20. Pressure compensation valve (REVERSE)
Swing valve
22. Pressure compensation valve (L.H.)
23. Spool
24. Pressure compensation valve (R.H.)
PC290LC-10 10-59
Control valve
1. Return spring
2. Merge-divide valve (for LS)
3. Valve (sequence valve)
4. Spring (sequence valve)
5. Merge-divide valve (main)
6. Return spring
Boom valve
8. LS shuttle valve
10-60 PC290LC-10
Control valve
9. Pressure compensation valve (LOWER)

10. Spool
11. Suction safety valve (LOWER)
12. Regeneration circuit check valve
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)
L.H. travel valve

15. Merge-divider valve (travel junction valve)
16. Return spring
18. Pressure compensation valve (FORWARD)
19. Spool
20. Suction valve (FORWARD)
21. Suction valve (REVERSE)
22. Pressure compensation valve (REVERSE)
Bucket valve
24. Pressure compensation valve (CURL)
25. Spool
26. Suction safety valve (CURL)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)
PC290LC-10 10-61
Control valve
Service valve
1. LS shuttle valve
2. Pressure compensation valve
3. Spool
4. Suction 2-stage safety valve
5. Suction safety valve
6. Unload valve
8. LS bypass plug
Structure
• The control valves of the following types are set.
6-spool valve (without service valve)
7-spool valve (6-spool valve with service valve)
• This control valve consists of a 6-spool valve (unit type) and a set of service valve. A merge-divider valve,
a variable back pressure valve and a boom hydraulic drift prevention valve are installed to it.
• Since all the valves are assembled together with connecting bolts and their passes are connected to each
other inside the assembly, the assembly is compact and easy to maintain.
• With one spool provided for one work equipment, this control valve is simple in structure.
10-62 PC290LC-10
Control valve
Hydraulic circuit diagram and name of valves

Hydraulic circuit diagram and name of valves
1. Arm valve
2. R.H. travel valve
PC290LC-10 10-63
Control valve
3. Swing valve
4. Boom valve
5. L.H. travel valve
6. Bucket valve
7. Service valve
8. Arm valve spool
9. R.H. travel valve spool
10. Swing valve spool
11. Boom valve spool
12. L.H. travel valve spool
13. Bucket valve spool
14. Service spool
16. Suction valve
17. Check valve (for boom regeneration circuit)
18. Check valve (for arm regeneration circuit)
22. LS bypass plug
27. Self-pressure reducing valve
28. Travel junction valve
31. Cooler check valve
33. Main relief valve (for boom, L.H. travel, bucket, and attachment circuits)
Set pressure: 35.4 ± 0.3 MPa {360.5 ± 3 kg/cm2}
When one-touch power max. switch is set to ON position: 38.0 ± 0.3 MPa {387 ± 3 kg/cm 2}
34. Main relief valve (for arm, R.H. travel, and swing circuits)
Set pressure: 35.4 ± 0.3 MPa {360.5 ± 3 kg/cm2}
When one-touch power max. switch is set to ON position: 38.0 ± 0.3 MPa {387 ± 3 kg/cm 2}
35. Unload valve (for boom, L.H. travel, bucket, and attachment circuits)
Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
36. Unload valve (for arm, R.H. travel, and swing circuits)
Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
40. Suction 2-stage safety valve
10-64 PC290LC-10
Control valve
1st stage set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}

2nd stage set pressure: 20.6 ± 0.5 MPa {210 ± 5 kg/cm2}
41. Suction safety valve for hydraulic drift prevention valve
Unload valve
1. LS circuit
2. Valve
3. Pump circuit
4. Tank circuit
5. Spring
Function
• When all control valves are at HOLD, this valve serves to drain as same amount of oil as the pump
delivery with swash plate angle at the minimum.
• The pump pressure becomes the pressure corresponding to the set load of spring (5) in the valve (referred
to as P1).
• Since LS pressure is drained from LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}.
Operation
• Pressure of pump circuit (3) is received by the end of valve (2).
• Since the control valve is in NEUTRAL position, pressure of LS circuit (1) is 0 MPa {0 kg/cm 2}.
• Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available.
• If this pressure grows larger than the force of spring (5), valve (2) moves to the left.
• Ports (b) and (c) are interconnected, and the pump pressurized oil flows to tank circuit (4)
• The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to tank circuit
(4).
• When this valve is actuated, the LS pressure becomes nearly equal to the C tank pressure.
• Since the pump delivery pressure - LS circuit pressure during unloading is larger than pump LS control
pressure, the signal is output to minimize the pump swash plate angle.
• During operation (when a given work is done within the delivery available with the minimum swash plate
angle), the delivery pressure corresponding to the minimum pump swash plate angle is set to LS pressure
+ P1 pressure.
• The LS differential pressure (dPLS) with the swash plate angle at the minimum becomes P1 pressure.
Operation of relief valve

• When cylinder reaches its stroke end, main relief valve opens.
• Pump delivery (Q) is relieved to the tank. (「For details, see " System diagram" of "Structure of CLSS
(PAGE 10-22)".
• Since the pump delivery pressure (PP) and LS pressure (PLS) do not flow neither to the upstream nor
downstream, they become approximately the same and LS differential pressure (dPLS) becomes 0 MPa
{0 kg/cm2}.
• As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve, LS valve operates to
make the pump swash plate angle maximum.
PC290LC-10 10-65
Control valve
• Mechanically, operation of PC valve has priority over that of LS valve.

• The pump is maintained at the minimum swash plate angle due to PC valve cut-off function.
Introduction of LS pressure
1. Main pump
2. Main spool
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function
• The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted and led to LS shuttle valve (7) as LS pressure.
• Connected to actuator port (B) through valve (4), and makes LS pressure C actuator load pressure.
10-66 PC290LC-10
Control valve
• In main spool (2), leading hole (a) with a small diameter also acts as an orifice.
• LS pressure works as source pressure when closing unload vale while control lever is operated, and this
pressure also functions as operating pressure when pressure compensation valve is compensated.
Operation
• When main spool (2) is operated, the pump pressure is transmitted to port (c) through leading hole (a) and
is led to LS circuit.
• When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens and the
pressurized oil flows.
LS bypass plug
1. Main pump
2. Main spool
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function
• This valve relieves the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
• Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
• Depending on the bypass flow from LS bypass plug (5), pressure loss is generated due to the circuit
resistance from orifice (c) of main spool (2) to LS shuttle valve (4).
• Effective LS differential pressure drops to improve a dynamic stability of the actuator.
Pressure compensation valve
When the work equipment is operated independently and the load pressure is the maximum
(When the load pressure is higher than other work equipment during a combined operation)
PC290LC-10 10-67
Control valve
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
• Pressure compensation valve works as the load check valve.
• If the pump pressure (LS pressure) is lower than the load pressure at port (c), shuttle valve (3) in pressure
compensation valve piston (4) interconnects spring chamber (E) and port (C).
• The force of spring (5) operates piston (4) and valve (2) to the closing direction.
Integrated pressure compensation valve

• When a high peak pressure or continuous and repetitive peak pressure (as in breaker operation) is
generated in the actuator circuit, valve (2) may collide with valve chamber seat (C), producing high stress
in the parts.
• To prevent this, a pressure compensation valve with integrated valve (2) and piston (4) is used.
• With this machine, this valve is adopted for the travel valve, bucket valve (cylinder bottom), and the
service valve.
10-68 PC290LC-10
Control valve
When compensated
(When the load pressure is lower than other work equipment during a combined operation)
Function
• The pressure compensation valve closes by the LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment.
• Since the spool meter-in upstream pressure of port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure port (A) pressure] - downstream pressure [port (B) pressure]
becomes equivalent to all the spools in operation.
• Pump flow is divided according to the ratio of the meter-in opening areas.
Operation
• Spring chamber (E) is interconnected to port (D).
• Piston (4) and valve (2) are moved in the closing direction (to the right) by the LS circuit pressure of port
(F) from other work equipment.
• Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with the LS
pressure.
PC290LC-10 10-69
Control valve
Area ratio of pressure compensation valve
Function
• The state of division changes according to the area ratio of pressure compensation portions (A1) and (A2).
Area ratio = (A2)/(A1)
• When the area ratio is equal to 1: As the spool meter-in downstream pressure is equal to the maximum
load pressure, the oil flow is divided in the ratio as same as the opening area ratio.
• When the area ratio is more than 1: As the spool meter-in downstream pressure is higher than the
maximum load pressure, the oil flow to the compensated side is divided in a ratio lower than the opening
area ratio.
• When the area ratio is below 1: As the spool meter-in downstream pressure is lower than the maximum
load pressure, the oil flow to the compensated side is divided in a ratio higher than the opening area ratio.
10-70 PC290LC-10
Control valve
Shuttle valve in pressure compensation valve

When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
Operation
• Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is
disconnected from port (C).
• Holding pressure at port (A) is transmitted to the spring chamber (B) to push piston (4) to the left so that
piston (4) is not separated from valve (2).
PC290LC-10 10-71
Control valve
When traveling
Structure
• Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve
without shuttle valve (5) is adopted.
10-72 PC290LC-10
Control valve
Boom regeneration circuit

When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)
1. Main pump
2. Boom valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the
cylinder head when the boom is lowered.
Operation
• When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from the
cylinder bottom flows to drain circuit (B) from the notch of boom spool (2).
• The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom
through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
PC290LC-10 10-73
Control valve
When cylinder head pressure is higher than bottom pressure (digging operation, etc.)
Function
• Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to
the head.
10-74 PC290LC-10
Control valve
Arm regeneration circuit

When cylinder head pressure is higher than bottom pressure
1. Main pump
2. Arm valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit installed between the cylinder head and cylinder bottom increases the oil flowing
to the cylinder bottom (pump delivery + regeneration flow) during arm IN operation in order to accelerate
the cylinder.
Operation
• When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the
cylinder head flows to drain circuit (B) through the notch of arm spool (2).
• The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder
bottom through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
PC290LC-10 10-75
Control valve
When cylinder head pressure is lower than bottom pressure
Function
• Check valve (6) installed to regeneration circuit (C) closes and shuts off the oil flowing from the cylinder
head to the bottom.
10-76 PC290LC-10
Control valve
Merge-divider valve
When oil flowing from two pumps are merged [pump merge-divider valve changeover signals (IS1)
and (IS2) are OFF]
1. Main spool
2. Spring
3. LS spool
4. Spring
5. LS circuit (for bucket valve)
6. LS circuit (for bucket valve)
7. LS circuit (for arm valve)
8. LS circuit (for arm valve)
9. Pump merge-divider EPC valve (for main spool changeover)
10. Pump merge-divider EPC valve (for LS spool changeover)
Function
• This valve merges the pressurized oil (P1) and (P2) from the two pumps or divides them (enables them to
flow to respective control valve groups).
• This valve merges or divides LS circuit pressures as well.
Operation
• Since drive signal (IS1) of the EPC valve for the main spool is OFF, the output pressure of the pump
merge-divider EPC valve is 0 MPa {0 kg/cm2}.
PC290LC-10 10-77
Control valve
• Main spool (1) is pressed to the right by spring (2). As a result, port (E) and (F) are interconnected.
• Pressurized oil (P1) and (P2) discharged from the two pumps merge at ports (E) and (F), and flow to the
control valve which requires the oil.
• Since drive signal (IS2) of the EPC valve for LS spool (3) is also OFF, LS spool (3) is pressed to the right
by spring (4). As a result, port (A) and (B) are interconnected and port (B) and (C) are interconnected.
• The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8)
are transmitted to all the pressure compensation valves.
When oil flowing from two pumps are divided [pump merge-divider valve changeover signals (IS1)
and (IS2) are ON]
Operation
• Since drive signal (IS1) of the main spool is ON, main spool (1) is moved to the left by the output pressure
from the pump merge-divider EPC valve. As a result, port (E) is disconnected from port (F).
• The pressurized oil from the two pumps are sent to respective control valve groups.
Pressure P1: To bucket, left travel, boom
Pressure P2: To swing, right travel, arm
• When drive signal (IS2) of the EPC valve for LS spool (3) becomes ON, LS spool (3) is also moved to the
left by the output pressure from the pump merge-divider EPC valve. As a result, port (A) and (C) are
interconnected, and other ports remain disconnected from each other.
• The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8)
are transmitted to respective control valves.
LS selector valve
10-78 PC290LC-10
Control valve
a The illustration shows the condition when the combined operation of swing and R.H. travel is performed.
[When pilot pressure (BP) is supplied]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing valve spool
6. R.H. travel valve spool
7. Arm valve spool
8. LS shuttle valve
9. LS circuit
Function
• This valve prevents the high LS pressure of the swing valve from entering the LS circuits of work
equipment valves when the swing and work equipment are in combined operation.
• This valve serves to improve operability of the work equipment by blocking the high pressure generated
during swing operation.
Operation
When pilot pressure (BP) is shut off
• Since pilot pressure (BP) is shut off, piston (3) is pressed to the left by force of spring (2).
• If the swing lever is moved, swing LS pressure (P1) passing through swing spool (5) enters port (A).
• Swing LS pressure (P1) presses valve (1) to the left, and port (A) and port (B) are interconnected.
• Swing LS pressure (P1) is transmitted from port (A) to LS shuttle valve (8) through port (B).
PC290LC-10 10-79
Control valve
When pilot pressure (BP) is supplied

• When pilot pressure (BP) is supplied, pilot pressure (BP) moves piston (3) to the right against the force of
spring (2).
• When piston (3) moves to the right, valve (1) disconnects port (A) and (B).
• Since port (A) and (B) is disconnected, swing LS pressure (P1) is not transmitted to LS shuttle valve (8).
• Swing LS pressure (P1) cannot affect other LS circuits, even if it rises.
Self-pressure reducing valve

Function
• This valve serves to reduce the delivery pressure of main pump and provide it for solenoid valves, EPC
valves, etc. for use as the control pressure.
Operation
When engine is stopped
• Poppet (11) is pressed against the seat by spring (12), so port (PR) is disconnected from port (TS).
• Valve (14) is pressed to the left by spring (13), so port (P2) is disconnected from (TS).
• Valve (7) is pressed to the left by spring (8), so port (P2) is disconnected from port (A2).
10-80 PC290LC-10
Control valve
PC290LC-10 10-81
Control valve
When load pressure (P2) is low

a When all control levers are in NEUTRAL position, or when load pressure (A2) is lower than output
pressure (PR) of the self-pressure reducing valve
• Force of spring (8) and the force exerted by the PR pressure (0 MPa {0 kg/cm 2}, when engine is stopped),
are applied to valve (7) in the direction to disconnect the circuit ports (P2) and (A2).
• When the pressurized oil flows in from port (P2), valve (7) balances at a position where [Force (Area fd x
Pressure P2) = Force of spring (8) + Force (Area fd x Pressure PR)] holds.
• The opening of valve (7) is adjusted so that pressure (P2) remains at a constant level higher than pressure
(PR).
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
10-82 PC290LC-10
Control valve
When load pressure (P2) is high

• As load pressure (A2) increases with the digging operation, etc, the pump delivery increases accordingly.
• Pressure (P2) increases, and [Force (Area fd x Pressure P2] becomes larger than [Force of spring (8) +
Force (Area fd x Pressure PR)]. As a result, valve (7) moves fully to the right.
• Since the area of the opening between ports (P2) and (A2) increases, the passage resistance reduces,
reducing the engine horsepower loss.
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
PC290LC-10 10-83
Control valve
When abnormally high pressure is generated

• If pressure (PR) of the self-pressure reducing valve becomes abnormally high, ball (16) contracts spring
(15) and separates from the seat.
• This allows the pressurized oil to flow to drain port (TS) from port (PR), lowering pressure (PR).
• As a result, components such as PPC valves and solenoid valves are protected from abnormally high
pressure.
10-84 PC290LC-10
Control valve
Travel junction valve

Function
• When travel control lever is operated for straight-travel, travel junction valve does not receive the pilot
pressure (PST) from travel junction solenoid valve, thus right and left travel circuits interconnect each
other, and equal amount of oil is supplied to right and left travel motors to secure straight-travel ability.
• When travel control lever is operated for turning, travel junction valve receives the pilot pressure (PST)
from travel junction solenoid valve, thus right and left travel circuits are shut off each other, and
independent amount of oil is supplied to right and left travel motors to secure turning ability.
PC290LC-10 10-85
Control valve
Operation
When pilot pressure (PST) is shut off (travel junction)
• If pilot pressure (PST) from the travel junction solenoid valve is shut off, travel junction spool (2) is pressed
back towards right by the force of spring (1). As a result, ports (PTL) and (PTR) are interconnected.
• If the oil flow rates to the R.H. and L.H. travel motors become different from each other, the oil flows
through the opening of travel junction spool (2) from port of higher pressure side to port of lower pressure
side supplying the difference of oil to the lower pressure side so that the oil flow rates to both motors will
be equalized.
10-86 PC290LC-10
Control valve
When pilot pressure (PST) is supplied (travel independent)
• When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2)
compresses spring (1) to the left side and ports (PTL) and (PTR) are disconnected.
• The oil flow rate to both right and left motors becomes independent.
Travel PPC shuttle valve
PPC: Abbreviation for Proportional Pressure Control
PC290LC-10 10-87
Control valve
Function
• If boom RAISE, arm IN or OUT, bucket CURL or DUMP operation is performed when the machine is
traveling up a steep, the pilot pressure from the travel PPC valve serves to restrict the travel of respective
spools of boom, arm and bucket valves so that the oil flow rates to respective cylinders are restricted.
• To limit the travel of the boom, arm or bucket spool, the pilot pressure from the travel PPC valve passes
through the internal circuit of respective control valves and acts on the spool.
Operation
When travel levers are in NEUTRAL
• The oil in the stroke limiting signal chamber (a) passes through orifices (5) and (6) of respective pistons (3)
and (4) build in the travel spring case, and then is drained through the travel PPC valve.
• When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left until it contacts the end face of spring case (2) (st0).
10-88 PC290LC-10
Control valve
When travel lever is operated
• If the right travel lever is moved to REVERSE (or FORWARD) position, the pilot pressure from the travel
PPC valve moves spool (7) to the left (or right).
• Spool (7) pushes piston (3) and orifice (5) is closed. As a result, stroke limiting signal chamber (a) and the
drain circuit from the travel PPC valve are disconnected.
• At this time, the pilot pressure from the travel PPC valve passes through orifice (6) of piston (4), acts on
the left end of piston (8) and pushes piston (8) to the right.
• When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left.
• Maximum travel of the spool is limited to (st1) that has reduction in travel by the amount of movement (st2)
of piston (8) to the right.
Boom hydraulic drift prevention valve
Function
• While boom is not operated by the right working equipment control lever, the hydraulic drift prevention
valve prevents pressurized oil to leak from boom cylinder botom through spool (1) to prevent the boom
from drifting hydraulically.
PC290LC-10 10-89
Control valve
Operation
In boom “RAISE“ operation
• When operating boom “RAISE“, the pressurized oil from the control valve exerts a left-hand force on the
right side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which
inside diameter is seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, the pressurized oil from the control valve passes through the opening of poppet (5) and flows
to the boom cylinder bottom.
10-90 PC290LC-10
Control valve
In boom “NEUTRAL“ operation
• When the boom is operated to “NEUTRAL“ position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of boom cylinder bottom exerts a right-hand force on the left side of ring-shaped
area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat
diameter (d2).
• The combined force of right-hand force on area (S) and the spring force of spring (4) moves poppet (5) to
the right.
• The circuit from control valve to boom cylinder bottom shuts off, then the oil pressure of the boom cylinder
bottom side is kept.
PC290LC-10 10-91
Control valve
In boom “LOWER“ operation
• When operating boom “LOWER“, the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the boom cylinder bottom flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) inside puppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
Arm hydraulic drift prevention valve
(if equipped)
Function
• While arm is not operated by the left working equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from arm cylinder head through spool (1) to prevent the arm from drifting
hydraulically.
10-92 PC290LC-10
Control valve
Operation
In arm “OUT“ operation
• During arm “OUT“ operation, the pressurized oil from the control valve exerts a left-hand force on the right
side of area (S) of ring-shaped surface, of which outside diameter is equal to diameter (d1) of poppet (5)
and of which inside diameter is equal to seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, pressurized oil from the control valve flows to the arm cylinder head through the opening of
poppet (5).
PC290LC-10 10-93
Control valve
In arm “NEUTRAL“ operation
• When the arm is operated to “NEUTRAL“ position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of arm cylinder head exerts a right-hand force on the left side of ring-shaped area
(S), of which outside diameter is equal to diameter (d1) of poppet (5) and of which inside diameter is equal
to seat diameter (d2).
• The combined force of right-hand force on area (S) and the reaction force of spring (4) moves poppet (5)
to the right.
• The circuit from control valve to arm cylinder head shuts off, then the oil pressure of the arm cylinder head
side is kept.
10-94 PC290LC-10
Control valve
ArmIn arm “IN“ operation
• When arm is operated “IN“, the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the arm cylinder head flows from orifice (c) to drain port (T) through orifice (a) and
chamber (b).
• Chamber (b) inside puppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
PC290LC-10 10-95
Control valve
Suction safety valve for drift prevention valve

Operation when abnormally high pressure is generated
• If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B)
opens check valve (6) to actuate safety valve (3).
• When the arm hydraulic drift prevention valve (optional) is installed to the arm cylinder head circuit, the
pressurized oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure,
whichever has higher pressure, opens check valve (6) or (6A) to actuate safety valve (3).
10-96 PC290LC-10
Control valve
Arm quick return valve

Function
• Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed.
• The valve reduces this pressure loss.
Operation
In arm “OUT“ operation
• In arm “OUT“ operation, the pilot pressure from the PPC valve pushes pilot piston (1).
• The pressurized oil in chamber (b) inside the valve is drained through orifice (c).
• The pressurized oil of the arm cylinder bottom side flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• If the pressure in chamber (b) drops lower than that of port (A), the force exerted on the pressure receiving
surface of [Area (S2) offd2 (surface of seat diameter)] on the port (A) side exceeds the combined force of
the force exerted on the pressure receiving surface [Area (S1) of fd1] on the chamber (b) side of valve (2)
and the spring force.
• (The result is, (Force exerted on surface of fd2 > Force exerted on surface of fd1 + Force of spring).
• Valve (2) is pressed to the right and pressurized oil flows from port (A) to port (B).
• The pressurized oil of the arm cylinder bottom side is drained directly to the tank from port (B).
PC290LC-10 10-97
Control valve
In arm “NEUTRAL“ operation
• When the arm is operated from arm “OUT“ to “NEUTRAL“, the pilot pressure from PPC valve is shut off.
• The pressurized oil that flows in through orifice (a) in valve (2) and is drained, is stopped by pilot piston (1).
• The holding pressure of the arm cylinder bottom side exerts a left-hand force on the right side of ring-
shaped surface, whose area is equal to the area of (S2 - S1) of valve (2).
• The combined force of the force exerted on the ring-shaped surface and the spring force of the spring (3)
moves valve (2) to the left and shuts off port (A) and port (B).
Variable back pressure valve
Function
• This valve creates back pressure in the drain circuit to prevent cavitation caused by negative pressure in
each actuator circuit (motors, cylinders, etc.).
• In order to reduce output loss, this valve reduces the back pressure in the drain circuit when any operation
other than the travel and swing is performed.
Operation
When engine is stopped
• Pressurized oil is not supplied from the main pump to self-pressure reducing valve (1).
• No oil pressure is transmitted from variable back pressure solenoid valve (3) to spring chamber (C), and
valve (6) is pressed to the right by the reaction force of spring (5).
• Drain circuit (A) of the control valve is interconnected to port (T) through orifice (b) of valve (6).
10-98 PC290LC-10
Control valve
When engine is running (during swing or travel operation)

• The pressurized oil (PR) from self-pressure reducing valve (1) flows to variable back pressure solenoid
valve (3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is “OFF“, pressurized oil (PR) is flown
to spring chamber (C) of variable back pressure valve (4).
• Pressurized oil (PR) transmitted to spring chamber (C) exerts a force on the left end face of valve (6)
(surface of fd), and it pushes valve (6) to the right as a combined force with the reaction force of spring
(5).
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows;PA = (Area of
surface fd) x Pressure PR + Reaction force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.
PC290LC-10 10-99
Control valve
When engine is running (other than swing or travel operation)

• The pressurized oil from self-pressure reducing valve (1) flows to variable back pressure solenoid valve
(3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is “ON“, the pressurized oil (PR) from
self-pressure reducing valve (1) flown to spring chamber (C) of variable back pressure valve (4) is drained
through variable back pressure solenoid valve (3).
• Only the reaction force of spring (5) pushes valve (6) to the right
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows;PA = Reaction
force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.
10-100 PC290LC-10
Control valve
Main relief valve
1. Spring
2. Poppet
Function
• This valve has two selectable settings for its set pressure.
• If the extra power is necessary, this valve is set to the high-pressure setting when pilot pressure (P) is
applied to it from the 2-stage relief solenoid valve.
• The relief valve set pressure is determined by the load at installed length of spring (1). (1st stage set
pressure)
• When the 1st stage set pressure is set correctly, the 2nd stage set pressure does not need to be set.
Setting the 1st stage set pressure completes the setting of the 2nd stage set pressure.
PC290LC-10 10-101
Control valve
Operation
When pilot pressure (P) is shut off (low pressure setting)
• The set pressure is determined by the load at installed length of spring (1).
When pilot pressure (P) is supplied (high pressure setting)

• The load at installed length of spring (1) is added with the force exerted by pilot pressure (P) applied to the
area of diameter (d1) of poppet (2), raising the set pressure to higher level.
Suction 2-stage safety valve
[Installed to port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function
• This valve has two settings for its set pressure.
• This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment
circuit selector solenoid valve.
• ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment
(breaker, crusher, etc.).
• The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure
side)
• The set pressure of the low-pressure setting is determined by the travel of the piston.
Operation
When pilot pressure (P) is shut off (high pressure setting)
• Since pilot pressure (P) is shut off, piston (2) is pressed to the left by force of spring (3).[Load at installed
length of spring (1) < Load at installed length of spring (3).]
• The load at installed length of spring (1) becomes maximum, inducing high-pressure setting.
• Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
10-102 PC290LC-10
Control valve
When pilot pressure (P) is supplied (low pressure setting)

• When pilot pressure (P) is supplied, the pilot pressure is transmitted to part (A) through passage (B).
• The pilot pressure acts on the pressure receiving diameter at part (A) [(d2) – (d1)] of piston (2).
• Piston (2) compresses spring (3) by receiving pilot pressure and moves to the right until it contacts holder
(4).
• Since spring (1) is expanded and reducing its load at installed length, the set pressure is lowered.
• The amount of pressurized oil for stroke of piston (2) is drained from passage (C) via chamber (D) .
PC290LC-10 10-103
Swing motor
Swing motor
MA: From control valve (left swing port)

MB: From control valve (right swing port)
B:From swing holding brake solenoid
S: From control valve (variable back pressure valve)
PI:2-stage relief solenoid valve
1. Reverse prevention valve
2. Swing 2-stage relief valve
10-104 PC290LC-10
Swing motor
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
PC290LC-10 10-105
Swing motor
10. Cylinder block

11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Specifications
Type KMF125ABE-6
Theoretical delivery (cm3/rev) 125
Swing 2-stage relief valve pressure (MPa {kg/cm2}) 28.4 {290｝
Low-pressure setting 180

Swing 2-stage relief oil flow (l/min)
High-pressure setting 70
Rated speed (rpm) 1,949
Brake release pressure (MPa{kg/cm2}) 1.4 ± 0.4 {14 ± 4}
Swing holding brake

When solenoid valve is “de-energized“
• When the swing holding brake solenoid valve is de-energized, the pressurized oil from the self-pressure
reducing valve is blocked.
• Port (B) is connected to tank circuit (T).
• Brake piston (7) is pushed downward by brake spring (1).
• Disc (5) and plate (6) are pushed against each other to apply the brake.
10-106 PC290LC-10
Swing motor
When solenoid valve is “energized“
• When the swing holding brake solenoid valve is energized, the valve is switched
• The pressurized oil from self-pressure reducing valve enters port (B), and flows into brake chamber (a).
• After entering chamber (a), the pressurized oil compresses brake spring (1) and moves brake piston (7)
upward.
• Disc (5) is separated from plate (6), releasing the brake.
Relief valve
• The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).
Function
• When the swing is stopped, control valve (6) blocks the motor outlet circuit, but the motor rotation is
continued by inertial force.
• If the pressure of motor outlet circuit becomes abnormally high, it may cause damage to the motor.
• In order to prevent the motor damage, the relief valve relieves the abnormally high pressure to port (S)
from the motor outlet (high-pressure side).
PC290LC-10 10-107
Swing motor
Operation
When swing is started
• When the swing control lever is moved to the “swing LEFT position“, the pressurized oil from the pump is
supplied to port (MA) through control valve (6).
• The pressure in port (MA) rises, the starting torque is generated in the motor, and the motor starts to
rotate.
• During swing acceleration, the pilot pressure from 2-stage relief solenoid valve (7) is applied to port (PI) to
limit the relief volume.
• The pressurized oil from the outlet of the motor returns to the tank through port (MB) and control valve (6).
10-108 PC290LC-10
Swing motor
When swing is stopped
• When the swing control lever is returned to “NEUTRAL“ from “swing RIGHT“ position, the supply of
pressurized oil from the pump to port (MA) is stopped.
• The pressurized oil from the motor outlet cannot return to the tank since the return circuit to the tank is
blocked by control valve (6). Thus, pressure in port (MB) increases.
• If the pressure in port (MB) becomes too high, the pressurized oil returns to the hydraulic tank through
relief valve (1) and port (S).
• Rotation resistance is exerted on the motor and the brake starts working.
• If the pressure in port (MB) becomes higher than that in port (MA), it presses shuttle valve (4).
• The pressure in chamber (C) becomes the same as that in port (MB), and increases to the set pressure of
relief valve (1).
• A high braking torque works on the motor, thereby stopping the motor.
• While relief valve (1) is actuated, the relieved pressurized oil and the pressurized oil from port (S) are
routed to port (MA) through the check valve (3).
• Thus, cavitations in port (MA) is prevented.
PC290LC-10 10-109
Swing motor
Swing 2-stage relief valve
1. Valve seat
2. Valve
3. Poppet
4. Spring
5. Spring
6. Piston
Function
• This valve has two selectable settings for set pressure.
• The set pressure of this valve is determined by the load at installed length of spring (4).
• During swing acceleration, this valve receives pilot pressure (PI) from the swing 2-stage relief solenoid
valve and decreases the relief quantity (drain quantity).
• If pressure (P) is constant, energy loss can be reduced by decreasing oil flow (Q), or relief quantity (drain
quantity), according to the formula of [Energy loss = Pressure (P) x Oil flow (Q)]. Decrease in energy loss
leads to improvement of fuel consumption.
A: When pilot pressure is “shut off“ (low-pressure setting)

B: When pilot pressure is “transmitted“ (high-pressure setting)
P: 28.4 MPa {290 kg/cm2}
Q1: 180 l/min
Q2: 70 l/min
10-110 PC290LC-10
Swing motor
Operation
When pilot pressure (PI) is shut off (low pressure setting)
• The set pressure is determined by the load at installed length of spring (4).
When pilot pressure (PI) is supplied (high pressure setting)

• During swing acceleration, pilot pressure (PI) from the swing 2-stage relief solenoid valve acts on the
power receiving area (d2 – d1).
• Spring (4) is compressed, the load at installed length of the spring is increased, and then the passage
between valve (2) and valve seat (1) is narrowed while the pump delivery is decreased by the controller.
As a result, the flow rate to hydraulic relief decreases when relief pressure is constant.
PC290LC-10 10-111
Swing motor
Swing motor reverse prevention valve
MA: From control valve (left swing port)

MB: From control valve (right swing port)
10-112 PC290LC-10
Swing motor

1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Explanatory drawing of effects
Function
• At the stop of swing operation, the upper structure may swing back. This is due to inertia of the mass of
the upper structure, the backlash and rigidity of the swing machinery system, and compressibility of the
hydraulic oil. This valve prevents such movement.
• The valve contributes to prevention of load spillage when the swing is stopped and also contributes to
reduction in the cycle time (enhances the positioning performance, enabling you to proceed to the next
work quicker than ever).
PC290LC-10 10-113
Swing motor
Operation
When brake pressure is generated in port (MB)
• Pressure (MB) is led to chamber (d) through notch (g).

• As (fD1 > fD2) holds in regards to circle areas of spool (5), spring (6) is compressed and spool (5) is
moved to the left.
• Port (MB) and chamber (e) are interconnected to each other.
• Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the
pressurized oil is blocked. Thus the braking force is ensured.
When motor reversing pressure is generated in port (MA)
• The trapped pressure in port (MB) turns the motor in the opposite direction. (1st reverse rotation)
• Reversing pressure is generated in port (MA). Pressure (MA) is transmitted to chamber (a).
• As (fD3 > fD4) holds in regard to circle areas of spool (2), spring (3) is compressed and spool (2) is
moved to the right.
• Port (MA) and chamber (b) are interconnected to each other.
• Port (b) is interconnected to port (f) through the drilled hole (h) in spool (5). This bypasses the reversing
pressure in port (MA) to port (T), thereby preventing the 2nd reverse rotation of the motor.
10-114 PC290LC-10
Travel motor
Travel motor
L.H. travel motor

PA: From control valve (L.H. travel REVERSE port)
PB: From control valve (L.H. travel FORWARD port)
R.H. travel motor
PA: From control valve (R.H. travel FORWARD port)
PB: From control valve (R.H. travel REVERSE port)
P: From travel speed increase solenoid valve
MA: MA pressure detection port
MB: MB pressure detection port
PC290LC-10 10-115
Travel motor
1. Output shaft
2. Motor case
3. Rocker cam
4. Piston
5. Cylinder block
6. Valve plate
7. End cover
8. Slow return valve
9. Brake spring
10-116 PC290LC-10
Travel motor
10. Brake piston

11. Plate
12. Disc
13. Regulator piston
14. Check valve
15. Counterbalance valve
16. Safety valve
17. Ball
18. Regulator valve
19. Spring
Specifications
Model HMV160ADT-2
Min. 85.3
Theoretical delivery (cm3/rev)
Max. 151.1
(Rated pressure: MPa {kg/cm2}) 37.3 {380}
At minimum 1,410
Rated speed (rpm) volume
At maximum 2,585
volume
Brake release pressure
1.18 {12}
(MPa {kg/cm2})
Travel speed changeover pressure
0.78 {8.0}
(MPa {kg/cm2})
PC290LC-10 10-117
Travel motor
Operation of travel motor

Travel speed at low-speed setting (motor swash plate angle is at maximum)
• When the solenoid valve is de-energized, the pilot pressure oil from the self-pressure reducing valve does
not flow to port (P).
• Regulator valve (21) is pushed to the right by spring (22).
• The pressurized oil flowing from the from control valve to end cover (7) through check valve (8) is stopped
by regulator valve (21).
• The fulcrum (a) of rocker cam (3) is located eccentric to the point of action (b) for the resultant force of
piston thrusts of cylinders (5).
• The resultant force of piston thrusts acts on rocker cam (3) as a moment that tilts the rocker cam toward
the maximum swash plate angle position.
• The pressurized oil in regulator piston (13) flows through orifice (c) in regulator valve (21), and is drained
into the motor case.
• Rocker cam (3) reaches the maximum swash plate angle position, thus, the motor capacity is maximized
and the travel speed is set to low-speed setting.
10-118 PC290LC-10
Travel motor
Travel speed at high-speed setting (motor swash plate angle is at minimum)
• When the solenoid valve is energized, the pilot pressure oil from the self-pressure reducing valve flows to
port (P).
• Regulator valve (21) is pressed to the left.
• The pressurized oil from the control valve flows through passage (d) of regulator valve (21), and enters
regulator piston (13).
• Regulator valve (13) is pressed to the right.
• Rocker cam (3) tilts toward the minimum swash plate angle position. The motor capacity is minimized and
the travel speed is set to high-speed setting when the rocker cam reaches the position.
PC290LC-10 10-119
Travel motor
Operation of parking brake

When starting travel
• When the travel lever is operated, the pressurized oil from the pump acts on counterbalance valve spool
(17) to make the parking brake circuit.
• The oil flows into chamber (e) of brake piston (10), compresses spring (9), and pushes piston (10) to the
left.
• Since the force pressing plate (11) and disc (12) against each other is eliminated, they are separated and
the brake is released.
10-120 PC290LC-10
Travel motor
When stopping travel
• When the travel lever is returned to NEUTRAL, counterbalance valve spool (17) returns to the neutral
position, and the parking brake circuit is blocked.
• The pressurized oil in chamber (e) of brake piston (10) is drained to the case through orifice (f) of brake
piston (10).
• Brake piston (10) is pressed to the right by spring (9).
• Plate (11) and disc (12) are pressed against each other, and the brake is applied.
• When brake piston (10) is returned, the flow of pressurized oil is restricted by slow return valve (8).
• This makes a delay in the application of the parking brake. The parking brake is applied after the machine
has stopped.
Brake valve
• The brake valve consists of check valve, counterbalance valve, and safety valve in a circuit as shown in
the diagram on the right.
• The function and operation of each component is as given below.
PC290LC-10 10-121
Travel motor
Counterbalance valve
Function
• When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the
motor.
As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the
machine will run away, which is extremely dangerous.
To prevent this these valves act to make the machine travel according to the engine speed (pump
discharge amount).
10-122 PC290LC-10
Travel motor
Operation
Operation when pressurized oil is supplied
• When the travel lever is operated, the pressurized oil from the control valve is supplied to port PA. It
pushes open suction safety valve (18a) and flows from motor inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by suction safety valve (18b) and spool (19), so the pressure at
the supply side rises.
PC290LC-10 10-123
Travel motor
• The pressurized oil at the supply side flows from orifice E1 and E2 in spool (19) to chamber S1. When the
pressure in chamber S1 goes above the spool switching pressure, spool (19) is pushed to the right in the
direction of the arrow.
As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor
starts to rotate.
10-124 PC290LC-10
Travel motor
Braking while travelling downhill
• If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure
at the motor inlet port will drop, and the pressure in chamber S1 through orifices E1 and E2 will also drop.
When the pressure in chamber S1 drops below the spool switching pressure, spool (19) is returned to the
left, in the direction of the arrow by spring (20), and outlet port MB is throttled.
As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor,
and this prevents the machine from running away.
In other words, the spool moves to a position where the pressure at the outlet port MB balances the
pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port
circuit and controls the travel speed according to the amount of oil discharged from the pump.
Suction Safety valve

Function
• When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor
are closed by the counterbalance valve. However, the motor is rotated by inertia, so the pressure at the
outlet port of the motor will become abnormally high and damage the motor or piping. The safety valve
acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to
the equipment.
PC290LC-10 10-125
Travel motor
Operation
When pressure in chamber MB has become high (when rotating clockwise)
• When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by
the check valve of the counterbalance valve, but the pressure at the outlet port rises because of the
inertia.
• If the pressure goes above the set pressure, the force produced by the difference in are between D1 and
D2 [x4(D12 - D22) x pressure] overcomes the force of the spring and moves the poppet to the left, so that
the oil flows to chamber MA in the circuit on the opposite side.
When pressure in chamber MA has become high (when rotating counterclockwise)
• When the travel is stopped (or when traveling downhill), chamber MA in the outlet port circuit is closed by
the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia.
10-126 PC290LC-10
Travel motor
• If the pressure goes above the set pressure, the force produced by the difference in area between D1 and
D3 [x4(D32 - D12) x pressure] overcomes the force of the spring and moves the poppet to the left, so the
oil flows to chamber MB in the circuit on the opposite side.
Operation of mechanism for varying set pressure
When starting travel (high-pressure setting)
• When the travel lever is operated, the pressurized oil from the pump actuated counterbalance valve spool
(19), and opens the pilot circuit to the safety valve. The oil passes from chamber G to passage H and
flows into chamber J, pushes the piston to the right, and compresses the spring to make the set load
larger. Because of this, the set pressure of the safety valve is switched to the high pressure setting, and a
large drawbar pull is made available.
PC290LC-10 10-127
Travel motor
When stopping travel (low-pressure setting)
• When the travel lever is placed in neutral, the pressure in chamber PA drops and counterbalance valve
spool (19) returns to the neutral position. While the counterbalance valve spool is returning to the neutral
position, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from
chamber G. The piston moves to the left, and the set load becomes smaller. Because of this, the set
pressure of the safety valve is switched to the low-pressure setting and relieves the shock when reducing
speed.
[Set pressure of safety valve]
When starting, when traveling: High-pressure setting When stopping: Lowpressure setting
40.2 MPa {410 kg/cm2} 27.5 MPa {280 kg/cm2}
10-128 PC290LC-10
PPC valve
PPC valve
Work equipment and swing PPC valve
L.H. work equipment control lever

P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
PC290LC-10 10-129
PPC valve
P3: To control valve (LEFT swing port)

P4: To control valve (RIGHT swing port)
R.H. work equipment control lever
P1: To control valve (boom LOWER port)
P2: To control valve (boom RAISE port)
P3: To control valve (bucket CURL port)
P4: To control valve (bucket DUMP port)
T: To hydraulic oil tank
10-130 PC290LC-10
PPC valve
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
PC290LC-10 10-131
PPC valve
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter
Operation
When control lever is in NEUTRAL position
• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) in spool (1).
When control lever is in fine control range
(When moved from NEUTRAL to fine control range)

• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
• The pilot pressure from the main pump is transmitted from port (P1) to port (A) through the fine control
hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
exerted by the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel.
• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
10-132 PC290LC-10
PPC valve
• Accordingly, the control valve spool moves to a position at which the pressure in port (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.
(When returned to fine control range)

• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the force
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessively reduced, spool (1) is depressed by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected
to pump pressure chamber (PP).
• The pump pressure is supplied until the pressure at port (P1) recovers to the level corresponding to the
lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
port (B) to replenish the port with pressurized oil.
PC290LC-10 10-133
PPC valve
When control lever is moved to stroke end

• Disc (5) depresses piston (4), and retainer (9) depresses spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').
10-134 PC290LC-10
PPC valve
Travel PPC valve

PC290LC-10 10-135
PPC valve

P1: To control valve (L.H. travel REVERSE port)
P2: To control valve (L.H. travel FORWARD port)
P3: To control valve (R.H. travel REVERSE port)
P4: To control valve (R.H. travel FORWARD port)
10-136 PC290LC-10
PPC valve
1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper
PC290LC-10 10-137
PPC valve
Operation
When control lever is in NEUTRAL position
• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) in spool (1).
(When moved from NEUTRAL to fine control range)

• When piston (4) is pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downwards.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
• The pilot pressure from the control pump is transmitted from port (P1) to port (A) through the fine control
hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel.
• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in port (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.
10-138 PC290LC-10
PPC valve
(When returned to fine control range)

• When lever (5) starts to return, spool (1) is pushed up by the force of centering spring (3) and the force
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessively reduced, spool (1) is depressed by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected
to pump pressure chamber (PP).
• The pump pressure is supplied until the pressure at port (P1) recovers to the level corresponding to the
lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
port (B) to replenish the port with pressurized oil.
PC290LC-10 10-139
PPC valve
When control lever is moved to stroke end

• Lever (5) depresses piston (4), and retainer (9) depresses spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').
10-140 PC290LC-10
PPC valve
1st-line attachment PPC valve (with EPC valve)

(if equipped)
a For details of operation, see "Work equipment and swing PPC valve(PAGE 10-129)".
PC290LC-10 10-141
PPC valve

P1: To control valve (service valve 1 port)
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
10-142 PC290LC-10
PPC valve
6. Block
7. Valve body
8. EPC valve
EPC valve
(if equipped)

C: To PPC valve (R.H. attachment)
1. Valve body
2. Plug
3. Spool
4. Push pin
5. Coil
PC290LC-10 10-143
PPC valve
6. Plunger
7. Connector
Function
• The EPC valve consists of the proportional solenoid portion and the hydraulic valve.
• When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the
amperage of current is generated and output to the control valve.
Operation
When signal current is zero amp. (coil is de-energized)

• Since the signal current from the controller does not flow through coil (5), coil (5) is de-energized.
• Spool (2) is pushed to the right by spring (3).
• Port (P) is blocked, so the pressurized oil from the front pump does not flow to the control valve.
• The pressurized oil from the control valve is drained to the tank through port (C) and port (T).
10-144 PC290LC-10
PPC valve
When signal current is minute (coil is energized)

• When minute signal current flows through coil (5), coil (5) is energized and the thrust pushing plunger (6)
leftward is generated.
• Push pin (4) pushes spool (2) to the left, and the pressurized oil from port (P) flows to port (C).
• The pressure in port (C) increases and the combined force of the force applied on surface (a) of spool (2)
and the reaction force of spring (3) become larger than the thrust of plunger (6).
• Spool (2) is pressed to the right, so port (P) is disconnected from port (C) and port (C) is connected to port
(T).
• Spool (2) moves to a position where the thrust of plunger (6) is equal to the total of the force exerted by the
pressure in port (C) and the force of spring (3).
• Thus, the circuit pressure between the EPC valve and the control valve is controlled in proportion to the
amperage of the signal current.
PC290LC-10 10-145
PPC valve
When signal current is maximum (coil is energized)

• Coil (5) is energized when the signal current flows through coil (5).
• As the signal current is the maximum, the thrust of plunger (6) is also maximized
• Spool (2) is pushed to the left by push pin (4).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and control valve is maximized.
• Port (T) is blocked, so no pressurized oil flows to the hydraulic tank.
10-146 PC290LC-10
PPC valve
2nd-line attachment PPC valve

(if equipped)
a For details of operation, see "Work equipment and swing PPC valve(PAGE 10-129)".
PC290LC-10 10-147
PPC valve

1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
10-148 PC290LC-10
PPC valve
6. Valve body
PC290LC-10 10-149
Solenoid valve
Solenoid valve
a The figure shows the valve for a machine ready for installation of attachment.
P1: From self-pressure reducing valve

A1: To PPC valve
10-150 PC290LC-10
Solenoid valve
A2: To control valve [Port (PX1) and (PX2)]

A3: To swing motor [Port (B)]
A4: To travel motor [Port (P)]
A5: To control valve [Port (PST)]
A6: To swing motor 2-stage relief valve
A7: To attachment circuit selector valve
ACC: To accumulator (for PPC circuit)
3. Swing holding brake solenoid valve
7. Attachment circuit selector solenoid valve (for machines ready for installation of attachment)
Solenoid valve
8. Coil (ON/OFF type)
9. Push pin
10. Valve spool
11. Sleeve
12. Block
13. Plug
Check valve
14. Plug
15. Plunger
Operation
Operation of check valve
• This valve is installed between port (P) and the PPC solenoid valve. When the engine is stopped, plunger
(1) is pushed back to the left by the reaction force of spring (2), so the passage between ports (ACC) and
(P) is blocked, keeping the pressure in the accumulator.
• When the engine is running, plunger (P) is pushed to the right with the pilot pressure that is sent to port (1),
so port (P) is connected to port (ACC).
PC290LC-10 10-151
Solenoid valve
Operation of solenoid valve
When solenoid valve is “de-energized“ (circuit is blocked)
• Coil (1) is de-energized when no signal current flows through coil (1).
• Spool (2) is pushed back to the left by reaction force of spring (3).
• As the passage between ports (P) and (A) is blocked, the pilot pressure is not fed to the actuator through
port (A).At the same time, the passage to port (T) is made, so the oil from the actuator is drained to the
hydraulic tank.
When solenoid valve is “energized“ (circuit is made)
• Coil (1) is energized when the signal current flows through coil (1).
• Spool (2) is pushed to the right by push pin (4).
• The passage between ports (P) and (A) is made, so the pilot pressure flows to the actuator through port
(A). At the same time, the passage to port (T) is blocked, so the oil from the actuator does not flow to the
hydraulic tank.
10-152 PC290LC-10
Attachment circuit selector valve (for high pressure
circuit)
Attachment circuit selector valve (for high pressure circuit)

(if equipped)
PI: From attachment circuit selector solenoid valve

ACC: To accumulator
ATT: To attachment
1. Spool
Function
• For a machine equipped with a breaker, this valve allows the oil from the breaker to return directly to the
hydraulic tank without passing through the main valve.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to interconnect the
attachment to the main valve.
Operation
When attachment other than breaker is installed
PC290LC-10 10-153
Attachment circuit selector valve (for high pressure
circuit)
• Spool (1) is pressed to the left by the force of spring (2).

• Since port (ATT) is disconnected from port (ACC), no oil flows to the accumulator.
When breaker is installed
• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is interconnected to port (ACC) and oil flows to the accumulator, so oil pulsation is absorbed by
the accumulator.
10-154 PC290LC-10
Attachment circuit selector valve (for low pressure
circuit)
Attachment circuit selector valve (for low pressure circuit)

(if equipped)
PI: From attachment circuit selector solenoid valve

V: To control valve attachment 1 port
ACC: To accumulator
ATT: To attachment
1. Spool
Function
• For a machine equipped with a breaker, this valve serves to interconnect between the main circuit from the
control valve to the breaker and the accumulator.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to disconnect the main
circuit from the accumulator.
PC290LC-10 10-155
circuit)
Operation
When attachment other than breaker is installed
• Spool (1) is pressed to the left by the force of spring (2).

• Port (ATT) is interconnected to port (V) and is disconnected from port (T). Thus, the attachment is
interconnected to the control valve.
10-156 PC290LC-10
circuit)
When breaker is installed
• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is disconnected from port (V) and is interconnected to port (T).
• The pressurized oil returning from the breaker returns directly to the hydraulic tank via port (T) without
passing through the control valve.
PC290LC-10 10-157
Center swivel joint
Center swivel joint
A1: To L.H. travel motor port (PB)

A2: From control valve (L.H. travel FORWARD port)
B1: To L.H. travel motor [Port (PA)]
B2: From control valve (L.H. travel REVERSE port)
C1: To R.H. travel motor [Port (PA)]
C2: From control valve (R.H. travel FORWARD port)
D1: To R.H. travel motor [port (PB)]
D2: From control valve (R.H. travel REVERSE port)
E1: To L.H. and R.H. travel motor [port (P)]
E2: From travel speed increase solenoid valve
DR1: From L.H. and R.H. travel motor [port (T)]
DR2: To hydraulic tank
1. Cover
10-158 PC290LC-10
Center swivel joint
2. Slipper seal
3. Rotor
4. Dust seal
5. O-ring
6. Cover
7. Shaft
PC290LC-10 10-159
Accumulator
Accumulator
PPC accumulator
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Gas to be used Nitrogen gas
Volume of gas (cc) 300
Charged pressure 1.18 {12}
(MPa {kg/cm2}) (at 80°C)
Max. operating pressure
6.86 {70}
(MPa {kg/cm2})
Function
• The accumulator is installed on the solenoid valve. If the engine is stopped with the work equipment raised,
the pressure of the compressed nitrogen gas in the accumulator develops the pilot pressure to be supplied
to the control valve. Therefore, the spool can be operated to lower the work equipment by its own weight.
10-160 PC290LC-10
Work equipment
Work equipment
Work equipment
1. Bucket
2. Bucket link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder
PC290LC-10 10-161
Work equipment shim
Work equipment shim

Outline
• There are two types of the work equipment shims; one is the iron shims and the other is the plastic shims.
• The work equipment shims are inserted so that the clearance in each joint of the work equipment will be
the standard value.
Function
Iron shims
• The iron shims are primarily inserted in the parts that need to be greased every 100 hours.
• One purpose of the iron shims is to reduce the play of the work equipment in the lateral direction.
a The shims need to be inserted on only the right or left side and do not need to be inserted on the
adjustment side, depending on the adjusting quantity of the clearance.
Plastic shims
• The plastic shims are primarily inserted in the parts that need to be greased every 500 hours.
• The purposes of the plastic shims are to reduce the play of the work equipment in the lateral direction and
prevent squeaks and scuffing caused by rubbing of the steel parts at the end faces of the joint portions.
• Combined with the greasing interval extension bushings, the plastic shims prevent squeaks caused by
lack of grease and extend the greasing intervals.
• The plastic shims are inserted in every contact face of each part so that the steel parts at the end faces of
the joint portion will not come in contact with each other.
a Combined with the greasing interval extension bushings and dust seals, the plastic shims extend the
greasing interval to 500 hours.
10-162 PC290LC-10
Bucket play adjustment shim
Bucket play adjustment shim

Outline
• The separated iron shims are used for the connection of arm and bucket.
• By adjusting the number of shims, play at connecting part can be adjusted.
a Play can be reduced by deleting some shims when the play becomes large.
PC290LC-10 10-163
Cab mount and cab tipping stopper
Cab and its attachments
Cab mount and cab tipping stopper
1. Front damper
2. Rear damper
3. Cab tipping stopper
Structure
• 4 dampers are located in front and rear of cab (2 each), and fix cab and floor frame onto revolving frame.
• Oil-filled damper is used to absorb vibration.
• Cab tipping stopper (3) installed at a place in the rear section aims to secure the cab when the machine
tips over.
• As shown in following table, various dampers are available upon its mounting location.
Color of identifying seal
Location of damper Bent of craw
(printing)
Front left Bent Red (205)
Front right Bent Red (205)
Rear left Not bent Green (270)
Rear right Not bent Green (270)
10-164 PC290LC-10
ROPS cab
ROPS cab
ROPS: Abbreviation for Roll-Over Protective Structure
1. Front window
2. Windshield wiper
3. Head lamp
4. Ceiling window
5. KOMTRAX communication antenna
6. KOMTRAX GPS antenna
7. Radio antenna
8. Door
9. Mirror
Function
• ROPS cab is a structure which protects the operator fastening a seat belt not to be crushed when the
machine tips over.
PC290LC-10 10-165
Electrical control system
Electrical system
Machine control system diagram

a Items marked with "*1" in drawing are the optional equipment.
10-166 PC290LC-10
PC290LC-10 10-167
10-168 PC290LC-10
Engine control function
1. Battery disconnect switch

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Engine shutdown secondary switch
8. Engine controller
9. Lock lever
10. PPC lock switch
11. Starting motor cut-off relay (for PPC lock)
12. Starting motor cut-off relay (for personal code)
13. Fuel control dial
14. Safety relay
15. Starting motor
16. Fuel supply pump
17. Sensors
18. Machine monitor
19. KOMTRAX terminal
20. Pump controller
Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a The engine does not start until the lock lever is set to the “LOCK“ position.
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal receives an engine cut command issued through external operation.
• When you cannot stop the engine due to stuck starting switch (6), engine shutdown secondary switch (7)
is usable for stopping the engine.
Starting the engine

• If starting switch (6) is turned to “ON“ position , engine controller (8) sends command current to fuel supply
pump (16).
PC290LC-10 10-169
For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an
electrical failure occurs.
• If starting switch (6) is turned to “START“ position when lock lever (9) is in the “LOCK“ position, starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in the “FREE“ position, starting motor cut-off relay (11) cuts off the starting current to
starting motor (15), thus the engine does not start. This is the neutral safety mechanism.
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the
signal to machine monitor (18).
Machine monitor (18) causes starting motor cut-off relay (12) to cut off the starting current to starting motor
(15), therefore the engine does not start.
Engine speed control

• Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8)
selects lower throttle signal, and sends command current to fuel supply pump (16).
Fuel supply pump (16) adjusts the fuel injection rate to control the engine speed.
Engine stop
• If starting switch (6) is turned to “OFF“ position, the current from ACC terminal of starting switch (6) to
engine controller (8) is cut off, and consequently the command current to fuel supply pump (16) is cut off.
Fuel supply pump (16) stops fuel feed, decreasing the engine speed until the engine stops.
Stopping the engine with engine shutdown secondary switch

• If engine shutdown secondary switch (7) is turned to “Stop Engine“ position, the current from ACC terminal
of starting switch (6) to engine controller (8) is forcibly cut off.
Above induces the same state as when starting switch (6) is turned to “OFF“ position, stopping the engine.
10-170 PC290LC-10
Engine and pump combined control function

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Register for PC-EPC valve
7. Pump controller
9. Machine monitor
10. Emergency pump drive switch
13. Sensors
16. One-touch power max. switch
17. Front pump oil pressure sensor
18. Rear pump oil pressure sensor
PC290LC-10 10-171
19. Oil pressure sensor

20. Oil pressure switch
21. Front pump
21a. Servo
21b. LS valve
21c. PC valve
22. Rear pump
22a. Servo
22b. LS valve
22c. PC valve
23. Control valve
24. Front pump PC-EPC valve
25. Rear pump PC-EPC valve
26. LS-EPC valve
Input and output signals
a. Front pump PC-EPC valve drive signal
b. Rear pump PC-EPC valve drive signal
c. Solenoid valve GND
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Oil pressure sensor signal
h. One-touch power maxi. switch signal
i. Oil pressure switch signal
j. 1st throttle signal
k. Supply pump control signal
l. Sensor signals
Function
• This function allows the operator to select any of the six working modes of P, E, L, ATT-P, ATT-E and B
with the working mode selector switch of the machine monitor. The most suitable combination of engine
torque (T) and pump absorption torque can be selected depending on the work contents of the machine. If
“None“ is selected for the attachment in the default setting of the service mode, one of the four modes of P,
E, L and B is selectable.
• The pump controller calculates the pump absorption upper limit torque based on the working mode, speed
setting by the fuel control dial, and actual engine speed, and controls the pump to maintain it near the
setting matching point for each mode even at high loads.
• When the engine speed is lowered, the controller prevents the engine from stopping by throttling the pump
absorption torque.
10-172 PC290LC-10
Control method in each mode

P, E, L, ATT-P and ATT-E modes
Matching point
Working mode Matching point
P and ATT-P 127.1kW/1,750 rpm
(During work) {170 HP/1,750 rpm}
E and ATT-E 108.2 kW/1,750 rpm
(During work) {145 HP/1,750 rpm}
• In P, E, ATT-P and ATT-E modes, the engine speed is always controlled so that it is kept around the
matching point specified for each mode.
• At light loads, the engine operates at high speeds. As the load increases, the engine speed decreases
while the torque is increased, until the matching point with pump absorption torque upper limit (PT) is
reached. [See (1) in graph]
• As the load increases further, the engine speed decreases further. [See (2) in graph]
• The controller lowers the pump absorption upper limit torque (PT) to reduce the load on the engine. [See
(3) in graph]
• As the engine load decreases, the engine speed increases. [See (4) in graph]
PC290LC-10 10-173
• The controller raises the pump absorption upper limit torque (PT) to maintain it near the matching point.
[See (5) in graph]
• To save fuel consumption, the controller lowers the engine matching speed (Nm) at low loads (low delivery
and torque). [See (6) in graph]
B and L modes
Working mode Partial output point
B 75 %
L 65 %
Matching point
Working mode Matching point
95.6 kW/1,600 rpm
B
{128 HP/1,600 rpm}
80.9 kW/1,700 rpm
L
{108 HP/1,700 rpm}
• In B or L mode, engine output is controlled to a constant level.
• The controller controls the pump absorption upper limit torque (PT) to keep the engine torque constant
along the equal engine horsepower curve.
10-174 PC290LC-10
Control function when travelling

• The engine speed (N) increases when if machine travels in P or ATT-P mode.
• Traveling the machine in E, ATT-E or B mode leaves the working mode unchanged, but raises the pump
absorption torque and engine speed (N) to values same as those in P mode.
• If the machine travels in L mode, the working mode and engine speed (N) do not change, but the pump
absorption torque is increased.
PC290LC-10 10-175
Control function that becomes available when emergency pump drive switch is turned on.
• Even if any abnormality occurs in the controller and no work is possible because the main pump does not
work properly, operating emergency pump drive switch (1) temporarily enables to maintain functions of the
machine with absorption torque quite similar to those in the E mode.
In this case, a constant current flows from the battery to the PC-EPC valve, so the oil pressure is sensed
by only the PC-EPC valve.
a: Emergency (when abnormal)
b: Normal (when normal)
a Emergency pump drive switch (1) is an alternative type. If the machine is operated at “Emergency (a)“
position when the machine is normal condition, Action Level “L03“ will be shown on the display.
10-176 PC290LC-10
Pump and valve control function

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Sensors
16. Front pump
16a. Servo
16b. LS valve
PC290LC-10 10-177
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
18d. Main relief valve
18e. Variable back pressure valve
21. LS-EPC valve

d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Pump merge-divider EPC valve (for main spool) drive signal
h. Pump merge-divider EPC valve (for LS spool) drive signal
i. Travel junction solenoid valve drive signal
j. 2-stage relief solenoid valve drive signal
k. Variable back pressure solenoid valve drive signal
l. 1st throttle signal
m. Fuel supply pump control signal
n. Sensor signals
Function
• The LS control function, cut-off function, and 2-stage relief function enable the machine to maintain the
optimum matching under various working conditions.
LS control function
• According to the actuator operation, the output pressure from the LS-EPC valve to LS valve varies in order
to change the selector point for pump delivery [LS set differential pressure (DLS)] in the LS valve.
• The build-up time of pump delivery will be optimized, and the ease of combined operation and fine control
will be improved.
10-178 PC290LC-10
A: 0 MPa {0 kg/cm2}
B: EPC pressure (Psig) = 1.8 MPa {18 kg/cm2}
Cut-off function
• This function increases PC-EPC current (J) to reduce the flow rate at relief, improving fuel consumption.
Operating for turning on cut-off function
When the one-touch power maximizing function is not activated and the average of front pump and rear
pump oil pressure sensor values is 27.9 MPa {285 kg/cm2} or higher.
The cut-off function does not work, however, while the machine is travelling, swing lock switch is in “ON“
position.
A: PC-EPC current at cut-off

2-stage relief function
• If the operating conditions of 2-stage relief function are met, relief pressure during work increases.
Operating conditions for 2-stage relief function Relief pressure
• When traveling 34.8 MPa
• When swing lock switch is turned to “ON“ position {355 kg/cm2}
• In boom LOWER operation O
• When one-touch power maximizing function is turned
on 37.2 MPa
• When L mode is selected {380 kg/cm2}
Variable back pressure function

• Set pressure of the back pressure valve varies depending on the operating conditions of the machine.
Operating conditions Setting of back pressure valve
When swinging and travelling High-pressure setting
When operation other than swinging or travelling Low-pressure setting
PC290LC-10 10-179
One-touch power maximizing function

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Sensors
14. One-touch power max. switch
17. Front pump
17a. Servo
17b. LS valve
17c. PC valve
18. Rear pump
18a. Servo
18b. LS valve
18c. PC valve
10-180 PC290LC-10
19. Control valve

19d. Main relief valve

d. CAN signal
e. 2-stage relief solenoid valve drive signal
f. Pump oil pressure sensor signal
g. One-touch power max. switch signal
h. 1st throttle signal
i. Fuel supply pump control signal
j. Sensor signals
Function
• By operating the one-touch power max. switch on the L.H. work equipment control lever knob, the power
is increased for a limited time.
• This can be used to increase digging force for a limited time, for example, when digging out a rock during
excavating work.
• If the one-touch power max. switch is pressed in P mode, E mode, ATT-P mode or ATT-E mode when the
load pressure is high, the hydraulic force will be increased by approx. 7%, and the horsepower will be
increased by approx. 12% to boost the digging force.
• The functions are automatically set as follows.
Function Setting
Engine and pump combined control Matching at rated output point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Cut-off function Cancel
a This function maintains the power maximizing operation as long as the one-touch power max. switch is
pressed. This function, however, is cancelled in about 8.5 seconds regardless of pressing of the switch.
PC290LC-10 10-181
Auto-deceleration function
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Sensors
9. Main pump
10. Control valve
a. CAN signal
b. Oil pressure sensor signal
c. Oil pressure switch signal
d. 1st throttle signal
e. Fuel supply pump control signal
f. Sensor signals
10-182 PC290LC-10
Function
• When all the control levers are set to NEUTRAL position for waiting for a dump truck or work, the engine
speed is automatically reduced to its controlled speed, and fuel consumption and noise are lowered.
• When any control lever is operated, the engine speed returns immediately to the speed set with the fuel
control dial.
Operation
When control lever in NEUTRAL position

• If all control levers are in NEUTRAL position for 4 seconds or more while the engine runs at a speed
higher than approx. 1,050 rpm, the engine speed is decelerated to approx. 1,050 rpm and held at this level
until any control lever is operated.
When control lever is operated

• If any control lever is operated when the engine speed is maintained at the controlled speed (approx.
1,050 rpm), the engine speed increases immediately to the speed set with the fuel control dial.
A: All work equipment control levers in “NEUTRAL“

B: All work equipment control levers in “OPERATED“
C: Fuel control dial set speed
D: Controlled engine speed (approx. 1,050 rpm)
E: 4 sec.
F: Max. 2 sec.
G: Max. 1 sec.
PC290LC-10 10-183
Engine automatic warm-up function

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
10. Air conditioner unit
14. Sensors
15. Hydraulic oil temperature sensor
16. Front pump
16a. Servo
16b. LS valve
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
10-184 PC290LC-10


e. Hydraulic oil temperature signal
f. 1st throttle signal
g. Fuel supply pump control signal
h. Sensor signals
PC290LC-10 10-185
Function
• Increases the engine speed automatically to warm up the engine if the coolant temperature is too low after
the engine starts.
• Has two different modes; "Heater warm-up" mode and "Normal warm-up" mode, automatically selected
depending on the purpose.
• Heater warm-up function warms up the coolant temperature for warmer air from blower.
• Normal warm-up function warms up the engine to prevent it from being damaged by operating in low
temperature.
Operating conditions 1
Machine specification: with air conditioner
Air conditioner: blower "ON"
Coolant temperature: Max. 55 °C
Ambient temperature: below 5 °C
Manual stationary regeneration: OFF
Soot accumulation amount: Max. 2 g/l
O O
If any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up is disabled (normal warm-up) Heater warm-up is enabled
Operational conditions 2
O
(all required)
Coolant temperature: Max. 30 °C
O
Engine speed: Max. 1,200 rpm
O O
Operation Operation
Engine speed: 1,200 rpm Engine speed: Min. 1,300 rpm
O O
Cancellation conditions Cancellation cod. CAN signalnditions
(either one required) (either one required)
Coolant temperature: Min. 30 °C
Auto Duration of automatic warming-up: Min. Coolant temperature: Min. 60 °C
10 minutes
Ambient temperature: min. 10 °C
Fuel control dial: held at over 70% of
Manual maximum speed for 3 seconds or more
O O
Cancellation
Engine speed: as desired
10-186 PC290LC-10
Overheat prevention function

a See "Engine automatic warm-up function" for the system circuit diagram.
• Prevents overheating to protect the engine and hydraulic components by reducing load on the pump and
lowering the engine speed if the coolant or hydraulic oil temperature becomes too high.
Operating condition Operation/Remedy Resetting condition
Hydraulic oil temperature:

Below 93°C
Travel Hi o Engine speed: Remains o • Under above condition,
Hydraulic oil temperature: unchanged. controller is returned to the
Min. 95°C Pump delivery : Throttled condition before operation
of function (automatic
reset).
Coolant temperature: Below

Engine speed: Remains
100°C
unchanged.
Working mode: P, E, ATT/P, Hydraulic oil temperature:
and ATT/E modes Pump delivery : Throttled
o o Below 100°C
Coolant temperature: Min. • Sends torque control signal
• Under above condition,
100 °C or Hydraulic oil to lower the pump
controller is returned to the
temperature: Min. 100 °C absorption torque and
condition before operation
reduce the load on the
engine.
reset).

Engine speed: Remains
102°C
unchanged.
Working mode: P, E, ATT/P, Hydraulic oil temperature:
and ATT/E modes Pump delivery : Throttled
o o Below 102°C
Coolant temperature: Min. • Sends torque control signal
102 °C or Hydraulic oil to lower the pump
temperature: Min. 102 °C absorption torque and
reduce the load on the
engine.
reset).

102°C
Working mode: B mode Hydraulic oil temperature:
o Engine speed: Remains o Below 102°C
Coolant temperature: Min. unchanged.
102 °C or Hydraulic oil • Under above condition,
Pump delivery : Throttled controller is returned to the
temperature: Min. 102 °C
reset).
PC290LC-10 10-187

105°C
Hydraulic oil temperature:
Below 105°C
All operations Engine speed: Low idle
o o Fuel control dial: Return the
Coolant temperature: Min. Alarm monitor: Lights up pointer to low idle (MIN)
105 °C or Hydraulic oil
Alarm buzzer: Sounds position.
temperature: Min. 105 °C
of function (manual reset).
Turbocharger protection function

a See "Engine automatic warm-up function(PAGE 10-184)" for the system circuit diagram.
• Prevents seizure of the turbocharger by limiting the engine speed if the engine speed is increased
exponentially when starting the engine.
Operating condition Operation

o Turbocharger protection
Engine oil pressure: Below 50 kPa {0.51 kg/cm2}
(See the figure below)
A: Start engine
B: Duration of turbocharger protection (approx. 0 - 20 sec.)
C: Modulating time (approx. 1 sec.)
D: 500 rpm
E: Approx. 1,050 rpm
F: 1,755 rpm (*1)
*1: Working mode: P mode
Fuel control dial: Full speed (MAX) position
When travel lever is operated
10-188 PC290LC-10
Swing control function

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Swing brake cancel switch
7. Swing lock switch
8. Pump controller
9. Machine monitor
12. Main pump
13. Control valve
14. Swing motor
14a. 2-stage relief valve
15. Swing holding brake solenoid valve

a. Swing brake cancel switch signal
b. Swing holding brake solenoid valve drive signal
c. CAN signal
d. Swing lock switch signal
e. Swing 2-stage relief solenoid valve drive signal
f. Oil pressure sensor signal
g. Oil pressure switch signal
PC290LC-10 10-189
Function
Swing lock and swing holding brake function
• On machines with swing lock (manual), swing can be locked at any position by turning swing lock switch
(1) to “ON“ position.
• Interlocked with the swing operation, the swing holding brake (automatic lock) prevents hydraulic drift from
occurring after the swing stops.
• Interlocked with the L.H. and R.H. work equipment control levers and attachment control pedals
operations, the swing holding brake is canceled to reduce the load on the swing equipment during
excavation work.
Swing lock
OFF ON
switch
Swing lock Not lighting Lights up
monitor
Function Swing holding brake Swing lock
• When the L.H. and R.H. work equipment • Swing holding brake works and lock the
control levers and attachment control swing of the upper structure.
pedals are set to NEUTRAL position, the • Even if the L.H. work equipment control
swing holding brake works in approx. 5 lever is operated for swing, the swing
sec. holding brake cannot be canceled, and
Operation
• When the L.H. and R.H. work equipment the upper structure does not swing.
control lever or attachment control pedal is
operated, the swing holding brake is
canceled and the upper structure
becomes free to swing.
A: A: When work equipment control lever or attachment control pedal is operated (Swing holding brake
“canceled“)
B:B: When work equipment control levers and attachment control pedals are in “NEUTRAL“ position
C: Swing holding brake “applied“
D:Approx. 5 sec.
10-190 PC290LC-10
Swing holding brake cancel function

• If any abnormality should occur in the controller and no swing is possible because the swing holding brake
does not work properly, operating swing brake cancel switch (2) releases the swing holding brake and
allows swing operation.
a: Cancel (when abnormal)
b: Normal (when normal)
Swing brake Cancel Normal
cancel switch (when controller has trouble) (when controller is normal)
Swing lock switch ON OFF ON OFF
Swing holding brake Swing holding brake
Swing brake Swing lock applied Swing lock applied
is released(*1) applied
*1: Hydraulic brake applied by relief valve.
a Even if swing brake cancel switch (2) is set to “CANCEL (a)“ position, swing holding brake is not released
while swing lock switch is set to “ON“ position.
a When the swing holding brake is released, only the hydraulic brake with the relief valve is effective for
holding the upper structure. So, note that, when the swing stops on a slope, a hydraulic drift may occur.
a Swing brake cancel switch (2) is of the alternative type. When the switch is turned to “CANCEL (a)“
position, the swing lock monitor in the machine monitor will blink.
Quick warm-up function

• If swing lock switch (1) is turned to “ON“ position, the pump cut-off function is cancelled and the main relief
pressure increases.
• If the work equipment is relieved with the main relief pressure increased, the hydraulic oil temperature
increases quickly and the warm-up time can be shortened.
Operating condition Main relief pressure
34.8 MPa {355 kg/cm2}
• Swing lock switch: ON O
37.2 MPa {380 kg/cm2}
PC290LC-10 10-191
Swing 2-stage relief function

• During swing acceleration, the set pressure of the swing 2-stage relief valve is changed to decrease the
flow rate to hydraulic relief and improve the fuel consumption ratio.
Operating condition Flow rate to hydraulic relief
• During swing acceleration 180 l/min
(excluding sharp change operation of swing O
direction) 70 l/min
Relation between set pressure and flow
A: When pilot pressure is “shut off“ (low-pressure setting)

B: When pilot pressure is “transmitted“ (high-pressure setting)
P: 28.4 MPa {290 kg/cm2}
Q1: 180 l/min
Q2: 70 l/min
Characteristics of 2-stage relief valve
A: Oil flow at low-pressure setting

B: Oil flow at high-pressure setting
C: Flow necessary for swing
Z: Area where the loss by relief flow is reduced (fuel consumption improved)
10-192 PC290LC-10
Travel control function
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Sensors
10. Travel alarm
11. Front pump
11a. Servo
11b. LS valve
11c. PC valve
12. Rear pump
12a. Servo
12b. LS valve
12c. PC valve
13. Control valve
14. Travel motor
PC290LC-10 10-193

17. LS-EPC valve
a. Oil pressure sensor signal
b. CAN signal
c. LS-EPC valve drive signal
d. Solenoid valve GND
e. Travel junction solenoid valve drive signal
f. Travel speed increase solenoid valve drive signal
g. Oil pressure sensor signal
h. Travel alarm buzzer operation signal
i. 1st throttle signal
j. Fuel supply pump control signal
k. Sensor signals
Function
Travel speed selector function
1. Travel speed “Manual“ change
• Switching the travel speed selector switch to “Hi“, “Mi“ or “Lo“ changes the motor capacity, which
changes the machine travel speed.
Lo Mi Hi
Travel speed selector switch
(low speed) (medium speed) (high speed)
Motor flow rate (%) 85 65 100
Motor capacity (Max.) (Min.) (Min.)
Travel speed (km/h) 3.0 4.1 5.5
2. Travel speed “Automatic“ change
1) Automatic change corresponding to engine speed
• If you adjust the engine speed to 1,500 rpm or less with the fuel control dial, the travel speed does
not switch to “Hi“ when the machine is traveling in “Mi“, and automatically changes to “Mi“ when the
machine is travelling in “Hi“.
2) Automatic change according to pump delivery pressure
• If the travel circuit oil pressure increases on an uphill with the travel speed selector switch in “Hi“,
and the travel circuit oil pressure of 33.3 MPa {340 kg/cm2} or above continues for 0.5 seconds or
more, the travel motor capacity is switched to that for medium speed travel (equivalent to “Mi“)
automatically (the travel speed switch position remains in “Hi“).
• If the travel circuit oil pressure decreases on a level ground or downhill during low speed travel
caused by the automatic speed change due to increase in the load on the travel circuit, and the
travel circuit oil pressure of 17.7 MPa {180 kg/cm2} or below continues for 0.5 seconds or more, the
travel motor capacity is switched back to that for speed of “Hi“ automatically.
10-194 PC290LC-10
A: 17.7 MPa {180 kg/cm2}

B:33.3 MPa {340 kg/cm2}
C: Min. 0.5 sec.
D: Min. 0.5 sec.
Pump control function when travelling
a For details, see "Engine and pump combined control function(PAGE 10-171)".
Travel junction function

• The controller detects the pilot pressure when travel control lever is operated, and judges the operator's
intention, the straight travel or turning operation.
• For straight-travel, a signal is sent to the travel junction solenoid valve, controlling the pump flow rate
between the right and left to be equal, to prevent travel deviation and improve straight-travel ability.
• For turning operation, the signal to the travel junction solenoid valve is shut off. This separates the pump
flow rate to the right and left travel motors from each other and improves the traction while turning.
PPC lock function

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Main pump
10. Control valve
PC290LC-10 10-195

Function
• Interlocked with the lock lever, PPC lock switch is turned off when the lock lever is moved to “LOCK“
position.
• When the PPC lock switch is turned off, current to the PPC lock solenoid valve is shut off. Even if each
control lever or pedal is operated, the work equipment and machine do not move.
Attachment flow control function
(Machine with provision for attachment)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Sensors
15. Front pump
10-196 PC290LC-10
15a. Servo
15b. LS valve
15c. PC valve
16. Rear pump
16a. Servo
16b. LS valve
16c. PC valve
17. Control valve
18. Attachment selector solenoid valve
20. Oil flow rate adjuster EPC valve for attachment
23. Attachment circuit selector valve (high pressure side)
24. Attachment circuit selector valve (low pressure side)
25. Attachment
26. Accumulator
d. CAN signal
e. Attachment selector solenoid valve drive signal
f. Oil flow rate adjuster EPC valve drive signal for attachment
g. Oil pressure switch signal
h. 1st throttle signal
i. Fuel supply pump control signal
j. Sensor signals
Function
• Setting of the working mode and oil flow rate on the machine monitor allows controlling the oil flow rate to
the attachment when the attachment control pedal is fully depressed.
• Attachment operation switches depending on the working mode as shown below.
Working mode Attachment operation
ATT–P、ATT–E Double–acting
B Single–acting
PC290LC-10 10-197
System component part

Engine controller

• The following is the list of the symbols used for signal category in the input/output signal table.
A: Power supply
B:Input
C: Ground/Shield/Return
D:Output
ECommunication
DRC26-60P(1)[ECM J1(CN-CE01)]
Pin No. Signal name Signal category
1 (*1) —
2 (*1) —
3 Crankcase pressure sensor B
4 (*1) —
5 Charge temperature sensor B
6 Intake air temperature (MAF) sensor B
7 CAN_C (+) E
8 CAN_B (+) (KOMNET/r) E
9 Bkup (camshaft) speed sensor (+) B
10 (*1) —
11 (*1) —
12 (*1) —
13 GND C
14 Coolant temperature sensor B
15 Charge pressure sensor B
16 Ambient pressure sensor B
10-198 PC290LC-10

17 CAN_C (-) E
18 CAN_B (-) (KOMNET/r) E
19 (*1) —
20 (*1) —
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow and temperature sensor B
24 Water-in-fuel sensor B
25 (*1) —
26 Ne (crankshaft) speed sensor (+) B
27 (*1) —
28 (*1) —
29 (*1) —
30 IMV(+) D
31 Engine oil pressure switch B
32 GND C
33 (*1) —
34 (*1) —
35 (*1) —
37 NE (crankshaft) speed sensor (-) C
38 (*1) —
39 (*1) —
40 IMV (-) C
41 (*1) —
42 (*1) —
43 Injector #4 (+) D
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 Injector #4 (-) C
59 GND C
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(2)[ECM J2(CN-CE02)]
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
PC290LC-10 10-199

5 (*1) —
6 EGR actuator (+) D
7 (*1) —
8 (*1) —
9 (*1) —
10 KVGT actuator (+) D
11 (*1) —
12 (*1) —
13 (*1) —
14 (*1) —
15 (*1) —
16 EGR actuator (-) C
17 (*1) —
18 GND C
19 (*1) —
20 KVGT actuator (-) C
21 GND C
22 (*1) —
23 (*1) —
24 CAN_B (+) E
25 CAN_B (-) E
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
32 KVGT speed sensor (+) B
33 KVGT speed sensor (-) C
34 Exhaust manifold pressure sensor B
35 (*1) —
36 (*1) —
37 (*1) —
38 KVGT position sensor B
39 (*1) —
40 (*1) —
41 (*1) —
42 (*1) —
43 (*1) —
44 Common rail pressure sensor B
45 (*1) —
46 GND C
47 GND C
48 EGR orifice temperature sensor B
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 (*1) —
54 (*1) —
55 (*1) —
56 (*1) —
10-200 PC290LC-10

57 (*1) —
58 (*1) —
59 EGR valve lift sensor B
60 (*1) —
DRC26-60P(3)[CN-CE03]
1 Continuous power supply (24 V) A
3 Starting switch ACC signal B
4 Intake air heater relay (+) D
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 System operating lamp D
10 (*1) —
13 GND C
14 (*1) —
15 (*1) —
16 (*1) —
17 CAN_A (+) (KOMNET/c) E
18 CAN_A (-) (KOMNET/c) E
19 GND C
20 (*1) —
21 GND C
22 GND C
23 (*1) —
24 (*1) —
25 (*1) —
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
30 (*1) —
31 GND C
32 GND C
33 (*1) —
34 (*1) —
35 (*1) —
36 (*1) —
37 (*1) —
38 (*1) —
39 (*1) —
40 (*1) —
41 GND C
43 GND C
44 (*1) —
PC290LC-10 10-201

45 KDOC inlet temperature sensor B
46 (*1) —
47 (*1) —
48 KDOC outlet temperature sensor B
49 Idle validation signal 1 B
50 Idle validation signal 2 B
51 Throttle signal B
53 (*1) —
54 KDPF outlet temperature sensor B
55 KDPF differential pressure sensor B
56 (*1) —
57 (*1) —
58 KDPF outlet pressure sensor B
59 (*1) —
60 (*1) —
Pump controller
10-202 PC290LC-10

AMP-81P [CN-CP01]
Pin No. Signal name Input/Output signal
1 Continuous power supply (24 V) Input
2 Continuous power return Input
3 Window washer Output
5 Continuous power return Input
6 Potentiometer power supply (5 V) Output
7 CAN (R)_H Input/Output
8 Service oil pressure sensor Input
9 (*1) —
10 (*1) —
11 Front pump oil pressure sensor Input
12 R.H. swing PPC oil pressure sensor Input
13 Boom LOWER PPC oil pressure sensor Input
14 Arm IN PPC oil pressure sensor Input
15 L.H. travel REVERSE PPC pressure sensor Input
16 (*1) —
17 (*1) —
18 GND (analog signal) —
19 (*1) —
20 Swing lock switch Input
21 Model selection 3 Input
22 (*1) —
23 (*1) —
24 Starting switch ACC signal Input
25 (*1) —
26 CAN (R)_L Input/Output
27 (*1) —
28 Hydraulic oil temperature sensor Input
29 (*1) —
30 Rear pump oil pressure sensor Input
31 L.H. swing PPC oil pressure sensor Input
32 Boom RAISE PPC oil pressure sensor Input
33 (*1) —
34 L.H. travel FORWARD PPC oil pressure sensor Input
35 Service PPC oil pressure switch Input
36 (*1) —
37 (*1) —
38 (*1) —
39 Swing brake cancel switch Input
41 (*1) —
42 One-touch power max. switch Input
44 (*1) —
45 CAN (C)_H Input/Output
46 GND (analog signal) Input
47 (*1) —
48 (*1) —
49 Front pump swash plate sensor Input
50 Bucket DUMP PPC oil pressure sensor Input
PC290LC-10 10-203

51 Arm OUT PPC oil pressure sensor Input
52 (*1) —
53 R.H. travel REVERSE oil pressure sensor Input
54 (*1) —
55 (*1) —
56 Wiper motor reverse (W) Input
57 (*1) —
60 (*1) —
61 Starting switch C signal Input
62 External start signal Input
63 NC —
64 CAN (C)_L Input/Output
65 (*1) —
66 (*1) —
67 (*1) —
68 Rear pump swash plate sensor Input
69 Bucket CURL PPC oil pressure sensor Input
70 (*1) —
71 (*1) —
72 R.H. travel FORWARD PPC oil pressure sensor Input
73 (*1) —
74 (*1) —
75 Wiper motor stop (P) Input
76 Cab front window open limit switch Input
78 (*1) —
79 PPC lock switch Input
81 (*1) —
AMP-40P [CN-CP02]
82 (*1) —
83 (*1) —
84 (*1) —
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 (*1) —
88 LS-EPC valve Output
89 Pump merge-divider EPC valve (LS) Output
90 (*1) —
91 (*1) —
92 (*1) —
93 Travel speed increase solenoid valve Output
94 Swing 2-stage relief solenoid valve Output
95 (*1) —
96 Front pump PC-EPC valve Output
97 Attachment oil flow rate adjustment EPC valve Output
98 (*1) —
10-204 PC290LC-10

99 (*1) —
100 System-in-use signal Output
101 Swing holding brake solenoid valve Output
102 (*1) —
103 (*1) —
104 Rear pump PC-EPC valve Output
105 (*1) —
106 (*1) —
107 Travel alarm Output
108 Battery relay drive Output
109 2-stage relief solenoid valve Output
110 (*1) —
111 (*1) —
112 Pump merge-divider EPC valve (main) Output
113 Variable back pressure solenoid valve Output
114 Wiper motor (-) Output
115 GND (solenoid) Input
116 Solenoid power supply Input
119 Wiper motor (+) Output
Fuel control dial
1. Knob
PC290LC-10 10-205
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate.
• As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes
and a throttle signal is sent to the engine controller.
• The hatched areas in the graph are abnormality detection areas. If the throttle voltage is within the area,
the engine speed drops down to low idle.
Resister for PC-EPC valve

1. Resistance
2. Connector
Specifications
Resistance: 20 z
Function
10-206 PC290LC-10
• When the emergency pump drive switch or the emergency work equipment drive switch is turned to “ON“
position, this resistor sends an electric current to each PC-EPC valve that is appropriate for their condition.
a No electric current flows in the normal condition.
CAN terminating resistor

CAN: Abbreviation for Controller Area Network
1. Connector (with built-in resistor)
Specifications
Resistance: 120 z
Function
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine can not be
operated.
Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Specifications
Contact type: Normally closed
PC290LC-10 10-207
Function
• This oil pressure switch is installed to the cylinder block. It detects engine oil pressure, and turns the
switch to "ON" position when the pressure goes below the specified value.
PPC oil pressure switch

1. Plug
2. Switch
3. Connector
Specifications
Contact type: Normally open
Operating (ON) pressure: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
Function
• Two sensors are installed to attachment PPC valve. They detect PPC oil pressure during attachment
operation and turn the switch to “ON“ position if the pressure is equal or higher than the specified
pressure.
10-208 PC290LC-10
Machine monitor system
1. Machine monitor
2. Battery
3. Pump controller
5. Air conditioner controller
6. KOMTRAX terminal
7. Sensors and switches
8. Wiper motor and window washer motor
9. Camera
a. Power supply
b. CAN signal
c. Sensor and switch signals
d. Drive signal
e. Camera signal
Function
• The monitor system keeps the operator informed of all machine functions, by monitoring the machine
conditions by using the sensors and switches installed in various parts of the machine and processing
them instantly to display on the machine monitor.
PC290LC-10 10-209
The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has trouble
2. Machine status display (coolant temperature, hydraulic oil temperature, fuel level, etc.)
3. Display of camera image
• The switches on the machine monitor have an operating function to control the machine.
Machine monitor
Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If an failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.
Precautions on the machine monitor display

• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this
is not a failure or a defect. Products having 10 or less black or bright spots conform the product
specification; such the condition is quite normal.
• When the engine is started, the battery voltage may drop suddenly, depending on the ambient
temperature and the condition of the battery. In this case, the machine monitor display may go off for a
moment. However, this phenomenon is not a failure.
• Continuous operation of the machine monitor may display blue bright spots on the screen having a black
background; it is quite normal.
Blue bright spots can never be a problem as the screen has usually blue or white background. (White in
the LCD is made up of red, green and blue.)

070-18P[CN-CM01]
10-210 PC290LC-10

3 GND (continuous power supply) —
4 GND (continuous power supply) —
5 External start signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) —
8 System operating lamp Input/Output
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 (*1) —
15 Fuel level sensor Input
16 Charge level (Alternator R terminal) Input
17 (*1) —
18 (*1) —
070-12P [CN-CM02]
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input
4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 (*1) —
7 CAN (C) terminating resistor terminal —
10 CAN (R) terminating resistor terminal —
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output
070-20P [CN-CM03]
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 (*1) —
12 (*1) —
13 (*1) —
14 (*1) —
PC290LC-10 10-211

15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) —
19 (*1) —
20 (*1) —
070-8P [CN-CM04]
1 Camera power supply (8 V) Output
2 Camera NTSC signal 1 Input
5 GND (Camera power supply) —
6 Switching camera 2 to original/mirror image Output
7 Switching camera 3 to original/mirror image Output
8 Shield GND —
10-212 PC290LC-10
Display
A: Standard screen
B: Check before starting screen
C: Maintenance interval warning screen
D: Warning screen
E: Guidance screen
F: Camera image screen
a Camera image screen (F) shown in the figure is when two or more cameras are installed
1. Message monitor
2. KDPF regeneration monitor
3. Engine stop monitor
4: Seatbelt monitor
5. Air conditioner monitor
6. Wiper monitor
PC290LC-10 10-213
7. Swing lock monitor

8. Engine preheating monitor
9. Service meter
10. Auto-deceleration monitor
11. Working mode monitor
12. Travel speed monitor
13. Fuel level gauge
14. Fuel level monitor
15. Eco gauge
16. Fuel consumption gauge
17. Hydraulic oil temperature monitor
18. Hydraulic oil temperature gauge
19. Engine coolant temperature monitor
20. Engine coolant temperature gauge
21. Radiator coolant level monitor
22. Charge level monitor
23. Engine oil pressure monitor
24. Engine oil level monitor
25. Air cleaner clogging monitor
26. Water separator monitor
27. Clock
28. Maintenance interval warning monitor
29. System status monitor
30. Action level monitor
31. ECO guidance
Gauge
Gauge Display item Description Remarks
Temperature Background • Indicates
Range
(°C) color corresponding
W1 105 Red temperature range.
(*1) • Alarm buzzer sounds
W2 102 Red
Engine coolant when the temperature
W3 100 Blue is 105°C or higher.
temperature
gauge W4 85 Blue • If the monitor
W5 60 Blue background appears
white, warm-up the
W6 30 White engine.
Temperature Background • Indicates
Range
(°C) color corresponding
H1 105 Red temperature range.
H2 102 Red
when the temperature
Hydraulic oil H3 100 Blue is 105°C or higher.
temperature H4 85 Blue • If the monitor
gauge H5 40 Blue background appears
white, warm up the
H6 20 White hydraulic
components.
10-214 PC290LC-10
Gauge Display item Description Remarks

Range Quantity (l) Background • Indicates
color corresponding
F1 304 Blue remaining fuel level.
(*1) F2 245 Blue
Fuel level gauge F3 200 Blue
F4 100 Blue
F5 60 Blue
F6 41 Red
• Indicates
instantaneous fuel
Segment Load level consumption
(average of fuel
consumption per 3
minutes) in 10 steps.
(*2) Light to (It is displayed when
Green 1 to 8
Eco gauge medium the user menu's
“ECO guidance“ o
“Display setting“ o
“Eco gauge display“
Orange 9、10 Heavy is set.)
• Indicates
accumulated engine
operating hours (the
Service meter 00000.0 h - 99999.9 h alternator is running).
(F4 switch changes it
to clock display.)
• Displays time.
• 12-hour display (AM/PM) (F4 switch changes it
Clock • 24-hour display to service meter
display.)
• Indicates average
fuel consumption.
(Display is switched
when the user menu's
“ECO guidance“ o
“Display setting“ o
“Fuel gauge display“
are specified.)
(*2)
• 1 day
Fuel • Split
consumption
• Not installed
gauge
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer
disappears.
*2: Display item is switched when the user menu's “ECO guidance“ o “Display setting“ are specified.
PC290LC-10 10-215
Caution monitor
Description
Monitor
Symbol Display item display Action level Remarks
Range
(Background monitor
color)
Lights up • Background color
Min. 102°C (Red) L02 changes depending
Min. 30°C or Lights up on the temperature
— detected.
below 102°C (Blue)
Engine coolant when the temperature
temperature is 105°C or higher.
Lights up • If the monitor
Below 30°C —
(White) background appears
white, warm-up the
engine.
Min. 102°C (Red) L02 changes depending
Min. 20°C or Lights up on the temperature
— detected.
below 102°C (Blue)
• Alarm buzzer sounds
(*1) when the temperature
Hydraulic oil is 105°C or higher.
temperature • If the monitor
Lights up background appears
Below 20°C —
(White) white, warm up the
hydraulic
components.

41Below 41 l —
(*1) (Red) changes depending
Lights up on the remaining fuel
Fuel level —
41Min. 41 l (Blue) level.
When • When failure is
abnormal detected with the
(*1) Lights up (*3) engine stopped, the
(When below (Yellow)
Radiator coolant specified L01 monitor lights up on
level level) the screen.
When normal Lights out —
• The monitor lights up
When charge
is defective on the screen and
alarm buzzer sounds
(*1) (Charge Lights up when failure is
(Red) L03
Battery charge voltage < detected while the
condition battery engine running.
voltage)
When • The monitor lights up
abnormal on the screen and
(*1) Lights up alarm buzzer sounds
(When below (Red) L03
Engine oil specified when failure is
pressure level) detected while the
engine running.
(*1) Lights up (*3)
(When below engine stopped, the
Eng. oil level (Yellow) L01 monitor lights up on
specified
level) the screen.
10-216 PC290LC-10
Description
Monitor
Range
(Background monitor
color)
(*1) Lights up (*3) engine running, the
(When above (Yellow)
Clogging of air specified L01 monitor lights up on
cleaner level) the screen.
(There is engine running, the
water Lights up monitor lights up on
(*1) — the screen.
collected (Red)
Water separator above the
specified
amount.)
When • The display changes
exceeding Lights up depending on the
—
maintenance (Red) time to/after the
interval maintenance.
• After the starting
Maintenance (*2) switch is turned to
interval warning “ON“ position , the
When Lights up monitor turns on if the
exceeding —
(Yellow) monitor light-up
maintenance conditions are met,
notifying time and then goes out in
30 seconds.
When action • When failure is
level “L04“ or Lights up detected in the
(Red) L04 and L03
“L03“ is machine system, the
System status detected monitor lights up.
• When the
When action Lights up (*3) background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.
(Red) L04 and L03
“L03“ is engine system, the
State of engine detected monitor lights up.
system • When the
detected
sounds.
(Red) L04 and L03
“L03“ is hydraulic system, the
State of detected monitor lights up.
hydraulic system • When the
detected
sounds.
State of KDPF level “L04“ or Lights up detected in the KDPF
system (Red) L04 and L03 system, the monitor
“L03“ is
detected lights up.
PC290LC-10 10-217
Description
Monitor
Range
(Background monitor
color)
• When the
detected
sounds.
When action • The monitor lights up
level “L04“ or Lights up when soot is
(Red) L03
“L03“ is deposited inside
detected KDPF or cleaning
Deposition of function is abnormally
soot on KDPF degraded.
When action Lights up (*3) When the
level “L01“ is (Yellow) L01 background color is
detected
red, the alarm buzzer
sounds.
• The monitor lights up
Engine Engine Lights up and alarm buzzer
overspeed overspeed is (Red) L02 sounds when engine
detected overspeed is
detected.
• When failure is
Sate of air When air (*3) detected in the air
Lights up
conditioner conditioner is conditioner system,
(Yellow) L01
system abnormal the monitor lights up.
When action Lights up • When failure is
level “L04“ is (Red) L04 detected on the
detected machine, the monitor
When action Lights up lights up.
level “L03“ is (Red) L03 When the
detected background color is
Action level
When action Lights up red, the alarm buzzer
level “L02“ is (Red) L02 sounds.
detected
When action Lights up (*3)
level “L01“ is (Yellow)
detected L01
*1: It is included in the check before starting items. After the staring switch is turned to “ON“ position, the
monitor turns on for two seconds, and changes to the standard screen if no failure is found.
*2: The notifying time is changeable from the items in “Maintenance mode display setting“ of the service mode.
*3: Monitor goes out after lighting up for 2 seconds.
Pilot monitor
Symbol Display item Description Remarks
• It operates automatically • Indicates preheat
at a low temperature. operating status.
Automatic (Symbol lights up as long
preheating as for approx. 30
seconds)
• It goes off after the engine
Preheating is started.
Elapsed time
after turning
Manual the starting Monitor
preheating switch to display
“HEAT
(Preheating)“
10-218 PC290LC-10

0 to 30 sec. Lights up
30 to 40 sec. Flashes
After 40 sec.
Lights out
or longer
One-touch • Indicates the
power max. Monitor display operating status of
switch one-touch power
One-touch Lights up maximizing function.
power max.
ON (Goes out if pressed for 8.5
seconds)
OFF Lights out
Swing lock Swing brake Monitor • Indicates swing lock
switch cancel switch display operating status.
OFF OFF Lights out
Swing lock ON OFF Lights up
OFF ON Flashes
ON ON Flashes
• Indicates front glass
INT: Intermittent operation
wiper operating
Wiper ON: Continuous operation condition.
Lights out: Holds in position
• Indicates air
Lights up: ON conditioner and air
Air conditioner blower operating
Lights out: OFF
status.
• Indicates whether
Lights up: Not fastened seatbelt is fastened.
Seatbelt
Lights out: Fastened
• Indicate the engine

Lights up: When engine is stopped operating status.
Engine stop
Lights out: While engine is running
• Indicate regenerating
KDPF Lights up: KDPF is being regenerated state of KDPF.
regeneration Lights out: KDPF regeneration is finished
• Indicate regenerating
state of KDPF.
• When manual
stationary
regeneration is
required, “KDPF soot
Lights up: KDPF regeneration is stopped deposition monitor“
Stop of KDPF
lights up.
regeneration Lights out: KDPF regeneration is finished
• State of the message

Message Lights up: There is unread message. is displayed.
(Unread) Lights out: No message
PC290LC-10 10-219

Message • State of the message
(No return Lights up: There is an already-read message is displayed.
message, but return message for it is not sent yet.
already-read Lights out: No message
message)
• Indicates auto-
Auto- Lights up: ON decelerator operating
deceleration Lights out: OFF status.
P: Heavy-duty operation • Displays working

E: Low-fuel consumption operation mode.
L: Fine operation
Working mode B: Breaker operation
ATT-P: Double-acting attachment operation
ATT-E: Double-acting attachment and low-
fuel consumption operation
• Displays travel speed
Lo: Low speed
setting.
Travel speed Mi: Middle speed
Hi: High speed
• Idle stop guidance • Guidance for
• Guidance on deterrence of hydraulic relief supporting the
ECO guidance • E-mode recommendation guidance machine operation
• Travel partial recommendation guidance and control are
• Low oil level guidance displayed.
Switches
10-220 PC290LC-10
No. Name Function Operation

Switches the auto-deceleration • When working mode is “L“, this switch
Auto-deceleration function ON/OFF. is always “OFF“ after engine started.
1 switch OFF io ON
Lights upON
[Numeric keypad: 1]
Not lightingOFF
Displays the working mode selector P: Heavy-duty operation
screen. ELow-fuel operation
(*1) L: Fine operation
Working mode selector B:Breaker operation
2 switch ATT-P: Double-acting attachment
[Numeric keypad: 2] operation
ATT-E: Double-acting attachment and
low-fuel operation
Changes the travel speed. • Speed is sequentially changed as
Travel speed selector Lo lights up: Low speed shown below.
3 switch Lo (Low speed) o Mi (Medium
Mi lights up: Medium speed speed) o Hi (High speed) o Lo (Low
[Numeric keypad: 3]
Hi lights up: High speed speed)
Stops the alarm buzzer. • The alarm buzzer stops sounding.
Buzzer cancel switch (Some alarm buzzer does not stop • The alarm buzzer sounds again if
4 another error worth alarming is
[Numeric keypad: 4] sounding even if the switch is
pressed.) detected.
Operates the front glass wiper. • Pressing the switch sequentially
(*2) changes the wiper operation.
INT: Intermittent operation
5 Wiper switch OFF (Stop) o INT (Intermittent) o
ON: Continuous operation ON (Continuous) o OFF (Stop)
[Numeric keypad: 5]
Not lighting Holds in position
Sprays washer fluid onto the front ON: Washer fluid is sprayed and
window glass. windshield wiper works continuously.
[When wiper stops]
(*2) OFF: Windshield wiper works twice
continuously and stops after the switch is
6 Window washer switch
released.
[Numeric keypad: 6]
[When wiper operates intermittently]
OFF: Windshield wiper works twice
continuously and returns to intermittent
operation after the switch is released.
Fan switch (increase) Controls the air flow of the air • The air flow increases immediately
7a conditioner in 6 levels. after the air conditioner adjustment
[Numeric keypad: 7] screen appears.
(Low, Medium 1, Medium 2,
Medium 3, Medium 4 and High) • The air flow decreases immediately
7b Fan switch (decrease) after the air conditioner adjustment
screen appears.
Temperature control Controls the temperature inside the • The preset temperature increases
8a switch (raise) cab. immediately after the air conditioner
[Numeric keypad: 8] (18.0℃ to 32.0℃: Setting is adjustment screen appears.
Temperature control available in 0.5°C steps) • The preset temperature decreases
8b switch (lower) immediately after the air conditioner
[Numeric keypad: 0] adjustment screen appears.
Operates the air conditioner and air • The air flow, combination of vents,
(*3) flow with automatic operation. and selection of FRESH/RECIRC air
AUTO lights up: Automatic are automatically selected according
9 Auto switch
operation to the set temperature immediately
[Numeric keypad: 9] after the air conditioner adjustment
screen appears.
Selects the air conditioner ON/OFF. • Switches to the air conditioner
(*4)
10 A/C ON lighted: Manual operation adjustment screen, and pressing it
Air conditioner switch again switches ON/OFF.
PC290LC-10 10-221
No. Name Function Operation

Not lighting: Stop OFF io ON
Changes the FRESH/RECIRC. • Switches to the air conditioner
FRESH/RECIRC air adjustment screen, and pressing it
11 changeover switch again switches FRESH/RECIRC.
RECIRC io FRESH
Selects the air vent mode from 6 • Switches to the air conditioner
modes. adjustment screen, and pressing it
1. Front vent again switches air vent mode.
1o2o3o4o5o6o1
2. Front and rear vents
12 Vent selector switch
3. Front, rear and foot vents
4. Foot vent
5. Foot and defroster vents
6. Defroster vent
Stop the fan and air conditioner. • The fan and air conditioner stop.
13 OFF switch
Light OFF: OFF
14a Guidance icon
「See "Guidance icon and function switch(PAGE 10-222)"
14b Function switch
*1: When the working mode is changed, the auto-decelerator function turns “ON“.
*2: When the front window is open, the wiper and washer do not operate even if the switch is pressed.
*3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to “High“ and does not
change even if the set temperature is reached.
*4: Air conditioner can not be operated while the fan stops.
Guidance icon and function switch

• Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
• No function is available if no guidance icon appears above the function switch.
• The following is the list of guidance icons and the functions displayed above the function switches.
Guidance
Item Function
icon
Selects user menu screen.
Background colors allow confirming the type of information
transmitted.
Selection of user mode • Gray: When the condition is normal
screen • Red: When soot accumulation abnormality (L3) is detected, or
exceeding maintenance interval
• Yellow: When soot accumulation abnormality (L1) is detected, or
exceeding maintenance interval warning
• Green: When there is unread KOMTRAX message
Switching clock/service Switches clock/service meter display.

meter
Switching to camera Switches to camera image display screen.

screen
10-222 PC290LC-10
Guidance
Item Function
icon
Enters selected/setting item.
Background colors allow confirming the type of information
Enter transmitted.
• Gray: When the condition is normal
• Green: When energy saving guidance is displayed
Return Returns to the previous screen or status.
Selects the item right above the current item

Switching the select item
(To the bottom item from the top item.)
Selects the item right below the current item

(To the top item from the bottom item.)
Green arrow: Selects the item on the right side of the tab.
Switching the select item White arrow: Selects the item on the right side of the current item.
(To the leftmost item from the rightmost item.)
Green arrow: Selects the item on the left side of the tab.
Switching the select item White arrow: Selects the item on the left side of the current item.
(To the rightmost item from the leftmost item.)
Selects the page right above the current page.

(To the bottom page from the top page.)
Selects the page right below the current page.

(To the top page from the bottom page.)
Clear Clears selected/displayed item.
Sets selected item back to default.

Restores default value
(Used for screen adjustment.)
Set Performs setting.
Starts function.
Start (Used for starting measurement of split fuel consumption on the fuel
consumption display screen.)
Stops operation.
Stop (Used for stopping measurement of split fuel consumption on fuel
consumption display screen.)
Saving Saves setting
PC290LC-10 10-223
Guidance
Item Function
icon
Switching to the name

Switches the current screen to the name setting screen
setting screen
Switching to ATT1 oil flow Switching the current screen to attachment 1 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Switching to ATT2 oil flow Switching the current screen to attachment 2 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Holds the value of the target item of monitoring.

HOLD
(Used when monitoring is turned on)
Resets the currently held value of the target item of monitoring.

Resetting the hold
(Used when monitoring is turned on)
Switching the fuel

Switches the graphs on the fuel consumption record screen.
consumption record screen
Switching to oil flow setting Switches to the attachment and breaker oil flow setting screen.
screen
Switches to the currently occurring failures list screen.

Switching to the currently Background colors allow confirming the type of information
occurring failures list transmitted.
screen • Red: When an action level of L2, L3 or L4 is displayed
• Yellow: When the action level of L1 is displayed
Display No. 1 camera Selects No. 1 camera image display screen.

screen

screen

screen
Display No. 1 and No. 2 Display both images of No. 1 and No. 2 cameras simultaneously.
camera screens
Operator mode function

• The operator can select the information to be displayed usually on the screen and the function to be used
by operating the switches.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
10-224 PC290LC-10
Category Display order (*2)

Item
(*1) V W X Y Z
KOMATSU logo screen 1 1 1 1 1
Password input screen 2 — — — —
Breaker mode check screen — — 2 — —
Checks before starting screen 3 2 3 2 2
Warning screen after check before starting — — — 3 —
A — — — —
Overdue maintenance time item screen 3
Working mode and travel speed check screen 4 3 4 4 4
Standard screen 5 4 5 5 5
Engine stop sub-switch screen
End screen
Selecting auto-deceleration function
Selecting working mode
Selecting travel speed
Stopping alarm buzzer
Operating windshield wiper
Operating window washer
Operating air conditioner
Operating camera mode display
B Switching between clock display and service meter display
Checking maintenance information
Setting and displaying user menu
• ECO Guidance
• Machine Setting
• KDPF Regeneration
• Maintenance
• Monitor Setting
• Message display (including KOMTRAX messages for user)
Displaying ECO guidance
Displaying caution monitor
C
Displaying KDPF regeneration
Displaying action level and failure code
LCD (Liquid Crystal Display) display condition checking function
D Service meter reading checking function
Access restriction setting/password changing function
*1: The items available in the operator mode are categorized as shown below.
A: Displays that appear since starting switch is turned to “ON“ position until the standard screen appears, and
the displays that appear after starting switch is turned to “OFF“ position .
B: Displays that appear when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied
D: Displays that require special switch operations.
*2: Display sequence from “ON“ of starting switch to the standard screen varies depending on the settings
and conditions of the machine as follows:
V: When engine start lock is set effective
W: When engine start lock is disabled
X: When working mode at start is set to “Breaker Mode (B)“.
Y: When a failure is detected during check before starting.
Z: When a maintenance time overdue is detected for an item.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)(PAGE 30-78)" section in Testing and adjusting.
a For how to set the engine start lock on/off, see " Password setting/cancel manual" .
PC290LC-10 10-225
Service mode function

• The functions in this mode are not displayed usually on the screen. Information display and various
settings can be made only by the technician through the special operation of the switches.
This mode is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring / Pre-defined
Monitoring / Custom
Abnormality Record Mechanical Systems
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Default Key-on Mode
Unit
With/Without Attachment
Camera
Diagnostic Tests Cylinder Cut-out
Regeneration for Service
KDPF Memory Reset
Adjustment Pump Absorption Torque (F)
Pump Absorption Torque (R)
Low Speed
Attachment Flow Adjustment
Cal F pump swash plate sensor
Cal R pump swash plate sensor
No Injection
KOMTRAX Settings Terminal Status
GPS & Communication Status
Modem Status
Service Message
a For how to operate the service mode functions, see "Service mode(PAGE 30-93)" section in Testing and
adjusting.
10-226 PC290LC-10
KOMTRAX system
KOMTRAX system
• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
• This system transmits various machine information by use of the radio communication. This system allows
the KOMTRAX operator to reference the information and provide various services to the customers.
• Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
KOMTRAX terminal
Type: TC330
1. GPS antenna connection

2. Machine harness connection (070-18P)
3. Machine harness connection (070-12P)
4. Communication antenna connection
PC290LC-10 10-227
KOMTRAX system

070-18P[CN-CK01]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P [CN-CK02]
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
Function
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of “KOMTRAX setting“ in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.
10-228 PC290LC-10
Sensors
Sensors
Ambient pressure sensor
1. Connector
2. Sensor
Function
• This sensor is installed to the air intake cover at the engine top side. It detects senses the atmospheric
pressure to output the corresponding variable voltage.
Output characteristics
Charge (boost) pressure and temperature sensor
1. Connector
2. Sensor
3. O-ring
PC290LC-10 10-229
Sensors
Function
• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its
temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for
temperature.
a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged
engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and
temperature".
Coolant temperature sensor
1. Connector
2. Sensor
3. O-ring
Function
• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
10-230 PC290LC-10
Sensors
Ne (crankshaft) speed sensor
1. O-ring
2. Sensor
3. Connector
Function
• This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to
the gear rotation.
Bkup (camshaft) speed sensor
1. O-ring
2. Sensor
3. Connector
Function
• This sensor, installed to the ring of cam shaft on the engine front cover, outputs the pulse voltage due to
the gear rotation.
PC290LC-10 10-231
Sensors
Common rail pressure sensor
1. Connector
2. Sensor
Function
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
Exhaust manifold pressure sensor
1. O-ring
2. Sensor
3. Connector
Function
• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects
the exhaust pressure to output the corresponding variable voltage.
EGR orifice temperature sensor
EGR: Abbreviation for Exhaust Gas Recirculation
10-232 PC290LC-10
Sensors
1. Connector
2. Sensor
3. Washer
Function
• This sensor, installed on the EGR gas piping between EGR cooler and EGR valve of the engine, converts
the temperature variation into the resistance variation, and outputs the corresponding signals.
EGR valve lift sensor
EGR: Abbreviation for Exhaust Gas Recirculation
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function
• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the
• The relation between stroke and output voltage is as shown in the following graph.
KVGT speed sensor

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
PC290LC-10 10-233
Sensors
1. Sensor
2. O-ring
3. Connector
Function
• This sensor, installed to KVGT in the engine, outputs the pulse voltage due to the rotation of KVGT
turbine.
a The 3-pole connector is applied for this sensor, however, available pins are the pin No. 1 and No. 2 only,
and it has no pin No. 3.
KVGT position sensor
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
10-234 PC290LC-10
Sensors
Mass air flow and temperature sensor
1. Connector
2. O-ring
3. Sensor
Function
• This sensor, installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The “MAF (Mass Air Flow)“ means the “intake air flow“.
KDPF differential pressure and outlet pressure sensor
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter
PC290LC-10 10-235
Sensors
1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor
Function
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
• The outputted pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is outputted as a pressure which is detected at low-pressure port (2).
KDOC inlet temperature sensor
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function
• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDOC outlet temperature sensor
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function
• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDPF outlet temperature sensor
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter
10-236 PC290LC-10
Sensors
1. Sensor
2. Connector
Function
• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
Crankcase pressure sensor
1. Connector
2. Sensor
3. O-ring
Function
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
PC290LC-10 10-237
Sensors
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Function
• This sensor, installed on the side face of the oil pan, turns “OFF“ by the lowered float, if the oil level
becomes lower than specified.
Fuel level sensor
10-238 PC290LC-10
Sensors
1. Connector
2. Float
3. Arm
4. Valve body
5. Spring
6. Variable resistor
Function
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
• The movement of the float activates the variable resistor through the arm. As a result, the source voltage
is changed according to the resistance change due to the arm angle change and is output as a signal.
Coolant level sensor
1. Float
2. Sensor
3. Connector
4. Reservoir tank
Function
• This sensor is integrated with reservoir tank, and is activated by the lowered float, if the coolant level
becomes lower than specified.
PC290LC-10 10-239
Sensors
Hydraulic oil temperature sensor
1. Connector
2. Plug
3. Thermistor
Function
• This sensor, installed on the suction pipe of main pump, senses the temperature variation as the change
in thermistor resistance, and outputs the corresponding signals.
Front pump oil pressure sensor
1. O-ring
2. Sensor
3. Connector
Function
• The sensor is installed in the control valve. It detects the delivery pressure of the front pump and outputs
variable voltage signal.
10-240 PC290LC-10
Sensors
Rear pump oil pressure sensor
1. O-ring
2. Sensor
3. Connector
Function
• The sensor is installed in the control valve. It detects the delivery pressure of the rear pump and outputs
variable voltage signal.
PPC oil pressure sensor

1. O-ring
2. Sensor
3. Connector
PC290LC-10 10-241
Sensors
Function
• PPC oil pressure sensors, 8 of which are installed to interconnect blocks in the pilot circuit between control
valves and PPC valve, and 4 of which are installed to travel PPC valves, detect the pilot pressures, and
output the corresponding variable voltage.
Air cleaner clogging sensor
1. Adapter
2. Hood
3. Indicator
4. Connector
Function
• This sensor is installed on the outlet side of the air cleaner.
• The sensor is turned the "ON" position if the air cleaner is clogged and the pressure level drops to the
specified level (negative pressure).
10-242 PC290LC-10
Sensors
Front pump swash plate sensor
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
Function
• This senor is installed to the front pump side of the main pump. It detects the stroke of servo piston and
outputs variable voltage signal.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
• The relation between oil flow of pump and output voltage is as shown in the following graph.
PC290LC-10 10-243
Sensors
Rear pump swash plate sensor
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
Function
• This senor is installed to the rear pump side of the main pump. It detects the stroke of servo piston and
outputs variable voltage signal.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
10-244 PC290LC-10
Sensors
• The relation between oil flow of pump and output voltage is as shown in the following graph.
Water-in-fuel sensor
1. Connector
2. Tube
3. Sensor
4. O-ring
Function
• This sensor is installed to the cup of fuel prefilter.
• This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.
PC290LC-10 10-245
10-246 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
20 Standard value table

4 20 Standard value table
PC290LC-10 20-1
Table of contents
Table of contents
20 Standard value table ..................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine related parts .......................................................................... 20-3
Standard value table for chassis related parts......................................................................... 20-5
20-2 PC290LC-10
Standard value table for engine related parts
Standard service value table

Applicable model PC290LC–10
Engine SAA6D107E–2
Category
Item Measuring conditions Unit Standard Service limit
Engine at rpm 1,955 ± 70 1,955 ± 70

• Coolant temperature: within full speed
Speed operating range At low idle rpm 1,050 ± 50 1,050 ± 50
• Swing lock switch: ON Rated rpm 2,050 2,050
speed
• Coolant temperature: within operating

range
• Hydraulic oil temperature: within operating kPa Min. 133 Min. 107
Boost pressure
range {mm Hg} {Min. 1,000} {Min. 800}
• Swing lock switch: ON
• Arm IN relief + power max.
Engine
outlet
• Coolant temperature: within (Between Bosch
operating range - 2.2
turbochar- index
Exhaust gas • At relief with arm IN ger and
color • Swing lock switch: ON KDPF inlet)
• After maintaining it at
steady-state for five seconds KDPF outlet
Bosch
(Tail pipe - 0.5
outlet) index
Engine
mm
• Coolant temperature: normal Intake valve 0.25 0.152 to 0.381
Valve clearance temperature Exhaust mm 0.51 0.381 to 0.762
valve
Compres- MPa Min. 2.41 Min. 1.69
sion
Compression • Engine oil temperature: 40 to pressure {kg/cm2} {Min. 24.6} {Min. 17.2}
pressure 60°C
Engine rpm
speed 250 to 280 250 to 280
• Coolant temperature: within operating
range
Blowby • Hydraulic oil temperature: within operating kPa Max 0.98 Max 1.96
pressure range {mmH2O} {Max. 100} {Max. 200}
• Arm IN relief + power max.
• When KCCV is circuit disconnected
Engine at MPa Min. 0.29 Min. 0.25
Engine oil • Coolant temperature: within full speed {kg/cm2} {Min. 3.0} {Min. 2.5}
pressure operating range
MPa Min. 0.10 Min. 0.07
• SAE15W-40 Oil At low idle
{kg/cm2} {Min. 1.0} {Min. 0.7}
EGR valve and • Coolant temperature: within
operating range MPa Min. 1.2 Min. 1.2
KVGT drive • Hydraulic oil temperature: At low idle
{kg/cm2} {Min. 12.0} {Min. 12.0}
pressure within operating range
Engine oil
• All speed range (inside oil pan) °C 80 to 110 120
temperature
PC290LC-10 20-3

Engine SAA6D107E–2
Category
• Between fan pulley and alternator pulley

Auto-
Fan belt tension • Deflection when pressed with thumb at 98 mm Auto-tentioner
N {10 kg} tentioner
Air conditioner • Between compressor pulley and fan pulley
compressor belt • Deflection when pressed with thumb at 60 mm 6.3 to 8.7 6.3 to 8.7
tension N {6.2 kg}
20-4 PC290LC-10
Standard value table for chassis related parts

Engine speed
• Coolant temperature: Within operating
range
At two pumps • Hydraulic oil temperature: Within
relieving operating range rpm 1,825 ± 100 1,825 ± 100
• Engine at high speed
Speed
• Power mode (P)
• At relief with arm IN
• Coolant temperature: Within operating
range
2. Speed at combined • Hydraulic oil temperature: Within
operation of pump operating range rpm 2,050 ± 100 2,050 ± 100
relief and one-touch • Engine at high speed
power maximization • Power mode (P)
• Arm IN relief + Left knob switch in ON
position
Speed when auto- • Engine at high speed
deceleration is • Auto-deceleration switch in ON position rpm 1,050 ± 100 1,050 ± 100
operated • All control levers in NEUTRAL position
Control valve spool stroke
• Engine stop Raise mm 11.5 ± 0.5 11.5 ± 0.5
Boom control valve • For measuring point, see Lower mm 9.5 ± 0.5 9.5 ± 0.5
"Control valve". CURL, mm 11.5 ± 0.5 11.5 ± 0.5
Arm control valve
Bucket mm 9.5 ± 0.5 9.5 ± 0.5
CURL,
Bucket control valve mm 9.5 ± 0.5 9.5 ± 0.5
Bucket
Left swing
Swing control valve mm 9.5 ± 0.5 9.5 ± 0.5
Right swing
FORWARD
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
REVERSE
PC290LC-10 20-5
Control lever stroke

Boom control lever • Engine stop mm 85 ± 10 85 ± 10
Arm control lever • At center of control lever grip mm 85 ± 10 85 ± 10
Bucket control lever • Read Max. value through travel end. mm 85 ± 10 85 ± 10
(except lever play in NEUTRAL position)
Swing control lever mm 85 ± 10 85 ± 10
Travel control lever mm 115 ± 12 115 ± 12
Work
mm Max 15 Max. 20
Play of control levers equipment
Travel mm Max. 20 Max 25
Operating effort of control lever and pedal
• Hydraulic oil temperature: Within N 15.7 ± 3.9 Max 24.5
Boom control lever operating range {kg} {1.6 ± 0.4 } {Max. 2.5}
N 15.7 ± 3.9 Max 24.5
Arm control lever • Control lever: At center of grip
• Pedal: At tip of pedal {kg} {1.6 ± 0.4 } {Max. 2.5}
• Read Max. value through travel end. N 12.7 ± 2.9 Max 21.6
Bucket control lever
{kg} {1.3 ± 0.3 } {Max. 2.2}
N 12.7 ± 2.9 Max 21.6
Swing control lever
{kg} {1.3 ± 0.3 } {Max. 2.2}
N 24.5 ± 5.9 Max 39.2
Travel control lever
{kg} {2.5 ± 0.6 } {Max. 4.0}
N 74.5 ± 18.6 Max 107.6
Travel control pedal
{kg} {7.6 ± 1.9 } {Max. 11}
20-6 PC290LC-10
Hydraulic
• Hydraulic oil temperature: Within
operating range
• Engine at high speed MPa 3.5 ± 1.0 3.5 ± 1.0
Unload pressure
• Power mode (P) {kg/cm } {36 ± 10 }
2 {36 ± 10 }
• Hydraulic pump output pressure with all
control levers in NEUTRAL position
• Hydraulic oil temperature: 34.8 (+1.5 /
Within operating range At normal MPa -1.2 ) 33.1 to 37.2
• Engine at high speed relief {kg/cm } {355 (+15 / {338 to 380}
2
• Power mode (P) -12 )}
Boom relief pressure • Hydraulic pump output
37.3 (+1.5 /
pressure with all
At power MPa -1.2 ) 36.1 to 39.7
measurement circuits
relieved maximizing {kg/cm } {380 (+15 / {368 to 405}
2
-12 )}
34.8 (+1.5 /
At normal MPa -1.2 ) 33.1 to 37.2
relief {kg/cm2} {355 (+15 / {338 to 380}
Arm relief pressure -12 )}
37.3 (+1.5 /
At power MPa -1.2 ) 36.1 to 39.7
maximizing {kg/cm2} {380 (+15 / {368 to 405}
-12 )}
34.8 (+1.5 /
At normal MPa -1.2 ) 33.1 to 37.2
relief {kg/cm } {355 (+15 / {338 to 380}
2
-12 )}
Arm
37.3 (+1.5 /
At power MPa -1.2 ) 36.1 to 39.7
maximizing {kg/cm } {380 (+15 / {368 to 405}
2
-12 )}
• Hydraulic oil temperature: Within MPa 30.3 ±1.5 28.4 to 32.3
Swing relief pressure operating range {kg/cm2} {310 ± 15 } {290 to 330 }
• Power mode (P) 38.7 (+1.0 /
• Hydraulic pump output pressure with all MPa -2.0) 36.8 to 40.2
Travel relief pressure
measurement circuits relieved {kg/cm 2} {395 (+10 / {375 to 410 }
• Sudden turning back must be avoided -20 )}
operating range 3.23 (+0.2 /
Control circuit oil • Engine at high speed MPa -0.3 ) 2.75 to 3.43
pressure • Self-pressure reducing valve output {kg/cm2} {33 (+2 / -3 {28 to 35 }
pressure with all control levers in )}
NEUTRAL position
• Hydraulic oil temperature: When all
Within operating range control
• Engine at high speed levers are MPa 3.5 ± 1.0 3.5 ± 1.0
• Power mode (P) in {kg/cm2} {36 ± 10 } {36 ± 10 }
LS differential • Travel speed: Hi NEUTRAL
pressure • Run either track idle. position
• LS differential pressure = 1.8 (+0.05 / 1.8 (+0.05 /
Hydraulic oil pump pressure When travel MPa -0.1 ) -0.1 )
– LS pressure levers at
{kg/cm } {18 (+0.5 /
2 {18 (+0.5 /
half travel
-1.0 )} -1.0 )}
PC290LC-10 20-7
Swing
operating range
• Engine at high speed deg. Max 165 Max 200
Overrun of swing • Power mode (P)
• Swing circle misalignment amount when (mm) (-) (-)
stopping after one turn
• For measuring posture, see "Swing 1"
• Hydraulic oil temperature: 90 deg. second 3.2 ± 0.3 Max 3.8
Within operating range
• Power mode (P)
Time required to start
• Time required to swing from
swinging 180 deg. second 4.7 ± 0.4 Max 5.9
swing start position to 90
degrees and 180 degrees
• For measuring posture, see
"Swing 1"
operating range
Time required to finish
• Power mode (P) second 28.6 ± 2.9 Max 34.8
swinging
• Time required to make five swings after
one swing
operating range
• Engine stop
• On slope of 15 degrees, set upper
structure crosswise and make matchmark
Swing drift on a slope mm 0 0
on inner race and outer race of swing
circle.
• Matchmark misalignment amount during 5
minutes
operating range
Leakage from swing • Engine at high speed l/min Max 5 Max. 10
motor • Swing lock switch ON
• Leakage in 1 minute during swing relief.
20-8 PC290LC-10
Travel
• Hydraulic oil temperature: 58.3 ( +6.5 /
Within operating range Lo second -5.3 ) 52.7 to 68.6
• Engine at high speed 48.0 ( +4.7 /
• Power mode (P) Mi second -3.9 ) 43.3 to 57.5
Travel speed (idle
running) • Time required to make five
idle turns of track off ground
after one idle turn 30.8 ( +1.6 /
Hi second -1.4 ) 30.8 to 35.2
"Travel 1"
• Hydraulic oil temperature: Lo second 24 ± 2.5 21.5 to 27.5
Within operating range Mi second 17 ± 2.5 14.5 to 20.5
Travel speed (actual • Power mode (P)
running) • Time required for traveling 20
m after 10 m trial run Hi second 13 ± 1.0 12.0 to 15.0
Travel 2
operating range
• Power mode (P)
• Travel speed: Lo mm
Travel deviation Max 150 Max 250
• Deviation while traveling 20 m (X) after
initial 10 m trial run on solid and level
ground
• For measuring posture, see Travel 2 and
3
operating range
• Engine stop
Hydraulic drift of • Park machine on a 12 deg. slope with the
mm 0 0
travel sprocket facing up the slope
• Travel distance of hydraulic drift of travel
for 5 minutes
• For measuring posture, see "Travel 4"
operating range
Leakage from travel
• Traveling with sprocket locked by using l/min 15 30
motor
pin
• Oil leakage for one minute during travel
relief
PC290LC-10 20-9
Work equipment
• Hydraulic drift of work equipment
Whole work • Hydraulic oil temperature: Within operating
mm Max 600 Max 900
equipment range
Boom cylinder • Level and flat ground mm Max 18 Max 27
Boom cylinder • Bucket filled up with dirt and sand, or at the mm Max 160 Max 240
rated load (0.8 m3: 1,440 kg)
• Horizontal boom top face, fully retracted
arm, fully extended bucket cylinder
• Engine stop
• Work equipment control lever in NEUTRAL
position
• Fall amount for 15 minutes as measured
Bucket cylinder every 5 minutes starting immediately after
initial setting mm Max 40 Max 58
drop amount
• Whole work equipment hydraulic drift
measured at tooth tip
• Boom cylinder: Cylinder retraction
• Arm cylinder: Cylinder extension
• Bucket cylinder: Cylinder retraction
• For measuring posture, see "Work
equipment 1"
• Work equipment speed
• Hydraulic oil temperature: Raise second 3.9 ± 0.4 Max 5.3
• Power mode (P)
Boom speed • Time required from raise
stroke end till bucket touches Lower second 3.0 ± 0.3 Max 4.3
ground
"Work equipment 2"
• Hydraulic oil temperature: CURL, second 4.4± 0.4 Max 5.3
• Power mode (P)
Arm speed
• Time required from in stroke Bucket second 2.9 ± 0.3 Max 3.8
end to OUT stroke end
"Work equipment 3"
• Hydraulic oil temperature: CURL, second 3.0 ± 0.3 Max 3.9
• Power mode (P)
Bucket speed
• Time required from in stroke Bucket second 2.3 ± 0.2 Max 2.9
end to OUT stroke end
"Work equipment 4"
20-10 PC290LC-10
• Time lag
• Hydraulic oil temperature: Within operating
range
• Engine at low idling
• Power mode (P)
• Set boom to the max. RAISE position. The
time required from grounding of the work
Boom time lag second Max 1.0 Max. 1.2
equipment until the front side of the
machine is lifted off. In this case, lower work
equipment to the ground by moving the
boom control lever to the LOWER side.
equipment 5"
range
• Power mode (P)
• Set arm to the max. DUMP position.
Operate the arm control lever to the " IN "
Arm time lag second Max. 2.0 Max. 2.8
side. The time required from when the arm
is stopped once at an approximately vertical
orientation until it starts moving to the IN
side again.
equipment 6"
range
• Power mode (P)
• Set bucket to the max. DUMP position
Operate bucket control lever to CURL side.
Bucket time lag second Max 1.0 Max 3.6
The time required from when the bucket is
stopped once at an approximately vertical
orientation until it starts moving to the CURL
side again.
equipment 7"
• Oil leakage
Oil leakage from • Hydraulic oil temperature: Within operating
cylinder range cc/min 4.5 20
Leakage from • Leakage amount for one minute with
center swivel joint cylinder or travel to be measured in relief cc/min 10 50
condition
PC290LC-10 20-11
Performance in combined operation

operating range
Travel deviation in • Power mode (P)
combined operation of • Travel speed: Lo mm Max 200 Max. 220
work equipment and • Deviation while traveling 20 m (X) after
travel initial 10 m trial run on solid and level
ground
• For measuring posture, see Travel 2 and
3
Pump swash plate sensor
• Hydraulic oil temperature: All control
Within operating range levers in
• Engine at high speed NEUTRAL V 1.35 ± 0.20 1.35 ± 0.63
• Power mode (P) position
Pump swash plate • Travel speed: Hi When
sensor output voltage • Run either track idle. running
track idle
off ground V 3.35 ± 0.20 3.35 ± 0.63
(lever to
stroke end).
Characteristics of PC flow control
operating range
• Power mode (P)
Time required for • Bucket at rated load (0.8 m3: 1,440 kg)
swinging from 0 to 90 • On hard and level ground, set arm 4.4 ± 0.4
vertically and lower back of bucket to second
deg. with boom (Reference value)
RASIE ground
• Time required for swinging from 0 to 90
deg. with boom RAISE
equipment 8"
20-12 PC290LC-10
Hydraulic pump
Applicable model PC290LC—10
Delivery Delivery
Item Measuring conditions Unit
new machine Repair limit
• Pump speed (rpm): 1,750 rpm
• PC-EPC current value (mA): 440 mA
• Test pump delivery pressure (MPa {kg/
cm2})
Performance of : P1 Q Q
hydraulic pump • Delivery pressure of another pump (MPa l/min
(See graph) (See graph)
{kg/cm2})
: P2
• Average delivery pressure (MPa {kg/cm2})
: Pp = (P1 + P2)/2
a Bring pump delivery pressure P1 and P2 as close as possible to the average pressure when measuring.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump delivery and the engine speed at the time of
measurement, and use them as a base for calculating the pump delivery the specified speed.
Posture of machine for measuring performance and measurement procedure

Control valve: Spool travel
PC290LC-10 20-13
Swing 1: Overrun when stopping swing, time required for starting swing , time required for swing
Swing 2: Amount of Hydraulic drift of swing
Travel 1: Travel speed (idle running)
Travel 2: Travel speed (actual run), travel deviation
20-14 PC290LC-10
Travel 3: Travel deviation
Travel 4: Hydraulic drift of travel
Work equipment 1: Hydraulic drift of the work equipment
Work equipment 2: Boom speed
PC290LC-10 20-15
Work equipment 3: Arm speed
Work equipment 4: Bucket speed
Work equipment 5: Boom time lag
Work equipment 6: Arm time lag
20-16 PC290LC-10
Work equipment 7: Bucket time lag
Work equipment 8: PC flow characteristics control
PC290LC-10 20-17
20-18 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
30 Testing Adjusting
5 30 Testing Adjusting
PC290LC-10 30-1
Table of contents
Table of contents
30 Testing Adjusting .......................................................................................................................... 30-1
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Checking engine speed ........................................................................................................ 30-9
Measuring boost pressure................................................................................................... 30-10
Measuring exhaust gas color............................................................................................... 30-11
Measuring and adjusting valve clearance ............................................................................. 30-13
Measuring compression pressure ........................................................................................ 30-16
Measuring blowby pressure ................................................................................................ 30-20
Measuring engine oil pressure............................................................................................. 30-21
Measuring EGR valve and KVGT oil pressure....................................................................... 30-22
Measuring fuel pressure ..................................................................................................... 30-23
Measuring fuel delivery, return and leakage .......................................................................... 30-29
Bleeding air from fuel system .............................................................................................. 30-34
Checking fuel circuit for leakage .......................................................................................... 30-36
Handling cylinder cutout mode operation.............................................................................. 30-37
Handling no injection cranking operation .............................................................................. 30-38
Checking and adjusting air conditioner compressor belt tension ............................................. 30-39
Replacing fan belt .............................................................................................................. 30-40
Power train............................................................................................................................... 30-41
Testing swing circle bearing clearance ................................................................................. 30-41
Testing and adjusting track shoe tension .............................................................................. 30-42
Releasing remaining pressure from hydraulic circuit .............................................................. 30-43
Measuring and adjusting of oil pressure in work equipment, swing, and travel circuits .............. 30-44
Measuring oil pressure in control circuit................................................................................ 30-48
Measuring and adjusting oil pressure in pump PC control circuit............................................. 30-49
Measuring and adjusting oil pressure in pump LS control circuit ............................................. 30-52
Measuring solenoid valve output pressure............................................................................ 30-57
Measuring PPC valve output pressure ................................................................................. 30-60
Adjusting play of work equipment and swing PPC valves....................................................... 30-62
Testing pump swash plate sensor ........................................................................................ 30-63
Isolating the parts causing hydraulic drift in work equipment................................................... 30-64
Measuring oil leakage......................................................................................................... 30-65
Bleeding air from hydraulic circuit ........................................................................................ 30-68
Cab and its attachments ............................................................................................................ 30-70
Checking cab tipping stopper .............................................................................................. 30-70
Adjusting mirrors ................................................................................................................ 30-71
Electrical system ...................................................................................................................... 30-73
Special functions of machine monitor ................................................................................... 30-73
Angle adjustment of rear view camera ............................................................................... 30-142
Handling voltage circuit of engine controller........................................................................ 30-144
Handling battery disconnect switch .................................................................................... 30-145
Testing diodes ................................................................................................................. 30-146
Pm clinic ................................................................................................................................ 30-147
Pm clinic service .............................................................................................................. 30-147
30-2 PC290LC-10
General information on testing and adjusting

Tools for testing and adjusting
Testing and Sym-
adjusting item bol Part No. Part Name Q'ty Remarks
Testing boost to 101 to 200 kPa { to 760 to 1,500
A 799-201-2202 Boost gauge kit 1 mmHg}
pressure
1 799-201-9002 Handy smoke checker 1
Testing exhaust
gas color B Commercially Bosch index: 0 to 9
2 Smoke meter 1
available
1 795-799-1131 Gear 1
Adjusting valve
C Commercially
clearance 2 Feeler gauge 1
available
1 795-502-1590 Gauge assembly 1 0 to 7 MPa {0 to 70 kg/cm2}
2 795-799-6700 Puller 1
Testing
Adapter
compression D 3 795-790-4411 1
pressure 4 6754-11-3130 Gasket 1
Commercially
5 Hose 1 Inside diameter: about 15 mm
available
1 799-201-1506 Blowby checker 1 0 to 10 kPa {0 to 1,000 mmH2O}
Testing blowby Commercially Plugs
2 1 Hose inside diameter: 24 mm
pressure E available
Commercially Pipe outside diameter: 25.4 mm,
3 Plugs 2 Pipe inside diameter: 20.4 mm
available
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1 799-101-5160 • Nipple 1 R1/8
Testing engine 799-101-5150 • Hose 1
oil pressure F 790-261-1150 • Hose 1
Pressure gauge: 60 MPa {600 kg/
2 790-261-1204 Digital hydraulic tester 1 cm2}
Pressure gauge: 1.0 MPa {10 kg/
3 799-401-2320 Gauge 1 cm2}
1 799-401-3100 Adapter 1
{25, 60, 400, 600 kg/cm2}
799-101-5160 • Nipple 1 R1/8
Testing EGR 2 799-101-5150 • Hose 1
valve drive G 799-261-1150 • Hose 1
pressure
799-101-5140 • Gauge 1 cm2}
PC290LC-10 30-3
Testing and Sym-

{25, 60, 400, 600 kg/cm2}
799-101-5160 • Nipple 1 R1/8
1 799-101-5150 • Hose 1
790-261-1150 • Hose 1
799-101-5140 • Gauge 1 cm2}
Testing fuel Adapter
795-790-4430 2
system H 3
pressure 6215-81-9710 O-ring 1
4 795-790-5110 Screw 1 M12 x 1.5 o R1/8
5 799-401-2320 Gauge 1 cm2}
6 795-790-5120 Screw 1 M14 x 1.5 o R1/8
700-201-2202 Boost gauge kit 1
799-101-5160 • Nipple 1 R1/8
7 799-401-2610 • Hose 1
to 101 to 200 kPa { to 760 to 1,500
799-401-2311 • Gauge 1 mmHg}
1 795-790-4700 Multimeter kit 1
2 6164-81-5790 Joint 1
3 07206-30812 Joint bolt 1
4 6754-71-1130 O-ring 1
Checking fuel Commercially
delivery, return 5 Stopwatch 1
J available
rate and
Commercially
leakage 6 Hose 1 Inside diameter: about 14 mm
available
Commercially Measuring cylinder
7 1
available
Commercially
8 Hose 1 Inside diameter: about 8 mm
available
Testing swing
Commercially Dial gauge
circle bearing K 1
available
clearance
Testing fuel Sensor adapter
circuit for Commercially
L 1
leakage available Pressure range:
Testing and Pressure gauge: 2.5, 6, 40, 60 MPa
adjusting oil 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
pressure in
work M 1 Pressure gauge: 60 MPa {600 kg/
equipment, 790-261-1204 Digital hydraulic tester 1 cm2}
swing, and
travel circuits
30-4 PC290LC-10
Testing and Sym-

{25, 60, 400, 600 kg/cm2}
Testing control 1
circuit source N 790-261-1204 Digital hydraulic tester 1 cm2}
pressure
799-101-5220 Nipple 1
2 Size: 10 x 1.25 mm
07002-11023 O-ring 1
Testing and 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
adjusting oil 1
pressure in P 790-261-1204 Digital hydraulic tester 1 cm2}
pump PC
control circuit 799-101-5220 Nipple 4
2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
{25, 60, 400, 600 kg/cm2}
1
790-261-1204 Digital hydraulic tester 1 cm2}
799-101-5220 Nipple 4
2 Size: 10 x 1.25 mm
07002-11023 O-ring 4
3 799-401-2701 Differential pressure gauge 1 50 MPa {500 kg/cm2}
Checking and Pressure range: 50 MPa {500 Kg/
adjusting pump 796T-440-1101 Sensor adapter 1 cm2}
LS control Q
circuit oil 796–440–1150 • Wiring harness 1
pressure 796T–440–1160 • Nipple 1
4 799–440–2350 • Washer 1
799–401–2340 • Coupling 1
07002–61823 • O-ring 1
Pressure range: 50 MPa {500 Kg/
7861–93–1812 • Pressure sensor 1 cm2}
Pressure range: 5 MPa {50 Kg/
5 796T-440-1200 Sensor adapter 1 cm2}
{25, 60, 400, 600 kg/cm2}
Testing 1
solenoid valve R 790-261-1204 Digital hydraulic tester 1 cm2}
output pressure
799-401-3100 Adapter 1 Size: 02
2
02896-11008 O-ring 1
{25, 60, 400, 600 kg/cm2}
Testing PPC 1
valve output Pressure gauge: 60 MPa {600 kg/
S 790-261-1204 Digital hydraulic tester 1 cm2}
pressure
799-401-3100 Adapter 1 Size: 02
2
799-401-3200 Adapter 1 Size: 03
Testing oil
leakage T 1
available
amount
Measuring
coolant
temperature — 799-101-1502 Digital temperature gauge 1 99.9 to 1,299°C
and oil
temperature
Testing 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
operating effort —
and depressing 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
effort
PC290LC-10 30-5
Testing and Sym-

Measuring
stroke and — Commercially
Scale 1
hydraulic drift available
Measuring
work Commercially
— Stopwatch 1
equipment available
speed
Measuring
— Commercially
voltage and Tester 1
available
resistance
Removal and
installation of
boost pressure — Commercially 3.26 mm torque wrench
Torque wrench 1
and available (KTC Q4T15 or equivalent)
temperature
sensors
Removal and
installation of
— 795-799-6210 Socket 1 27 mm deep socket
engine oil
pressure switch
Removal and
installation of 19 mm deep socket
coolant — 795T-981-1010 Socket 1
temperature (MITOLOY 4ML-19 or equivalent)
sensor
30-6 PC290LC-10
Sketch of tools for testing and adjusting

Note) Komatsu will not be held responsible for special tools manufactured according to these sketches.
Q4: Sensor adapter
Note) Komatsu will not be held responsible for special tools manufactured according to these sketches.
Q4: Nipple
PC290LC-10 30-7
Q5: Sensor adapter
-: Socket
30-8 PC290LC-10

Checking engine speed
a Check the engine speed by using the 4) Operate the left work equipment control lever
troubleshooting support or monitoring function of to relieve the arm circuit at the IN stroke end
the machine monitor. and test the engine speed.
5. Testing speed (around rated speed) at 2-
a Measure the engine speed under the following
pomp relief + one-touch power maximizing
conditions.
function
• Coolant temperature: within operating range
1) Start the engine and operate the arm cylinder
• Hydraulic oil temperature: within operating
to “arm IN” stroke end.
range
2) Set the fuel control dial to the full speed
Testing (MAX) position and set the working mode to
the Power mode (P).
1. Preparation work
3) While operating the left work equipment
Operate the machine monitor so that the engine
control lever to relieve the arm circuit at “arm
speed can be monitored.
IN” stroke end and pressing the one-touch
a For the operating method of the machine power maximizing switch, test the engine
monitor, see "Special functions of machine speed.
monitor(PAGE 30-73)".
a The one-touch power maximizing function is
a Monitoring code: 01002 Engine speed reset automatically in approximately 8.5
seconds even if the switch is kept pressed.
Accordingly, test the engine speed in that
period.
a You may check with the swing lock switch
ON (In this case, you do not need to operate
the one-touch power maximizing switch.)
6. Testing auto-deceleration speed
1) Start the engine, set the fuel control dial to
full speed position (MAX), and turn the auto-
deceleration function ON.
2) Set all the control levers and pedals for work
equipment, swing, and travel to the neutral
2. Testing low idle speed position and measure the engine speed
when the auto-deceleration operates.
1) Start the engine and set the fuel control dial
to the low idle (MIN) position. a The engine speed lowers to a certain level
2) Set all the control levers and pedals for work approximately 5 seconds after all the levers
equipment, swing, and travel to the neutral and pedals are set to NEUTRAL position.
position and test the engine speed. This level is the auto-deceleration speed.
3. Testing high idle speed
1) Start the engine and set the fuel control dial
to the full speed (MAX) position.
2) Set the working mode in the Power Mode (P)
and set the auto-deceleration to OFF.
3) Set the swing lock switch to ON position.
4) Set all control the levers and pedals for work
equipment, swing, and travel to the neutral
position and test the engine speed.
4. Testing 2-pomp relief speed
1) Start the engine and operate the arm cylinder
to “arm IN” stroke end.
2) Set the swing lock switch to OFF position.
3) Set the fuel control dial to the full speed
(MAX) position and set the working mode to
the Power mode (P).
PC290LC-10 30-9
Measuring boost pressure

a Testing tools a If oil is left in the hose, the gauge does not
Sym- work. Accordingly, be sure to purge the oil.
Part No. Part Name 4. Set the working mode to the Power mode (P)
bol
A 799-201-2202 Boost gauge kit and turn the swing lock switch ON.
a If the swing lock switch is turned to the ON
k Park the machine on a level ground and
position, the main relief valve is set for high-
lower the work equipment to the ground.
pressure relief.
a Test the boot pressure under the following 5. While running the engine at high idle, relieve the
condition. arm circuit and measure the boost pressure.
• Coolant temperature: within operating range Boost pressure Min. 107 kPa {800
• Hydraulic oil temperature: within operating mmHg}
range
• Swing lock switch ON
• Arm IN relief + One-touch power max.
Testing
1. Open the engine hood and remove boost
pressure pickup plug (1) from the intake air
connector.
6. After finishing measurement, remove the

measuring tools and return the removed parts to
their original position.
Checking the machine monitor

Testing of boost pressure is available from the
troubleshooting support or monitoring function of
the machine monitor.
2. Install nipple [1] of boost gauge kit A and a For the operating method of the machine monitor,
connect them to gauge [2]. see "Special functions of machine monitor".
a Monitoring code: 36500
3. Run the engine at middle or higher speed and

drain oil from the hose.
a Insert the hose connector into the gauge
halfway to open the self-seal on the hose
side repeatedly, and the oil will be purged.
a If Pm kit (A) is available, you can drain the oil
by using the oil draining coupling (790-261-
1130) in that kit.
30-10 PC290LC-10
Measuring exhaust gas color

a Testing tools 2) Insert the exhaust gas intake pipe in port (3)
Symbol for the removed plug.
Part No. Part Name
3) Start the engine and, while the arm IN circuit
799-201-9002 Handy smoke checker is relieved and engine is run at full speed, .
1 absorb the exhaust gas to the filtering paper
B
Commercially operating the handle of smoke checker B1.
Smoke meter
2 available
a Absorbing time: 1.4 ± 0.2 sec.
k Be careful not to touch any hot part when

removing or installing the testing tools.
k After KDPF regeneration is started, high-

temperature exhaust gas spurts from the
inspection port, potentially causing burn
injury. Therefore, you must stop KDPF
regeneration from the machine monitor
before starting the inspection. (For the
stopping procedure of KDPF regeneration,
see the Operation and Maintenance Manual.) 4) Remove the filter paper and compare it with
the attached scale to make a judgment.
a Test the exhaust gas color under the following 5) After finishing measurement, remove the
conditions. measuring tools and return the removed
• Coolant temperature: within operating range parts to their original position.
• At relief with arm IN 3. Testing by using smoke meter B2
a If an air source and a electric power source are
not available in the field, use handy smoke
checker B1. When recording official data, etc.,
use smoke meter B2.
Testing
1. Open engine hood and remove step (1) and plug
(2).
3 Plug:
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug:
1) Connect the probe hose, receptacle of the
Seizure prevention compound (LC-G) accelerator switch and air hose to smoke
meter B2.
a Limit the supplied air pressure to 1.5 MPa
{15 kg/cm2} or below.
2) Connect the power cable to the AC100V
receptacle.
a Before connecting the power cord, make
sure that the power switch of the smoke
meter is turned off.
3) Insert probe [1] of the smoke meter B2 into
port (3) for the removed plug.
4) Loosen the cap nut of the suction pump and
set a filter paper there.
2. Testing by using handy smoke checker B1
1) Fit a sheet of filter paper to smoke checker a Place the filter paper securely so that the
B1. exhaust gas does not leak.
PC290LC-10 30-11
5) Turn on the power switch of smoke meter

B2.
6) Start the engine and, while the arm IN circuit

is relieved, .depress the accelerator pedal of
smoke meter B2 to absorb the exhaust gas
to the filtering paper.
7) Place the filter paper contaminated with
exhaust gas on new filter papers (more than
10 sheets) in the filter paper holder and read
the indicated value.
8) After finishing measurement, remove the
measuring tools and return the removed
parts to their original position.
30-12 PC290LC-10
Measuring and adjusting valve clearance

a Testing instrument • Hose (7): KVGT actuator drive pressure
Sym- circuit (constant-pressure passage)
Part No. Part Name • Hose (8): KVGT actuator drive pressure
bol
1 795-799-1131 Gear circuit (adjustment passage)
C Commercially 5. Remove clamp (9).
2 Feeler gauge 6. Disconnect connector (10).
available
• Connector (10): Intermediate connector (INJ
k Park the machine on a level ground and CYL 1&2)
k Turn the battery disconnect switch to the

OFF position and remove the key.
a Test and adjust the valve clearance under the

following condition.
• Coolant temperature: Normal temperature
Testing
1. Open the engine hood and remove step (1)
7. Remove cylinder head cover (11).

a When removing blowby duct (12), take care
that the O-ring will not fall from it.
a Since the O-ring is fitted to the flywheel
housing side of blowby duct (12), it may be
removed together with cylinder head cover
(11).
2. Disconnect connectors (2) to (5).

• Connector (2): KVGT stroke sensor (SVGT)
• Connector (3): KVGT speed sensor
(VGT_REV)
• Connector (4): Connector box (INTER
CONNECT)
• Connector (5): EGR gas temperature sensor
(EXHAUST GAS TEMPERATURE)
3. Disconnect EGR circuit tube (6) from the flange
and tube.
8. Remove covers (13) and (14).
4. Disconnect hoses (7) and (8).
PC290LC-10 30-13
9. Remove plug (15) under the starting motor and a If you can move the rocker arm of air intake
insert gear C1. valves (IN) with the hand by the valve
clearance, adjust the valves marked with ○ in
the valve arrangement drawing.
a If you can move the rocker arms of exhaust
valves (EX) by hand by the valve clearance
amount, adjust the valves marked with ● in
the valve arrangement drawing.
a Valve arrangement drawing
10.Rotate the crankshaft forward with gear C1 and

align the yellow paint (line) of vibration damper
(16) with engine oil pan mounting bolt (17).
a The end of bolt (17) is painted yellow.
a When the crankshaft is set as above, the
piston in the No. 1 or No. 6 cylinder is not set
to the compression top dead center (TDC).
Take care. (76 to 88 degrees before 12.If the valves marked with ○ were adjusted, rotate
compression top dead center) the crankshaft forward 1 turn and align the
yellow paint (line) of vibration damper (16) with
engine oil pan mounting bolt (17), and then
adjust the valves marked with ● in the valve
arrangement drawing.
a If the valves marked with ● were adjusted,
adjust the valves marked with ○.
13.After completing measurement, remove the
measuring tools and return the machine to the
original condition.
a Be sure to remove gear C1 .
3 EGR circuit tube (6) (flange side):
24 ± 4Nm {2.45 ± 0.41 kgm}
3 EGR circuit tube (6) (tube side):
10.5 ± 0.5Nm {1.07 ± 0.05 kgm}
3 Hose (7):
25 ± 1.5Nm {2.55 ± 0.15 kgm}
3 Hose (8):
15 ± 1Nm {1.53 ± 0.10 kgm}
3 Cylinder head cover (11) mounting
nut:
24 ± 4Nm {2.45 ± 0.41 kgm}
11.Check the movement of the rocker arm of the No.
1 cylinder to inspect the valve clearance.
Adjusting
After testing, adjust the valve clearance according
a If the valve clearance is in the following
to the following procedure, if necessary.
range, it is normal.
1. While fixing adjustment screw (18), loosen lock
Intake valve 0.152 to 0.381 mm nut (19).
Exhaust valve 0.381 to 0.762 mm
30-14 PC290LC-10
2. Insert feeler gauge C2 in the clearance between

rocker arm (20) and crosshead (21) and adjust
the valve clearance with adjustment screw (18).
a With feeler gauge C2 inserted, turn
adjustment screw (18) to a degree that you
can move feeler gauge C2 lightly.
a Adjust the valve clearance to within the
following target value.
Intake valve 0.25 ± 0.05 mm
Exhaust valve 0.51 ± 0.05 mm
3. While fixing adjustment screw (18), tighten lock
nut (19).
3 Lock nut (19):
24 ± 4Nm {2.45 ± 0.41 kgm}
a After tightening locknut (19), check the valve
clearance again.
4. After finishing adjustment, remove the testing

tools and return the removed parts.
a Be sure to remove gear C1 .
24 ± 4Nm {2.45 ± 0.41 kgm}
10.5 ± 0.5Nm {1.07 ± 0.05 kgm}
3 Hose (7):
25 ± 1.5Nm {2.55 ± 0.15 kgm}
3 Hose (8):
15 ± 1Nm {1.53 ± 0.1 kgm}
3 Cylinder head cover (11) mounting
nut:
24 ± 4Nm {2.45 ± 0.41 kgm}
PC290LC-10 30-15
Measuring compression pressure

a Testing tools
Sym-
Part No. Part Name
bol
1 795-502-1590 Gauge assembly
2 795-799-6700 Puller
3 795-790-4411 Adapter
D
4 6754-11-3130 Gasket
5 Commercially Hose inside diameter: about
available 15 m
k Park the machine on level ground and lower

the work equipment to the ground.
6. Remove retaining nut (6), then remove inlet
k Turn the battery disconnect switch to the connector (7).
OFF position and remove the key. 7. Remove holder (8).
8. Remove injector (9).
k When testing the compression pressure,
take care not to get yourself burned by a Using puller D2, remove injector (9) with
touching the exhaust manifold or KDPF, or impacts of a slide hammer.
get caught in a rotating part.
a Do not remove injector (9) by prying its top
up.
a Test the intake air pressure under the following
conditions.
• Engine oil temperature: 40 to 60°C
Testing
1. Remove the cylinder head cover and set the
piston of the tested cylinder to the compression
top dead center. For detail, see "Measuring and
adjusting valve clearance(PAGE 30-13)".
a When the cylinder is at the compression top
dead center, the rocker arm of the cylinder
can be moved by the valve clearance with
the hand.
2. Remove fuel spray prevention cap (1), then
remove the sleeve nut and disconnect high-
pressure tube (2).
a When measuring compression pressure, fuel
spurts from the disconnected portion of the
common rail side. Therefore you must
connect hose D5 and drain fuel to an oil pan.
k Do not use high-pressure pipes with

bending modification.
3. Loosen injector terminal nuts (3) and remove the
harness terminals from the injector.
9. Place gasket D4 to the end of adapter D3 and
a Insulate the terminals with tape, etc. so that insert the adapter into the injector mounting
the adjacent ones of them will not touch each bore.
other. 10.Fix adapter D3 with injector mounting holder (8).
4. Remove rocker arm assembly (4).
a Tighten holder (8) mounting bolts alternately.
a When removing rocker arm assembly (4),
use care not to drop the support and shaft. 3 Holder (8) mounting bolt
5. Remove crossheads (5). 8 ± 0.8 Nm {0.82 ± 0.08 kgm}
30-16 PC290LC-10
11.Install crosshead assembly (5) and rocker arm

assembly (4).
3 Rocker arm assembly (4) mounting
bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
12.Adjust the valve clearance.
a See "Measuring and adjusting valve
clearance(PAGE 30-13)".
15.Connect gauge assembly D1 to adapter D3.

a If a small amount of oil is applied to the
connecting portions of gauge assembly D1
and adapter D3, air will not leak easily.
13.Connect connectors (11) to (15).

(VGT_REV)
CONNECT)
• Connector (14): EGR gas temperature
sensor (EXHAUST GAS TEMPERATURE)
16.Set all the cylinders to the "cylinder cutout mode
• Connector (15): Intermediate connector (INJ
operation".
CYL 1&2)
14.Connect hoses (16) and (17) and tube (18). a Turn the battery disconnect switch to the ON
• Hose (16): KVGT actuator drive pressure position, and then turn the starting switch to
circuit (constant-pressure passage) the ON position.
3 Hose (16): a For the setting method of "no injection

cranking", see "Special functions of machine
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
monitor(PAGE 30-73)".
• Hose (17): KVGT actuator drive pressure
circuit (adjustment passage)
3 Hose (17):
15 ± 1 Nm {1.53 ± 0.1 kgm}
• Tube (18): EGR circuit
24 ± 4 Nm {2.45 ± 0.41 kgm}
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
17.Test the compression while cranking the engine

by the starting motor.
a Read the pressure when the gauge pointer is
stabilized.
PC290LC-10 30-17
a If the compression pressure is in the 4] There is a worn part or an uneven seat

following range, it is normal. contact mark on seating face (e) at the
1.69 MPa top end of the inlet connector.
Compression pressure
{17.2 kg/cm2} or above a If high-pressure fuel leaks through the
Engine speed 250 to 280 rpm inlet connector, the seal face has fine
streaks or cracks.
18.After completing measurement, remove the
original condition.
a Install the injector and high-pressure pipe
according to the following procedure.
1) Direct the fuel inlet hole of the injector toward
the air intake manifold side and install it to
the cylinder head.
a Mate the injector's projection (a) to notch
(b) of the holder and then set them to the
cylinder head.
5) Coat the O-ring and head side of inlet

connector (7) with engine oil.
2 O-ring and head side of inlet
connector (7):
Engine oil (EO10W30-LA)
6) Secure inlet connector (7) by tightening
retaining nut (6) lightly.
a After tightening lightly, tighten to the
specified torque. Tighten to the specified
torque for each cases. Insufficient or
excessive torque may cause the fuel
2) Tighten holder mounting bolts (19) three to
leakage into the engine.
four threads.
3) Set inlet connector (7). a Install inlet connector (7) so that its
positioning ball will be at the guide groove
a Press it in until you feel the ring clicks in.
on the head side.
4) Check inlet connector (7). If it has any of the
following faults, replace it. 3 Retaining nut (6) (tightening
1] Burrs or wear is recognizable in the inlet lightly):
connector front-end (a) and back-end (b) 15 ± 5 Nm {1.53 ± 0.51 kgm}
portions. 7) Tighten mounting bolts (19) of holder (8)
2] There is foreign matter in the edge filter at alternately.
rear end (c) of the inlet connector.
3 Holder (8) mounting bolt (19):
3] Cracks or deterioration is recognizable in
O-ring of the inlet connector upper portion 8 ± 0.8 Nm {0.82 ± 0.08 kgm}
(d). 8) Tighten retaining nut (6) of inlet connector
(7).
3 Retainer (6):
50 ± 5 Nm {5.1 ± 0.51 kgm}
30-18 PC290LC-10
9) Tighten sleeve nuts (20) of high-pressure 14)Install the head cover.

pipe (2) in the order of cylinder head (21) 3 Cylinder head cover mounting
side and common rail (10) side. bolt:
3 Sleeve nut (20): 24 ± 4 Nm {2.45 ± 0.41 kgm}
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
10)Install fuel spray prevention cap (1).

11)Install crosshead assembly (5) and rocker
arm assembly (4).
3 Mounting bolt (22) of rocker arm
assembly (4):
36 ± 5 Nm {3.67 ± 0.51 kgm}
12)Adjust the valve clearance.
a See "Measuring and adjusting valve
clearance(PAGE 30-13)".
13)Tighten injector terminal nut (3).
3 Terminal nut (3):
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a Check that the injector harness does not
interfere with the rocker arm.
PC290LC-10 30-19
Measuring blowby pressure

a Testing tools install tool and adapter [1] of blowby checker E1
Symbol to hose (3), and connect gauge [2].
Part No. Part Name
1 799-201-1504 Blowby checker 3 Clamp:
Commercially Plug (Hose inside 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
2 diameter: 24 mm)
available
E Plug (Hose
outside diameter:
Commercially 25.4 mm, Pipe
3
available inside diameter:
20.4 mm)

a Test the blowby pressure under the following

conditions.
4. Start the engine, set the work equipment mode
range
to Power mode (P), and turn the swing lock
Testing switch ON.
1. Open the engine hood and remove step (1). a If the swing lock switch is turned to the ON
position, the main relief valve is set for high-
pressure relief.
5. While running the engine at high idle, relieve the
arm circuit and measure the blowby pressure.
a Read the gauge for blowby pressure when
the pointer is stabilized.
Blowby Max. 1.96 kPa{200 mm H2O}
pressure
2. Disconnect hose (2) on the KCCV gas outlet

side and plug the hose with plug E2 and stop the
KCCV hose insertion pipe with E3.
3 Clamp:
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

3. Disconnect hose (3) on the KCCV gas inlet side,

plug the KCCV hose insertion pipe with E3,
30-20 PC290LC-10
Measuring engine oil pressure

a Testing tools 4. Run the engine and measure the engine oil
Sym- pressure at high idle and low idle.
Part No Part Name
bol a If the engine oil pressure is in the following
799-101-5002 Hydraulic tester range, it is normal.
799-101-5160 ・ Nipple
1 0.25 MPa
799-101-5150 ・ Hose At high idle
{2.5 kg/cm2} or above
F 790-261-1150 ・ Hose
0.07 MPa
During low idle
2 790-261-1204 Digital hydraulic tester {0.7 kg/cm2} or above
3 799-401-2320 Gauge

a Test the intake air pressure under the following

conditions.
Testing
1. Open the side cover on the right side of the
machine body and remove oil pressure pickup
port plug (1) from the engine oil filter. 5. After completing measurement, remove the
original condition.
2. Install nipple [1] and hose [2] of hydraulic tester

F1 and connect them to gauge F3.
a The nipple and hose in digital hydraulic tester
F2 may be used.
3. Start the engine and turn the auto-deceleration

OFF.
PC290LC-10 30-21
Measuring EGR valve and KVGT oil pressure

a Testing tools a The nipple and hose in digital hydraulic tester
Sym- G3 may be used.
Part No. Part Name
bol
1 799-401-3100 Adapter
799-101-5002 Hydraulic tester
799-101-5160 • Nipple
G 2 799-101-5150 • Hose
790-261-1150 • Hose
799-101-5140 • Gauge
3 790-261-1204 Digital hydraulic tester


4. Run the engine and measure the oil pressure at
• Hydraulic oil temperature: within operating range
low idle.
Testing a If the EGR valve drive oil pressure is in the
1. Open the engine hood and remove step (1) following range, it is normal.
1.2 MPa
During low idle
{12.0 kg/cm2} or above
2. Disconnect hose (2).

circuit (adjustment passage)
5. After completing measurement, remove the
original condition.
3 Hose (2):
15 ± 1.0 Nm {1.53 ± 0.10 kgm}
3. Install adapter G1 and nipple [1] and hose [2] of

hydraulic tester G2 and connect them to gauge
[3].
3 Adapter G1:
15 ± 1.0 Nm {1.53 ± 0.10 kgm}
a Use gauges [3] of 2.5 MPa {25 kg/cm2}.
30-22 PC290LC-10
Measuring fuel pressure

a Testing tools
Sym-
Part No. Part Name
bol
799-101-5160 - Nipple
1 799-101-5150 - Hose
790-261-1150 - Hose
799-101-5140 - Gauge
2 790-261-1204 Digital hydraulic tester
795-790-4430 Adapter
3
H 6215-81-9710 O-ring
4 795-790-5110 Screw
5 799-401-2320 Gauge
6 795-790-5120 Screw
799-201-2202 Boost gauge kit
799-101-5160 - Nipple
7
799-401-2610 - Hose
799-401-2311 - Gauge
k When removing and installing the fuel system inspection equipment, stop the engine and wait for
30 seconds until the remaining pressure is released from the fuel circuit. (Do not start inspection
work immediately after the engine is stopped since remaining pressure is present.)
k Park the machine on level ground and lower the work equipment to the ground.
a Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the
supply pump and in the return circuit between the supply pump/common rail/ injector and fuel tank.
k Since the pressure in the high-pressure circuit from the supply pump through the common rail to
the injector is very high and dangerous, do not measure it.
PC290LC-10 30-23
A: Low-pressure circuit inspection position (fuel main filter inlet side)

B: Low-pressure circuit inspection position (fuel main filter outlet side)
C: Return circuit inspection position (supply pump drain port)
D: Negative pressure circuit inspection position (supply pump inlet)
30-24 PC290LC-10
207 to 650 kPa

Testing At high idle
{2.11 to 6.63 kg/cm2}
Testing low-pressure circuit (fuel main filter inlet 207 to 500 kPa
side) Cranking
1. Open the side cover on the right side of the {2.11 to 5.1 kg/cm2}
machine body and remove fuel pressure pickup
port plug (1) on the fuel main filter inlet side.

2. Install adapter H3 and nipple [1] and hose [2] of original condition.
hydraulic tester H1 and connect them to gauge 3 Fuel pressure pickup plug (1):
[3].
32 ± 4 Nm {3.26 ± 0.41 kgm}
a When installing adapter H3, be sure to install
the O-rings.
3 Adapter H3:
32 ± 4 Nm {3.26 ± 0.41 kgm}
a Use gauges [3] of 2.5 MPa {25 kg/cm2}.
a The nipples and hoses in digital hydraulic
tester H2 may be used.
3. Start the engine and measure the pressure in

the low-pressure circuit with the engine at high
idle.
a If the engine cannot be started, you can
measure the fuel pressure while rotating the
engine using the starting motor. However, to
protect the starting motor, do not rotate the
engine for more than 20 seconds
continuously.
a If the pressure in the low-pressure circuit (on
the fuel main filter inlet side) is in the
following range, it is normal.
PC290LC-10 30-25
Testing low-pressure circuit (pressure

difference)
1. Remove fuel pressure pickup plug (1) at the fuel
main filter inlet side and fuel pressure pickup
plug (2) on the outlet side.
4. Obtain the pressure difference in the low-

pressure circuit.
a Pressure difference in low-pressure circuit =
Pressure on fuel main filter inlet side -
Pressure on fuel main filter outlet side
2. Install adapters H3 to the inspection holes on
the inlet side and outlet side, and then install a If the pressure difference in the low-pressure
nipples [1] and hoses [2] of hydraulic tester H1 circuit is in the following standard range, it is
and connect them to gauges [3]. normal.
At high idle Max. 81 kPa
a When installing adapter H3, be sure to install
Cranking {0.83 kg/cm2}
the O-rings.
3 Adapter H3: a If the pressure is higher than the criteria, the
32 ± 4 Nm {3.26 ± 0.41 kgm} fuel main filter may be clogged. In this case,
replace the fuel main filter and test again.
a Use gauges [3] of 2.5 MPa {25 kg/cm2}. 5. After completing measurement, remove the
a The nipples and hoses in digital hydraulic measuring tools and return the machine to the
tester H2 may be used. original condition.
3 Fuel pressure pickup plugs (1), (2):
32 ± 4 Nm {3.26 ± 0.41 kgm}
3. Start the engine and measure the pressure on

the inlet aide and outlet side of the low-pressure
circuit with the engine at high idle.
a If the engine cannot be started, you can
continuously.
30-26 PC290LC-10
Testing return circuit a If the engine cannot be started, you can

1. Remove cover (1). measure the fuel pressure while rotating the
continuously.
a If the pressure in the return circuit is in the
following range, it is proper.
At high idle 18.6 kPa
Cranking Max. {0.19 kg/cm2}
2. Remove joint bolt (2) of the fuel return hose

between the supply pump and fuel cooler.

original condition.
3 Joint bolt (2):
19.6 to 29.4 Nm {2 to 3 kgm}
3. Install screw H4, and nipple [1] and hose [2] of
hydraulic tester H1 instead of joint bolt (2), and
connect them to gauge H5.
a When installing screw H4, be sure to install
the seal washer.
3 Screw H4:
19.6 to 29.4 Nm {2 to 3 kgm}
4. Start and measure the pressure in the return

circuit while the engine is run at full speed.
PC290LC-10 30-27
Testing negative-pressure circuit

1. Remove joint bolt (3) of the fuel hose between
the fuel pre-filter and supply pump.

original condition.
2. Install screw H6, and nipple [1] and hose [2] of 3 Joint bolt (3):
boost gauge kit H7 instead of joint bolt (3), and 25.4 to 34.3 Nm {2.59 to 3.5 kgm}
connect them to gauge [3].
a When installing screw H6, be sure to install
the seal washer.
3 Screw H6:
25.4 to 34.3 Nm {2.59 to 3.5 kgm}
3. Start the engine and measure the pressure in

the negative pressure circuit with the engine at
high idle.
a If the pressure in the negative pressure
circuit is in the following standard range, it is
normal.
At high idle -305 mmHg or below
a If the pressure is higher than the criteria, the

fuel pre-filter may be clogged. In this case,
replace the fuel pre-filter and test again.
30-28 PC290LC-10
Measuring fuel delivery, return and leakage

a Testing tools
Sym-
Part No. Part Name
bol
1 795-790-4700 Multimeter kit
2 6164-81-5790 Joint
3 07206-30812 Joint bolt
4 6745-71-1130 O-ring
Commercially Stopwatch
5
J available
Commercially Hose (inside diameter:
6 about 14 mm)
available
7
available
Commercially Hose (inside diameter:
8 about 8 mm)
available
k Park the machine on level ground and lower the work equipment to the ground.
a Since some fuel flows out during check, prepare an oil pan of about 20 l .
k When removing and installing the fuel system inspection equipment, stop the engine and wait for
30 seconds until the remaining pressure is released from the fuel circuit. (Do not start inspection
work immediately after the engine is stopped since remaining pressure is present.)
A: Supply pump delivery inspection position

B: Supply pump return rate inspection position
C: Leakage from pressure limiter inspection position
D: Injector return rate inspection position
PC290LC-10 30-29
a In order to protect the starting motor, it is

Testing prohibited to continue cranking for more than
Testing supply pump delivery 20 seconds. “Crank the engine for 15
1. Remove cover (1). seconds, then stop for 15 seconds and crank
it again for 15 seconds.“ Do the
measurement in this manner.
2. Remove fuel spray prevention cap (2).

3. Loosen clamp (4) for spill tube (3) on the
delivery side of the supply pump and disconnect
a If the supply pump delivery is in the following
the spill tube (3).
standard range, it is normal.
When cranking (for 30
seconds) 70 ml or more
4. Install hose J6 to the connector on the discharge

side of the supply pump.
a Hose J6 may be clamped with a hose band
for the ease of the work. 6. After completing measurement, remove the
original condition.
3 Spill tube (3) mounting sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
3 Clamp (4) mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
5. Crank the engine for 30 seconds and measure

the delivery with measuring cylinder J7.
30-30 PC290LC-10
Testing supply pump return rate a If the engine cannot be started, you can
1. Disconnect fuel return hose (2) on the return measure the fuel pressure while rotating the
side of the supply pump. engine using the starting motor. However, to
continuously. “Crank the engine for 15
seconds, then stop for 15 seconds and crank
2. Install cap nut [1] of tester kit J1 to fuel return

hose (2) side to prevent the fuel from flowing out.
a When installing cap nut [1], be sure to install
the seal washer.
3. Install joint J2 to the supply pump side and
secure it with joint bolt J3.
a If the return rate from the supply pump is in
a When installing joint J2 and joint bolt J3, be
the following range, it is proper.
sure to install the seal washer.
During low idle
3 Joint bolt J3: Max. 575 ml
(For 30 sec)
19.6 to 29.4 Nm {2.0 to 3.0 kgm} Cranking
4. Install hose J8 to joint J2. Max. 575 ml
(min. 150 rpm, for 30
seconds)
5. Run the engine at low idle and measure the fuel

return rate during 30 sec by using measuring
cylinder J7. 6. After completing measurement, remove the
original condition.
3 Mounting joint bolt (1) of fuel return
hose (2):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
PC290LC-10 30-31
Testing leakage from pressure limiter a If the engine cannot be started, you can
1. Remove joint bolt (1) of the pressure limiter and measure the fuel pressure while rotating the
disconnect spill tube (2). engine using the starting motor. However, to
2. Install cap nut [1] of tester kit J1 to spill tube (2)

side to prevent the fuel from flowing out.
the seal washer.
3. Install joint J2 to the pressure limiter side and
secure it with joint bolt J3.
a If the leakage from the pressure limiter is in
a When installing joint J2 and joint bolt (3), be
the following range, it is proper.
sure to install the seal washer.
During low idle
3 Joint bolt J3: Max. 8 ml
(For 30 sec)
24 ± 4 Nm {2.45 ± 0.41 kgm} Cranking
4. Install hose J8 to joint J2. Max. 5 drops/min.
(min. 150 rpm, for 30
seconds)
original condition.
3 Mounting joint bolt (1) of spill tube (2):
24 ± 4 Nm {2.45 ± 0.41 kgm}
5. Run the engine at low idle and measure the fuel

leakage in 30 seconds by using measuring
cylinder J7.
30-32 PC290LC-10
Testing injector return rate from injector a If the engine cannot be started, you can
a The fuel return rate from the injector is tested
while spill tube (2) of the pressure limiter is
connected. Accordingly, before testing the return
rate from the injector, check that the leakage
from the pressure limiter is normal.
1. Remove check valve (1) of the cylinder head it again for 15 seconds.“ Do the
and disconnect spill tube (2). measurement in this manner.
2. Install cap nut [1] of tester kit J1 to spill tube (2)

side to prevent the fuel from flowing out. a If the return rate from the fuel injector is in the
following range, it is normal.
During low idle
the seal washer. Max. 125 ml
3. Install joint J2 to the cylinder head side and (For 30 sec)
secure it with joint bolt J3. Cranking
(min. 150 rpm, for 30 Max. 45 ml
a When installing joint J2, be sure to install the seconds)
seal washer.
3 Joint bolt J3:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4. Install hose J8 to joint J2.

original condition.
3 Mounting check valve (1) of spill tube
5. Run the engine at low idle and measure the fuel (2):
return rate in 30 seconds by using measuring
cylinder J7. 24 ± 4 Nm {2.45 ± 0.41 kgm}
PC290LC-10 30-33
Bleeding air from fuel system

a If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
Bleeding air
1. Fill the fuel tank up with fuel.
a Add fuel until the fuel level gauge reaches
green range. (Turn the starting switch to ON
position and check the fuel level from the
gauge.)
machine.
3. Loosen hand primer (1) and pull it out, and then
operate it forward and backward.
a Operate the hand primer (1) until it becomes
heavy.
a The plug at the top of the fuel main filter head
does not need to be removed.
4. After bleeding air, push in and tighten hand

primer (1).
30-34 PC290LC-10
Route for bleeding air from fuel circuit

Fuel tank o prefilter o feed pump o main filter o metering unit o fuel tank
PC290LC-10 30-35
Checking fuel circuit for leakage

a Testing tools a Check the high-pressure circuit for fuel
Symbol leakage focusing on the area to which color
Part No. Part Name
checker L is sprayed.
Developer for dye
Commercially
L penetrant check a If any fuel leakage is detected, repair it and
available
perform inspection again from Step 1.
k Very high pressure is generated in the high- a If no fuel leakage is detected, inspection is
pressure circuit of the fuel system. If fuel completed.
leaks while the engine is running, it presents
a serious danger that could result in a fire.
After checking the fuel system or removing
its parts, check it for fuel leakage according
to the following procedure.

a Clean and degrease the engine and the parts

around it in advance so that you can find easily
fuel leakage.
Testing
1. Spray color checker (developer) L to the fuel
supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
3. Stop the engine and check the fuel piping and
devices for fuel leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
a If any fuel leakage is detected, repair it and
4. Start the engine and keep it running at low idle.
6. Start the engine and keep it running at high idle.
8. Run the engine at high idle, then load it.
a Relieve the arm circuit at the IN stroke end.
30-36 PC290LC-10
Handling cylinder cutout mode operation

a The cylinder cut-out test mode operation means
to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for the Cylinder Cut-
out Mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston or piston ring
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.
PC290LC-10 30-37
Handling no injection cranking operation

a No-injection cranking means to crank the engine
by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
30-38 PC290LC-10
Checking and adjusting air conditioner compressor belt tension

k Park the machine on a level ground and a Check each pulley for breakage, wear of the
lower the work equipment to the ground. V-groove, and contact of the V-belt with V-
groove.
Testing
a When the V-belt has so elongated that no
1. Open the engine hood and remove belt guard allowance for adjustment is left or it has a cut
(1). or crack, replace it with a new one.
a If the V-belt is replaced, adjust and check the
tension again after operating the machine for
one hour.
a After tightening the bolts, check the belt
tension again according to the above
procedure.
2. Press the intermediate point of the belt between

fan pulley and compressor pulley with a finger
and measure deflection (a) of the belt.
• Belt depressing force: 60 N {6.2 kg}
• Belt reflection: 6.3 to 8.7 mm
5. After completing adjustment, return the machine

to original condition.
3. After finishing testing, return the machine status

as it was.
Adjusting
a If the belt deflection is improper, adjust it
1. Loosen bolts (1) (four pcs.) , then loosen nut (2).
2. Tighten or loosen jack bolt (3) to position
compressor (4).
3. After positioning compressor (4), tighten nut (2)
until it reaches boss (5).
3 Sleeve nut:
108 to 132 Nm {11 to 13.5 kgm}
4. Tighten bolts (1) (four pcs.).
3 Bolt:
59 to 74 Nm {6 to 7.5 kgm}
PC290LC-10 30-39
Replacing fan belt

a The auto-tensioner is provided for the fan belt. • Check each pulley for breakage and crack.
Thus, testing and adjustment of the belt is
usually not necessary.
a Disconnect the air conditioner compressor belt
before replacing the fan belt.
a Place the machine on a level ground and lower
Replacing
1. Set a wrench to portion A (width across flats:
12.7 mm) of the tensioner assembly (3), and turn
the wrench in the direction opposite to the
winding-up direction to decrease the fan belt (2)
tension.
k Firmly set the wrench on tensioner

assembly (3) at portion A before applying
turning force to the wrench. (If you try to
rotate the wrench before it is fully
inserted due to strong spring force of
tensioner assembly (3), it can disengage
and cause serious physical injuries.)
k After removing fan belt (2), slowly and

carefully restore tensioner assembly (3).
k Be careful not to catch your fingers

between the pulley and fan belt (2) during
work.
2. Replace fan belt (2).
30-40 PC290LC-10
Power train
Power train
Testing swing circle bearing clearance
a Testing tools a The value indicated by dial gauge K is the
Sym- clearance of the bearing.
Part No. Part Name
bol
Commercially Dial gauge
K
available
k Be careful not to put a hand or foot under the

undercarriage, while taking measurement.
Testing
1. Fasten dial gauge K to swing circle outer race
(1) or inner race (2), and touch the probe to the
end surface of inner race (2) or outer race (1) on
the opposite side.
a Set dial gauge K in the front side or rear side
6. Return the machine to the condition of step 2
of the machine.
and check that dial gauge K indicates zero point.
a If zero value is not indicated, repeat the steps
3 through 5.
2. Set the work equipment to the maximum reach

posture and set the bucket tip to the height of the
under side of the revolving frame.
a At this time, the front side of the upper
structure rises and the rear side lowers.
3. Set the reading of dial gauge K to the zero point.
4. Set the arm almost perpendicular to the ground

and lower the boom until the front part of the
tracks float by 150 to 200 mm.
a At this time the front of the upper structure
rises and the rear lowers.
5. From this state, read the dial gauge K value.
PC290LC-10 30-41

Testing and adjusting track shoe tension
Testing a You can add grease until dimension (b)
between the idler guide and the track
1. Run the engine at low idle and move the
machine forward by the length of track on frame end becomes 0 mm. If the tension
is still low, the pins and bushings will
ground, and then stop slowly.
become excessively worn. In this case,
2. Place square bar [1] on the track shoes between
turn 180 deg. , or replace the pins and
the idler and the 1st carrier roller.
bushings.
a As the square bar [1], use an angle steel, etc.
which deflects less.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
• Standard maximum clearance (a): 10 to 30
mm
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.
k Do not loosen the valve more than one

turn. Otherwise, the valve jumps out
Adjusting because of the high-pressure grease
inside.
a If the track tension is improper, adjust it
according to the following procedure. 2) To check that the tension is proper, run the
1. Increasing tension engine at low idle and move the machine
forward by the length of track on ground,
1) Add grease through grease fitting (1) by
then stop slowly.
using a grease gun.
3) After adjusting, check the track tension again
2) To check that the tension is proper, run the
according to the above procedure.
engine at low idle and move the machine
forward by the length of track on ground,
then stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.
30-42 PC290LC-10
Hydraulic system
Hydraulic system
Releasing remaining pressure from hydraulic circuit
Releasing remaining pressure a The engine does not start unless the lock
lever is set to the LOCK position.
1. Releasing remaining pressure from hydraulic
4) Repeat above steps 2) and 3) two to three
tank
times, and all remaining pressure is released
k The hydraulic tank is airtight and from the piping completely.
3. Releasing remaining pressure from swing
pressurized, so release the remaining
motor circuit
pressure from it when removing a hose or
a plug connected to it. a Release the remaining pressure from the
swing motor circuit by performing the
1) Lower the work equipment to the ground in a
procedure for 2 (Releasing remaining
stable posture and stop the engine.
pressure from hydraulic cylinder circuit).
2) Loosen oil filler cap (1) of the hydraulic tank
4. Releasing remaining pressure from travel
gradually to release the air in the tank.
motor circuit
a The control valve spool of the travel motor
circuit is open, so the pressure in this circuit
can be released by performing the operation
for "Release remaining pressure from
hydraulic tank".
2. Releasing remaining pressure from hydraulic

cylinder circuit
k When disconnecting a pipe between a

hydraulic cylinder and the control valve,
release the remaining pressure from the
piping according to the following
procedure.
1) Release the residual pressure from the
hydraulic tank. For details, see "Releasing
residual pressure from hydraulic tank" .
a Leave the oil filler cap of the hydraulic
tank removed.
2) Set the starting switch to ON position and set
the lock lever to the FREE position, and then
operate the right and left work equipment
control levers forward, backward, to the right,
and to the left.
a The control valve is operated by the
pressure in the accumulator. The
pressure in the accumulator is used up,
however, after the work equipment
control levers are operated two to three
times.
3) Start the engine and run it at low idle for 5
seconds to raise the pressure in the
accumulator.
PC290LC-10 30-43
Hydraulic system
Measuring and adjusting of oil pressure in work equipment, swing, and

travel circuits
a Testing instrument
Sym-
Part No. Part Name
bol
M 1
790-261-1204 Digital hydraulic tester

the work equipment to the ground. Then,
release the remaining pressure referencing
"Releasing remaining pressure from
hydraulic circuit(PAGE 30-43)".
Testing
a The oil pressure in the work equipment, swing,
and travel circuits (pump discharge pressure)
can be checked by using monitoring function of
the machine monitor. (For details, see "Special
functions of machine monitor(PAGE 30-73)".)
• Monitoring code: 01100 F pump pressure
• Monitoring code: Monitoring code: 01101 R
pump pressure
a Test the oil pressure in the work equipment,
swing, and travel circuits under the following
condition.
• Hydraulic oil temperature: Within operating 2) Start the engine and keep it running until the
range hydraulic oil temperature rises to the
1. Preparation work operating range.
k Lower the work equipment to the ground

and stop the engine. After the engine
stops, operate the control lever several
times to release the remaining pressure in
the piping. Then loosen the oil filler cap
slowly to release the pressure inside the
hydraulic tank.
1) Open the side cover on the right side of the
machine body and connect oil pressure
gauge [1] of hydraulic tester M1 to ports (1)
and (2).
a Use an oil pressure gauge for 60 MPa 2. Combination of pump, actuator, and valve
{600 kg/cm2}. a When the oil flow from the pumps is divided,
• (1): Rear pump discharge pressure the front pump and rear pump actuate each
pickup port actuator independently as shown on the
• (2): Front pump delivery pressure pickup table. Note that the relieved valve varies
port depending on the actuator.
a When the work equipment circuit or swing
circuit is relieved singly, the oil flows from the
pumps are merged. When the travel circuit is
relieved singly, the oil flows from the pumps
are divided.
30-44 PC290LC-10
Hydraulic system
a The actuators in the table are arranged in the 3) Measure hydraulic oil pressure when the
order that the control valves are viewed from cylinder is relieved while the engine is
the front of the machine. (As for the service running at full speed.
valve, the table shows an example in which
a The pressure at the time when the main
an attachment is installed.)
relief valve is relieved is displayed.
P- Ac-
u- tua- Valve to be relieved a If the one-touch power maximizing switch
mp tor is not pressed, the low relief pressure is
(R unload valve) (R main relief valve) obtained. If the former is pressed, the
At- high relief pressure is obtained.
tach- Suction-safety valve a If the swing lock switch is set to the ON
ment position, the 2-stage relief valve is kept
Buc-
Rear
R main relief valve ON and the high relief pressure is

ket
obtained. Therefore, keep the swing lock
L.H
tra- R main relief valve switch at the OFF position.
vel 5. Testing swing relief pressure
Boo- 1) Start the engine, set the working mode to the
R main relief valve
m Power Mode (P), and turn the swing lock
(Pump merge-divider valve) (Travel junction valve) switch ON.
(Self-pressure reducing valve) 2) Measure hydraulic oil pressure when the
Swi- engine is running at full speed and the swing
Swing motor safety valve
ng circuit is relieved.
Front
R/H
a Hydraulic oil pressure when the swing
tra- F main relief valve
motor safety valve is relieved is
vel
Arm F main relief valve displayed.
(F unload valve) (F main relief valve) a The swing motor relief pressure is lower
(Centralized safety valve) (Back pressure valve) than that of the main relief valve.
3. Measuring unload pressure 6. Testing travel relief pressure
1) Start the engine, set the working mode to the 1) Start the engine and lock the travel
Power Mode (P), and turn the auto- mechanism.
decelerator OFF.
k Put pin [2] between the sprocket and
2) Set all control levers and pedals to the
neutral and measure the oil pressure while track frame to lock the travel
running the engine at full speed. mechanism securely.
a Hydraulic oil pressure when the unload

valve unloads is displayed.
2) Set the working mode to the Power Mode

(P).
3) Measure the pressure when the engine is
4. Testing work equipment relief pressure running at full speed and the travel circuit is
1) Start the engine and operate the cylinder to relieved.
be tested to the stroke end.
2) Set the working mode to the Power Mode k Before operating the travel lever
(P). (pedal), check the pin position and
locked direction of the travel again.
PC290LC-10 30-45
Hydraulic system
a The pressure at the time when the main a Amount of adjustment per turn of holder:
relief valve is relieved is displayed. The Approx. 20.5 MPa {Approx. 209 kg/cm2}
travel circuit is always relieved at high 4) While fixing holder (5), tighten lock nut (6).
pressure.
7. Work after finishing testing 3 Lock nut: 49 to 58.8 Nm {5 to 6
After finishing measurement, remove the kgm}
Adjusting
a Adjustment of the unload valve is not available.
1. Adjusting work equipment and travel relief
pressure
a If the relief pressure of the work equipment
circuit and travel circuit is abnormal, adjust
main relief valves (3) and (4) of the main
relief valve according to the following
procedure.
• (3): Front main relief valve 5) Connect the pilot hose.
• (4): Rear main relief valve 6) After finishing adjustment, check the oil
pressure again according to the above
a When adjusting the main relief valve on the measurement procedure.
front pump, remove the cover under the 2. Adjusting swing relief pressure
control valve.
1) If the swing relief pressure is improper, adjust
a When adjusting the main relief valve for the swing 2-stage relief valve (7) according to
rear pump circuit, remove the fuel tank cover. the following procedure.
a Adjust only the low relief pressure of the
main relief valve. If the low relief pressure is
adjusted, the high relief pressure is set
automatically.
a The low relief pressure is the pressure under
the following condition: the 2-stage relief
solenoid valve is not energized and the pilot
pressure is not applied to the selector port.
2) While fixing pressure adjustment screw (8),

loosen locknut (9).
3) Adjust the pressure by rotating pressure
adjustment screw (8).
a If the pressure adjustment screw is
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure
is decreased.
1) Disconnect the pilot hose.
2) While fixing holder (5), loosen lock nut (6). a Quantity of adjustment per turn of
3) Turn holder (5) to adjust the pressure. pressure adjustment screw:
a If the holder is 7.68 MPa {78.3 kg/cm2}
4) While fixing pressure adjustment screw (8),
• turned clockwise, the pressure is
tighten locknut (9).
increased.
• turned counterclockwise, the pressure 3 Lock nut: 58.8 to 78.4 Nm {6 to 8
is decreased. kgm}
30-46 PC290LC-10
Hydraulic system
5) After finishing adjustment, check the oil

pressure again according to the above
measurement procedure.
PC290LC-10 30-47
Hydraulic system
Measuring oil pressure in control circuit

a Testing tools 4. Measure hydraulic oil pressure, when the engine
Sym- is running at full speed and all the control levers
Part No. Part Name are set to the neutral.
bol
1
N
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
k Lower the work equipment to the ground and

stop the engine. After the engine stops,
operate the control lever several times to
release the remaining pressure in the piping.
Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
a For the checking procedure on the machine 5. After finishing measurement, remove the
monitor, see "Checking oil pressure with sensor measuring tools and return the removed parts to
adapter (special tool)(PAGE 30-55)." their original position.
Testing a The control circuit source pressure may be

tested at oil pressure pickup port plug (2) on
1. Remove pressure pickup port plug (1). the hydraulic pump.
2. Install nipple N2 and connect it to oil pressure

gauge [1] of hydraulic tester N1. a Do not adjust the relief valve of the control
circuit basic pressure.
a Use an oil pressure gauge for 6.0 MPa {60
kg/cm2}.
3. Start the engine and keep it running until the

hydraulic oil temperature rises to the operating
range.
30-48 PC290LC-10
Hydraulic system
Measuring and adjusting oil pressure in pump PC control circuit

a Testing instrument
Sym-
Part No. Part Name
bol
1
P
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

Then loosen the oil filler cap slowly to 2) Install nipple P2 to rear control pressure port
release the pressure inside the hydraulic (4) (the other ports are equipped with
tank. nipples) and connect them to oil pressure
gauge [1] of hydraulic tester P1.
a Before testing the oil pressure in the pump PC
control circuit, check that the oil pressure in the a Use an oil pressure gauge for 60 MPa
work equipment, swing, and travel circuits and {600 kg/cm2}.
the source pressure of the control circuit are
proper.
Testing
1. Testing PC valve output pressure (servo
piston inlet pressure)
a Measure the PC valve output pressure
(servo piston inlet pressure) and pump
discharge pressure simultaneously and
compare them.
1) Remove pressure pickup port plug (4).
• (1): Front pump delivery pressure pickup
port 3) Start the engine and keep it running until the
• (2): Rear pump discharge pressure hydraulic oil temperature rises to the
pickup port operating range.
• (3): Front control pressure pickup port
• (4): Rear control pressure pickup port
4) Measure the pump discharge pressure and

PC valve output pressure (pressure at servo
piston inlet) at the same time after setting the
machine to the following conditions with the
engine running at full speed.
• Working mode: P mode
(Turning 2-stage relief ON switches to
high-pressure relief)
PC290LC-10 30-49
Hydraulic system
• Work equipment, swing and travel: Arm 3) Start the engine and keep it running until the
IN to hydraulic relief hydraulic oil temperature rises to the
operating range.
a Judgment method:
If the ratio between the pump discharge
pressure and the PC valve output
pressure (servo piston output pressure)
reaches the following value, the
pressures are proper.
Oil pressure to be Ratio of oil pressure
checked
Pump delivery pressure 1
PC valve output
Approximately 0.6 (3/5)
pressure
a If the PC valve or the servo piston is

defective, the PC valve output pressure 4) Measure the hydraulic oil pressure with all
(servo piston output pressure) comes to the control levers set to the neutral and the
the same pressure as the pump engine running at full speed and at low idle.
discharge pressure, or almost 0.
2. Testing PC-EPC valve output pressure a If the PC-EPC valve output pressure
changes as shown below, it is normal.
machine body and remove oil pressure Engine Operate the Hydraulic
pickup plugs (5) and (6). control levers.
2.9 MPa
• (5): Front PC mode selector pressure Low idle
{30 kg/cm2}
pickup port NEUTRAL
• (6): Rear PC mode selector pressure 0 MPa
High idle
pickup port {0 kg/cm2}
Adjusting
a If either of the following problem occurs and the
PC valve seems to be defective, adjust PC
valves (7) and (8) according to the procedure
shown below.
• As the work load increases, the engine
speed decreases remarkably.
• The engine rpm is normal but the work
equipment speed is low.
2) Install nipple P2 and connect it to oil • (7): Front pump PC valve
pressure gauge [1] of hydraulic tester P1. • (8): Rear pump PC valve
a Use an oil pressure gauge for 6.0 MPa
{60 kg/cm2}.
30-50 PC290LC-10
Hydraulic system
a The width across flats of the PC valve locknut is

13 mm and that (inside width) of the adjusting
screw is 4 mm.
Do not turn any lock nuts and adjustment screws
other than the above because doing so affects
the hydraulic pump performance.
1. Loosen lock nut (9).

a Before loosening the locknut, make a match
mark on the end face of the adjustment
screw to indicate the original position of the
adjustment screw (so that you can return the
adjustment screw to the original position if
you turn it in the opposite direction).
2. Adjust the pressure by rotating adjustment
screw (10) to the right or left.
a Turn the adjusting screw in the following
directions.
• Turn it clockwise when the work
equipment speed is low (to increase
pump absorption torque).
• If the engine speed lowers when the work
load increases, turn it to the right. (The
pump absorption torque will decrease.)
3. Tighten lock nut (9).
3 Lock nut: 27 to 34 Nm {2.8 to 3.5kgm}
4. After the adjustment, make sure that the PC

valve output pressure (servo piston inlet
pressure) is normal according to the
measurement steps explained earlier.
PC290LC-10 30-51
Hydraulic system
Measuring and adjusting oil pressure in pump LS control circuit

a Testing instrument • (4): Rear control pressure pickup port
Sym-
Part No. Part Name
bol
799-101- Hydraulic tester
5002
1
790-261- Digital hydraulic tester
1204
790-101- Nipple (10 x 1.25 mm)
5220
2
07002- O-ring
11023
799-401- Differential pressure gauge
3
2701
796T-440- Sensor adapter
1101 (50 MPa {500 kg/cm2})
796–440– • Wiring harness
Q
1150
796T-440– • Nipple
1160
4 799-401–
• Washer
2350
799-401– • Coupling
2340
07002– • O-ring
61823
7861-93–
• Pressure sensor
1812
796T-440- Sensor adapter
5
1200 (5 MPa {50 kg/cm2}) 2) Install nipple Q2 to rear control pressure
pickup port (4) (the other ports are equipped
k Lower the work equipment to the ground and with nipples) and connect them to oil
stop the engine. After the engine stops, pressure gauge [1] of hydraulic tester Q1.
a Use an oil pressure gauge for 60 MPa
{600 kg/cm2}.
tank.
a Before testing the oil pressure in the pump LS

control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the source pressure of the control circuit are
proper.
Testing
1. Testing LS valve output pressure (servo
piston inlet pressure)
a Measure the LS valve output pressure (servo 3) Run the engine and raise the hydraulic oil
piston inlet pressure) and the pump temperature to the operating range and raise
discharge pressure simultaneously and up the track to be tested.
compare them.
• When measuring the front circuit: right
1) Remove pressure pickup port plug (4). track
• (1): Front pump delivery pressure pickup • When measuring the rear circuit: left track
port
• (2): Rear pump discharge pressure k Provide a enough work space to run
pickup port the track idle off the ground.
• (3): Front control pressure pickup port
30-52 PC290LC-10
Hydraulic system
a To obtain the LS differential pressure,

measure the pump discharge pressure and
LS pressure (actuator load pressure) at the
same time and calculate the difference.
machine body and remove oil pressure
pickup plugs (5) and (6).
• (1): Front pump delivery pressure pickup
port
• (2): Rear pump discharge pressure
pickup port
4) Measure the pump discharge pressure and

PC valve output pressure (pressure at servo
piston inlet) at the same time after setting the
machine to the following conditions with the
engine running at full speed.
• Work equipment, swing and travel:
Measure when all of these levers are in
neutral and when the travel lever is
moved halfway (to rotate the raised track
shoe).
a Run the raised track idle, paying enough • (5): Front load pressure pickup port
attention to the surroundings for safety. • (6): Rear load pressure pickup port
a Measurement conditions and judgment
method:
If the ratio between the pump discharge
pressure and LS valve output pressure
(servo piston input pressure) reaches the
following value, the pressures are correct.
Position of levers
Travel lever set
All levers and at half stroke
pedals are at
(run track idle off
neutral
ground)
Pump 2) Install nipples Q2 to pressure pickup ports
Measure value is
Oil pressure to be checked
delivery (5) and (6) (pickup ports (1) and (2) are
regarded as 1.
pressure equipped with nipples) and connect them to
differential pressure gauge Q3 or to the oil
pressure gauge of hydraulic tester Q1.
Almost same
LS valve pressure Approximately a When using the differential pressure
out put 0.6 (3/5) of gauge:
pressure above pressure Connect the pump delivery pressure
hose to the high pressure side (back
side) and connect the LS pressure hose
to the low pressure side (lower side).
5) After finishing measurement, remove the As the differential pressure gauge needs
measuring tools and return the removed DC 12 V power supply, connect it to one
parts to their original position. battery.
2. Testing LS differential pressure
PC290LC-10 30-53
Hydraulic system
a When using the oil pressure gauge:

Use the oil pressure gauge of 60 MPa
{600 kg/cm2} with the graduation by 1
MPa {10 kg/cm2}.
The differential pressure is approximately
4 MPa {40 kg/cm2} at the maximum, so
perform the measurement by using a
gauge alternately.
• The figure shows the pump discharge
pressure side.
4) While running the engine at full speed under

the following condition, measure the pump
discharge pressure and LS pressure
(actuator load pressure) simultaneously.
• Travel speed: Hi
• Work equipment, swing and travel:
Measure when all of these levers are in
neutral and when the travel lever is
moved halfway (to rotate the raised track
shoe).
• The figure shows the LS pressure side.
a Run the raised track idle, paying enough
attention to the surroundings for safety.
a Calculating LS differential pressure (when
the pressure gauge is used):
LS differential pressure = Pump
discharge pressure - LS pressure
a If LS differential pressure is in the
following conditions, it is judged normal.
LS differential
Lever control pressure
When all control levers are in 3.5 ± 1.0 MPa
NEUTRAL position {36 ± 10 kg/cm2}
3) Run the engine and raise the hydraulic oil
1.8 +0.05/-0.1
temperature to the operating range and raise MPa
When a travel lever is moved
up the track to be tested.
halfway (Raised track runs idle) {18 +0.5/-1.0 kg/
• When measuring the front circuit: right cm2}
track
• When measuring the rear circuit: left track
k Provide a enough work space to run
3. Testing LS-EPC valve output pressure
the track idle off the ground.
1) Remove pressure pickup port plug (7).
30-54 PC290LC-10
Hydraulic system
2) Install nipple Q2 and connect it to oil 5) After finishing measurement, remove the
pressure gauge [1] of hydraulic tester Q1. measuring tools and return the removed
a Use an oil pressure gauge for 6.0 MPa
{60 kg/cm2}. Checking oil pressure with sensor
adapter (special tool)
Testing
Operate the machine monitor, select "Monitoring /
Pre-defined" or "Monitoring" so that the service
pressure can be monitored.
a For the operating method of the machine monitor,
see "Special functions of machine monitor".
a Monitoring code: 01141 Service Pressure
Sensor
• Monitoring / pre-defined screen
3) Start the engine and keep it running until the

hydraulic oil temperature rises to the
operating range.
4) Measure the oil pressure when the engine is
running at full speed and the travel speed
switch and travel control lever are operated.
a If the LS-EPC valve output pressure
changes as follows, it is normal.
Travel speed Travel control Hydraulic

lever
Approximately
2.9 MPa • Monitoring screen
Lo NEUTRAL
{Approx. 30 kg/
cm2}
Fine travel lever 0 MPa
Hi control (Note) {0 kg/cm2}
Note: Operate the travel lever to a degree
that the PPC oil pressure switch is just
turned on (position before the tracks start
moving).

machine and connect service oil pressure
PC290LC-10 30-55
Hydraulic system
connector (1) (P49) to the connector of a sensor

adapter assembly Q4 (pressure range: 50 MPa
{500 kg/cm2}).
k Sensor adapter Q5 (pressure range: 5

MPa {50 kg/cm2}) is used for the
monitoring, the value indicated on the
monitor needs to be multiplied by 1/10.
Take care.
1. While fixing adjustment screw (10), loosen lock

nut (11).
2. Turn adjusting screw (10) to adjust the pressure.
a Turn the adjusting screw in the following
directions.
• Turned clockwise, the differential
pressure is increased.
• Turned counterclockwise, the differential
pressure is decreased.
2. Install nipple Q2 to the oil pressure pickup plug
and connect them to the sensor adapter a Amount of adjustment (LS differential
assembly Q4. pressure) per turn of adjustment screw:
1.1 MPa {10.8 kg/cm2}
3. While fixing adjustment screw (10), tighten lock
nut (11).
3 Lock nut:
49 to 68.6 Nm {5 to 7 kgm}
3. Start the engine and keep it running until the

hydraulic oil pressure rises to the operating
range.
4. Monitor the oil pressure while running the engine
at low idle or high idle.
measuring tools and return the machine to the 4. After finishing adjustment, check that the LS
original condition. valve output pressure (servo piston inlet
pressure) is correct according to the testing
Adjusting procedure described above.
a If the LS differential pressure is improper, adjust
LS valves (8) and (9) according to the following
procedure.
• (8): Front LS valve
• (9): Rear LS valve
30-56 PC290LC-10
Hydraulic system
Measuring solenoid valve output pressure

a Testing tools a When testing at hoses (2) to (7), remove the
Sym- undercover of the control valve.
Part No. Part Name
bol
1
R
799-401-3100 Adapter (size: 02)
2
02896-11008 O-ring

tank.
2. Install adapter R2 and connect the currently
a Before testing the solenoid valve output disconnected hose again.
pressure, check that the control circuit source 3. Install nipple [2] and connect it to pressure
pressure is normal. gauge [3].
a Measure the solenoid valve outlet pressure a Use an oil pressure gauge for 6.0 MPa {60
under the following conditions: kg/cm2}.
• Hydraulic oil temperature: Within operating a The figure shows the testing tools connected
range to outlet hose (1) of the PPC lock solenoid
valve.
Testing
1. Disconnect outlet hoses (1) to (7) of the solenoid
valves to be measured.
No. Target solenoid valves of measurement
1 PPC lock solenoid valve
2 2-stage relief solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed increase solenoid valve
5 Travel junction solenoid valve
6 Swing 2-stage relief solenoid valve
Attachment selector solenoid valve
7
(for the machine with the attachment)
a When testing at hose (1), remove the

undercover (rear side) of the operator's cab.
4. Start the engine.

5. Run the engine at high idle, operate the control
levers and switches to energize or de-energize
the solenoid valve, and measure the output
pressure.
PC290LC-10 30-57
Hydraulic system
a For the conditions for turning ON or OFF, see

the operation table of each solenoid valve.
a The operating status of each solenoid valve
can be checked by using monitoring function
of the machine monitor. (For details, see
"Special functions of the machine monitor".)
• Monitoring code: 02300 Solenoid 1
• Monitoring code: 02301 Solenoid 2
a If the output pressure is as shown in the table,
the solenoid valve is normal.
Solenoid valve Outlet pressure
OFF(de-energized) 0 MPa {0 kg/cm2}
ON (energized) 2.9 MPa {30 kg/cm2}
Operating condition
(1) Operation table of PPC lock solenoid valve
LOCK position OFF
PPC lock lever
FREE ON
(2) Operation table of 2-stage relief solenoid valve

Overheat 1st setting is ON.
Overheat 2nd setting is ON. OFF
When all the signals for work equipment, swing and travel are OFF.
Swing lock switch is ON.
Travel signal is ON.
When L mode is selected ON
When the boom LOWER signal is ON
Signals other than the "swing only"
When the working mode When one-touch power are ON.
is P or E. max. switch is ON. "Swing only " is ON.
OFF
Other than the above conditions
(3) Operation table of swing holding brake solenoid valve
Signals of work equipment and swing (Work equipment includes All are OFF. OFF
attachment.) Any one is
ON
ON.
(4) Operation table of travel speed increase solenoid valve

Overheat 2nd setting is ON.
Arm crane is installed.
Fuel control dial is at 1,500 rpm or below.
Travel speed switch is at Lo. OFF
Travel signal is OFF.
Travel speed switch:
Mi, Hi When F or R pump pressure is 34.7 MPa
Travel signal is ON.
{340 kg/cm2} or above.
30-58 PC290LC-10
Hydraulic system

When F or R pump pressure is 20.4 MPa
{200 kg/cm2} or below. ON
Other than the above conditions
(5) Operation table of travel junction solenoid valve

Travel steering signal is ON.
When " travel only" When F or R pump pressure ON
signal is ON. is 24.5 MPa {250 kg/cm2} or
Travel steering signal is OFF.
above.
Other than the above conditions OFF
(6) Operation table of 2-stage relief valve

When
boom
When RAISE When F pump
boom PPC pressure is
RAISE pressure is rising and 20.6
signal is 2.2 MPa MPa {210 kg/
When the swing signal is ON but except ON {22 kg/ When arm cm2} or above
when the swing back operation is turned cm2} or signal is ON
on below OFF
When F pump
pressure is
When pump flow is decreasing
divided and 25.5 MPa
{260 kg/cm2}
or above
Other than the above conditions OFF
(7) Operation table of attachment selector solenoid valve (attachment installation specification)
Working mode: Other than B mode OFF
Working mode: When B mode is set ON
PC290LC-10 30-59
Hydraulic system
Measuring PPC valve output pressure

a Testing tools a Before starting the measurement, disconnect a
Sym- hose of control valves on the target circuits (1) to
Part No. Part Name (12).
bol
1
S
799-401-3100 Adapter size: 02)
2
799-401-3200 Adapter size: 03)
a Check that the control circuit source pressure is

correct before testing the PPC valve outlet
pressure.
a Test the PPC valve outlet pressure under the
following condition.
Hydraulic oil temperature: within operating range
a The outlet pressure of the following PPC valve
can be checked by using monitoring function of N- Circuit to be N- Circuit to be
o. measured o. measured
machine monitor.
Bucket CURL Swing RIGHT
(For details, see "Special functions of machine 1 (White) 7 (None)
monitor(PAGE 30-73)".) Bucket DUMP
2 (Black) 8 Swing LEFT (red)
Monitoring code: 07200 Arm Curl PPC pressure
Monitoring code: 07600 Arm Dump PPC Travel L.H Travel R.H
3 FORWARD (Red) 9 FORWARD (Green)
pressure
Travel L.H Travel R.H
Monitoring code: 07300 Bucket CURL PPC 4 10 REVERSE (Blue)
REVERSE (None)
pressure
Boom LOWER
Monitoring code: 07301 Bucket DUMP PPC 5 (Brown) 11 Arm IN (Blue)
pressure Boom RAISE
Monitoring code: 07400 Boom RAISE PPC 6 (Green) 12 Arm DUMP (Yellow)
pressure
• The colors in ( ) are the colors of the bands
Monitoring code: 07500 Boom LOWER PPC installed for piping identification.
pressure
Monitoring code: 09001 Swing LEFT PPC
pressure
Monitoring code: 09002 Swing RIGHT PPC
pressure
Monitoring code: 07102 Travel Fwd LH PPC
pressure
Monitoring code: 07103 Travel Fwd RH PPC
pressure
Monitoring code: 07104 Travel Rev LH PPC
pressure
Monitoring code: 07105 Travel Rev RH PPC
pressure
30-60 PC290LC-10
Hydraulic system
Testing
1. Disconnect hydraulic hose (2) of the tested PPC 5. After finishing measurement, remove the
circuit, install adapter S2, and connect hydraulic measuring tools and return the removed parts to
hose (2) again. their original position.
2. Install nipple [1] of hydraulic tester S1 to adapter
S2 and connect oil pressure gauge [2].
a Use an oil pressure gauge for 6.0 MPa {60
kg/cm2}.
a The figure shows the testing tools installed to
the hydraulic hoses of the bucket dump PPC
circuit.
3. Start the engine and set the working mode to the

Power Mode (P).
4. Measure the pressure when the engine is

running at full speed and the control lever of the
circuit to be measured is kept at the neutral
position and at the full stroke.
a If PPC valve output pressure is at the level
shown below, it is correct.
Lever control Hydraulic
When control
lever is in
0 MPa {0 kg/cm2}
NEUTRAL
position
Almost the same pressure as
When control the control circuit source
lever is moved to pressure (See "Standard values
stroke end table")
PC290LC-10 30-61
Hydraulic system
Adjusting play of work equipment and swing PPC valves

a If the right and left work equipment levers have
large play, adjust them according to the following
procedure.
a The play of the lever measured at a position of
200 mm from the pivot must be 0.5 to 3 mm.
Adjusting
1. Remove boot (1).
2. Loosen locknut (2) and tighten disc (3) until it
touches the heads of four pistons (4).
a Do not move the piston at this time.
3. Fix the position of disc (3) and tighten locknut (2)
to the specified torque.
3 Lock nut: 93.1 to 112.7 Nm {9.5 to 11.5
kgm}
4. Install boot (1).
30-62 PC290LC-10
Hydraulic system
Testing pump swash plate sensor

a Before testing pump swash plate sensor, check a Testing condition and judgment: If the voltages
that oil pressure in work equipment, swing, and are as shown in the table, pump swash plate
travel circuits, control circuit source pressure, sensor is correct.
and no-load travel speed are correct. Pump swash plate
Lever control sensor voltage
a Test pump swash plate sensor under the
following conditions. All control levers and
pedals are at neutral. 1.35 ± 0.63 V
Travel lever is at stroke
range end.
• Working mode: P mode 3.35 ± 0.63 V
(run track idle off
Testing output voltage of pump swash plate ground)
sensor
a Output voltage of pump swash plate sensor can
be checked by using monitoring function of
machine monitor.
(For the operating method, see " Special
functions of machine monitor(PAGE 30-73)
Special functions of the machine monitor" .)
• Monitoring code:
01138 F pump sw plate sensor volt
01140 R pump sw plate sensor volt
Testing
1. Start the engine and raise the track on the side
to be tested, by using the work equipment, and
prepare for running the track idle.
• When testing front pump: right track
• When testing rear pump: left track
k Provide a enough work space to run the

track idle off the ground.
2. Set the working mode to the Power Mode (P)
and set the travel speed to the High.
3. Set the swing lock switch to ON position.
4. While running the engine at full speed, set all the
levers and pedals for work equipment, swing,
and travel to the neutral, and then set the travel
lever to stroke end in order to run a track idle,
and measure the voltage during each operation.
k While taking care of safety around the
machine, run the raised track idle.
PC290LC-10 30-63
Hydraulic system
Isolating the parts causing hydraulic drift in work equipment

a If the work equipment (cylinder) drifts 2) Operate the arm control lever to the arm IN
hydraulically, perform check to see if the position.
problem is in the cylinder seal or control valve • If the lowering speed is increased at this
according to the following procedure. time, the cylinder seal is defective.
Checking • If the lowering speed does not change at
this time, the control valve is defective.
1. Checking boom cylinder and bucket cylinder
a Operate the control lever with the engine
1) Set the work equipment in the same posture
starting switch in the ON position.
as when measuring hydraulic drift, and stop
the engine. a If there is no more pressure in the
accumulator, run the engine for
a Put a weight equivalent to the rated load
approximately 10 seconds to charge the
or fill the bucket with the earth and sand.
accumulator.
[Reference] In case of the hydraulic drift is
caused by defective cylinder packing, the
reason why the drift speed becomes faster by
above mentioned operation is as follows:
1) If the work equipment is set to the above
posture (where the work equipment holding
pressure is applied to the bottom side), the
oil leaks from the bottom side to the head
side. The volume on the head side is less
than that on the bottom side by the volume of
the rod, so the pressure in the head side is
increased by the oil flowing in from the
2) When testing the boom cylinder, set the bottom side.
boom control lever to the RAISE position. 2) As the inner pressure in the head side is
When testing the bucket cylinder, set the increased, it is balanced with the pressure in
bucket control lever to the CURL position. the bottom side at a certain level (which
• If the lowering speed is increased at this depends on the leak quantity), and the
lowering speed is reduced.
time, the cylinder seal is defective.
3) If the circuit on the head side is opened to
• If the lowering speed does not change at
this time, the control valve is defective. the drain circuit by the above operation of the
lever (the bottom side is closed by the check
a Operate the control lever with the engine valve at this time), the oil in the head side
starting switch in the ON position. flows in the drain circuit. As a result, the
a If there is no more pressure in the pressure is in balanced and the lowering
accumulator, run the engine for speed is increased.
3. Testing PPC valve
Measure the hydraulic drift of the work
accumulator.
2. Checking arm cylinder equipment when the work equipment lock lever
is in the LOCK and FREE positions with the
1) Move the arm cylinder to about 100 mm accumulator charged fully.
before the IN stroke end and stop the engine.
a Operate the control lever with the engine
starting switch in the ON position.
a If there is no more pressure in the
accumulator, run the engine for
accumulator.
a If there is any difference in the hydraulic drift
between LOCK and FREE positions, the
PPC valve is defective (some internal
defect).
30-64 PC290LC-10
Hydraulic system
Measuring oil leakage

a Component to be checked 1) Move the arm cylinder to the arm IN stroke
Sym- end and stop the engine.
Part No Part Name
bol
Available on k Release the remaining pressure from
T Measuring cylinder
the market the piping on the arm cylinder head
side. For details, see "Releasing
a Measure the oil leakage under the following remaining pressure from hydraulic
condition. circuit" (Operate the lever to arm IN
• Hydraulic oil temperature: within operating only, however).
range
2) Disconnect hose (2) on the cylinder head
Testing side and block the hose end by a flange.
1. Measurement of leakage from boom cylinder
k Take care not to disconnect the hoses
1) Extend the boom cylinder to the boom
on the cylinder bottom side.
RAISE stroke end and stop the engine.
a Use the following part to block on the
k Release the remaining pressure from hose end.
the piping on the boom cylinder head 07379-00640 (Flange #06)
remaining pressure from hydraulic
circuit" (Operate the lever to the boom
RAISE direction only, however).
2) Disconnect hose (1) on the cylinder head
side and block the hose end by a flange.
k Take care not to disconnect the hoses

on the cylinder bottom side.
hose end.
07379-00640 (Flange #06)
3) Run the engine at full speed and relieve the
arm circuit by moving the arm IN.
k Take care not to "move the arm OUT".

4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the
leak for 1 minute.
5) After finishing testing, return the machine
status as it was.
3. Measurement of oil leakage from bucket
cylinder
1) Move the bucket cylinder to the bucket
3) Run the engine at full speed and relieve the CURL stroke end and stop the engine.
boom circuit by raising the boom.
k Release the remaining pressure from
k Take care not to "lower the boom". the piping on the bucket cylinder head
4) Start measuring the oil leakage 30 seconds remaining pressure from hydraulic
after relieving is started, and measure the circuit" (Operate the lever in the
leak for 1 minute. bucket CURL direction only, however).
status as it was. 2) Disconnect hose (3) on the cylinder head
2. Measurement of oil leakage from arm side and block the hose end by a flange.
cylinder
PC290LC-10 30-65
Hydraulic system
k Take care not to disconnect the hoses a After measuring one time, swing 180 deg.,
on the cylinder bottom side. and then measure the leak again.
status as it was.
hose end.
5. Measurement of oil leakage from travel
07379-00640 (Flange #06) motor
1) Remove the travel motor cover.
2) Run the engine, lock the travel mechanism,
and stop the engine.
k Put pin [1] between the sprocket and

track frame to lock the travel
mechanism securely.

bucket circuit by curling the bucket.
k Takecare not to perform "bucket

DUMP operation".
4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the
leak for 1 minute. 3) Disconnect drain hose (5) of the travel motor
5) After finishing testing, return the machine and block the hose end by a plug.
status as it was.
4. Measurement of oil leakage from swing
hose end.
motor
07376-70422 (plug #04)
1) Disconnect two drain hoses (4) and block the
hose side end by plugs.
hose end.
07376-70522 (Plug #05)
4) Run the engine at full speed, relieve the

travel circuit, and measure the oil leakage.
k Before operating the travel lever,

check the pin position and locked
2) Set the swing lock switch to the ON position. direction of the travel again.
swing circuit by swinging. k Wrong operation of the lever can
cause the personal injury. Make the
a Start measuring the oil leakage 30
signals and checks securely.
seconds after relieving is started, and
measure the leak for 1 minute. a Start measuring the oil leakage 30
seconds after relieving is started, and
measure the leak for 1 minute.
30-66 PC290LC-10
Hydraulic system
a Take measurement several times, moving

the motor a little each time (i.e. change
the position of the valve plate and
cylinder, and that of the cylinder and
piston each time).
status as it was.
PC290LC-10 30-67
Hydraulic system
Bleeding air from hydraulic circuit

q: Execution of work
o: Go to next procedure
Air bleeding procedure and item
1 2 3 4 5 6
Bleeding air Checking oil
from Starting the Bleeding air Bleeding air Bleeding air
level and
hydraulic engine from cylinder from swing from travel
operating
pump motor motor
machine
• Replacement of
hydraulic oil q q
q q q q
• Cleaning (See note) (See note)
strainer
• Replacing
return oil filter q o o o q
element
• Replacing or
repairing
hydraulic pump q q q o o q
• Removal of
suction piping
• Replacing or
repairing
control valve
q q o o q
• Removal of
Detail of work, remarks
control valve
piping
• Replacement
or repair of
cylinder q q o o q
• Removal of
cylinder piping
• Replacing or
repairing swing
motor
q o q o q
• Removal of
swing motor
piping
• Replacing or
repairing travel
motor
q o o q q
• Removal of
travel motor
piping
• Replacing or
repairing swivel
joint q o o o q
• Installing swivel
joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
2) After oil containing no bubbles flows out,
Bleeding air tighten air bleeder (1).
1. Air bleeding from hydraulic pump 3 Air bleeder: 7.8 to 9.8 Nm {0.8 to
1.0 kgm}
a Keep the oil filler cap of the hydraulic tank
loosened while the air is bled from the
hydraulic pump.
1) Loosen air bleeder (1) and check that oil
oozes out from it.
30-68 PC290LC-10
Hydraulic system
3 Air bleeder: 27.5 to 35.3 Nm {2.8 to

3.6 kgm}
2. Starting engine
When running the engine after performing step 1,
let it low-idle for 10 minutes.
6. Bleeding air from swivel joint
a When the automatic warm-up operation is 1) Run the engine at low speed.
started due to low engine coolant 2) Raise a track and run it idle slowly (forward
temperature, stop the engine once and and reverse directions) to bleed air. Apply the
cancel the automatic warm-up operation same procedure to the right and left tracks.
using the fuel dial. (You can cancel the 7. Checking oil level and starting work
automatic warm-up function by turning the
1) Run the engine, retract the arm cylinder and
starting switch to the ON position and
bucket cylinder to the stroke end, lower the
keeping the fuel dial in the MAX position for 3
work equipment to the ground, and stop the
seconds or longer.)
engine.
3. Bleeding air from cylinder
a When the cylinder has been replaced, bleed
the air before connecting the work equipment.
The above step is necessary particularly
when boom cylinder is installed on work
equipment because the LOWER side does
not move to the stroke end in this state.
1) Run the engine at low idle for approximately
5 minutes.
2) While running the engine at low speed, raise
and lower the boom four to five times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not 2) Check the oil level using sight gauge (3) on
cause the relief. the rear side of the hydraulic tank.
3) While running the engine at full speed,
perform step 2). a If the oil leakage is between lines (H) and
4) While running the engine at low idle speed, (L), it is normal.
move the piston rod to the stroke end and a If the oil level is below line (L), add new
relieve the oil. oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) to 4).
4. Bleeding air from swing motor
1) Run the engine at low speed.
2) Swing to the right and left slowly to bleed air.
5. Bleeding air from travel motor
1) Run the engine at low speed.
2) Loosen air bleeder (2) and check that oil
oozes out from it.
3) After oil containing no bubbles flows out,
tighten air bleeder (2).
PC290LC-10 30-69

Checking cab tipping stopper
a Check the cab tipping stopper according to the following procedure.

Checking
1. Check the tightening torque of the mounting bolt
(2) of the lock plate (1).
3 Bolt (2): 98 to 123 Nm {10 to 12.5kgm}
[Reference]
• Note that the tightening torque for mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4): 245 to 309 Nm {25 to
31.5kgm}
30-70 PC290LC-10
Adjusting mirrors
1. Mirror Installation position
3. Adjusting mirror (b)

Adjust mirror (b) so that the operator can see a
person at the rear right end of the machine.
a Install the mirror as shown below.
(L): 26° (M): 86° (N): 420 mm (P): 135 mm
a If the mirror is hard to adjust, loosen mirror
bolts (3).
3 Bolt (4) of mirror: 6.0 to 7.0 Nm {0.61
to 0.71 kgm}
2. Adjusting mirror (a)

Adjust mirror (a) so that the operator can see a
person in the rear left end of the machine.
(G): 17° (H): 89° (J): 67 mm (K): 172 mm
bolts (2).
a Fix mirror stay (1) while the mirror is opened • Adjust the mirror so that the side of the
to the maximum position. machine is reflected in it as shown below.
to 0.71 kgm}
4. Adjusting mirror (c)

Adjust mirror (c) in such way that it best
commands a view of the side face of fuel tank
• Adjust the mirror so that the side of the that situates in the blind angle when seen from
machine is reflected in it as shown below. the operator's seat.
PC290LC-10 30-71

(Q): 2° (R): 15° (S): 136 mm
bolts (4).
to 0.71 kgm}
30-72 PC290LC-10
Electrical system
Electrical system
Special functions of machine monitor
PC290LC-10 30-73
Electrical system
Upper part of machine monitor (display portion)

(a): Multi-information display
a When the engine is started, the battery voltage
may drop suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the screen display of the machine
monitor may go off for a moment. This
phenomenon is not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated
by the icon which is displayed just above the
function switch on the screen of the multi-
information display panel (a).
a If the icon for a function switch is not displayed,
that function switch is not working.
Lower part of machine monitor (switch portion)

[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer stop
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals Air conditioner switch
a Each switch has the function indicated by the
icon on it and the function of inputting a numeral.
a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of the multi-
information display panel (a).
30-74 PC290LC-10
Electrical system
Ordinary functions and special functions of machine monitor

The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-information display panel.
Some information are displayed automatically according to the configuration of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
PC290LC-10 30-75
Electrical system
Operator mode (outline) Service mode

A Display of KOMATSU logo(PAGE 30-79) Monitoring / Pre-defined(PAGE 30-94)
A Display of inputting password(PAGE 30-79) Monitoring / Custom(PAGE 30-98)
Display of check of breaker mode(PAGE 30- Abnormality Record (Mechanical Systems)
A 79) (PAGE 30-107)
Display of check before starting(PAGE 30- Abnormality Record (Electrical Systems)
A 79) (PAGE 30-108)
Display of warning after check before
A starting(PAGE 30-80) Maintenance record(PAGE 30-109)
Display of ending of maintenance interval
A (PAGE 30-80) Maintenance Mode Setting(PAGE 30-110)
Display of check of working mode and travel
A speed(PAGE 30-80) Phone Number Entry(PAGE 30-113)
A Display of standard screen(PAGE 30-80) Default (Key-On Mode)(PAGE 30-113)
A Display of end screen(PAGE 30-81) Default (Unit)(PAGE 30-114)
Display of engine shutdown secondary Default (With/Without Attachment)(PAGE
A switch screen(PAGE 30-81) 30-115)
B Selection of auto-deceleration(PAGE 30-81) Default (Camera)(PAGE 30-116)
Diagnostic Tests (Cylinder Cut-out)(PAGE
B Selection of working mode(PAGE 30-81)
30-117)
Diagnostic Tests (Regeneration for Service)
B Selection of travel speed(PAGE 30-82) → (PAGE 30-118)
Operation to stop alarm buzzer(PAGE 30- (Spe- Diagnostic Tests (KDPF Memory Reset)
B 82) cial (PAGE 30-120)
opera- Adjustment (Pump Absorption Torque (F))
B Operation of windshield wiper(PAGE 30-82) tion)
(PAGE 30-121)
Adjustment (Pump Absorption Torque (R))
B Operation of window washer(PAGE 30-83)
(PAGE 30-121)
Operation of air conditioner/heater(PAGE Adjustment (Low Speed)(PAGE 30-122)
B 30-83)
Operation to display camera mode (if Adjustment (Attachment Flow Adjustment)
B camera is installed)(PAGE 30-83) (PAGE 30-124)
Operation to display clock and service Adjustment (Cal F pump swash plate
B meter(PAGE 30-84) sensor)(PAGE 30-125)
Check of maintenance information(PAGE Adjustment (Cal R pump swash plate
B 30-84) sensor)(PAGE 30-130)
Setting and display of user mode (including
Adjustment (Pump calibration: Matching
B KOMTRAX messages for user)(PAGE 30-
speed check)(PAGE 30-131)
84)
C Display of ECO guidance(PAGE 30-85)
speed calibration)(PAGE 30-136)
C Display of caution monitor(PAGE 30-86) No Injection(PAGE 30-137)
KOMTRAX Settings (Terminal Status)
C Display of KDPF regeneration(PAGE 30-86)
(PAGE 30-138)
Display of action level and failure code KOMTRAX Settings (GPS and
C (PAGE 30-88) Communication Status)(PAGE 30-139)
KOMTRAX Settings (Modem Information)
O (Special operation) (PAGE 30-140)
Function of checking display of LCD (Liquid Service Message(PAGE 30-140)
D Crystal Display)(PAGE 30-89)
Function of checking service meter(PAGE
D 30-90)
Function of changing attachment/
D maintenance password(PAGE 30-90)
30-76 PC290LC-10
Electrical system
a Group of screens or functions in operator mode

A: Display or function from turning ON of starting switch to switching to the standard screen is over, and
display after starting switch is turned OFF
B: Display or function when the machine monitor switches are operated
C: Display or function when certain conditions are met
D: Display or function when operation of special switches is required
PC290LC-10 30-77
Electrical system
Operator mode (Outline) Display of action level and failure code(PAGE

30-88)
a Only outline of the operator mode is described in
this section. O (Special operation)
Function of checking display of LCD (Liquid
For details of contents and operations of each Crystal Display)(PAGE 30-89)
function and display, see "Structure and function
Function of checking service meter(PAGE 30-
standard", or the "Operation and Maintenance 90)
Manual".
Function of changing attachment/
a The following are the screens or functions of the maintenance password(PAGE 30-90)
operator mode explained in this section
(including some items which need special
operations). a Display sequence in operator mode
The contents of display from the time when
Display starting switch is turned ON to time when screen
pattern changes to standard screen depends on the
A B C D E setting and condition of the machine.
Display of KOMATSU logo 1 1 1 1 1 A: When the engine start lock is set effective
(PAGE 30-79) B: When the engine start lock is set ineffective
Display of inputting password 2 C: When working mode at start is set to breaker
(PAGE 30-79) mode (B)
Display of check of breaker 2
mode(PAGE 30-79) D: When there is abnormal item in check-before-
starting items
Display of check before starting 3 2 3 2 2
(PAGE 30-79) E: When an overdue maintenance item is
Display of warning after check 3 discovered
before starting(PAGE 30-80)
Display of ending of 3
maintenance interval(PAGE 30-
80)
Display of check of working 4 3 4 4 4
mode and travel speed(PAGE
30-80)
Display of standard screen 5 4 5 5 5
(PAGE 30-80)
Display of end screen(PAGE 30-81)
Display of engine shutdown secondary switch
screen(PAGE 30-81)
Selection of auto-deceleration(PAGE 30-81)
Selection of working mode(PAGE 30-81)
Selection of travel speed(PAGE 30-82)
Operation to stop alarm buzzer(PAGE 30-82)
Operation of windshield wiper(PAGE 30-82)
Operation of window washer(PAGE 30-83)
Operation of air conditioner/heater(PAGE 30-
83)
Operation to display camera mode (if camera
is installed)(PAGE 30-83)
Operation to display clock and service meter
(PAGE 30-84)
Check of maintenance information(PAGE 30-
84)
Setting and display of user mode (including
KOMTRAX messages for user)(PAGE 30-84)
Display of ECO guidance(PAGE 30-85)
Display of caution monitor(PAGE 30-86)
Display of KDPF regeneration(PAGE 30-86)
30-78 PC290LC-10
Electrical system
Display of KOMATSU logo a If this screen is displayed, call the person

When starting switch is turned to ON position, responsible for the operation of KOMTRAX in
KOMATSU logo is displayed for 2 seconds. your Komatsu distributor and ask for remedy.
a After the KOMATSU logo screen is displayed for
2 seconds, the screen changes to "Password
input" screen, or "Check before starting" screen.
Display of check of breaker mode

When the starting switch is turned ON, if the
working mode is set to the breaker mode[B], a
message to inform the operator of starting in the
Display of inputting password
breaker mode is displayed on the screen.
After the KOMATSU logo screen is displayed, the
screen to input the engine start lock password is k If an attachment other than the breaker is
displayed. used while the working mode is set to the
a This screen is displayed only when the engine breaker mode[B], the machine may move
start lock function is enabled. unexpectedly or may not operate normally or
the hydraulic components may be damaged.
a If correct password is input, the screen changes
to "Check before starting" screen. a After operation to check of the breaker mode is
finished, the screen changes to "Display of
a The machine monitor has some password
check before starting".
protect functions other than the engine start lock.
Those functions are independent from one If [No] is selected: Working mode is set to
another. economy mode [E]
If [Yes] is selected: Working mode is set to
breaker mode [B]
a The following screen may be displayed instead

of the above "Password input" screen.
Display of check before starting
When the screen changes to the check before
starting screen, the check before starting is
performed for 2 seconds.
a If any abnormalities are detected in the check
before starting, the screen changes to "Warning
after the check before starting" screen or
"Overdue Maintenance" screen.
PC290LC-10 30-79
Electrical system
a If no abnormalities were detected in the check

before starting, display changes to "Working
Mode and Travel Speed Check" screen.
a The monitors (6 monitors) on the screen shows
the items currently subjected to the check before
starting.
Display of check of working mode and travel

speed
If the check before starting is finished normally, the
screen for checking the working mode and travel
speed is displayed for 2 seconds.
a After the "Working mode and travel speed
check" screen is finished, the screen changes to
Display of warning after check before starting the "Standard" screen.
If any abnormalities are detected in the check
before starting, the alarm monitor is displayed on
the screen.
a The figure shows how air cleaner clogging
monitor (a) warns of clogging on air cleaner.
Display of standard screen

If the machine monitor starts normally, the standard
screen is displayed.
a Service meter (a) or clock is displayed in the top
center area of the screen (use [F4] to switch the
Display of ending of maintenance interval display the service meter and clock).
If the check before starting detected a maintenance
item that is near or overdue the set interval, the a Right end of the screen displays ECO gauge (b)
maintenance monitor is displayed for 30 seconds to (turn on or off the display in the operator mode).
urge the operator to perform maintenance.
a This screen is displayed only when the
maintenance reminder function is enabled. If the
remaining time of any item is 30 hours or less,
the yellow icon is displayed. If the remaining
time of any item is 0 hour or less, the red icon is
displayed.
a The maintenance reminder function is enabled
or disabled by using the machine monitor in the
service mode.
30-80 PC290LC-10
Electrical system
Display of end screen a If the auto-deceleration is set to ON, large

When starting switch is turned to OFF position, the monitor (a) and auto-deceleration monitor (b) are
end screen is displayed for 5 seconds. displayed simultaneously.
a Another message may be displayed on the end a If the auto-deceleration is set to OFF, auto-
screen due to the message display function of deceleration monitor (b) goes off.
KOMTRAX.
Selection of working mode

Display of engine shutdown secondary switch Select desired working mode according to the
screen
following procedure.
Turning on the secondary engine stop switch
displays the "Secondary Engine Stop Switch in 1. While the standard screen is displayed, press
Operation" screen on every screen except the end the working mode selector switch, and the
screen. working mode selection screen is displayed.
a Secondary engine stop switch is provided in the a Following figure shows the working mode
lower left side corner of the operator's seat. It is selection screen when "with attachment" is
used when you cannot stop the engine by set. (If "with attachment" is not set in service
turning the starting switch to the OFF position. mode, attachment mode "ATT/P", "ATT/E"
are not displayed.)
If you turn OFF the secondary engine stop switch,

2. Operate the function switches or working mode
the KOMATSU logo mark appears once and then
selector switch to select the desired working
the standard screen is restored.
mode and enter the selection.
Selection of auto-deceleration Function switch
While the ordinary screen is displayed, if the auto- • [F3]: Moves to lower item
deceleration switch is pressed, large auto- • [F4]: Moves to upper item
deceleration monitor (a) is displayed for 2 seconds • [F5]: Cancels selection and returns to
and the setting of the auto-deceleration is changed. standard screen
• [F6]: Enters selection and returns to standard
a Each time the auto-deceleration switch is screen
pressed, the auto-deceleration is changed in the Working mode selector switch
order of [ON] o [OFF] o [ON]. • Pressed Moves to lower item
• Kept pressed Enters selection and returns to
standard screen
PC290LC-10 30-81
Electrical system
a If you do not touch any of the function

switches and working mode selector switch
for 5 seconds, the selection is determined
and the screen changes to the standard
screen.
Selection of travel speed

While the standard screen is displayed, if the travel
speed selector switch is pressed, large travel speed
monitor (a) is displayed for two seconds and the
setting of the travel speed is changed.
3. When the ordinary screen is displayed again,
large working mode monitor (a) is displayed for 2 a Travel speed setting sequentially changes
seconds, and then the setting of the working between [Lo] o [Mi] o [Hi] o [Lo] in this order
mode is changed to the selected mode. every time the switch is pressed.
a When large monitor (a) is displayed, the a When large monitor (a) is displayed, the display
display of working mode monitor (b) is of travel speed monitor (b) is changed, too.
changed, too.
Operation to stop alarm buzzer

<Precautions for selecting breaker mode [B]>
While the alarm buzzer is sounding, if the alarm
• If breaker mode[B] is selected, both of the
buzzer cancel switch is pressed, the alarm buzzer
control of the hydraulic pump and the setting
stops.
of the hydraulic circuit are changed.
• If an attachment other than the breaker is a Even if the alarm buzzer cancel switch is
used, the machine may move unexpectedly pressed, the screen display does not change.
or may not operate normally or the hydraulic
components may be damaged. Operation of windshield wiper
• After the breaker mode is selected, the While the ordinary screen is displayed, if the wiper
screen to confirm the selection of the breaker switch is pressed, large wiper monitor (a) is
mode is displayed (The buzzer sounds displayed for 2 seconds and the wiper starts or
intermittently while this screen is displayed). stops.
• If the setting is confirmed on this screen, the a The window washer does not operate if the
screen changes to the standard screen. window limit switch is "ON".
If "No" is selected: Screen returns to working
mode selecting screen a The wiper setting changes sequentially between
If [Yes] is selected: Working mode is set to [INT] o [ON] o [OFF] o [INT] every time you
breaker mode [B] press the switch.
30-82 PC290LC-10
Electrical system
a When the wiper is set to INT or ON, large

monitor (a) is displayed and the display of wiper
monitor (b) is changed at the same time.
a If the wiper is set to OFF, large monitor (a) is not
displayed and the wiper monitor disappears.
a Up to three cameras can be connected. When

the camera mode is selected, however, only the
image of camera 1 is always displayed at first.
Operation of window washer

While the ordinary screen is displayed, if the
window washer switch is pressed, the washer fluid
is splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation of air conditioner/heater

While the standard screen is displayed, if the air
conditioner switch is pressed, "Air-conditioner
Adjustment" screen is displayed. a If any caution is issued with the display panel in
the camera mode, the corresponding caution
a While "Air-conditioner Adjustment" screen is
monitor is displayed at the left top of the screen
displayed, if you do not touch any switch for 5
(excluding the low hydraulic oil temperature
seconds, the screen changes to the standard
caution monitor).
screen.
a If no control lever is operated for 10 seconds

Operation to display camera mode (if camera
while a failure enough to display an user code is
is installed)
occurring with the display panel in the camera
If [F3] is pressed, the multi-display changes to the
mode, the screen returns to the standard screen
camera image (Set the connection of the camera in
and displays information about that failure.
the service mode).
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
PC290LC-10 30-83
Electrical system
a When 2-camera image display [F4] is selected,

images of cameras 1 and 2 are displayed on the
right and left side of the screen.
You can specify which of image of cameras 1
and 2 to appear on the right side and which on
the left side from "Camera" in the service mode.
The image of camera 3 is displayed only singly.
Operation to display clock and service meter

While the standard screen is displayed, if [F4] is
pressed, the service meter and the clock are
displayed alternately in section (a).
a When selecting the clock display, perform the Setting and display of user mode (including
time adjustment, 12-hour or 24-hour display KOMTRAX messages for user)
setting, and summer time setting by using the To enter the user mode, press [F6] to display the
user mode functions. "User Menu" screen while the standard screen is
displayed.
Check of maintenance information

You can check the maintenance information on the a The User Menu has following menus.
maintenance screen by pressing [F6] while the
maintenance monitor is displayed. ECO Guidance
Machine setting
When the maintenance monitor does not appear,
KDPF regeneration
press [F6] and then press [F1] or [F2]. Then make
sure the display is switched to the maintenance Maintenance
screen. Monitor setting
Check mail
[KOMTRAX message]
• There are two types of KOMTRAX message;
one is for the user and the other is for the
technician.
• For user:
It denotes the messages transmitted from the
KOMTRAX base station to users. Upon
receiving a message, the message monitor is
displayed on the standard screen. Operate this
"Check mail" when viewing contents of a
message.
• For technician:
a To reset the remaining time after finishing It refers to the messages transmitted to the
maintenance, more operations are necessary. technicians from the KOMTRAX base station.
When a message is received, the standard
screen does not display any information relevant
to the message received. To view contents of a
30-84 PC290LC-10
Electrical system
message, operate "Display service message" of a The lamp for the guidance on deterrence of
the service menu in the service mode. hydraulic relief goes out automatically after
10 seconds has passed since it appeared, or
Display of ECO guidance if the function switch [F5] is pressed.
When the machine is set in a certain operating
condition, the ECO Guidance screen is displayed
automatically to urge the operator to perform the
energy-saving operation.
a "ECO Guidance" screen is displayed when the
following conditions are met while this display
function is set to enabled in operator mode.
a Conditions for display:
• Idle stop guidance
If no lever is operated for a period of at least 5
minutes and the engine keeps running at idle
speed during this period, the guidance on idle
stop is displayed on the monitor. This function • E-mode recommendation guidance
helps reduce unnecessary fuel consumption by If light-load work continues for 10 or more
alerting the operator to stop the engine while minutes in P- or ATT/P-mode, E-mode
waiting for the next operation, or during a break. recommendation guidance is displayed. This
a The lamp for the idle stop guidance goes out function helps reduce unnecessary fuel
automatically when the lever operation is consumption by alerting the operator to turn on
resumed, or if the function switch [F5] is E-mode.
pressed. a The lamp for the E-mode recommendation
guidance goes out automatically after 10
seconds has passed since it appeared, or if
the function switch [F5] is pressed.
• Guidance on deterrence of hydraulic relief

If relieving lasts for 3 or more seconds during
operation, guidance on deterrence of hydraulic
relief is displayed on the monitor. • Travel partial recommendation guidance
If machine travel in the travel mode Hi and the
fuel control dial at MAX continues for 2 or more
minutes, the travel partial recommendation
guidance is displayed. When traveling the
machine for a long period of time, moving the
fuel control dial from MAX to a lower position
helps reduce fuel consumption.
a The lamp for the travel partial
recommendation guidance goes out
automatically after 10 seconds has passed
since it appeared, or if the function switch
[F5] is pressed.
PC290LC-10 30-85
Electrical system
• Low oil level guidance If an error serious enough to display a alarm monitor
If the amount of time the machine can be of Action Level [L02], [L03] or [L04] occurs, the
operated that is projected from the remaining alarm monitor is displayed at the center of the
fuel level and the latest average fuel monitor screen until the error is eliminated.
consumption drops to less than 8 hours, the low
oil level guidance is displayed.
a The lamp for the low oil level guidance goes
out automatically after 10 seconds has
passed since it appeared, or if the function
switch [F5] is pressed.
Display of KDPF regeneration

1. KDPF regeneration
k During the KDPF regeneration, the

exhaust temperature may become higher
than that of the former models. To prevent
Display of caution monitor being burnt, do not stand near the
If an error that is serious enough to display Action exhaust pipe. In addition, to prevent a fire,
Level "L01" alarm monitor on the standard screen or do not bring any combustible matter near
camera mode screen occurs, a large alarm monitor the exhaust pipe outlet.
is displayed on the screen once and is continuously
shown in window (a). k If there is a thatched roof, dead leaves,
paper, or other combustible matter near
a On the camera mode screen, the alarm monitor the machine, set KDPF regeneration to
flashes at the left upper of the screen when a stop to prevent a fire caused by the high-
caution is issued. temperature exhaust gas during the KDPF
regeneration. For the setting procedure,
see the Operation and Maintenance
Manual.
KDPF (Komatsu Diesel Particulate Filter) is a
device used to capture soot in exhaust gas and
purify the gas. If any soot has accumulated to a
certain level inside the filter, it is burnt
automatically to keep the KDPF performance
high. This purification process is called
"regeneration".
30-86 PC290LC-10
Electrical system
If an operation that may lower the filtering

function of the KDPF has continued for a long
period of time, the regeneration may be
performed to protect the KDPF system,
regardless of the accumulated soot.
2. Manual stationary regeneration

There are 2 levels of monitor displays to request
the manual stationary regeneration, depending
on the degree of emergency.
k If the work is continued while the red

During the KDPF regeneration, KDPF
regeneration monitor (1) lights up in the standard KDPF soot accumulation monitor (2) is
screen. displayed, the KDPF or engine may
encounter a problem. If KDPF soot
a Even if KDPF regeneration monitor (1) lights accumulation monitor (2) lights up, be
up, the machine does not need to be stopped sure to perform the manual stationary
and the operator can continue work normally, regeneration process.
as long as the alarm monitor is not displayed
at the center of the standard screen. 1) When the degree of emergency is low
If KDPF soot accumulation monitor (2) is
yellow (Action level (3): L01), the following
screen is displayed first.
The KDPF regeneration is performed

automatically in the normal state, but the soot
may not be burnt or the filtering function may not
be recovered sufficiently, depending on the The action level goes off in 2 seconds and
operating condition. Since KDPF soot the following standard screen appears.
accumulation monitor (2) lights up in this case,
stop the machine in a safe place and perform
the manual stationary regeneration process. For
the execution procedure, see the Operation and
Maintenance Manual.
PC290LC-10 30-87
Electrical system
If the lock lever is set to the LOCK position or

all the work equipment control levers are set
in NEUTRAL, the "KDPF Regeneration"
screen is displayed once for every 2 hours
after the occurrence. However, if the manual
stationary regeneration operation is not
performed, the screen returns to the
standard screen after 30 seconds.
If the lock lever is set to the LOCK position or

all the work equipment control levers are set
in NEUTRAL, the "KDPF Regeneration"
screen is displayed after 3 seconds. Then,
until the manual stationary regeneration
process is performed, the "KDPF
Regeneration" screen or the standard screen
with the alarm monitor lighted is displayed
automatically according to the position of the
a If KDPF soot accumulation monitor (2) is lever.
yellow, stop the work, and then stop the
machine in a safe place and perform the
manual stationary regeneration process.
2) When the degree of emergency is high
k If the work is continued without

performing the manual stationary
regeneration and the soot quantity
exceeds the allowable limit, action
level monitor "L04" lights up and the
machine needs to be repaired.
a If KDPF soot accumulation monitor (2)

becomes red, immediately stop the
machine in a safe place and perform the
manual stationary regeneration process.
Display of action level and failure code

If an abnormality that displays an action level and a
failure code occurs on the standard screen or
camera mode screen, the alarm monitor lights up.
a If KDPF soot accumulation monitor (2) is

red, the engine maximum output and
maximum speed are limited to protect the
engine and KDPF system.
If KDPF soot accumulation monitor (2) is red
(Action level (3): L03), the following screen is
displayed.
30-88 PC290LC-10
Electrical system
If the alarm monitor lights up, press function switch De- Action buzzer Alarm Remedy
[F5] to display the "Occured error list". gree of level moni-
emer- tor
• [F1]: Move to next page (screen) (if displayed)
gency
• [F2]: Move to previous page (screen) (if
High Stop
displayed)
immediately and
• [F5]: To return to standard screen perform
On the "Occurring abnormality list" screen, the ○ checking and
following information is displayed. (Con- maintenance.
L04 ○
(a): Alarm monitor tinu- Ask your
ous) Komatsu
(b): Action level (3 digits)
distributor for
(c): Failure code (5 or 6 digits) testing and
(d): Failure code name repair services.
(e): Message Stop work, move
machine to safe
(f): Telephone No. (if registered) place, stop it,
a This screen display appears only when a and perform
○ checking and
problem (failure code) for which an action level
L03 (Inter- ○ maintenance.
is set occurs.
mittent) Ask your
a The telephone No. is displayed only when the Komatsu
telephone number is registered in the service distributor for
mode. testing and
repair services.
a If multiple problems occur simultaneously, all the I Stop work, and
codes are displayed repeatedly in order. then run the
a Because the information of the displayed failure engine at
code is logged in the abnormality record in the medium speed
○ with no load, or
service mode, check the details in the service
stop it. If the
mode. L02 (Inter- ○
condition does
mittent)
a The "Occured error list" automatically returns to not improve, ask
the standard screen after 30 seconds. your Komatsu
distributor for
a Since "Occured error list" cannot be displayed testing and
from the screen on which the camera mode is repair services.
displayed, move to "Occured error list" from the Some functions
standard screen side. are restricted,
but the machine
can work. After
finishing work,
L01 perform
(For 2 checking and
― ○ maintenance.
seconds
only) Ask your
Komatsu
distributor to
perform testing
or repairs as
Low necessary.
Function of checking display of LCD (Liquid

a Actions to take given by action levels to operator Crystal Display)
(Excerpt from the Operation and Maintenance
LCD (Liquid Crystal Display) display condition
Manual) checking functio
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
PC290LC-10 30-89
Electrical system
• Switch operations (simultaneous): [4] + [F2]

a When finishing the operation of the switches,
release "F2" first.
a If there is a display error in the LCD, only that
part is indicated in black.
a To return to the former screen, press any one of
the function switches.
Reference: An LCD panel, as one of its
characteristics, sometimes shows black spots
(spots that remain unlit) and bright spots (spots that
do not go off).
If the number of the bright points and black points Function of changing attachment/
does not exceed 10, The LCD panel is not faulty or maintenance password
defective. Selecting the Usage Limitation Setting displays the
password input screen when you proceed to setting
of the circuit breaker or attachment, or maintenance
resetting Observe the following procedure when
using the Usage Limitation Setting.
1. While the standard screen is displayed, perform
the following operation with the numeral input
switches.
• Operation of switches (While pressing [4],
press the switches in order):
[ 4 ]＋[ 5 ] o [ 5 ] o [ 5 ]
a This operation of the switches is not
accepted until 10 minutes pass after the
starting switch is turned to ON position.
Function of checking service meter
When checking the service meter with the starting
switch in the OFF position, operate the numeral
input switches as follows to display only the service
meter section.
• Switch operations (simultaneous): [4] + [1]
a There is some time lag in start of the LCD, so
hold down the switches until the service meter is
displayed.
a If you release one of the switches, the monitor
goes off.
Reference: After the machine monitor is used
continuously over a long period of time, blue points 2. After the "Usage Limitation PASSWORD screen
(points that remain lit) may appear on this screen. It is displayed, input the current password using
does not indicate that the LCD panel is faulty or the numeral input switches and validate it using
defective. the function switch.
• [F5]: Deletes the entered numbers/Restores
the standard screen
• [F6]: Validates the entered password
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the
message to request inputting the password
again is displayed.
30-90 PC290LC-10
Electrical system
3. After the "Usage Limitation Setting" screen is

a The password for the Usage Limitation and
displayed, select a setting using the function
the engine start lock password are not
switch.
identical.
• [F3]: Moves to lower item 4. Changing a password
• [F4]: Moves to upper item After the "Usage Limitation New Password
• [F5]: Cancels the selection and return the Input" screen is displayed, input a new
display to the preceding screen password with the numeral input switches and
• [F6]: Validates the selection validate it with the function switch.
• [F5]: Deletes the entered numbers/Returns
the display to the preceding screen
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the
message to request inputting the password
again is displayed.
a Set a new password in 4 to 6 digits (a
passowrd of 3 or less digits or 7 or more
Usage limitation ON/OFF digits is not accepted).
After the "Usage Limitation ON/OFF" screen is
displayed, select a desired one using the
function switch.
• OFF: Password input screen is not displayed
• ON: The password input screen for setting of
the circuit breaker or attachment, or
maintenance resetting appears.
• [F3]: Moves to lower item
• [F4]: Moves the selection sequentially to the
upper items
• [F5]: Cancels the selection and return the
display to the preceding screen
• [F6]: Validates the selection
After the "Usage Limitation New Password
Input" screen is displayed again, input the new
password again with the numeral input switches
and validate it with the function switch.
• [F5]: Deletes the entered numbers/Restores
the standard screen
a If the input password is different from the
entered in the first time, the message to
request reentry is displayed.
PC290LC-10 30-91
Electrical system
If the screen to notify completion of setting is

displayed and then the standard screen is
displayed, the password has been changed
successfully
30-92 PC290LC-10
Electrical system
Service mode a The menu items which can be selected in the

To change the mode of the machine monitor to the service menu are as follows (including some
service mode from the operator mode, perform the items which need special operations).
following operation. Monitoring / Pre-defined(PAGE
This operation is always required when you use the 01 30-94)
service mode. Monitoring / Custom(PAGE 30-
02 98)
1. Check of screen display and operation of
switches Abnormality Record (Mechanical
While the standard screen is displayed, perform Systems)(PAGE 30-107)
03
the following operation by using the numeral Abnormality Record (Electrical
input switches. Systems)(PAGE 30-108)
• Operation of switches (While pressing [4], Maintenance record(PAGE 30-
04 109)
press the switches in order):
[4]＋[1] o [ 2 ] o [ 3 ] Maintenance Mode Setting
05
a This operation of the switches is accepted (PAGE 30-110)
only while the standard screen is displayed. Phone Number Entry(PAGE 30-
06 113)
Default (Key-On Mode)(PAGE
30-113)
Default (Unit)(PAGE 30-114)
07
Default (With/Without
Attachment)(PAGE 30-115)
Default (Camera)(PAGE 30-116)
Diagnostic Tests (Cylinder Cut-
out)(PAGE 30-117)
Diagnostic Tests (Regeneration
08 for Service)(PAGE 30-118)
Diagnostic Tests (KDPF Memory
Reset)(PAGE 30-120)
2. Selection of service menu Adjustment (Pump Absorption
When the "Service Menu" screen is displayed, Torque (F))(PAGE 30-121)
the service mode is selected. Select the desired Adjustment (Pump Absorption
service menu by using the function switches or Torque (R))(PAGE 30-121)
numeral input switches. Adjustment (Low Speed)(PAGE
• [F3]: Moves to lower item 30-122)
• [F4]: Moves to lower item Adjustment (Attachment Flow
• [F5]: Return the display to the standard Adjustment)(PAGE 30-124)
screen (operator mode) Adjustment (Cal F pump swash
• [F6]: Validate the selection plate sensor)(PAGE 30-125)
09
a If you input a 2-digit code by using the Adjustment (Cal R pump swash
plate sensor)(PAGE 30-130)
numeral input switches, the corresponding
menu is directly selected. This will allow you
to validate the selection using [F6]. Adjustment (Pump calibration:
Matching speed calibration)
(PAGE 30-136)
Adjustment (Pump calibration:

Matching speed check)(PAGE
30-131)
10 No Injection(PAGE 30-137)
PC290LC-10 30-93
Electrical system
KOMTRAX Settings (Terminal

Status)(PAGE 30-138)
KOMTRAX Settings (GPS and
11 Communication Status)(PAGE
30-139)
KOMTRAX Settings (Modem
Information)(PAGE 30-140)
12 Service Message(PAGE 30-140)
30-94 PC290LC-10
Electrical system
Monitoring / Pre-defined
The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which control them.
In the monitoring / pre-defined, monitoring items
that are used frequently in daily work are selected
beforehand.
1. Selecting the menu
Select "Monitoring / Pre-defined" on the "Service
Menu" screen.
2. Check of monitering / pre-defined information

After the "Monitoring / Pre-defined" screen is
displayed, you can check the items displayed in
the troubleshooting support by using the function
switches.
• [F1]: Move to the next page (screen)
• [F2]: Move to the previous page (screen)
• [F4]: Selects hold or its releasing
(If hold is selected, a diagonal line is
displayed on the HOLD portion)
• [F5]: Return to service menu screen
a You can select and check any items not
displayed in "Monitoring / Pre-defined" from
the "Monitoring items."
a If the working mode is changed to breaker

mode [B], the screen to confirm the change
of the setting is displayed as in changing the
working mode on the standard screen.
PC290LC-10 30-95
Electrical system
List of monitoring / pre-defined items (SI unit indicates the default values)
Support screen (1/14) Machine basic items
Applicable
No. ID Item name Unit (SI)
equipment
1 01002 Engine speed r/min ENG
2 04107 Coolant temperature °C ENG
3 37212 Engine oil switch ENG
4 18400 Intake temperature °C ENG
5 04401 Hydr. oil temperature °C PUMP
Battery power
6 03203 supply V ENG
Support screen (2/14) Machine base

Applicable
equipment
KDOC 1 inlet
2 47300 temperature °C ENG
3 36400 Rail pressure MPa ENG
Rail pressure
4 36200 MPa ENG
command
5 48000 IMV current A ENG
IMV current
6 48001 A ENG
command
Support screen (3/14) EGR,KVGT actuator
Applicable
equipment
2 48100 Turbo speed r/min ENG
3 18100 EGR Valve Position mm ENG
EGR solenoid
4 48600 mA ENG
current
5 48700 KVGT position mm ENG
KVGT solenoid
6 48800 mA ENG
current
Support screen (4/14) Engine temperature-related items
Applicable
equipment
3 04107 Coolant temperature °C ENG
4 18400 Intake temperature °C ENG
5 18500 Charge temperature °C ENG
EGR orifice
Support screen (5/14) Air intake/exhaust pressure, etc.

Applicable
equipment
2 37400 Ambient pressure kPa ENG
3 36500 Charge pressure-A kPa ENG
Exhaust manifold
4 48300 pressure kPa ENG
30-96 PC290LC-10
Electrical system
Support screen (5/14) Air intake/exhaust pressure, etc.

Applicable
equipment
6 48200 Mass air flow kg/min ENG
Support screen (6/14) Post treatment-related items
Applicable
equipment
KDPF outlet
KDPF delta
KDPF 1 outlet
KDOC 1 inlet
KDOC 1 outlet
6 36400 Rail pressure MPa ENG
Support screen (7/14) Engine-related items
Applicable
equipment
2 37212 Engine oil switch ENG
3 48400 Crankcase pressure kPa ENG
KDOC 1 inlet
5 36500 Charge pressure-A kPa ENG
Support screen (8/14) F & R pumps basic items
Applicable
equipment
2 01100 F pump pressure MPa PUMP
3 01101 R pump pressure MPa PUMP
PC-EPC sol current
4 01300 (F) mA PUMP
PC-EPC sol current
5 01302 (R) mA PUMP
Support screen (9/14) F & R pumps application items
Applicable
equipment
F pump
4 01137 dispalcement cc/rev PUMP
R pump
PC290LC-10 30-97
Electrical system
Support screen (10/14) F pump application items

Applicable
equipment
Service pressure
3 01141 MPa PUMP
sensor
PC-EPC sol current
4 01300 (F) mA PUMP
F pump
6 01500 LS-EPC sol current mA PUMP
Support screen (11/14) R pump application items
Applicable
equipment
Service pressure
3 01141 MPa PUMP
sensor
PC-EPC sol current
4 01302 (R) mA PUMP
R pump
6 01500 LS-EPC sol current mA PUMP
Support screen (12/14) PPC pressure
Applicable
equipment
Boom raise PPC
2 07400 pressure MPa PUMP
Boom Lower PPC
3 07500 MPa PUMP
Pressure
Arm Curl PPC
4 07200 MPa PUMP
Pressure
Arm Dump PPC
Applicable
equipment
Swing right PPC
Swing left PPC
Bucket CURL PPC
4 07300 MPa PUMP
Pressure
Bucket DUMP PPC
Applicable
equipment
Travel Fwd LH PPC
30-98 PC290LC-10
Electrical system

Applicable
equipment
Travel Fwd RH PPC
Travel Rev LH PPC
Travel Rev RH PPC
Monitoring / Custom a Selection with function switches: Select an

The machine monitor can monitor the condition of applicable equipment using [F1] or [F2], and
the machine in real time by receiving signals from select an item using [F3] or [F4] and
various switches, sensors, and actuators installed to determine it using [F6].
many parts of the machine and the information from
a Selection with numeral input switch: Select a
the controllers which control them.
desired item by entering the corresponding
The monitoring function allows you to select a 5-digit code and then validate it using [F6].
desired monitoring item.
a If the color of the selection cursor changes
from yellow to red, selection of the item is
Select "Monitoring" on the "Service Menu"
entered.
screen.
a You can select up to six monitoring codes at
the same time. Note, however, that six items
may not be available depending on how they
are displayed on the screen.
2. Selecting monitoring item

After the "Monitoring selection menu" screen for
monitoring item selection is displayed, select the
item to be monitored by using the function
switches or numeral input switches. 3. Getting machine monitor ready for monitoring
• [F1]: Move to left item After selecting monitoring items, set the machine
• [F2]: Move to right item monitor ready for monitoring by using the
• [F3]: Moves to lower item function switch or numeral input switch.
• [F4]: Moves to upper item
• [F5]: Returns to standard screen (operator a Execution by use of function switches:
mode) Double-click [F6] or hold it down (for
• [F6]: Validate the selection approximately 2 seconds).
a In setting of the monitoring, each time a Execution using numeral input switch:
function switch [F2] is pressed, sequential [99999] and press [F6].
switching among [ENG] o [KDPF] o a When monitoring only two items, for example,
[PUMP] o [MON] o [ENG] takes place in select them and enter them by using [F6]. If
this order. (Pressing [F1] induces the [F6] is pressed once more at this time, the
sequential switching in the reverse order.) machine monitor is set ready for monitoring.
PC290LC-10 30-99
Electrical system
a If monitoring items are selected up to the limit

number, the machine monitor is
automatically set ready for monitoring.
6. Changing machine setting mode during

monitoring
To change the setting of the working mode,
travel speed, or auto-deceleration during
4. Performing monitoring
monitoring, operate the corresponding switch
After the "Monitoring" screen for execution is
under the current condition to turn on the
displayed, perform the necessary operation of
applicable mode.
the machine and check the monitoring
information. a If the setting is changed during monitoring,
the new setting is held even after the screen
a Monitoring information is indicated by value,
returns to the standard screen after
ON/OFF, or special display.
monitoring is finished.
a The unit of display can be selected in SI unit,
metric unit, or inch unit with the Default
function in the service mode.
a If the working mode is changed to breaker

mode [B], the screen to confirm the change
5. Holding monitoring information of the setting is displayed as in changing the
The monitoring information can be held and working mode on the standard screen.
released with the function switches.
• [F4]: Selects hold or its releasing
(If hold is selected, a diagonal line is
displayed on the HOLD portion)
• [F5]: Returns the display to monitoring
selection menu screen
7. Saving monitoring item

A function switch lets you save and delete the
selected item.
• [F1]: MEMORY
30-100 PC290LC-10
Electrical system
• [F2]: CLEAR
a When you saved a monitoring item, selecting

"Monitoring" again displays the screen that
confirms whether you want to display the
once saved item.
a When you saved an item, you can display it
as may times as you want until it is deleted.
a If you save an item when another item is
saved already, the currently saved item is
overwritten by the last one.
a In addition to [F2], using [F6] in the following
screen allows deleting a saved monitoring
item.
• KOMTRAX terminal screen
• With/Without Attachment screen
• Functional specification screen
• Air conditioner setting screen
PC290LC-10 30-101
Electrical system
Monitoring items table

Monitoring item Unit (Default: SI) Equipment
Code No. (Displayed on screen) in charge Remarks
SI Metric Imperial
01002 Engine speed r/min rpm rpm ENG
04107 Coolant temperature ℃ ℃ °F ENG
48000 IMV current A A A ENG
48001 IMV current command A A A ENG
03203 Battery power supply V V V ENG
37212 Engine oil switch ON • OFF ENG
36400 Rail pressure MPa kg/cm2 psi ENG
37400 Ambient pressure kPa kg/cm2 psi ENG
18400 Intake temperature °C °C °F ENG
18500 Charge temperature °C °C °F ENG
Display in
absolute
value
36500 Charge pressure-A kPa kg/cm2 psi ENG (including
ambient
pressure)
48100 Turbo speed r/min rpm rpm ENG
48200 Mass air flow kg/min kg/min lb/min ENG
Exhaust manifold
48300 kPa kg/cm2 psi ENG
pressure
48400 Crankcase pressure kPa kg/cm 2 psi ENG
18100 EGR Valve Position mm mm in ENG
48500 EGR orifice temperature °C °C °F ENG
48600 EGR solenoid current mA mA mA ENG
48700 KVGT position mm mm in ENG
48800 KVGT solenoid current mA mA mA ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
Throttle position sensor
03000 V V V ENG
volt
04105 Coolant temp sensor volt V V V ENG
Ambient pressure sensor
37401 V V V ENG
volt
18401 Intake temp sensor volt V V V ENG
18501 Charge temp sensor volt V V V ENG
Charge pressure sensor
36501 V V V ENG
volt
36401 Rail pressure sensor volt V V V ENG
Exh manifold press. sens
48301 V V V ENG
volt
Crankcase pressure sens
48401 V V V ENG
volt
EGR valve pos sensor
18101 V V V ENG
volt
EGR orifice temp sens
48501 V V V ENG
volt
48701 KVGT position sensor volt V V V ENG
17500 Engine power mode - ENG
48900 Engine operation mode - ENG
08402 Selection of droop switch - ENG
31701 Throttle Position % % % ENG
31706 Final throttle position % % % ENG
18600 Inject fueling command mg/st mg/st mg/st ENG
30-102 PC290LC-10
Electrical system

SI Metric Imperial
36200 Rail pressure command MPa kg/cm2 psi ENG
37300 Fuel rate (Note 1) l/h l/h gal/h ENG
WIF: Water
18800 Water in fuel ON • OFF ENG
In Fuel
20216 ECM build version - ENG
20217 Calibration data version - ENG
18900 ECM internal temp °C °C °F ENG
20400 ECM S/N - ENG
47000 KDPF outlet pressure kPa kg/cm2 psi KDPF
KDPF out pressure
47001 V V V KDPF
sensor volt
47100 KDPF delta pressure kPa kg/cm2 psi KDPF
KDPF delta press. sensor
47101 V V V KDPF
volt
47300 KDOC 1 inlet temperature °C °C °F KDPF
KDOC 1 inlet temp sens
47301 V V V KDPF
volt
KDOC 1 outlet
47400 temperature °C °C °F KDPF
KDOC 1 outlet temp sens
47401 V V V KDPF
volt
KDPF 1 outlet
47200 temperature °C °C °F KDPF
KDPF 1 outlet temp sens
47201 V V V KDPF
volt
47500 Dozing fuel rate l/h l/h gal/h KDPF
47700 Soot level estimation g/L g/L g/gal KDPF
47800 Ash level estimation g/L g/L g/gal KDPF
2nd Eng. Speed rpm rpm
01601 r/min PUMP
Command
01100 F pump pressure MPa kg/cm2 psi PUMP
01101 R pump pressure MPa kg/cm2 psi PUMP
07400 Boom raise PPC pressure MPa kg/cm2 psi PUMP
Boom Lower PPC kg/cm2 psi
07500 MPa PUMP
Pressure
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07600 Arm Dump PPC pressure MPa kg/cm2 psi PUMP
Bucket CURL PPC kg/cm2 psi
07300 MPa PUMP
Pressure
Bucket DUMP PPC
07301 MPa kg/cm2 psi PUMP
pressure
09001 Swing left PPC pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC pressure MPa kg/cm2 psi PUMP
Travel Fwd LH PPC
pressure
Travel Fwd RH PPC
pressure
Travel Rev LH PPC
pressure
Travel Rev RH PPC
pressure
01137 F pump dispalcement cc/rev cc/rev cc/rev PUMP
F pump sw plate sensor
01138 V V V PUMP
volt
01139 R pump dispalcement cc/rev cc/rev cc/rev PUMP
PC290LC-10 30-103
Electrical system

SI Metric Imperial
R pump sw plate sensor
01140 V V V PUMP
volt
04401 Hydr. oil temperature °C °C °F PUMP
01300 PC-EPC sol current (F) mA mA mA PUMP
01302 PC-EPC sol current (R) mA mA mA PUMP
01500 LS-EPC sol current mA mA mA PUMP
Merge-divide sol current
08000 mA mA mA PUMP
main
Merge-divide sol current
08001 mA mA mA PUMP
LS
01700 Attachment sol current mA mA mA PUMP
03200 Battery voltage V V V PUMP
04402 Hydr. temp. sensor volt V V V PUMP
2nd Eng. Speed
01602 % % % PUMP
Command
Main Pump Absorb
13113 Nm kgm lbft PUMP
Torque
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP
01141 Service pressure sensor MPa kg/cm2 psi PUMP
Swing ON • OFF PUMP
Travel ON • OFF PUMP
Boom Lower ON • OFF PUMP
Pressure
01900 Boom Raise ON • OFF PUMP
Switch 1
Arm curl (IN) ON • OFF PUMP
Arm dump
(OUT) ON • OFF PUMP
Bucket Curl ON • OFF PUMP
Bucket
Dump ON • OFF PUMP
Pressure
01901
Switch 2 Service ON • OFF PUMP
Travel
steering ON • OFF PUMP
Travel
ON • OFF PUMP
Junction
Swing brake ON • OFF PUMP
Merge-
Solenoid ON • OFF PUMP
02300 divider
valve 1
2-stage
ON • OFF PUMP
Relief
Travel
Speed ON • OFF PUMP
Swing
pressure cut ON • OFF PUMP
off
Solenoid Service
02301 ON • OFF PUMP
valve 2 Return
Variable
back press ON • OFF PUMP
Lever Sw. ON • OFF PUMP
Swing
Switch Input Release ON • OFF PUMP
02200
1 SW.
Swing brake
ON • OFF PUMP
SW.
30-104 PC290LC-10
Electrical system

SI Metric Imperial
Model select
ON • OFF PUMP
1
Model select
ON • OFF PUMP
2
Model select
ON • OFF PUMP
Switch Input 3
02201
2 Model select
ON • OFF PUMP
4
Model select
ON • OFF PUMP
5
Overload
ON • OFF PUMP
Alarm
Switch Input Key switch
02202 (ACC) ON • OFF PUMP
3
Switch Input Lock Lever
02203 ON • OFF PUMP
4 SW
Window
ON • OFF PUMP
Switch Input Limit SW.
02204 P Limit SW. ON • OFF PUMP
5
W Limit SW. ON • OFF PUMP
20229 Pump controller Ass'y P/N - PUMP
20403 Pump controller Serial No. - PUMP
20230 Pump controller prog. P/N - PUMP
Pump controller prog. -
20212 PUMP
version
04300 Battery charge volt V V V MON
04200 Fuel level sensor volt V V V MON
Key switch ON • OFF MON
Start ON • OFF MON
Monitor Preheating ON • OFF MON
04500 Input 1 Light ON • OFF MON
Radiator
ON • OFF MON
coolant level
Aircleaner ON • OFF MON
Monitor Eng. oil level ON • OFF MON
04501 Input 2 Battery
charge volt ON • OFF MON
Swing brake
ON • OFF MON
Sw.
Engine
Monitor shutdown
04502 Input 3 ON • OFF MON
secondary
switch
Seat belt
ON • OFF MON
Sw.
F1 ON • OFF MON
F2 ON • OFF MON
Monitor F3 ON • OFF MON
04503 Function
Switches F4 ON • OFF MON
F5 ON • OFF MON
F6 ON • OFF MON
PC290LC-10 30-105
Electrical system

SI Metric Imperial
SW1 ON • OFF MON
SW2 ON • OFF MON
Monitor 1st SW3 ON • OFF MON
04504 & 2nd Row
Switches SW4 ON • OFF MON
SW5 ON • OFF MON
SW6 ON • OFF MON
SW7 ON • OFF MON
SW8 ON • OFF MON
Monitor 3rd SW9 ON • OFF MON
04505 & 4th Row
SW11 ON • OFF MON
SW12 ON • OFF MON
Monitor 5th SW13 ON • OFF MON
04506 Row SW14 ON • OFF MON
20227 Monitor Ass'y P/N - MON
20402 Monitor serial No. - MON
20228 Monitor prog. P/N - MON
20200 Monitor prog. version - MON
55300 Aircon compressor status ON • OFF MON
55000 Aircon outside temp. code - MON
55100 Aircon inside temp. code - MON
55200 Aircon mode data(mon) - MON
Aircon mode data(aircon
55201 - MON
ECU)
Only when
20260 KOMIRAX Ass'y P/N - MON KOMTRAX
is used
Only when
20418 KOMTRAX Serial No - MON KOMTRAX
is used
Only when
20261 KOMTRAX Prog. P/N - MON KOMTRAX
is used
Only when
ID Key Controller Ass'y P/ -
20262 MON ID key is
N
used
Only when
ID key controller Serial -
20419 MON ID key is
No.
used
Only when
ID Key Controller Prog. P/ -
20263 MON ID key is
N
used
a Listing order of monitoring items in table

The monitoring items are listed in the order of display on the Monitoring selection menu screen for
monitoring item selection.
a Unit
The display unit can be set to SI, meter, or inch as required (select a desired unit from "Unit" of "Default").
mg/st in the display unit is an abbreviation for milligram/stroke.
30-106 PC290LC-10
Electrical system
a Applicable equipment
ENG: The engine controller detects monitoring information.
KDPF: Engine controller is in charge of detecting monitoring information.
PUMP: The pump controller detects monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: Fuel Rate (Code No. : 37300) is theoretical fuel consumption ratio. (Since it is a theoretical value,
there is some differences between the actual fuel consumption ratio).
PC290LC-10 30-107
Electrical system
Abnormality Record (Mechanical Systems) (a): Occurrence order of abnormalities from

The machine monitor classifies and logs the failures latest one/Total number of abnormalities in the
which occurred in the past or which are occurring at log
present into the mechanical system abnormality, (b): Failure codes
and electrical system abnormality. (c): Detail of failure
To check the mechanical system abnormality record, (d): Number of occurrences (displayable range:
perform the following procedures. 0 to 65,535 times)
(e): Service meter reading at first occurrence
a For the failure code list, see "40 Failure code list (f): Service meter reading at last occurrence
for troubleshooting". • [F1]: Move to next page (screen) (if
1. Selecting the menu displayed)
Select "Abnormality Record" on the "Service • [F2]: Move to previous page (screen) (if
Menu" Screen. displayed)
• [F5]: Return to the "Abnormality Record"
screen
a If no failure is logged, the message of "No
Error" is displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrences is one (first
occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
2. Selecting sub menu When the latest service meter reading is
After the "Abnormality Record" screen is recovered, the value at the recovery time is
displayed, select "Mechanical Systems" by displayed, thus the above readings may not
using the function switches or numeral input be the same.
switches. a If [E] is displayed on the left of a failure code,
• [F3]: Moves to lower item the abnormality is still occurring or
• [F4]: Moves to upper item restoration of it has not been confirmed.
• [F5]: Return the display to the service menu
screen a For all the failure codes that the machine
• [F6]: Validate the selection monitor can record, see the "Failure code
table".
a You may enter a 2-digit code by using the
numeral input switches to select the item of
that code and enter it by using [F6].
4. Clearing abnormality record

A contents of the mechanical system
abnormality record cannot be cleared.
3. Information displayed on abnormality record
screen
On the "Mechanical Systems" abnormality
record screen, the following information is
displayed.
30-108 PC290LC-10
Electrical system
Abnormality Record (Electrical Systems) (b): Failure codes

The machine monitor classifies and logs the failures (c): Detail of failure
which occurred in the past or which are occurring at (d): Number of occurrences (displayable range:
present into the mechanical system abnormality, 0 to 65,535 times)
and electrical system abnormality. (e): Service meter reading at first occurrence
To check the electrical system abnormality record, (f): Service meter reading at last occurrence
perform the following procedures. • [F1]: Move to next page (screen) (if
displayed)
a For the failure code list, see "40 Failure code list • [F2]: Move to previous page (screen) (if
for troubleshooting". displayed)
1. Selecting the menu • [F3]: Moves to lower item
Select "Abnormality Record" on the "Service • [F4]: Moves to upper item
Menu" Screen. • [F5]: Return to the "Abnormality Record"
screen
a If no failure is logged, the message of "No
Error" is displayed.
a In the electrical systems abnormality record
screen, up to 20 cases currently stored are
displayed.
If the number of the cases reaches 21, the
code that occurred most recently is displayed
and the oldest code is deleted.
a If the number of occurrences is one (first
occurrence), the service meter reading at the
2. Selecting sub menu first occurrence and that at the last
After the "Abnormality Record" screen is occurrence are the same.
displayed, select "Electrical Systems" by using a If [E] is displayed on the left of a failure code,
the function switches or numeral input switches. the abnormality is still occurring or
• [F3]: Moves to lower item restoration of it has not been confirmed.
• [F5]: Return the display to the service menu a For all the failure codes that the machine
screen monitor can record, see the "Failure code
• [F6]: Validate the selection table".
a You may enter a 2-digit code by using the

that code and enter it by using [F6].
4. Clearing abnormality record

1) While the "Electrical Systems" abnormality
record screen is displayed, press the
numeral input switches as follows.
3. Information displayed on abnormality record
screen • Operation of switches (While pressing [4],
On the "Electrical Systems" abnormality record press the switches in order):
screen, the following information is displayed. [4]＋[1] o [ 2 ] o [ 3 ]
(a): Occurrence order of abnormalities from
latest one/Total number of abnormalities in the
log
PC290LC-10 30-109
Electrical system
a The following figure shows the screen

displayed when the items are cleared one
by one (which is a little different from the
screen displayed when all the items are
cleared together).
2) Check that the screen is set in the clear

mode, and then clear the items one by one or
together by using the function switches.
a If the screen is set in the clear mode, icon
[CLEAR] is indicated above [F2].
• [F2]: Delete all items 4) If the screen to notify completion of clearing
• [F3]: Moves to lower item is displayed and then the "Electrical
• [F4]: Moves to upper item Systems" (clear mode) screen is displayed,
• [F5]: Return to the "Abnormality Record" the clearing of the abnormality record is
screen completed.
• [F6]: Delete items one by one a After a while, the screen returns to the
a To clear items one by one: Select the item "Electrical Systems" screen of
to be cleared by using [F3] or [F4] and abnormality record.
press [F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the information is not cleared.
Maintenance record
The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
When maintenance is performed, if the remaining
time is reset in the operator mode, the number of
maintenance times is recorded in this record.
3) After the "Electrical Sys. Error Reset" screen 1. Selecting the menu
is displayed, press the function switches. Select "Maintenance Record" on the "Service
• [F5]: Return to "Electrical Systems Menu" screen.
Abnormality Record" screen (delete
mode)
• [F6]: Perform deletion
30-110 PC290LC-10
Electrical system
The following information is displayed on the

screen.
(a): Maintenance items
(b): Replacement time elapsed up to present
(c): Service meter reading (SMR) at previous
replacement
2. Selecting maintenance item

After the "Maintenance Record" screen is
displayed, select a maintenance item to be
checked by using the function switches or
numeral input switches.
• [F1]: Move to the next page (screen)
• [F2]: Move to the previous page (screen)
• [F3]: Moves to lower item Maintenance Mode Setting
• [F4]: Moves to upper item The actuating condition of the maintenance
• [F5]: Return the display to the service menu reminder function in the operation mode can be set
screen and changed by using this menu.
a You may enter a 2-digit code by using the • To enable or disable the function
numeral input switches to select the item of • To change set replacement interval (by item)
that code. • To initialize all set replacement intervals
Select "Maintenance Mode Setting" on the
"Service Menu" screen.
a The following items can be selected on

"Maintenance Record" screen.
49 Cleaning and replacement of cleaner
2. Selecting sub menu
01 Engine Oil Change After the “Maintenance Mode Setting” screen is
02 Engine Oil Filter Change displayed, select an item to change the setting
03 Fuel Main Filter Change with the function switches or the numeral input
41 Fuel Pre Filter Change switches.
04 Hyd Oil Filter Change • [F1]: Move to the next page (screen)
05 H/Tank Breather Change • [F2]: Move to the previous page (screen)
07 Damper Case Service • [F3]: Moves to lower item
08 Final Drive Oil Change Interval • [F4]: Moves to upper item
09 S/Machinery Oil Change
screen
10 Hydraulic Oil Change
• [F6]: Validate the selection
47. KCCV filter change
48 KDPF filter cleaning a You may enter a 2-digit code by using the
3. Items displayed on Maintenance Record screen that code and enter it by using [F6].
PC290LC-10 30-111
Electrical system
4. Contents of “Maintenance Notice Time Setting”

a The following items can be selected on the
After selecting “Maintenance Notice Time
“Maintenance Mode Setting” screen.
Setting", if the screen is displayed, select the
00 Maintenance Mode Change desired setting with the function switches.
49 Air Cleaner cleaning / Change Interval
01 Engine Oil Change Interval
02 Eng Oil Filter Change Interval
03 Fuel Main Filter Change Interval
41 Fuel Pre Filter Change Interval
04 Hyd. oil filter change interval
05 H/tank breather change interval
07 Damper Case Service Interval
08 Final Drive Oil Change Interval
09 S/Machinery oil change interval
10 Hydraulic Oil Change Interval
99 All Default Value
• Default value: “Maintenance Notice Time” set
3. Contents of “Maintenance Mode Change”
in machine monitor (Recommended by the
After selecting “Maintenance Mode Change” and
manufacturer and not changeable).
the screen is displayed, select the desired
• Set value code: Maintenance interval that
setting with the function switches.
can be freely set. Maintenance reminder
• ON: Functions of all maintenance items are
function works according to this set time in
set effective in operator mode
operator mode (which is set in increments of
• OFF: Maintenance reminder functions of all
10 hours).
maintenance items are disabled in operator
• [F3]: Decrease set value
mode
• [F4]: Increase set value
• [F5]: Cancel setting before enter and return
to the "Maintenance Mode Change" screen.
• [F5]: Cancel selection and return to the
• [F6]: Enter selection and return to the
"Maintenance Mode Change" screen
"Maintenance Mode Setting" screen
• [F6]: Enter selection and return to the
"Maintenance Mode Change" screen
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
5. Setting of each maintenance item
30-112 PC290LC-10
Electrical system
After selecting each maintenance item to display • [F5]: Cancel setting before enter and return
its setting screen, perform the setting by using to the "Maintenance Mode Change" screen.
the function switches. • [F6]: Enter setting and return to
• ON: Function of each maintenance item "Maintenance Mode Change" screen
selected is enabled in the operator mode
a After entering the selection with the [F6] key,
• OFF: Function of each maintenance item
return to the "Maintenance Mode Setting"
selected is disabled in the operator mode
screen by pressing [F5], and the setting will
• [F3]: Move to lower set value
be made.
• [F4]: Move to upper set value
• [F5]: Cancel selection and return to the a If the set value of an item of which
"Maintenance Mode Change" screen maintenance reminder function is set to "ON"
• [F6]: Enter selection and return to the is changed after one operating hours or more
"Maintenance Mode Change" screen from the setup, the change is recognized as
a reset of the remaining time.
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
7. Function of All Default Value

After selecting "All Default Value" and the screen
is displayed, set with the function switches.
6. Contents of setting of set value of each
maintenance item
After selecting the set value of each
maintenance item, if the screen is displayed,
perform the setting for the item with the function
switches.
• If this function is executed, the set values of

all the maintenance items are initialized.
• [F5]: Returns to “Maintenance Mode Setting”
screen
• [F6]: Enters initialization
• Default value: “Maintenance Notice Time” set a A while after [F6] is pressed, the initialization
in machine monitor (Recommended by the completion screen is displayed. Then, if the
manufacturer and not changeable). “Maintenance Mode Setting” screen is
• Set value code: Maintenance interval that displayed, initialization is completed.
can be freely set. Maintenance reminder
function works according to this set time in
operator mode (which is set in increments of
25 hours).
PC290LC-10 30-113
Electrical system
Phone Number Entry a Up to 14 digits can be input from the left.

The telephone number, which is displayed together Input nothing in the surplus positions.
with the "Occured error list" in the operator mode, a If one of the input digits is wrong, move to
can be input and changed according to the following that digit (its background changes to orange)
procedure. and overwrite it to correct.
If a telephone number is not input by using this
a If [F6] is pressed without inputting a digit,
function, no telephone number is displayed in the
there is not information of phone number
operator mode.
Accordingly, no phone number is displayed
1. Selecting the menu in the operator mode.
Select "Phone Number Entry" on the "Service
Menu" screen.
Default (Key-On Mode)

2. Registering and changing phone number Use the menu of "Default" to check or change
After the "Phone Number Entry" screen is various settings of the machine monitor and
displayed, register or change the phone number machine.
• [F2]: Delete all input No.
Use the sub menu of "key-on Mode" to set the
• [F3]: Move to left position (if not blank)
working mode selected and displayed on the
• [F4]: Move to right position (if not blank)
machine monitor when the starting switch is turned
• [F5]: Reset input digit/Return the display to
to ON position.
the service menu screen
• [F6]: Confirm input 1. Selecting the menu
Select "Default" on the "Service Menu" screen.
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Electrical system
• [F6]: Validates the selection and returns the

display to the default screen
a Factory default is "Mode at Previous Key-off".
a If "With Attachment" is not selected, selection
of the Attachment /P-Mode and Attachment/
E-mode is disabled.
a If you change the setting to "Without
attachment" when Attachment/P-mode [ATT/
P] or Attachment/E-mode [ATT/E] is selected,
turning on the starting switch displays Power
mode [P] when [ATT/P] is selected and
2. Selecting sub menu displays economy mode [E] when [ATT/E] is
After the "Default" screen is displayed, select selected.
"Key-on Mode" by using the function switches or
a If the engine is stopped with the working
numeral input switches.
mode set to breaker mode [B] in the operator
a Select this sub menu as in the case of mode, Breaker Mode [B] is always displayed
selecting a menu on the "Service Menu" when the starting switch is turned to ON
screen. position, regardless of the above setting.
3. Selecting mode
After the "Key-on Mode" screen is displayed, Default (Unit)
select the mode to be set by using the function Use the menu of "Default" to check or change
switches. various settings of the machine monitor and
• Power mode: [P] is displayed when the machine.
starting switch is set to the ON position Use the sub menu of "Unit" to select the unit of the
• Economy mode: [E] is displayed when the data displayed for monitoring, etc.
starting switch is set to the ON position. 1. Selecting the menu
• Lifting mode: [L] is displayed when the Select "Default" on the "Service Menu" screen.
starting switch is set to the ON position.
• Breaker mode: [B] is displayed when the
starting switch is set to the ON position.
• Attachment mode/P-mode: [ATT/P] is
displayed when the starting switch is set to
the ON position.
• Attachment mode/E-mode: [ATT/E] is
displayed when the starting switch is set to
the ON position.
• Mode at previous key-off: The mode selected
the last time is displayed when the starting
switch is set to the ON position.
• [F4]: Moves to upper item 2. Selecting sub menu
• [F5]: Cancels the selection and returns the
PC290LC-10 30-115
Electrical system
After the "Default" screen is displayed, select

"Unit" by using the function switches or numeral
input switches.
a Select this sub menu as in the case of
selecting a menu on the "Service Menu"
screen.

After the "Default" screen is displayed, select
"With/Without Attachment" by using the function
switches or numeral input switches.
3. Selecting unit screen.
After the "Unit" screen is displayed, select the
unit to be set by using the function switches.
• [F6]: Validates the selection and returns the
a Factory default is "SI Unit".
3. Selecting With/Without
After the "With/Without Attachment" screen is
displayed, select the setting by using the
function switches.
• Without Attachment: When attachment is not
installed
• With Attachment: For machines with
provision for attachment
Default (With/Without Attachment) display to the default screen
Use the menu of "Default" to check or change • [F6]: Validates the selection and returns the
various settings of the machine monitor and display to the default screen
machine.
Use the sub menu of "With/Without Attachment" to
configure attachment setting when the attachment
is installed or removed.
Select "Default" on the "Service Menu" screen.
30-116 PC290LC-10
Electrical system
a When an attachment is installed, if this

setting is not configured correctly, the setting
of attachment in the operator mode cannot
be performed. As a result, the attachment
may not work normally or the hydraulic
components may be damaged.
3. Selection of camera setting

After the "Camera" screen for setting is
displayed, select the setting by using the
function switches.
• Without Attachment: Camera is not selected.
• With Attachment: Image of connected
camera is displayed in original position (as in
Default (Camera) mirror, used for back monitor)
Use the menu of "Default" to check or change • [Я]: Image of connected camera is displayed
various settings of the machine monitor and in reverse position (as seen directly, when
machine. used as front or side monitor)
• [R]: Image of connected camera is displayed
Use the sub menu of "Camera" to configure camera
in original position (as in mirror, used for back
setting when the camera is installed or removed.
monitor)
1. Selecting the menu • [F3]: Moves to lower item
Select "Default" on the "Service Menu" screen. • [F4]: Moves to upper item
• [F5]: Cancel the setting before validation and
returns the display to the Default screen
• [F6]: Validates the selection made in each
step
a Camera 1 does not provide switching
between [Я] and [R] .
a After entering the setting of each column by
using [F6], return to the "Default" screen by
using [F5], and the setting is effective.
a If a camera is connected but not configured
normally by using this function, the icon of
2. Selecting sub menu camera is not displayed above [F3] in the
After the "Default" screen is displayed, select operator mode. Accordingly, the image of the
"Camera" using the function switch or numeral camera cannot be seen.
input switches. a If the camera is installed, check that the right
a Select this sub menu as in the case of and left portions of the displayed image are
selecting a menu on the "Service Menu" correct.
screen.
PC290LC-10 30-117
Electrical system
Diagnostic Tests (Cylinder Cut-out)

The operator can perform "Cylinder Cut-out mode"
operation and KDPF regeneration/reset operation
with the machine monitor.
Cylinder Cut-out mode operation means to run the
engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to identify a
cylinder that does not output power normally
(combustion in it is abnormal).
Select "Testing" on the "Service Menu" screen.
a If two or more cameras are connected, be 2. Selecting sub menu

sure to configure them from camera 1 in After the "Testing" screen is displayed, select
order. "Cylinder Cut-out" by using the function switches
or numeral input switches.
a The simultaneous display function of two
images becomes effective when camera 1 a Select this sub menu as in the case of
and camera 2 are configured. selecting a menu on the "Service Menu"
screen.
30-118 PC290LC-10
Electrical system
a This operation may be performed while the

engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes blue, the
cylinder is reset.
a If the machine monitor resets a Cut-out
cylinder but the engine controller cannot
reset that Cut-out cylinder, the background
(a) of the cylinder No. becomes red.
a The cut-out cylinder is not automatically reset
even after returning to the operator mode.
3. Selecting cylinder to be cut out Accordingly, be sure to perform the resetting
After the "Cylinder Cut-out" screen is displayed, operation after the Cylinder Cut-out operation
select a cylinder to be Cut out by using the is finished.
function switches. 5. Holding displayed data
• [F1]: Move to left item Each time [F4] is pressed during the Cylinder
• [F2]: Move to right item Cut-out operation, the displayed data is newly
• [F4]: Select hold or release held (c) (the real-time data is kept displayed on
(If hold is selected, a diagonal line is the left side).
displayed on the HOLD portion) While the data is held, if [F4] is pressed, the data
• [F5]: Return to the testing screen holding function is reset.
• [F6]: Validate the selection
a The holding function is available for a
a This operation may be performed while the cylinder, regardless of whether it is cut out or
engine is running. not.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white, the
cylinder is cut out.
a If the machine monitor cuts out a cylinder but
the engine controller cannot cut out that
cylinder, the background (a) of the cylinder
No. becomes yellow.
a One or more cylinders can be cut-out.
a During the Cylinder Cut-out operation, the
auto-deceleration function can be enabled. If
the auto-deceleration is set to ON, auto-
deceleration monitor (b) is displayed. [Reference]
• If a normally operating cylinder is disabled,
the following phenomena occur.
1) The engine speed lowers.
2) The value (quantity) of final injection
command increases.
• If the engine is running near the full speed,
however, the engine speed may not lower for
the reason of engine control.
• In this case, lower the engine speed by using
the fuel control dial and judge by increase of
the injection rate command.
Diagnostic Tests (Regeneration for Service)

4. Resetting cutout cylinder The operator can perform "Cylinder Cut-out mode"
When changing a cylinder to be cut out or when operation and KDPF regeneration/reset operation
Cylinder Cut-out operation is finished, select a with the machine monitor.
cut-out cylinder to be reset with the function The forced regeneration for service means the
switches. method of burning soot by performing the KDPF
regeneration, regardless of the soot accumulation.
PC290LC-10 30-119
Electrical system

1) KDPF forced regeneration (Stationary

manual regeneration)
2. Selecting sub menu Select "Stationary manual regeneration" on
After the "Testing" screen is displayed, select the "Regeneration for Service" screen.
"Regeneration for Service" by using the function • [F5]: Return to the testing screen
switches or numeral input switches. • [F6]: Perform the stationary manual
regeneration.
selecting a menu on the "Service Menu" a The forced regeneration for service can
screen. be performed only when the lock lever is
in the LOCK position and the fuel control
a While the KDPF is in the stationary manual dial is the low idle (MIN) position.
regeneration or stopped in the KDPF
regeneration mode, "Regeneration for a When performing the stationary manual
Service" cannot be selected. regeneration, confirm the surrounding
area is safe and check that there is no
person or combustible matter around. If
the machine needs to be moved again,
move it to a safe place to ensure safety,
and then perform the operation from the
first.
a The forced regeneration for service stops
automatically after 40 minutes. However,
if the regeneration is started when the
soot accumulation is above 4 g/L and if
the soot accumulation is above 1.9 g/L
after 40 minutes, the automatic manual
regeneration is started and continued
3. Setting regeneration for service until the soot accumulation decreases to
If the "Regeneration for Service" screen is 1.9 g/L.
displayed, the following information is displayed
as well as the KDPF regeneration condition. Set
the KDPF regeneration according to the given
messages.
(a): Soot accumulation level
(b): KDPF is being regenerated
(c): Selectable items
(d): Message
2) Finish of regeneration
30-120 PC290LC-10
Electrical system
If the forced regeneration for service is

completed, "Regeneration completed." is
displayed on the screen.

After the "Testing" screen is displayed, select
"KDPF Memory Reset" by using the function
3) Stopping of regeneration
If [F6] is pressed during the stationary a Select this sub menu as in the case of
manual regeneration, "Stop manual selecting a menu on the "Service Menu"
stationary regeneration?" is displayed on the screen.
screen. Confirm the stop with the function
switch.
• [F5]: Do not stop regeneration (Continue
manual stationary regeneration)
• [F6]: Stop regeneration
3. Setting KDPF memory reset

On the "KDPF Memory Reset" screen, select an
item to be reset.
• [F3]: Move the selection mark to the lower
item
• [F4]: Move the selection mark to the upper
Diagnostic Tests (KDPF Memory Reset) item
The operator can perform "Cylinder Cut-out mode" • [F5]: Return to the testing screen
operation and KDPF regeneration/reset operation • [F6]: Validate the selection
with the machine monitor.
KDPF information reset operation means to reset
the information on KDPF saved in the machine. This
operation should be performed when the KDPF is
cleaned or replaced or when the engine controller is
replaced.
After "Do you want to reset?" is displayed,

confirm the reset with the function switch.
• [F5]: Return to the previous screen
PC290LC-10 30-121
Electrical system
• [F6]: Enter reset
3. Selecting pump absorption torque setting

After the "Pump Absorption Torque (F)" screen
If the reset was finished normally, "Reset
is displayed, select a set value in the right
completed." is displayed on the screen. If the
column by using the function switches.
reset was finished abnormally, "Reset failed." is
• Set value code: For actual torque adjustment
displayed on the screen.
value, see the table shown in the next page
a Perform the KDPF replacement reset after • [F3]: Increase set value
replacing the KDPF. • [F4]: Decrease set value
• [F6]: Confirm setting and return to the
a Perform the KDPF cleaning reset after
adjustment menu screen
cleaning the KDPF.
a The 3-digit number in the left column do not
a Perform the KDOC replacement reset after
change since it is the code of this function.
replacing or cleaning KDOC.
Adjustment (Pump Absorption Torque (F))

The machine monitor allows for adjustment of
various items related to the machine with the
machine monitor.
The sub menu of Pump Absorption Torque (F) is
used to finely adjust the absorption torque of the
front hydraulic pump.
Select "Adjustment" on the "Service Menu"
screen.
a Relationship between set value code and

torque offset value
Set value Torque offset value
Code
coder
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
2. Selecting sub menu 006 -19.6 Nm {-2 kgm}
After the "Adjustment" screen is displayed, 007 -29.4 Nm {-3 kgm}
select "Pump Absorption Torque (F)" using the 008 -39.2 Nm {-4 kgm}
function switches or numeral input switches.
Adjustment (Pump Absorption Torque (R))
a Select this sub menu as in the case of The machine monitor allows for adjustment of
selecting a menu on the "Service Menu" various items related to the machine with the
screen. machine monitor.
30-122 PC290LC-10
Electrical system
The sub menu of Pump Absorption Torque (R) is

used to finely adjust the absorption torque of the
rear hydraulic pump.
screen.
a Relationship between set value code and

torque offset value
Set value Torque offset value
Code
coder
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
2. Selecting sub menu 002 +19.6 Nm {+2 kgm}
After the "Adjustment" screen is displayed,
003 +9.8 Nm {+1 kgm}
select "Pump Absorption Torque (R)" using the
022 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
a Select this sub menu as in the case of 006 -19.6 Nm {-2 kgm}
selecting a menu on the "Service Menu" -29.4 Nm {-3 kgm}
007
screen.
008 -39.2 Nm {-4 kgm}
Adjustment (Low Speed)

machine monitor.
The sub menu of Low Speed is used to finely adjust
the travel speed at Low setting.
screen.
3. Selecting pump absorption torque setting

After the "Pump Absorption Torque (R)" screen
is displayed, select a set value in the right
column by using the function switches.
• Set value code: For actual torque adjustment
value, see the table shown in the next page
select "Low speed" using the function switches
or numeral input switches.
screen.
PC290LC-10 30-123
Electrical system
3. Selecting low speed

After the "Low Speed" screen for setting is
displayed, select a set value in the right column
by using the function switches.
• Set value code: For the actual travel speed
at Low setting, see the table shown in the
next page.
a Relationship between set value and travel

speed at Low setting
Travel speed at
Code Set value coder
Low
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h
30-124 PC290LC-10
Electrical system
Adjustment (Attachment Flow Adjustment)

machine monitor.
The sub menu of "Attachment Flow Adjustment"
allows for fine adjustment of the oil flow to the
attachment during combined operation.
screen.
a Relationship between set value and

distribution of oil flow to attachment
Set value Distribution of flow to
Code
coder attachment
000 50%
001 70%
044
002 100%
003 40%

select "Attachment Flow Adjustment" by using
the function switches or numeral input switches.
screen.
3. Selecting set value code for oil flow distribution

After the screen of "Attachment Flow
Adjustment" is displayed, select a set value in
the right column by using the function switches.
• Set value code: For actual distribution of oil
flow, see the table shown below
PC290LC-10 30-125
Electrical system
Adjustment (Cal F pump swash plate sensor)

The machine monitor allows for adjustment of various items related to the machine with the machine monitor.
The F pump swash plate sensor calibration sub menu is used to calibrate the sensor installed on the actual
machine to eliminate deviation of the sensor signal made when the front pump swash plate sensor is
removed and installed or replaced with new one.
a The pump swash plate sensor needs to be adjusted in the following cases.
Calibration of front pump Calibration of rear

swash plate sensor pump swash plate
sensor
Removal and installation or replacement of front pump
Necessary ―
swash plate sensor
Removal and installation or replacement of rear pump
― Necessary
swash plate sensor
Replacement of main pump assembly Necessary Necessary
Replacement of pump controller Necessary Necessary
Adjustment and disassembly of front pump PC valve Necessary ―
Adjustment and disassembly of pump PC valve ― Necessary
a Before calibrating the pump swash plate sensor,

Test the pump swash plate sensor to
Check that the pump swash plate sensor is normal.
a A rough flow of calibration of the pump swash plate sensor is as follows.
In adjustment menu of service menu • Working mode: P mode
screen.

select "Cal F pump swash plate sensor" by
using the function switches or numeral input
switches.
a Select this item similarly to an item on the
"Service Menu" screen.
1. Preparation for calibration

Before starting calibration, set the machine
under the following condition.
• Hydraulic oil temperature: 50℃
30-126 PC290LC-10
Electrical system
4. Calibration of front pump swash plate sensor for 3) When the speed of the track running idle is
the maximum angle stabilized, hold down [F1] of the machine
1) After the "Cal F pump swash plate sensor monitor to start calibration.
max" is displayed, calibrate the front pump A bar is displayed during calibration.
swash plate sensor for the maximum angle Keep running the track idle until calibration is
by running track idle off the ground and finished.
operating the function switches.
[F1]: START
[F2]: CLEAR
[F5]: Return to the adjustment screen
[F6]: Confirm setting
4) Calibration is finished successfully, "OK" is

displayed for the State of adjustment to show
that calibration for the maximum angle is
completed.
Press [F6] to go to calibration for the
2) Raise the right track off ground by using the minimum angle.
work equipment and move the right travel
lever to the stroke end to run the right track
idle off the ground.
• Fuel control dial: Max.
• Right travel lever: Max.
Travel direction may be set in either of
forward and reverse.
• Swing lock switch may be set in either of
ON and OFF.
Either will do.
k Provide a enough work space to run

the track idle off the ground.
If calibration is finished unsuccessfully, "NG"
is displayed for the State of adjustment and
k While taking care of safety around the the failure cause code is displayed. Referring
machine, run the raised track idle. to the failure cause codes in Table 1, find out
and remove the cause and repeat calibration.
PC290LC-10 30-127
Electrical system
4) Calibration is finished successfully, "OK" is

a The calibration value can be initialized by
displayed for the State of adjustment to show
holding down CLEAR button [F2].
that calibration for the minimum angle is
If the calibration value is initialized, completed.
"READY" is displayed for the State of Press [F6] to return to the Adjustment screen.
adjustment on the screen.
5. Calibration of front pump swash plate sensor for
the minimum angle
1) After the "Cal F pump swash plate sensor
min" is displayed, set all the levers in neutral
and
Perform calibration on the Min. side of the
front pump swash plate sensor with the
function switches.
[F1]: START
[F2]: CLEAR
[F5]: Return to the adjustment screen
[F6]: Confirm setting
If calibration is finished unsuccessfully, "NG"
is displayed for the State of adjustment and
the failure cause code is displayed. Referring
to the failure cause codes in Table 1, find out
and remove the cause and press [F6] to
repeat the calibration for the minimum angle.
2) Wait under the following conditions:

• All levers: NEUTRAL
Fuel control dial may be at any position.
3) Hold down [F1] of the machine monitor to
start calibration.
A bar is displayed during calibration.
Keep all the levers in NEUTRAL until a The calibration value can be initialized by
calibration is finished. holding down CLEAR button [F2].
If the calibration value is initialized,
"READY" is displayed for the State of
adjustment on the screen.
30-128 PC290LC-10
Electrical system
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
MIN MAX
Cause Pump Description Remedy
code Calibration Calibration
of swash of swash Calibration
plate plate of IT
A-1 ● ● ● Engine speed signal is 0 rpm Check that engine is started
Hydraulic oil temperature is Check hydraulic oil
A-2 ● ● ●
low temperature (Min. 45 °C)
Check hydraulic oil
temperature (Calibration of
Hydraulic oil temperature is
A-3 ● ● ● swash plate: Max. 85°C,
high
Calibration of pump IT: Max.
55°C)
A-4 ● ● ● Engine overheats Check for overheat
Pump pressure sensor (F, R) Perform troubleshooting for
A-6 ● ● ●
is defective pump pressure sensor
Pump swash plate (F, R) Perform troubleshooting for
A-7 ● ● -
sensor is defective pump swash plate sensor
Arm IN PPC pressure sensor Perform troubleshooting of
A-8 - - ●
is defective arm IN PPC pressure sensor
- - ● PC-EPC abnormality Perform troubleshooting of
A-9
PC-EPC
Defective CAN
A-A - - ● communication (Eng, Monitor, Perform troubleshooting of
Pump) CAN
Perform troubleshooting
- - ● Bucket CURL PPC pressure
A-B bucket CURL PPC pressure
sensor is defective
sensor
Pump pressure of calibrated Perform troubleshooting of
B-1 ● - -
pump is above standard value relief valve and pump
Set all control levers to
B-3 ● ● - Lever is not in NEUTRAL NEUTRAL position.
C-1 - ● -
pump is below standard value relief valve and pump
C-2 - ● - Travel speed setting is not Hi Set travel speed switch to Hi
from the monitor.
Fuel control dial is not set to Set fuel control dial to Max.
C-3 - ● ●
Max. position position.
Set travel lever to full stroke
C-4 - ● - Both tracks are running and work equipment lever to
neutral.
Check the service flow rate
Oil flow from two pumps are (Normally oil from the pump is
C-5 - ● -
not divided diverted when the travel
circuit is relieved singly)
- ● - Travel PPC pressure sensor is Perform troubleshooting of
C-6 travel PPC pressure sensor
defective
- ● - Travel PPC pressure is below
C-7 Set travel lever to full stroke.
standard value
Arm IN when the arm IN circuit
relieved
PPC pressure is below the
E-1 - - ● Set arm IN lever to full stroke.
specified level or arm IN
PPC pressure sensor in the
normal range
Pump pressure (F, R) is out of Perform troubleshooting of
E-2 - - ●
the specified range relief valve and pump
PC290LC-10 30-129
Electrical system
Object
MIN MAX
plate plate of IT
Engine speed is out of the Set the engine to Hi idle
E-3 - - ●
specified range speed.
Engine torque is out of the Perform troubleshooting of
E-4 - - ●
specified range engine and pump
PC-EPC current is out of the Perform troubleshooting of
E-5 - - ●
specified range PC-EPC current
When bucket CURL circuit is
relieved, bucket CURL PPC
pressure is below the Set bucket CURL lever to full
E-6 - - ●
specified value or bucket stroke.
CURL PPC pressure sensor is
within the normal range.
Working mode is not set to [P] Set working mode is to [P] or
E-7 - - ●
or [ATT/P] [ATT/P].
Swing emergency stop switch Set swing emergency stop
E-8 - - ●
is not set to ON position switch to ON position.
Swing lock switch is not set to Set swing lock switch to ON
E-9 - - ●
ON position position.
Air conditioner is set to ON Set air conditioner to OFF
E-A - - ●
position position.
Output voltage of pump swash
Perform troubleshooting of
FF ● ● - plate sensor is out of
swash plate sensor
calibration range
KDPF regeneration is
G-1 - - ● End KDPF regeneration.
underway
30-130 PC290LC-10
Electrical system
Adjustment (Cal R pump swash plate sensor)

under the following condition
• Hydraulic oil temperature: 50°C
screen.

select "R pump swash plate sensor calibration"
by using the function switches or numeral input
switches.
screen.
4. Perform the subsequent calibration procedure

according to "Adjustment (F pump swash plate
sensor calibration)".
PC290LC-10 30-131
Electrical system
Adjustment (Pump calibration: Matching speed check)

The machine monitor allows for adjustment of various items related to the machine with the machine monitor.
The pump calibration function allows checking the matching speed when the arm IN circuit or bucket CURL
circuit is relieved, and also allows setting an appropriate matching speed with the engine when the pump or
pump controller is replaced.
a The pump calibration (calibration of matching speed) is required in the following cases.
Calibration of front pump swash

plate sensor
Replacement of engine ―
Replacement of main pump assembly Necessary
Replacement of pump controller Necessary
Adjustment and disassembly of front pump PC valve Necessary
Adjustment and disassembly of pump PC valve Necessary
Replacement of main valve ―
When main relief valve is adjusted or replaced ―
a The following shows an the outline of flow of calibration of the pump.

In adjustment menu of service menu 2. Selecting the menu
screen.

After the "Adjustment" screen is displayed, input
"40" using the numeral input switches and press
"F6".
a This function is not added to the menu list
since it is required only when replacing a
pump, adjusting or disassembling a PC valve,
or replacing a pump controller.

• Implement warm-up operation for 30 minutes
or more.
• Hydraulic oil temperature: 50 ℃
• Air conditioner: OFF
30-132 PC290LC-10
Electrical system
4. Selection of the matching speed check menu a Set the bucket CURL circuit relief
After the "Pump calibration" screen is displayed, matching after you have set the arm IN
select "Check matching speed" using the circuit relief matching.
function switches or numeral input switches. Arm lever: Set the arm IN lever to full
a Select it when you need to check the stroke (do this setting when you perform
machine for any trouble or its current state. the arm IN circuit relief matching)
The selection method is the same as that of Bucket lever: Set the bucket CURL lever
the "Service Menu" screen. to full stroke (do this setting when you
perform the bucket CURL circuit relief
matching)
(Conditions)
kA sufficient space must be secured

since you need to operate the work
equipment during the check.
k Pay attention to safety of the

[Reference] environment when operating the work
• Alphabets in the upper right corner of the equipment.
screen represent the following situations.
D: Default
F: Factory default (the setting done when
shipped from the plant (normal))
U: User's calibration value
5. Check of matching speed (relief of arm IN
circuit)
1) When the "Matching speed check" screen is
displayed, relieve the arm IN circuit and
check the matching speed using the function
switch.
[F1]: START
[F5]: Return the display to the pump
calibration screen. 3) Relieve the arm IN circuit and, after the
engine speed stabilized, hold down [F1] on
the machine monitor to start the check.
Since the screen displays a bar on it as long
as the check of the matching speed is
continued, maintain the relief operation until
the check is over.
2) In the following conditions, operate the arm

or bucket lever to check the relief matching.
(Operation)
Operate the arm or bucket lever according to
the instructions on the arm IN circuit or
bucket CURL circuit relief screen.
4) As the correction is normally completed, the
result is displayed.
PC290LC-10 30-133
Electrical system
Press [F6] to proceed to relief of the bucket

CURL circuit.
2) Wait under the following conditions.

• Hydraulic oil temperature: 50 ℃
The standard value to which results of the • Working mode: P mode
matching speed check are compared • Fuel control dial: Max.
new • Air conditioner: OFF
Item Unit machine 3) Hold down [F1] of the machine monitor to
Check of start the check.
Engine rpm Since the screen displays a bar on it as long
matching 1750 ± 50
speed
speed as the check of the matching speed is
F pump 34.8 + 7.8 / continued, maintain the relief operation until
pressure MPa the check is over.
Pump -11.2
pressure R pump
pressure MPa 3.5 ± 1.0
When the check ended abnormally, "NG" is

indicated on the screen along with the failure
cause code. So, reference the failure cause
code on Table 2 to identify the cause and
retry the matching speed check again.
4) As the correction is normally completed, the

result is displayed.
Press [F6] to return to the "Pump calibration"
screen.
6. Check of matching speed (relief of bucket CURL

circuit relieved)
1) When the "Matching speed check" screen is
displayed, relieve the bucket CURL circuit
and check the matching speed using the
function switch.
[F1]: START
[F5]: Return the display to the arm IN circuit
relief screen
The standard value to which results of the
matching speed check are compared
30-134 PC290LC-10
Electrical system
new
Item Unit machine
Check of
Engine rpm
matching 1750 ± 50
speed
speed
F pump 34.8 + 7.8 /
pressure MPa
Pump -11.2
pressure R pump
pressure MPa 3.5 ± 1.0
When the check ended abnormally, "NG" is

indicated on the screen along with the failure
cause code. So, reference the failure cause
code on Table 1 to identify the cause and
retry the matching speed check again.
PC290LC-10 30-135
Electrical system
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
MIN MAX
plate plate of IT
A-1 ● ● ● Engine speed signal is 0 rpm Check that engine is started
Hydraulic oil temperature is Check hydraulic oil
A-2 ● ● ●
low temperature (Min. 45 °C)
Check hydraulic oil
temperature (Calibration of
Hydraulic oil temperature is
A-3 ● ● ● swash plate: Max. 85°C,
high
Calibration of pump IT: Max.
55°C)
A-4 ● ● ● Engine overheats Check for overheat
Pump pressure sensor (F, R) Perform troubleshooting for
A-6 ● ● ●
is defective pump pressure sensor
Pump swash plate (F, R) Perform troubleshooting for
A-7 ● ● -
sensor is defective pump swash plate sensor
Arm IN PPC pressure sensor Perform troubleshooting of
A-8 - - ●
is defective arm IN PPC pressure sensor
- - ● PC-EPC abnormality Perform troubleshooting of
A-9
PC-EPC
Defective CAN
A-A - - ● communication (Eng, Monitor, Perform troubleshooting of
Pump) CAN
Perform troubleshooting
- - ● Bucket CURL PPC pressure
A-B bucket CURL PPC pressure
sensor is defective
sensor
B-1 ● - -
pump is above standard value relief valve and pump
Set all control levers to
B-3 ● ● - Lever is not in NEUTRAL NEUTRAL position.
C-1 - ● -
pump is below standard value relief valve and pump
C-2 - ● - Travel speed setting is not Hi Set travel speed switch to Hi
from the monitor.
Fuel control dial is not set to Set fuel control dial to Max.
C-3 - ● ●
Max. position position.
Set travel lever to full stroke
C-4 - ● - Both tracks are running and work equipment lever to
neutral.
Check the service flow rate
Oil flow from two pumps are (Normally oil from the pump is
C-5 - ● -
not divided diverted when the travel
circuit is relieved singly)
- ● - Travel PPC pressure sensor is Perform troubleshooting of
C-6 travel PPC pressure sensor
defective
- ● - Travel PPC pressure is below
C-7 Set travel lever to full stroke.
standard value
Arm IN when the arm IN circuit
relieved
PPC pressure is below the
E-1 - - ● Set arm IN lever to full stroke.
specified level or arm IN
PPC pressure sensor in the
normal range
Pump pressure (F, R) is out of Perform troubleshooting of
E-2 - - ●
the specified range relief valve and pump
30-136 PC290LC-10
Electrical system
Object
MIN MAX
plate plate of IT
Engine speed is out of the Set the engine to Hi idle
E-3 - - ●
specified range speed.
Engine torque is out of the Perform troubleshooting of
E-4 - - ●
specified range engine and pump
PC-EPC current is out of the Perform troubleshooting of
E-5 - - ●
specified range PC-EPC current
When bucket CURL circuit is
relieved, bucket CURL PPC
pressure is below the Set bucket CURL lever to full
E-6 - - ●
specified value or bucket stroke.
CURL PPC pressure sensor is
within the normal range.
Working mode is not set to [P] Set working mode is to [P] or
E-7 - - ●
or [ATT/P] [ATT/P].
Swing emergency stop switch Set swing emergency stop
E-8 - - ●
is not set to ON position switch to ON position.
Swing lock switch is not set to Set swing lock switch to ON
E-9 - - ●
ON position position.
Air conditioner is set to ON Set air conditioner to OFF
E-A - - ●
position position.
Output voltage of pump swash
Perform troubleshooting of
FF ● ● - plate sensor is out of
swash plate sensor
calibration range
KDPF regeneration is
G-1 - - ● End KDPF regeneration.
underway

speed calibration)
• Implement warm-up operation for 30 minutes
or more.
• Emergency swing stop switch: ON
2. Selecting the menu 3. Selecting sub menu
Select "Adjustment" on the "Service Menu" After the "Adjustment" screen is displayed, input
screen. "40" using the numeral input switches and press
"F6".
a This function is not added to the menu list
since it is required only when replacing a
pump, adjusting or disassembling a PC valve,
or replacing a pump controller.
PC290LC-10 30-137
Electrical system
• [F6]: Perform initialization
4. Selection of the matching speed check menu

After the "Pump calibration" screen is displayed,
• When [F6] is pressed, if the "Pump
select "Calibrate matching speed" using the
calibration" screen is displayed and alphabet
letter "D" is indicated at the right top of the
a Select it when you need to check the screen, initialization is completed.
machine for any trouble or its current state.
a The selection method is the same as that of
the "Service Menu" screen.
No Injection
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
5. Perform the subsequent calibration procedure insufficient lubrication with oil. To prevent this, the
referencing the section of "Check of matching machine monitor allows for cranking the engine
speed". without injecting fuel to lubricate the engine before
6. Return to default starting it.
After the "pump calibration" screen is displayed,
Set the no injection cranking while the engine is
select "Return to default" by using the function
stopped.
a Select this sub menu as in the case of Select "No Injection" on the "Service Menu"
selecting a menu on the "Service Menu" screen.
screen.
2. Confirmation screen
30-138 PC290LC-10
Electrical system
When the "No injection" screen is displayed, the a This function can be selected even while
message to ask if no injection cranking should engine is running. If no injection cranking is
be performed appears. Answer with the function attempted, however, the message, "Engine
switch. is running. Turn the key OFF once." is
• [F5]: Do not perform (Return to Service menu displayed on the screen.
screen)
• [F6]: Perform
And the "Confirmation screen" appears to

disable the attempted no injection cranking in
3. Starting no injection cranking the following cases.
If no injection cranking (fuel injection in no • Communication between the monitor and
cylinders) becomes effective, "No Injection." is engine controller is not normal.
displayed on the screen. Under this condition, • Engine was started before the message "No
crank the engine by using the starting motor. injection cranking is available" appears on
the screen.
a While the screen is changing to the following
screen, the screen of "Getting Ready." is
displayed.
a Limit the duration of cranking to 20 seconds
to protect the starting motor.
KOMTRAX Settings (Terminal Status)

The setting and operating status of KOMTRAX can
be checked by using the menu of "KOMTRAX
Settings".
4. Finishing no injection cranking "KOMTRAX Settings" is used to check the setting
After cranking is finished, turn the key to the condition of the KOMTRAX terminal.
OFF position. 1. Selecting the menu
Switching from the above screen to another is Select "KOMTRAX Settings" on the "Service
not available. Menu" screen.
5. Prohibiting no injection cranking
If the operator tries to perform the no injection
cranking while the engine is running, the
message "Engine is running" is displayed and
the no injection cranking is not enabled.
PC290LC-10 30-139
Electrical system
KOMTRAX Settings (GPS and Communication

Status)
Settings".
"GPS & Communication Status" is used to check
the positioning and communication status of the
KOMTRAX terminal.
Select "KOMTRAX Settings" on the "Service
Menu" screen.
2. Selecting submenu
After the “KOMTRAX Settings” screen is
displayed, select “Terminal Status” with the
a Select this submenu as in the case of
screen.

After the "KOMTRAX Settings" screen is
displayed, select "GPS & Communication
Status" with the function switches or numeral
input switches.
screen.
3. Contents displayed on the terminal status
screen
On the "Terminal Status" screen, the following
information is displayed.
• Terminal: Model name of the KOMTRAX
communication modem
• Sign-up test: Status of sign-up test underway
• GMT time: Greenwich Mean Time (add 9
hours to it for Japan time)
• [F5]: Returns the display to the KOMTRAX
settings screen
3. Contents displayed on GPS & Communication

Status screen
On the "GPS & Communication Status" screen,
the following items are displayed.
• Positioning: GPS positioning status
• Communication: Communication
environment and connection status of the
communication modem
• Number of message(s) not yet sent: Number
of mails that are saved on the machine
monitor and have not yet been transmitted
settings screen
30-140 PC290LC-10
Electrical system
IP addresses (2 addresses) of the modem are

displayed.
settings screen
a An IP address is a unique number assigned
to each modem that is used when
communication between the modem and
server is turned on.
KOMTRAX Settings (Modem Information)

Settings".
Modem status is used to check the IP address of
the KOMTRAX communication modem.
Select "KOMTRAX Settings" on the "Service
Menu" screen. Service Message
Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
checked by using this function.
If a received message has return mail setting, a
return mail can be sent by using the numeral input
switches.
1. Selecting menu
Select "Service Message" on the Service Menu
screen.

After the "KOMTRAX Settings" screen is
displayed, select "Modem Status" with the
screen.
2. Displaying message (read-only)

If a message is received, the content is
displayed. If there is no message, "No message"
is displayed.
screen
a This message is different from that sent for
the operator with the machine monitor in the
operator mode
3. Modem status displayed
PC290LC-10 30-141
Electrical system
a Since this message is special for the

technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
3. Displaying message (message with return mail

function)
If a message provides the Numeric Input line
under the text, input a proper number by using
the numeral input switches and enter it by using
the function switch, and the information is
returned to the KOMTRAX base station.
settings screen
• [F6]: Validates and returns the input value.
a This message is different from that sent for
the operator with the machine monitor in the
operator mode
a Since this message is special for the
technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
30-142 PC290LC-10
Electrical system
Angle adjustment of rear view camera

a Adjust the camera so that persons in area (w) at a Claw of cover (2) is made of plastic, it is
1 meter around the machine is displayed on the easily damaged while removing, therefore
machine monitor in the operator cab. take special care at work.
If the image displayed on the monitor is out of 2. Remove two bolts (3).
position, remove cover (1) of the camera and adjust 3. Remove cover (1).
the installation angle (A) of the rear view camera. a Note the locations and quantities of shims
Angle (A) is adjustable within the range shown in (6).
the figure below. Use care shims (6) may be removed along
with cover (1).
Adjusting
1. Remove cover (1) by inserting flat-head
screwdriver [1] in the hole in cover (2) and
pressing the internal pawl.
4. Loosen camera mounting bolts (4) (3 places)

and adjust camera installation angle (A) so that
corner (B) of mounting bracket (5) matches with
horizontal line (C) of the camera.
PC290LC-10 30-143
Electrical system
a Set shims (6) to cover (1) or insert them from

outside of cover after the bolts are tightened
lightly.
a A part of the machine is displayed on the

monitor screen.
5. After adjusting, tighten bolts (4).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install covers (1) and (2).
a Adjust the vertical clearance between the
counterweight and cover (1) to 2 mm or less
using shims (6).
30-144 PC290LC-10
Electrical system
Handling voltage circuit of engine controller

1. Disconnect connector between the engine
controller and engine. (Be sure to turn the
starting switch to the OFF position when
performing the connecting work.)
2. If a T to adapter is inserted in or connected to
the connector between the engine controller and
engine harness for troubleshooting, do not start
the engine.
a You can turn the starting switch to the OFF or
ON position, but must not turn it to the
START position.
PC290LC-10 30-145
Electrical system
Handling battery disconnect switch

1. Pull out switch key (1) whenever you have
turned the battery disconnect switch OFF.
kA serious accident can result if someone

turns switch key (1) ON inadvertently.
2. Check the operating condition of each controller
with system operating lamp (2) to prevent
abnormal stop by cutting out the battery power
supply circuit while the controllers are in
operation.
1) When cutting out the battery power supply
circuit, turn the starting switch to the OFF
position and check that the system operating
lamp has gone out, and then turn the battery
disconnect switch to the OFF position.
2) If the battery disconnect switch is turned to
the OFF position (to cut out the battery power
supply circuit) while the system operating
lamp is lighting up, the data loss error may
occur in the controllers. Do not operate the
battery disconnect switch while the system
operating lamp is lighting up.
3) The system operating lamp goes out within 2
minutes after the starting switch is turned to
the OFF position.
4) Even if the starting switch is in the OFF
position, the system operating lamp may light
up since the KOMTRAX terminal may
perform communication.
5) Even if the system operating lamp is off, it
may seem to be lighting slightly because of a
very little current inside the controller. This
phenomenon does not indicate abnormality.
• The KOMTRAX terminal performs
communication periodically even if the
starting switch is kept in the OFF position,
thus it starts and stops repeatedly.
• The starting and stopping period (sleep
cycle) of the KOMTRAX terminal varies
with the communication condition,
operation stop time, etc., and the terminal
may keep lighting up for a maximum of
about 1 hour.
6) To cut out the battery circuit for maintenance
while the system operating lamp is lighting
up, turn the starting switch to the ON position
and then return to the OFF position, and the
lamp goes out within 2 minutes.
After the system operating lamp goes out,
turn the battery disconnect switch to the OFF
position immediately.
30-146 PC290LC-10
Electrical system
Testing diodes
a Test the diode array (8-pin) and the single diode 2) Apply the leads of the multi meter as
(2-pin) according to the following procedure. explained below and check the movement of
the pointer.
a The continuity directions of the diode array are
as follows. 1] Apply the red (+) lead of the multimeter to
the anode (P) of the diode and apply the
black (–) lead to the cathode (N).
2] Apply the red (+) lead of the multimeter to
the cathode (N) of the diode and apply
the black (–) lead to the anode (P).
3) Judge the quality of the diode by the
movement of the pointer.
• The pointer does not move in 1] but
moves in 2]: The diode is normal (The
moving range (resistance) depends on
the type and selected range of the tester,
however).
• The pointer moves in both 1] and 2]: The
diode is defective (internal short circuit).
a The continuity direction of the single diode is
• The pointer moves in neither of 1] and 2]:
indicated on the surface of the diode.
The diode is defective (internal
Testing discontinuity).
1. When using a digital multi meter
1) Set the multi meter to the diode range and
read the indicated value.
a When an ordinary circuit tester is used,
the voltage of the tester-internal battery is
indicated.
2) Apply the red (+) lead of the multimeter to the
anode (P) of the diode and apply the black
(–) lead to the cathode (N), and check the
indicated value.
3) Judge the quality of the diode by the
indicated value.
• Displayed value does not change: No
continuity (defect)
• Displayed value changes: Continue
(normal) (note)
Note: In the case of a silicon diode, a
value in the range from 460 to 600 mV is
indicated.
2. When using an analog multi meter

1) Set the multi meter in the resistance range.
PC290LC-10 30-147
Pm clinic
Pm clinic
Pm clinic service
Model Serial No. Service meter
T PC290LC-10 _________ hours
Customer name Date of check Serviceman
//
Specifications
Main components Attachment Shoe width
BoomT Standard T ( ) T Breaker T 600 mm
ArmT Standard T ( ) T() T 700 mm
Bucket T Standard T ( ) T() T()
Check of oil and coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T()
T Hydraulic oil T Final case oil
Ambient Temperature Height above sea level
°C m
Operator's comment
Visual check result
Mechanical system "Abnormality Record" Electrical system abnormality record

__times/ 1st at ___hrs. / last at
989EKX __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
AA10NX __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
AB00KE __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
B@BAZG __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
B@BAZK __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
B@BCNS __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
B@BCZK __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
B@HANS __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
CA234 __times/ 1st at ___hrs. / last at ___hrs.
___hrs.
30-148 PC290LC-10
Pm clinic
Highest reading on coolant temperature gauge
Coolant temperature gauge level Engine coolant temperature Color of monitor light (a)
6 105°C
Red
5 102°C
4 100°C
3 85°C Blue
2 60°C
1 30°C White
Highest reading on hydraulic oil temperature gauge
Coolant temperature gauge level Engine coolant temperature Color of monitor light (a)
6 105°C
Red
5 102°C
4 100°C
3 85°C Blue
2 40°C
1 20°C White
PC290LC-10 30-149
Pm clinic
Check items related to engine
30-150 PC290LC-10
Pm clinic
Check items related to oil pressure
PC290LC-10 30-151
Pm clinic
Check sheet
Check sheet (PC290LC-10)
Model Serial No. Service meter Customer name Date of check Inspector
//
1. Engine
Testing conditions
Operation of work equipment
temperature sensor system

Measured value
Auto-deceleration
L.H. knob switch

Fuel control dial
Service limit
Working mode
Check item
Standard
Unit
No.
NO
Engine oil rpm 1,885 to 1,885 to
1 pressure 2,025 2,025
All levers in
Engine oil MAX MPa Min. 0.29 0.25
NEUTRAL
2 pressure {kg/cm2} {Min. 3.0} {2.5}
Engine oil OFF 1,000 to 1,000 to
3 rpm
pressure All levers in 1,100 1,100
Engine oil MIN MPa Min. 0.10 0.07
OFF NEUTRAL
4 pressure P {kg/cm2} {Min. 1.0} {0.7}
Engine oil rpm 1,950 to 1,950 to
5 pressure Arm IN to 2,150 2,150
ON hydraulic kPa
Blowby Max 0.98 1.96
6 pressure MAX relief {mmH2-
{Max. 100} {200}
O}
Engine oil All levers in rpm 950 to 950 to
7 pressure ON OFF 1,150 1,150
NEUTRAL
30-152 PC290LC-10
Pm clinic
2. Work equipment speed

Testing conditions

Measured value
Fuel control dial
Service limit
Working mode
Check item
Standard
Unit
No.
NO
Work equipment posture,
etc.
Work equipment
1 Boom Raise extended fully PC240 second 3.5 to 4.3 Max 5.3
P
PC240 second 4.0 to 4.8 Max 5.3
2 Arm IN E PC240 second 4.0 to 5.0 Max 5.7
Horizontal boom
L top face PC240 second 7.1 to 8.7 Max 10.0
Arm dump PC240
3 (OUT) second 2.6 to 3.2 Max 3.8
Boom top
MAX horizontal Arm
4 Bucket Curl cylinder retracted PC240 second 2.7 to 3.3 Max 3.9
fully
P
Swing (5 Work equipment extended
5 turns) fully Swing right and left second 25.7 to 31.5 Max 34.8
Travel One track raised LO LC second 53.0 to 64.8 52.7 to 68.8

and run idle MI LC second 44.1 to 52.7 43.3 to 57.5
6 (five turns
forward and
idle running) HI LC second 29.4 to 32.4 30.8 to 35.2
reverse
3. Hydraulic drift of work equipment
Testing conditions

Measured value
Fuel control dial
Service limit
Working mode
Check item
Standard
Unit
No.
NO
Work equipment posture,
etc.
Hydraulic drift
measured at Boom top horizontal, Arm
Engine stop mm/15
1 bucket tooth cylinder retracted fully, Max 600 Max 900
minutes
tip Bucket loaded
PC290LC-10 30-153
Pm clinic
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Testing conditions 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/
cm2} cm2} cm2} cm2} cm2}

Testing tools
L.H. knob switch

Fuel control dial
Working mode
No.
NO
R pump main
F pump main
R pump LS
F pump LS
Control
Self- A
pressure All levers in - - - -
1
reducing NEUTRAL
valve OFF
Main relief B B B B
2 valve (low -
pressure) Arm Dump
Main relief relief C C C C
3 valve (low ON -
pressure)
Unload All levers in D1 D1 D2 D2 -
4
valve NEUTRAL
Right track run E1 E2
MA- idle, Lever
P - - -
X moved
halfway
5 LS valve Left track run E1 E2
idle, Lever
- - -
moved
OFF
halfway
Swing lock F F
switch ON, - - -
Swing Right swing
motor relief
6 Swing lock F F
safety
valve switch ON, - - -
Left swing
relief
30-154 PC290LC-10
Pm clinic
[1] [2] [3] [4] [5]

{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/

Testing tools
L.H. knob switch

Fuel control dial
No.
Working mode
NO
R pump main
F pump main
R pump LS
F pump LS
Control
Right track G
locked ,Right - - - -
track forward
relief
Main relief
Right track G
valve,
locked , Right - - - -
travel
track reverse
motor
relief
7 safety
Left track G
valve,
locked, Left - - - -
travel
track forward
junction
relief
valve
Left track G
locked, Left - - - -
track reverse
relief
Oil pressure to be checked Unit Standard Service limit
A (Control source
2.93 to 3.43 {30 to 35} 2.75 to 3.43 {28 to 35}
pressure)
B (Work equipment
33.6 to 36.3 {343 to 370} 33.1 to 37.2 {338 to 380}
relief pressure, low)
C (Work equipment
new machine
36.1 to 38.8 {368 to 395} 36.1 to 39.7 {368 to 405}

relief pressure, high) MPa
D (Unload pressure) {kg/ D1 to D2 = 2.5 to 4.5 {26 to 46} D1 to D2 = 2.5 to 4.5 {26 to 46}
E (LS differential cm2}
E1 to E2 = 1.7 to 1.85 {17 to 18.5} E1 to E2 = 1.7 to 1.85 {17 to 18.5}
pressure)
F (Swing relief
28.8 to 31.8 {295 to 325} 28.4 to 32.3 {290 to 330}
pressure)
G (Travel relief
36.7 to 39.7 {375 to 405} 36.8 to 40.2 {375 to 410}
pressure)
* Gauge connection changing work: Exchange hoses of gauges [3] and [4].
PC290LC-10 30-155
Pm clinic
[1] [2] [3a] [4a] [5]

{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/

Testing tools
L.H. knob switch

Fuel control dial
No.
Working mode
R pump servo
NO
F pump servo
R pump main
F pump main
Control
Servo Arm Dump H1 H1 H2 H2
8 MAX P OFF -
piston relief
new machine
H (Servo control H1 : H2 = 1 : 0.6

-
pressure) (Oil pressure ratio)
* Gauge connection changing work: Change gauges [3] and [4] to 60 MPa {60 kg/cm 2} and exchange
hoses of [3], [4], and [5] gauges.
30-156 PC290LC-10
Pm clinic
[1] [2] [3b] [4b] [5a]

{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/

Testing tools
L.H. knob switch

Fuel control dial
No.
Working mode
NO
R pump main
F pump main
R pump (R)
F pump (F)
LS-EPC
MIN - - J1 J1 -
PC-EPC(F) P All levers - - J2 J2 -
valve PC- in - - J3 J3 -
9 E
EPC (R) NEU-
valve L TRAL - - J4 J4 -
B - - J5 J5 -
Travel K1
speed:
LO Travel - - - -
lever in
NEU-
OFF TRAL
MAX
Travel K2
LS-EPC speed: MI
10 P Travel - - - -
valve
lever
operated
Travel K3
speed: HI
Travel - - - -
lever
operated
PC290LC-10 30-157
Pm clinic

J1 (PC-EPC valve output
Approximately 2.9 {Approximately 30}
pressure 1)
pressure 2)
pressure 3)
new machine

MPa 2.01 {21}
pressure 4)
{kg/
cm2} Approximately 1.57 {Approximately 16}
pressure 5)
K1 (LS-EPC valve output
pressure 1)
Approximately 1.7 {Approximately 17.5}
pressure 2)
0 {0}
pressure 3)
30-158 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
40 Troubleshooting
6 40 Troubleshooting
PC290LC-10 40-1
40 Troubleshooting
Table of contents
Table of contents
40 Troubleshooting............................................................................................................................ 40-1
General information on troubleshooting ........................................................................................ 40-9
Instruction on troubleshooting ............................................................................................... 40-9
How to proceed troubleshooting .......................................................................................... 40-11
Testing before troubleshooting ............................................................................................ 40-12
Testing procedure before troubleshooting............................................................................. 40-14
Preparation work for troubleshooting of electrical system....................................................... 40-42
Classification and procedure for troubleshooting ................................................................... 40-46
Symptom of probable failure and troubleshooting No............................................................. 40-49
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-55
Connector list and layout .................................................................................................... 40-57
Connector contact identification........................................................................................... 40-68
T-branch box and T-branch adapter table ........................................................................... 40-105
Fuse list and location.........................................................................................................40-111
Precautions for cleaning and replacing KDPF (KCSF, KDOC) .............................................. 40-113
Failure codes table........................................................................................................... 40-115
Troubleshooting by failure code (Display of code) ...................................................................... 40-124
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-124
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-125
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-126
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-127
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-128
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-129
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-130
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-131
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-132
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-133
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-134
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-135
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-136
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-141
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-143
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-145
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-146
Failure code [B@BCNS] Engine Coolant Overheat ............................................................. 40-147
Failure code [B@BCZK] Radiator Coolant Level Low .......................................................... 40-148
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-150
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-151
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-152
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-154
Failure code [CA131] Throttle Sensor High Error................................................................. 40-156
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-158
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-160
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-162
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-164
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-166
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-170
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-172
Failure code [CA234] Eng Overspeed ................................................................................ 40-175
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-176
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-177
40-2 PC290LC-10
40 Troubleshooting
Table of contents
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-178

Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-180
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-181
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-194
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-195
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-198
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-200
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-203
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-205
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-207
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-208
Failure code [CA442] Battery Voltage High Error................................................................. 40-210
Failure code [CA449] Rail Press Very High Error................................................................. 40-211
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-212
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-214
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-215
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-216
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-218
Failure code [CA553] Rail Press High Error ........................................................................ 40-220
Failure code [CA559] Rail Press Low Error......................................................................... 40-223
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-225
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-226
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-228
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-230
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-232
Failure code [CA697] ECM Int Temp Sensor High Error ....................................................... 40-234
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-235
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-236
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-237
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-241
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-242
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-244
Failure code [CA1695] Sensor 5 Supply Volt Low Error ....................................................... 40-246
Failure code [CA1696] Sensor 5 Supply Volt High Error....................................................... 40-248
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-250
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-252
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-254
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-256
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-258
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-268
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-269
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-270
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-271
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-272
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-273
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-275
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-278
PC290LC-10 40-3
40 Troubleshooting
Table of contents
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-279

Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-280
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-282
Failure code [CA2357] EGR Differential Pressure ............................................................... 40-284
Failure code [CA2373] Exh Manifold Press. Sens Volt ......................................................... 40-285
Failure code [CA2374] Exhaust Manifold Press Sens Low Error ........................................... 40-287
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-289
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-291
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-293
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-295
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-297
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-299
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-301
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-302
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-303
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-306
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-308
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-310
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-312
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-313
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-314
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-316
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-318
Failure code [CA3251] DOC Inlet Temp High Error .............................................................. 40-321
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-324
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-325
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-328
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-330
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-333
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-336
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-344
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-347
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-355
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-359
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-362
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-366
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-367
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-369
Failure code [D110KB] Battery Relay Output Voltage .......................................................... 40-370
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-372
Failure code [D811MC] KOMTRAX Error............................................................................ 40-375
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-376
......................................................................................................................... 40-377
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-379
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-380
Failure code [DA20MC] Pump Controller............................................................................ 40-381
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-382
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-384
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-387
Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con)........................................ 40-389
Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con) ........................................ 40-391
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-395
40-4 PC290LC-10
40 Troubleshooting
Table of contents
Failure code [DAF0MC] Monitor Error ................................................................................ 40-396

Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-397
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-399
Failure code [DAFGMC] GPS Module Error........................................................................ 40-400
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-401
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) ............................................ 40-403
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-404
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-405
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-406
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-410
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-415
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-419
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-421
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-422
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-425
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality........................................ 40-428
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-430
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-433
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality .................................. 40-436
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ..................................... 40-439
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ...................................... 40-442
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-445
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-448
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-451
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-454
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-457
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-460
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality....................................... 40-463
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ...................................... 40-466
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-473
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-475
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-477
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-479
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-482
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-485
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-487
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-489
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-491
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-493
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit...................................................... 40-495
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-497
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-499
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ................................................. 40-501
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ................................................. 40-503
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-505
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-507
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-509
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-511
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-513
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-515
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-517
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-519
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ................................................ 40-521
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ................................................ 40-523
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-525
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ................................................... 40-527
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-529
PC290LC-10 40-5
40 Troubleshooting
Table of contents
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-531

Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-533
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-535
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-537
Troubleshooting of electrical system (E-mode) .......................................................................... 40-539
E-1 Engine does not start (Engine does not rotate).............................................................. 40-539
E-2 Manual preheating system does not work..................................................................... 40-545
E-3 Automatic preheating system does not work................................................................. 40-548
E-4 Preheating monitor does not light up when preheater is operated ................................... 40-550
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-552
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow.................................................................................... 40-555
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow ............................................................................ 40-556
E-8 Coolant temperature monitor lights up in white while engine is running ........................... 40-557
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-558
E-10 Charge level monitor lights up while engine is running ................................................. 40-559
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-560
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-561
E-13 Water separator monitor lights up while engine is running ............................................ 40-562
E-14 Coolant temperature monitor lights up in red while engine is running............................. 40-563
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-564
E-16 Engine oil pressure monitor lights up in red while engine is running .............................. 40-565
E-17 Fuel gauge indicate either full or empty and does not move.......................................... 40-566
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-567
E-19 Coolant temperature gauge indicate either Min or Max and does not move.................... 40-568
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor
Max) .................................................................................................................. 40-569
E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move ............. 40-570
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min
nor Max) ............................................................................................................ 40-572
E-23 Content of display on machine monitor is different from that of actual machine .............. 40-573
E-24 Machine monitor does not display some items ............................................................ 40-574
E-25 Function switch does not work................................................................................... 40-575
E-26 Automatic preheating system does not work (In cold season)....................................... 40-576
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration
E-28 Auto-deceleration is not actuated or canceled when lever is operated ........................... 40-578
E-29 Working mode selector screen selection screen is not diplayed when working mode
E-30 Engine or hydraulic pump setting does not change when working mode is
changed............................................................................................................. 40-581
E-31 Travel speed monitor does not change when travel speed switch is operated ................ 40-582
E-32 Travel speed does not change when travel speed is shifted ......................................... 40-583
E-33 Alarm buzzer does not stop sounding......................................................................... 40-584
E-34 When starting switch is turned to OFF position, service meter is not displayed............... 40-585
E-35 Service mode cannot be selected .............................................................................. 40-586
E-36 Any of work equipment, swing and travel does not work............................................... 40-587
E-37 Any of work equipment, swing and travel can not be locked ......................................... 40-589
E-38 Machine can not swing while swing brake cancel switch is canceled............................. 40-590
E-39 Swing brake does not operate while swing brake cancel switch is locked ...................... 40-592
E-40 One-touch power maximizing function does not work or monitor is not displayed ........... 40-594
E-41 One-touch power maximizing function cannot be released ........................................... 40-596
E-42 Travel alarm does not sound when machine travels..................................................... 40-597
E-43 Travel alarm does not stop sounding when machine stops ........................................... 40-598
E-44 Horn does not sound ................................................................................................ 40-599
E-45 Horn does not stop sounding..................................................................................... 40-601
E-46 Wiper monitor does not light up or go out when wipper switch is operated ..................... 40-602
E-47 Wiper does not operate when wipper switch is operated .............................................. 40-603
40-6 PC290LC-10
40 Troubleshooting
Table of contents
E-48 Window washer does not operate when window washer switch is operated................... 40-605
E-49 BOOM LOWER indication is not displayed properly with monitoring function ................. 40-606
E-50 ARM DUMP indication is not displayed properly with monitoring function ...................... 40-607
E-51 ARM IN indication is not displayed properly with monitoring function............................. 40-608
E-52 BOOM RAISE indication is not displayed properly with monitoring function ................... 40-609
E-53 BUCKET CURL indication is not displayed properly with monitoring function ................. 40-610
E-54 BUCKET DUMP indication is not displayed properly with monitoring function ................ 40-611
E-55 SWING indication is not displayed properly with monitoring function ............................. 40-612
E-56 TRAVEL indication is not displayed properly with monitoring function............................ 40-613
E-57 Service is not displayed properly with monitoring function ............................................ 40-614
E-58 Attachment hydraulic circuit cannot be changed.......................................................... 40-617
E-59 KOMTRAX system does not work properly ................................................................. 40-618
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-619
Information mentioned in troubleshooting table (H mode) .................................................... 40-619
System chart for hydraulic system ..................................................................................... 40-620
Failure mode and cause table ........................................................................................... 40-622
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-630
H-2 Engine speed lowers significantly or engine stalls ......................................................... 40-633
H-3 Any of work equipment, swing and travel does not work ................................................ 40-635
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-636
H-5 Fine control performance or response is poor ............................................................... 40-637
H-6 Boom operation lacks speed or power ......................................................................... 40-638
H-7 Arm operation lacks speed or power ............................................................................ 40-640
H-8 Bucket operation lacks speed or power........................................................................ 40-642
H-9 Work equipment does not move in single operation....................................................... 40-643
H-10 Hydraulic drift of boom is large .................................................................................. 40-644
H-11 Hydraulic drift of arm is large ..................................................................................... 40-645
H-12 Hydraulic drift of bucket is large ................................................................................. 40-646
H-13 Time lag of work equipment is large ........................................................................... 40-647
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-649
E-15 One-touch power maximizing function does not work .................................................. 40-650
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-651
H-17 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-652
H-18 In combined operations of swing and travel, travel speed drops largely......................... 40-653
H-19 Machine does not travel straight ................................................................................ 40-654
H-20 Travel speed is too low ............................................................................................. 40-655
H-21 Machine is hard to steer or travel power is low ............................................................ 40-657
H-22 Travel speed does not change, or travel speed is too low or high.................................. 40-659
H-23 One of tracks dose not run ........................................................................................ 40-660
H-24 Upper structure does not swing to the right or left ........................................................ 40-661
H-25 Upper structure swing only to the right or left .............................................................. 40-662
H-26 Swing acceleration is poor or swing speed is low (both right and left) ............................ 40-663
H-27 Swing acceleration is poor or swing speed is low (either right or left)............................. 40-664
H-28 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-665
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-666
H-30 Shock is large when upper structure stops swinging.................................................... 40-667
H-31 Large unusual noise is heard when upper structure stops swinging .............................. 40-668
H-32 Swing drift on a slope is large while swing holding brake is applied............................... 40-669
H-33 Swing drift on a slope is large while swing holding brake is released............................. 40-670
H-34 Attachment circuit cannot be changed while attachment is installed.............................. 40-671
H-35 Oil flow in attachment circuit cannot be controlled ....................................................... 40-672
Troubleshooting of engine (S-mode)......................................................................................... 40-673
Information mentioned in troubleshooting table (S mode)..................................................... 40-673
S-1 When starting switch is turned to START position, engine does not crank ....................... 40-674
S-2 When engine cranks, smoke does not come out ........................................................... 40-675
S-3 Engine does not start while fuel is injected (Incomplete combustion)............................... 40-676
PC290LC-10 40-7
40 Troubleshooting
Table of contents
S-4 Startability is poor....................................................................................................... 40-677

S-5 Engine does not pick up smoothly ............................................................................... 40-679
S-6 Engine stops during operation ..................................................................................... 40-680
S-7 Engine runs rough or is unstable ................................................................................. 40-682
S-8 Engine lacks power .................................................................................................... 40-683
S-9 Exhaust smoke is black (KDPF clogs up early) ............................................................. 40-685
S-10 Engine oil consumption is too much ........................................................................... 40-687
S-11 Oil becomes contaminated early ................................................................................ 40-688
S-12 Fuel consumption is excessive .................................................................................. 40-689
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-690
S-14 Engine oil pressure drops ......................................................................................... 40-691
S-15 Fuel is contaminated in engine oil .............................................................................. 40-692
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)................................. 40-693
S-17 Coolant temperature rises too high (Overheating) ....................................................... 40-694
S-18 Unusual noise is heard ............................................................................................. 40-695
S-19 Vibration is excessive ............................................................................................... 40-696
S-20 Automatic regeneration is operated frequently ............................................................ 40-697
S-21 Active regeneration is operated for long ..................................................................... 40-698
S-22 White smoke comes out in the process of active regeneration ...................................... 40-699
40-8 PC290LC-10
40 Troubleshooting
General information on troubleshooting
Instruction on troubleshooting
(Rev. 2010/03)
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with two or more service technician, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring and the like, turn the battery disconnect switch to OFF position while
the system operating lamp is turned off.
k When removing the plug or cap from a component which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported
symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation
and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1)Are abnormal symptoms detected in the machine?
2)Make checks before starting day's work.
3)Make checks of other items.
4)Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Confirming failure
See the extent of the failure by yourself, and judge whether it is a real failure or a problem caused by the
handling or operating the machine.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
PC290LC-10 40-9
40 Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the causes of failure,
then use the troubleshooting flowchart to locate the failure exactly.
a The basic procedure for troubleshooting is as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is removed, the same failure may occur again, unless the root cause of the
failure is repaired. To prevent this, always investigate why the cause of the failure occurred. Then, remove
the root cause.
40-10 PC290LC-10
40 Troubleshooting
How to proceed troubleshooting

(Rev. 2007/12)
PC290LC-10 40-11
40 Troubleshooting
Testing before troubleshooting

Judge-
No. Role ment Remedy
value
1 Check for unusual noise and smell - Correct
2 Check for dirt around engine - Remove
3 Check for water leakage around engine - Correct
4 Check for oil leakage around engine - Correct
5 Check for leakage from fuel line - Correct
6 Check of radiator for clogging - Remove
a: Engine, lubricating oil and coolant
7 Check of level and type of fuel - Refilling of oil

8 Check for foreign material in fuel - Clean and drain
9 Check of fuel pre-filter - Replace
10 Check of fuel main filter - Replace
Between
11 Check of level (in oil pan) and type of engine oil Refilling of oil
H and L
Between Refilling of coolant
12 Check of coolant level (in sub tank)
H and L
Air
cleaner
clogging
monitor is
13 Check of air cleaner clogging not Clean or replace
displayed
on
machine
monitor
14 Check for dirt around KDPF - Remove
15 Check for gas leakage around KDPF - Correct
1 Check for unusual noise and smell - Correct
Check for oil leakage -
b: Hydraulic and mechanical equipment
2 Correct
Between
3 Check of hydraulic oil level Refilling of oil
H and L
4 Check of hydraulic oil strainer - Clean and drain
5 Check of hydraulic oil filter - Replace
Between
6 Check of swing machinery case oil level Refilling of oil
H and L
Between Refilling of oil
7 Check of damper case oil level
H and L
8 Check of final drive case oil level - Refilling of oil
from cylinder
9 Air bleeding -
40-12 PC290LC-10
40 Troubleshooting
Judge-
No. Role ment Remedy
value
1 Check of battery terminal for looseness and corrosion - Retighten or replace
2 Check of alternator terminal for looseness and corrosion - Retighten or replace
3 Check of starting motor terminal for looseness and corrosion - Retighten or replace
20 to 30 Charge or replace
4 Check of battery voltage (with engine stopped)
V
Between
5 Check of battery electrolyte level Add or replace
H and L
Check of wiring harness for discoloration, burnt areas and cover
6 peeling - Repair or replace
Check for coming off of wiring harness clamp and sagging of wiring -
7 Correct
harness
c: Electrical parts
8 Check of grounding - Correct

9 Check for loose connector and damaged lock - Repair or replace
10 Check of connector pin for corrosion, bends and deformation - Repair or replace
Dry, clean or
11 Check for water and foreign material in connector -
replace
12 Check of wiring harness for open circuit and short circuit - Repair or replace
13 Check of fuse for blowout and corrosion ― Replace
After few
minutes
Check of alternator voltage (when engine speed is medium or of
14 higher) Replace
operation:
27.5 to
29.5 V
Check of battery relay operation sound (When the starting switch is
15 turned to ON or OFF position) - Replace
16 Check and cleaning of rear view camera - Clean or repair
1 Check of undercarriage - Correct
d: Exterior parts
2 Check of handrails and steps - Correct
3 Check of rear view mirrors - Clean or repair
1 Check of gauges and monitors - Clean or replace

e: Interior parts
2 Check of seat belt - Replace
PC290LC-10 40-13
40 Troubleshooting
Testing procedure before troubleshooting

Walk-around check
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated combustibles around hot engine parts such as the engine, KDPF, and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
failures.
a a1 and a2, —, b1, b2, — refer to the symbols in the table on the previous page.
a1. and b1. Check for unusual noise and smell
Check for unusual noise and smell.
Some causes of unusual noise and smell can damage the machine if they are left as they are. Therefore, stop
the machine immediately when you find any abnormality.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.)
on hot engine parts such as the engine, KDPF, turbocharger, etc.
a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check any oil leaks from the engine and any water leaks from the cooling system. If any of them is abnormal,
carry out a repair.
a5. Check for leakage from fuel line
Check any fuel leaks and damaged hoses and tubes. If any of them is abnormal, carry out a repair.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the radiator.
For removal of dirt from the radiator, see the Operation and Maintenance Manual, "Cleaning and testing of
radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner condenser fins (machine with
the air conditioner)".
a14. Check around KDPF and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around KDPF.
a15. Check around KDPF for gas leakage
Check piping between the turbocharger and KDPF and joints of KDPF for gas leakage (sticking soot, etc.) If
any abnormality is found, repair.
b2. Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage and hoses for cracks and excessive wear, check that the
clearance between them is within the normal range, and then repair any abnormalities.
b3. Check of hydraulic equipment, hydraulic tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the battery.
c16. Check and cleaning of rear view camera
Check the rear view camera for any defect, and repair any failures.
d1. Check of undercarriage (track, sprocket, idler and guard) for abnormalities, wear, loose bolts and
oil leakage from roller
Repair any abnormalities.
d2. Check of handrails and steps for abnormalities and loose bolts
Repair any abnormalities and retighten any loose bolts.
d3. Check and cleaning of rear view mirrors
Check and repair any abnormalities and breakage of the rear view mirrors.
40-14 PC290LC-10
40 Troubleshooting
Clean the mirror surfaces and adjust their angles so that the operator can see the area behind machine at the
operator's seat.
e1. Check of gauges and monitors for abnormalities
Check the gauges and monitors inside the operator cab. If any of them is abnormal, replace it.
Clean up the surfaces.
e2. Check of seat belt and mounting hardware
Check the hooks, locks and hook fittings for damage. If any of them has a problem, replace.
Testing in accordance with testing procedure
a. Engine, lubricating oil and coolant
a7. Check of level and type of fuel
k Fuel is flammable and dangerous. Do not bring any open flame near fuel.
k When adding fuel, take care not to let it overflow.
k Wipe off any spilt fuel. If fuel has spilt over dirt and sand, remove the dirt and sand, too.
1. Turn the starting switch to the ON position and check the fuel level with fuel level gauge (1) in the monitor
panel.
After checking, return the switch to OFF position.
2. If the fuel level is low, open fuel filler cap (F) of the fuel tank and add fuel through the oil filler port to the
necessary level, referring to the position of float gauge (G).
3. After adding fuel, push float gauge (G) straight down with fuel filler cap (F) and tighten fuel filler cap (F)
securely while taking care the float gauge (G) will not be caught in tab (2) of fuel filler cap (F).
PC290LC-10 40-15
40 Troubleshooting
• If breather hole (3) in the oil filler cap is clogged, the pressure in the tank decreases and fuel may not
be supplied. To prevent this, clean the breather hole.
a8. Check for foreign material in fuel

1. Open the side cover on the rear right side of the machine.
2. Place a container under drain hose (1) to receive the drained fuel.
3. Turn drain valve (2) to "OPEN" position (O) to discharge the sediment and water in the bottom together
with the fuel.
4. When only the clean fuel flows out, turn drain valve (2) to "CLOSE" position (S).
5. Close the side cover.
a9. Check of fuel pre-filter

k Immediately after the engine is stopped, its parts and oil will still be very hot may burn your hands
on contact. Therefore, wait until they have cooled down before starting the work.
k High pressure is generated in the engine fuel piping system while the engine is running. Wait for at
least 30 seconds after stopping the engine until the internal pressure decreases, and then replace
the filter.
k Do not bring any open flame near the filter.
40-16 PC290LC-10
40 Troubleshooting
a Komatsu genuine fuel filter cartridges use a special filter with a high filtration efficiency. When replacing,
be sure to use a Komatsu genuine cartridge.
a The common rail fuel injection system of this machine consists of parts that are more precise compared
with the conventional injection pump and nozzle. If a fuel filter cartridge other than Komatsu genuine one
is used, foreign material may enter, which can cause a trouble in the injection system. Never use a
substitute.
a When testing and servicing the fuel system, be extremely careful that no foreign material enters. If any dirt
sticks, remove it completely by using fuel.
• Prepare a container to receive fuel.
• Prepare the filter wrench.
Check of water separator, and drainage of water and sediments
1. Open the side cover.
• The water separator is integrated with fuel pre-filter (1).
2. Transparent cap (2) lets you identify the water level and presence/absence of sediments. If water or
sediments are found, place a container under drain hose (3) to receive the drained water and sediments.
3. Loosen drain valve (4) to drain the water.
4. If drain hose (3) starts to discharge fuel, close drain valve (4) immediately.
a The sensor is installed in this machine for detecting accumulation of water in transparent cap (2).
a If water separator monitor (5) lights up in red on the machine monitor, it indicates that water is
accumulated in transparent cap (2). Drain water from the cap.
a If water in transparent cap (2) is frozen, the water separator monitor may not light up. And after the
engine starts, if the frozen water is melted into water due to the increased temperature surrounding fuel
pre-filter (1), water separator monitor may suddenly light up. Drain water frequently during the cold
season even if water separator monitor (5) is not lit up.
a If water in transparent cap (2) is frozen, drain water only after confirming that it has completely melted.
a If you cannot visually identify the presence of water due to stains on transparent cap (2), clean
transparent cap (2) when replacing fuel pre-filter cartridge (1).
PC290LC-10 40-17
40 Troubleshooting
a When you have removed drain valve (4) for the above cleaning process, coat the O-ring with grease
and tighten drain valve until it touches the bottom.
Replacing fuel pre-filter cartridge
1. Turn valve (1) at the bottom of the fuel tank to the "CLOSE" (S) position.
3. Place a container under the fuel pre-filter cartridge to receive the fuel.
4. Loosen drain valve (2) and drain water and sediments from transparent cup (3), and also drain all the fuel
from filter cartridge (4).
5. Disconnect connector (5). Wrap the removed connector with a vinyl bag and the like to protect it from
being exposed to fuel, oil and water.
6. Using the filter wrench, rotate transparent cap (3) to remove. (This cap is reused.)
7. Using the filter wrench, rotate filter cartridge (4) to remove.
8. Install currently removed transparent cap (3) to the bottom of the new filter cartridge.
a At this time, replace O-ring (6) with a new one.
9. When installing the transparent cap, apply a thin film of oil to the O-ring, set it against the sealing surface
of filter cartridge (4), and then tighten the transparent cap by turning 1/4 to 1/2 turn.
a If the transparent cap is over tightened, fuel will leak because the O-ring will have been damaged. If the
transparent cap is not tightened sufficiently, fuel will also leak through the clearance of the O-ring.
Therefore, observe the tightening angle.
10.Clean the filter holder, fill the new filter cartridge with clean fuel, apply a thin film of oil to the O-ring , and
then install the new filter cartridge on the filter holder.
a Be sure to add fuel through 8 small holes (A) from the dirty side without removing center cap (B).
a After filling with the fuel, remove cap (B) at the center before installing the fuel pre-filter.
a Add clean fuel and take care that dirt will not be mixed in it. Add fuel without removing cap (B) so that
dirt will not enter the clean side of the central part.
40-18 PC290LC-10
40 Troubleshooting
11.When installing the filter cartridge, tighten it by 3/4 turn after the O-ring comes in contact with the sealing
surface of the filter holder.
a If the filter cartridge is over tightened, fuel will leak because the O-ring is damaged. If the filter cartridge
is not tightened sufficiently, fuel will also leak through the clearance of the O-ring. Therefore, observe
the tightening angle.
a When using a filter wrench for tightening, take care not to leave flaws or dents on the filter.
12.Make sure that drain valve (2) is securely closed.
13.Remove the vinyl bag wrapping connector (5) and connect connector (5).
a If connector (5) is exposed to water, the sensor may malfunction, lighting up the water separator
monitor. Whenever disconnecting connector (5), take care not to allow the connector to come in
contact with water.
a If connector (5) does come in contact with water, dry it completely prior to connecting it.
a10. Check of main filter

k High pressure is generated in the engine fuel piping system while the engine is running. Wait for at
least 30 seconds after stopping the engine until the internal pressure decreases, and then replace
the filter.
k Do not bring any open flame near the filter.
a Komatsu genuine fuel filter cartridges use a special filter with a high filtration efficiency. When replacing,
be sure to use a Komatsu genuine cartridge.
a The common rail fuel injection system of this machine consists of parts that are more precise compared
with the conventional injection pump and nozzle. If a fuel filter cartridge other than Komatsu genuine one
is used, foreign material may enter, which can cause a trouble in the injection system. Never use a
substitute.
a When testing and servicing the fuel system, be extremely careful that no foreign material enters. If any dirt
sticks, remove it completely by using fuel.
• Prepare a container to receive fuel.
PC290LC-10 40-19
40 Troubleshooting
• Prepare the filter wrench.

1. Turn valve (1) at the bottom of the fuel tank to the "CLOSE" (S) position.
3. Place a container under the filter cartridge to receive the fuel.
4. Using the filter wrench, rotate filter cartridge (2) to remove.
a If the filter cartridge is removed, the fuel drips from the filter head.
Do not leave the machine with the filter cartridge removed to prevent the fuel from flowing out.
5. Clean the filter holder. Apply a thin film of oil to the packing of the new filter cartridge and install the
cartridge to the filter holder.
a Replace inside seal (3) with a new one.
a Do not fill the new filter cartridge with fuel.

a Remove cap (A) at the center before installing the filter cartridge.
40-20 PC290LC-10
40 Troubleshooting
6. When installing the filter cartridge, tighten it by 3/4 turn after the O-ring comes in contact with the sealing
surface of the filter holder.
a If the filter cartridge is over tightened, fuel will leak because the O-ring is damaged. If the filter cartridge
is not tightened sufficiently, fuel will also leak through the clearance of the O-ring. Therefore, observe
the tightening angle.
7. Turn valve (1) at the fuel tank bottom to "OPEN" (O) position.
8. Bleed air according to the following procedure.
1) Fill the fuel tank up with the fuel (until the float is in the upper limit position).
2) Loosen feed pump knob (4) and draw it out once, then push and pull several times until its movement
becomes stiff.
• You do not need to remove the plugs at the head of the fuel pre-filter and fuel main filter.
• If fuel is used up, bleed air by operating feed pump knob (4) in the same manner.
3) Push in and tighten feed pump knob (4).

9. After replacing the filter cartridge, run the engine at low idle for approximately 10 minutes.
10.Check the filter sealing surface for fuel leakage. If fuel is leaking, check whether the filter cartridge is
appropriately tightened. If fuel leakage recurs after the check, remove the filter cartridge by following the
steps 1 to 4 and check the O-ring for damage or foreign matter being caught. If any of the above problems
are detected on the O-ring, replace the cartridge with a new one. Then, perform step 5 and after.
a11. Check of level (in oil pan) and type of engine oil
a If the engine has been operated, wait for at least 15 minutes after stopping it, and check the oil level.
a When checking, set the machine in a horizontal position.
a When the ambient temperature is low, moisture in the blowby gas may be condensed and water or
emulsion may stick to the oil level gauge or oil filler cap and drained oil may be milky. This phenomenon is
not abnormal, as long as the coolant level has not decreased.
1. Stop the engine.
2. Open up the engine hood.
3. Remove oil level gauge (G) and wipe gauge oil off with a cloth.
PC290LC-10 40-21
40 Troubleshooting
4. Insert oil level gauge (G) fully and pull it out.
5. If the oil level is between stamps H and L on oil level gauge (G), it is at the correct level.
If the oil level is below L, add oil through oil filler port (F).
6. If the oil level is above line H, drain the extra engine oil through drain valve (P) at the bottom of the engine
oil pan and check the oil level again.
7. If the oil is at the correct level, tighten the oil filler cap securely and close the engine hood.
a12. Check of coolant level (in sub tank)

k The radiator cap does not need to be opened for the usual check. Check the coolant level in the
sub tank side while the engine is cold.
k Immediately after the engine is stopped, the coolant is hot and pressure is accumulated in the
radiator.
If the cap is opened under these conditions, you may get burn injury. If you need to remove the
radiator cap, wait until the temperature drops before you do. Then rotate the cap slowly to release
the pressure and remove it with care.
1. Open the side cover at the rear left side of the machine and check whether the coolant level is between
lines FULL and LOW on sub tank (1) (see following figure). If there is not enough coolant, add it through
the coolant filler port of sub tank (1) until the level reaches line FULL.
2. After adding the coolant, tighten the cap securely.
3. If the sub tank is vacant, coolant may have leaked.
After checking, repair any failures immediately. If no failure is found, check the coolant level in the radiator.
If the level is low, add coolant to the radiator first and then to the sub tank.
40-22 PC290LC-10
40 Troubleshooting
4. If sub tank (1) is dirty and it is difficult to check the coolant level, clean it.
a13. Check of air cleaner for clogging

k When using compressed air for cleaning, put on personal protective items such as protective
eyeglasses, gloves, dust mask, etc. to protect yourself from dirt that will fly out.
k Removing the outer element from the air cleaner body forcibly is dangerous .
When working in high places or on unstable footing, you may fall off due to the reaction when you
pull out the outer element. Take care.
Measuring
Clean the air cleaner element if air cleaner clogging monitor (1) on the monitor panel lights up.
a Do not clean the element until the air cleaner clogging monitor lights up on the monitor panel. If the
element is cleaned frequently before the air cleaner clogging monitor on the monitor panel lights up, the
true performance of the air cleaner will not be realized and the filtration efficiency will decrease.
a If the outer element is checked or cleaned while the engine is running, the dirt sticking to it will fall into the
inner element side more frequently and enter and damage the engine. Be sure to stop the engine before
cleaning.
PC290LC-10 40-23
40 Troubleshooting
Cleaning of outer element

a Do not leave or store the element in direct sunlight before or after cleaning it.
a Replace the outer element after cleaning it six times or after using it for one year. When replacing the outer
element, replace the inner element, too.
a If the air cleaner clogging monitor (1) lights up soon after cleaning when the outer element has not been
cleaned up to six times, replace both the inner and outer elements.
1. Open the side cover at the rear left side of the machine and disengage four hooks (2) to remove cover (3).
2. Hold and pull out outer element (5) while swinging it up, down and laterally and rotating element to the left
and right.
a Never remove inner element (6). If it is removed, dirt will enter and cause engine troubles.
a Do not use a tool such as screwdriver.
a After removing outer element (5), check that the inner element has not come off or tilted. If the inner
element is tilted, push it in straight by hand.
3. After removing outer element (5), cover the inner element (6) with a clean cloth or tape to prevent dirt from
sticking to it.
4. Remove any dirt stuck to the inside of air cleaner body (7) and cover (3) with a piece of clean cloth, etc.
a When cleaning the element, do not tap it or bump it against other objects.
5. If dirt has piled up on vacuator valve (4) installed on cover (3), remove it.
40-24 PC290LC-10
40 Troubleshooting
6. Blow dry compressed air (Max. 0.2 MPa {2.1 kg/cm2}) along the inside folds of the outer element.
7. Next, blow air along the outside folds, and blow again along the inside folds.
a After cleaning, light up the inside of the element to check it. If the element has a small hole or a thin
area, replace it.
8. Remove the cloth or tape covering inner element (6).

9. Check and remove any dirt, oil, etc. sticking to the sealing surface of the cleaned or new element.
a If the element or O-ring used for more than one year is cleaned and reused, it can cause a trouble.
Therefore, do not reuse it.
a Do not use the element if its folds, gasket or seal is damaged.
10.Push the outer element straight into the air cleaner body by hand while swinging it up, down and laterally.
a Install the air cleaner element so that its bottom (end with no hole) (C) will be on cover (3) side.
If the air cleaner element is installed in reverse, it may be broken and the engine may be damaged
seriously.
PC290LC-10 40-25
40 Troubleshooting
11.Install cover (3) according to the following procedure.

1) Set cover (3) to the element.
a Be sure to install cover (3) so that vacuator (4) is at the bottom (A).
2) Hitch the tips of hooks (2) to the projection of the air cleaner body to lock.
a Hitch hooks (2) diagonally (top and bottom, or right and left) to lock.
a After installing cover (3), check for clearance between air cleaner body and cover (3). If there is any
clearance, remove and install cover (3) correctly.
12.Peel off a seal after cleaning the element each time.
40-26 PC290LC-10
40 Troubleshooting
Replacement of element
1. Remove outer element (5). For details, see "Cleaning of outer element".
2. Remove inner element (6) and install new inner element (6) quickly to air cleaner body (7).
a Do not clean or reuse the inner element. When replacing the outer element, also replace the inner
element.
seriously.
a If the outer element and cover are installed while the inner element is not installed securely, the outer
element may be broken. Install the inner element securely.
3. Push the outer element straight into the air cleaner body by hand while swinging it up, down and laterally.
seriously.
4. Replace O-ring (8) of cover (3) with a new one.
PC290LC-10 40-27
40 Troubleshooting
5. Install cover (3). For details, see "Cleaning of outer element".

6. Replace seal (9) of cover (3) with a new one.
b. Hydraulic and mechanical equipment

b3. Check of hydraulic oil level
k If the oil filler cap is removed quickly, the oil may spurt out. Therefore rotate the oil filler cap slowly
to release the internal pressure and then remove it.
1. Set the work equipment in the posture as shown below and, after stopping the engine, check the oil level
and add new oil if necessary.
a If the work equipment posture is not as shown below, start the engine, fully retract the cylinder rod for
arm and bucket at engine low idle. Then lower the boom until bucket teeth touch the ground, then stop
the engine.
2. Turn the starting switch to the ON position within 15 seconds after stopping the engine and operate each
control lever (work equipment and travel) to the stroke end in each direction to release the internal
pressure.
40-28 PC290LC-10
40 Troubleshooting
3. Open the side cover on the right side of the machine and check sight gauge (G). If the oil level is between
lines H and L, it is at the correct level.
a If the oil level is below line L, add oil through oil filter port (F).
a Do not add oil to above line H. If too much is added, it may damage the hydraulic circuit and spurt out.
a If the oil level is higher than level H, stop the engine. After the hydraulic oil has cooled, drain excessive
oil through drain plug (P) under the suction tube.
Since the oil level fluctuates according to the oil temperature, note the following when checking it.
• Before operation (oil temperature: 10 to 30°C), the oil level should be at the center between lines H
and L.
• During normal operation (oil temperature: 50 to 80°C), the oil level should be near line H.
b4. Check of hydraulic oil strainer
1. Stop the engine and remove oil filler cap (F) of the hydraulic tank to release the internal pressure.
2. Remove the bolts to remove cover (1).
3. When removing the bolts, keep pressing down cover (1) since it may be flung toward you by spring (2).
4. Pull out rod (3) from the top, and take out spring (2) and strainer (4).
5. Remove dirt from strainer (4) and clean it using cleaning oil. If strainer (4) is damaged, replace it with a
new one.
6. Insert and set strainer (4) in projected portion (5) of the tank.
7. While pressing down spring (2) with the projection at the bottom of cover (1), install the bolts. Tighten the
mounting bolts.
PC290LC-10 40-29
40 Troubleshooting
b5. Check of hydraulic oil filter

1. On a level and firm ground, set the work equipment to the posture as shown below and stop the engine.
2. Remove oil filler cap (F) of the hydraulic tank to release the internal pressure.
3. Remove the bolts to remove cover (1).

When removing the bolts, keep pressing down cover (1) since it may be flung toward you by spring (2).
4. Remove spring (2), valve (3) and strainer (4), and remove element (5).
• Check the bottom of filter case, and if there is any dust etc., remove it. At this time, take extreme care
that dirt does not enter the hydraulic tank.
5. Clean the removed parts using cleaning oil.
6. Install new element (5).
7. Place strainer (4), valve (3) and spring (2) onto the element.
8. Set cover (1) and install it with the mounting bolts while pressing it by hand.
9. Tighten the mounting bolts.
40-30 PC290LC-10
40 Troubleshooting
10.Install oil filler cap (F).

11.Run the engine at low idle speed for 10 minutes to bleed air.
12.Stop the engine.
b6. Check of swing machinery case oil level
1. Remove oil level gauge (G) and wipe gauge oil off with a cloth.
2. Insert oil level gauge (G) fully into the guide.
3. Pull out oil level gauge (G) and check the oil level. If the oil level is between stamped lines (H) and (L) on
the oil level gauge, it is at the correct level.
4. If the oil level is below line (L) on oil level gauge (G), add oil through oil filler (F).
5. If the oil level is above line (H) of oil level gauge (G), loosen drain valve (P) to drain the excessive oil.
• When draining the oil, place an oil container under drain valve (P).
6. After checking the oil level and adding oil, install oil level gauge (G) and oil filler cap (F).
PC290LC-10 40-31
40 Troubleshooting
b7. Check of damper case oil level

k Before checking the oil level, stop the machine in a level place and wait for at least 30 minutes
after the engine is stopped.
2. Remove plug (G) and check the oil level. If the oil level is near the lower edge of the plug hole, there is
sufficient oil. If the oil level is insufficient, remove plug (F) and add oil through the hole of plug (F) up to the
lower edge of the hole for plug (G).
a Since an excessive oil can cause overheat, it must be drained to the specified oil level.
3. Install plug (G) and plug (F).
4. Close the side cover.
b8. Check of final drive case oil level

k Since the oil may spurt out due to internal pressure, rotate the plug gradually from its side to
release the internal pressure and then remove it carefully.
• Refill capacity (right and left, respectively): 5.0 l

• Prepare the handle.
1. Set the final drive with TOP mark at the top, and the straight line connecting the mark and plug (p) is
vertical to the ground surface.
2. Place the fuel receiving container under plug (P).
3. Remove plug (P) and (F) using the handle to drain oil.
a Check the O-ring attached to the plug for damage. Replace it, if any.
4. Tighten plug (P).
5. Supply oil through the hole for plug (F).
6. If oil flows out from the hole for plug (F), install plug (F).
3 Plugs (P) and (F):
68.6 ± 9.8 Nm {7 ± 1 kgm}
40-32 PC290LC-10
40 Troubleshooting
k Plug (F) is provided in two locations. To add oil, use the hole that is easier to use or the internal
gear can not be seen through it.
b9. Performing air bleeding

• For the procedure for bleeding air from the fuel system, see Testing and adjusting, "Bleeding air from fuel
circuit".
• For the procedure for bleeding air from the hydraulic equipment, see Testing and adjusting, "Bleeding air
from each part".
c. Electrical parts
c1. Check of battery terminal for looseness and corrosion
1. Open the side cover at the rear left side of the machine, remove two nuts (1) on the battery top, and
remove two battery covers (2).
2. Check the battery cable terminals for looseness and corrosion.
c2. Check of alternator terminal for looseness and corrosion

• Check alternator terminal B (1) for open circuit, looseness and corrosion.
PC290LC-10 40-33
40 Troubleshooting
c3. Check of starting motor terminal for looseness and corrosion

• Check starting motor terminal B (1) and terminal C (2) for open circuit, looseness and corrosion.
c4. Testing of battery voltage (when engine stops)

• Test the battery voltage by using the battery tester while the engine is stopped.
c5. Check of battery electrolyte level
Check before operating the machine.
k Do not use the battery while its electrolyte level is below LOWER LEVEL. If it is used under that
condition, its inside will deteriorate, its service life will be shortened and it may lead to an
explosion.
k Since the battery produces combustible gas that can explode, do not bring any open flame near it.
k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or skin.
If it does, wash it away with water and contact your doctor.
a Do not add battery electrolyte to above the UPPER LEVEL mark. If too much is added, it can damage the
painted surface of the machine and corrode the parts.
a As refined water (example: commercially available battery fluid) added to the battery may freeze, add it
before starting work for the day so that it will not freeze.
• When checking the electrolyte level through the side face of the battery
1. Clean around the electrolyte level lines with a cloth dampened with water and check that the electrolyte
level is between UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.)
a Do not clean the battery with a dry cloth because static electricity may cause an explosion.
40-34 PC290LC-10
40 Troubleshooting
2. If the electrolyte level is below the center between the U.L. and L.L. lines, remove cap (2) and add refined
water (example: commercially available battery fluid) to the U.L. line immediately.
3. After adding the purified water, tighten cap (2) securely.
a If you have added refined water above the U.L. line, take some of it out using a syringe or similar tool.
Neutralize the liquid that has been taken out by using sodium bicarbonate or other suitable liquid, and
wash it out with a large amount of water.
• When electrolyte level cannot be checked through the side face of the battery
1. Remove cap (2) on the top of the battery. (described previously)
2. Look into electrolyte level check opening (3) to check the electrolyte level. If the electrolyte level is below
sleeve (4), be sure to add refined water (example: commercially available battery fluid) up to the sleeve
bottom (U.L. line).
• (A) Correct level: Since the electrolyte level reaches to the sleeve bottom, the shape of the electrode
plates will appear distorted due to the surface tension.
• (B) Low: Since the electrolyte level does not reach the sleeve bottom, the shape of the electrode plates
will appear straight.
3. After adding the refined water, tighten cap (2).
a If you have added refined water above the U.L. line, take some of it out using a syringe or similar tool.
Neutralize the liquid that has been taken out by using sodium bicarbonate or other suitable liquid, and
wash it out with a large amount of water.
c6. Check of wiring harness for discoloration, burn and cover peeling
PC290LC-10 40-35
40 Troubleshooting
• Check the wiring harness and cables for discoloration and burn.
a Discoloration and burn indicate that short circuit or ground fault is in the circuit.
• Check the wiring harnesses and cables for damage and peeling of the covers.
• If any fault are found, repair or replace the wiring harness or cable.
c7. Check for coming off of wiring harness clamps and sagging of the wiring harness
• Check the wiring harnesses for sagging and play caused by coming off of the clamp.
a In particular, carefully check the wiring harness around the hot and movable parts.
• If any part is off the clamp, secure it by clamp again.
c8. Check of grounding

a Check the ground terminal for looseness and rusting in particular.
• Check the connection of ground terminals (2) and (T01).
• Open the side cover at the rear left of the machine.

• Check the connection of ground terminal (T08).
• Check ground terminals (T04) to (T07), (T09), and (T10) for connection.
40-36 PC290LC-10
40 Troubleshooting
• Open the undercover of the engine.

a Connection of the engine ground cable can be checked by removing the undercover of the engine.
• Check the connection of ground cable (T12) of engine controller (EC).
• Cab ground T02
PC290LC-10 40-37
40 Troubleshooting
a Since (T02) is situated at the bottom on the rear left side of the cab and connected to (T01), it is not
particularly necessary to be checked.
c9. Check for loose connectors and damaged locks

• Pull the male and female halves of the connector by hand to check the condition of their connection.
• If the connection is not proper, connect it securely.
• Check the connector for unlocking and check its lock portion and housing for cracks.
• Check lock screws (L) of engine controller (EC) for looseness.
a Use a hexagonal wrench with 4 mm width across flats.
c10. Check of connector pin for corrosion, bends and deformation

• Disconnect the connector and check the pins for corrosion, bending and resession. Check that the female
pins have not expanded.
• If any pin is found to be defective, repair or replace it.
a If the pins are not shiny, apply contact restorer to them and connect and disconnect several times to shine
them. (If the pins do not become shiny, connect and disconnect the connector ten times)
c11. Check for water and foreign material in the connector
• Disconnect the connector and check whether there is water, dirt, sand, etc. in it.
40-38 PC290LC-10
40 Troubleshooting
a If there is sand or foreign matter in the connector, check the seal for damage.
• If the seal is defective, repair or replace it.
• Dry the moisture in the connector using a drier.
• Remove foreign matter in the connector using a cloth or other material, and blow compressed air against
the inside of the connector.
c12. Check of wiring harness for open or short circuit

• Check the connections (crimped parts) between each connector pin and wiring harness.
• If there is any open circuit in wiring harness or connector as illustrated in (A), repair or replace them.
PC290LC-10 40-39
40 Troubleshooting
• Check whether any pins are touching any adjacent pins due to peeling of the insulation, defective crimping
of the pin, etc.
c13. Check of fuse for blowout and corrosion
a When replacing a fuse, be sure to turn off the power (turn the starting switch to OFF position) and turn the
battery disconnect switch to OFF position.
• A fusible link is a large-capacity fuse.
• If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse holder,
replace the fuse.
• Replace the fuse with a new one of the same capacity.
Remove the cover at the right rear of the operator seat, and the fuse holder is seen.
Remove the top cover of the air cleaner and remove the battery relay cover, and fusible links (F04) and (F05)
are seen.
c14. Check of alternator voltage (when engine speed is medium or higher)

1. Open up the engine hood.
2. Connect the positive (+) line of the tester to alternator terminal (B) and connect the negative (-) line to the
chassis ground.
3. Start and warm up the engine and measure the voltage while running the engine at a medium or a higher
speed.
40-40 PC290LC-10
40 Troubleshooting
• If the voltage is abnormal, repair or replace the alternator.

c15. Check of battery relay operation sound
1. Open the side cover on the left side of the machine.
2. Check whether the battery relay operation sound is heard when the starting switch is turned to the ON/
OFF positions.
• If the operation sound is not heard, check the related circuits, referring to E-1 in the E mode.
• If the related circuits are free from abnormalities, replace the battery relay.
PC290LC-10 40-41
40 Troubleshooting
Preparation work for troubleshooting of electrical system

a When carrying out troubleshooting of an electric
circuit related to the machine monitor, engine
controller, pump cont roller, or KOMTRAX
communication MODEM, expose the related
connectors according to the following procedure.
a Disconnect and connect the connectors, which
have a special locking device, according to the
Preparation work
1. Machine monitor
1) Remove the screws (three pcs.) mounting
cover (1). 4) Insert or connect troubleshooting T-adapters
in or to connectors CM01, CM02, and CM04
a One of the three screws is covered with on machine monitor (7).
cap (2).
a Disconnect connector P31 of the sunlight
sensor and remove cover (1).
1) Remove the undercover.
a The engine controller is mounted on the
2) Remove a mounting bolt and duct (6).
engine (on the counterweight side).
3) Insert a flat-head screwdriver in slit (3) and
2) Insert or connect troubleshooting T-adapters
pull it up around projection (4) to remove
in or to connectors ECMJ1, ECMJ2, and
cover (5).
CE03 on engine controller (8).
a Connectors are fixed with screw. Loosen
the screws before disconnecting them.
a When returning, tighten the screw to the
specified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
3. Pump controller
40-42 PC290LC-10
40 Troubleshooting
1) Slide the operator's seat and seat stand to a The connectors of the pump controller
the forward end. have a special locking mechanism.
2) Remove the five mounting bolts and cool & Disconnect them according to steps (a) to
hot box (9). (c) and connect them according to steps
(d) to (f) as shown below.
a While removing the cool and hot box,
disconnect the drain hose. Disconnection: (a) Unlock - (b) Slide lever
3) Remove the two mounting bolts, one - (c) Disconnect connector.
fastener, and magazine box (10). Connection: (d) Position connector - (e)
4) Remove the three mounting bolts and cover Slide lever - (f) Lock.
(11).
5) Remove the seven mounting bolts and cover
(14).
4. KOMTRAX communication module

1) Slide the operator's seat and seat stand to
the forward end.
6) Connect test adapters to connectors CP01 2) Remove the five mounting bolts and cool &
and CP02 of pump controller (15). hot box (9).
a Connect the adapters to only the harness. a While removing the cool and hot box,
disconnect the drain hose.
3) Remove the two mounting bolts, one
fastener, and magazine box (10).
4) Remove the three mounting bolts and cover
(11).
5) Remove the seven mounting bolts and cover
(14).
6) Connect troubleshooting T-adapters to

connectors CK01 and CK02 of KOMTRAX
communication module (15).
PC290LC-10 40-43
40 Troubleshooting
a Disconnection and connection of connector

The connector of the boost pressure
temperature sensor has a special locking
mechanism. Disconnect it according to steps
(a) - (b), and connect it according to steps (c)
- (d) as shown below.
Disconnection: (a) Unlock - (b) Disconnect
connector.
Connection: (c) Connect connector - (d) Lock.
5. Ambient pressure sensor (AMBAIR

PRESSURE)
Engine Ne speed sensor (Crank sensor)
Engine Bkup speed sensor (Cam sensor)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, engine oil pressure
switch have a special locking device. a Removal and installation of sensor
Disconnect them in the order of steps (a) – A torx wrench is necessary for removal and
(c) and connect them in the order of steps (d) installation of the boost pressure
– (f) as shown below. temperature and sensor. See "Tools for
Disconnection: (a) Slide lever - (b) Unlock - testing, adjusting and troubleshooting".
(c) Disconnect connector. 7. Supply pump IMV solenoid (Fuel regulator)
Connection: (d) Connect connector - (e) Lock a Disconnection and connection of connector
- (f) Slide lever.
The connector of the supply pump IMV
solenoid has a special locking mechanism.
Disconnect it according to steps (a) to (b),
and connect it according to steps (c) to (d) as
shown below.
connector.
a Removal and installation of sensor

A deep socket is necessary for removal and
installation of the engine oil pressure switch.
See "Tools for testing, adjusting and
troubleshooting".
6. Boost pressure temperature sensor (BOOST
PRES & IMT)
8. Common rail pressure sensor (Fuel rail
press)
40-44 PC290LC-10
40 Troubleshooting

The connector of the common rail pressure
sensor has a special locking mechanism.
Disconnect it according to steps (a) to (b),
and connect it according to steps (c) to (d) as
shown below.
connector.
9. Engine coolant temperature sensor (Coolant

temp)
The connector of the engine coolant
temperature sensor has a special locking
mechanism. Disconnect it according to steps
(a) to (b), and connect it according to steps
(c) to (d) as shown below.
connector.
a Precautions for disconnecting connector
The direction of the lock on the connector
varies depending on position at which the
tightening of the sensor has been stopped
and the lock may be in a direction in which it
is difficult to unlock (lock faces the engine or
downward).
In this case, pinch the lock in direction (a) by
bent-longnose pliers [1] (commercially
available), and the lock is unlocked.
The lock clicks when it is unlocked, so
disconnect the connector after a click is
heard.
a Removal and installation of sensor

A deep socket is necessary for removal and
installation of the engine coolant temperature
sensor. See Testing and adjusting,
"Troubleshooting tools table".
a Precautions for connecting connector

Take care not to connect the connector
reversely.
Engage lock (e) on the wiring harness side
with triangular projection (f) on the sensor
side (Do not engage lock (e) with square
guide (g) on the opposite side of triangular
projection (f)).
PC290LC-10 40-45
40 Troubleshooting
Classification and procedure for troubleshooting

Classification of troubleshooting
Mode Content
Display of Troubleshooting by failure code
code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
S-mode Troubleshooting engine
Procedure for troubleshooting

If a problem occurs in the machine, go to the corresponding troubleshooting section according to the following
procedure.
1. Troubleshooting procedure to be taken when action level and failure code are displayed on
machine monitor:
If an action level and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding [Display of code] according to the displayed failure code.
a If multiple problems occur simultaneously, all the failure codes for the problems are displayed
repeatedly in order. Record all the failure codes.
2. Troubleshooting procedure to be taken when action level and failure code are not displayed on
normal screen of machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1])
1) If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and
then see if the trouble is still detected. (See [*2])
a A failure code of the mechanical system cannot be deleted.
a If abnormality related to air conditioner is displayed in electrical system abnormality record, perform
"Check with self-diagnosis" in "Air conditioner".
2) If no failure code is recorded in the abnormality record, a failure that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the problem which seems to be a failure again and select the same problem from
the table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out
troubleshooting corresponding to that problem in the [E-mode], [H-mode], or [S-mode].
3. Actions to take after failure is repaired
Referring to following page, delete all failure codes in electrical system abnormality record.
[*1]、[*2]
1. On the normal operation screen, while pressing number key [4] in the panel switch section, press [1], [2],
and [3] in this order.
2. On the service menu screen, press switch [F3] (▽) in the panel switch section twice, and then select "03
Abnormality Record".
3. Press switch [F6] in the panel switch section to confirm, and then enter the "Abnormality record" screen.
40-46 PC290LC-10
40 Troubleshooting
4. Press switch [F6] in the panel switch section to confirm, and then enter the "Mechanical system failure
record" screen.
5. Press switch [F3] (▽) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a A failure code of the mechanical system cannot be deleted.
6. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
7. Similarly to 2 and 3, enter the "Electrical system abnormality record" screen.
8. Press switch [F3] (▽) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a If [E] is displayed on the left of a failure code, that failure code is "active" (the failure is still occurring or
normal resetting is not confirmed yet). If [E] is not displayed on the left of a failure code, that failure
code is "non-active" and disappears in the following clearing step. Accordingly be sure to take record
of that failure code.
9. While pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order to enter the
"Clearing mode". (Same as 1)
10.Press switch [F2] (CLEAR) in the panel switch section.
11.Press switch [F6] in the panel switch section to clear all failure codes temporarily.
12.Press switch [F5] (return) in the panel switch section to return to the "Electrical system abnormality record"
screen. Check if there is any failure code still displayed and take record.
13.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
PC290LC-10 40-47
40 Troubleshooting
14.Take record of information of all columns.

a Similarly to the electrical system abnormality record, if "E" is displayed on the left of a failure code, that
failure code is "active"
(the failure is still occurring or normal resetting is not confirmed yet).
15.Press switch [F2] (CLEAR) in the panel switch section to clear all codes temporarily. Check if "Abnormal"
is still displayed and take record. (Same as 10 in [*1] and [*2])
16.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
40-48 PC290LC-10
40 Troubleshooting
Symptom of probable failure and troubleshooting No.
Problem and troubleshooting number

Troubleshooting
No. Problem
Index
Action level, failure code
Action level is displayed on machine monitor. If function key [F5] is pressed,
1 occurring failures list is displayed. Take actions by
The failure code is displayed on the mechanical system abnormality record screen following the
2
failure code.
3 The failure code is displayed on the electrical system abnormality record screen
Troubleshooting
No. Problem
Index
Phenomena related to engine
4 Starting performance is poor. S-4
5 Engine does not start E-1, S-1
6 When starting switch is turned to "START" position, engine is not rotated S-1, E-1
7 Engine is cranked but exhaust gas does not come out S-2
8 Fuel is injected but engine does not start S-3
9 Engine does not pick up smoothly S-5
10 Engine stops during operation S-6, H-2
11 Engine runs rough or is unstable S-7
12 Engine lacks power S-8
13 Exhaust gas color is black (KDPF is prematurely plugged) S-9
14 Oil consumption is increased. S-10
15 Oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Oil pressure drops S-14
19 Fuel in oil S-15
20 Oil is mixed with water (milkiness) S-16
21 Coolant temperature rises too high (overheating) S-17
22 Unusual noise is heard S-18
23 Vibration is excessive S-19
24 Frequency of automatic regeneration is increased S-20
25 A longer time is taken for forced regeneration S-21
26 White smokes are emitted during forced regeneration. S-22
27 Manual preheater does not operate. E-2
28 Automatic preheating function does not work. E-3
29 While preheater is operating, preheating monitor does not light up. E-4
30 Automatic warm-up system does not work (in cold weather). E-26
When auto-decelerator switch is operated, auto-decelerator monitor does not light
31 up or does not go off. E-27
32 Auto-decelerator is not operated or canceled with lever. E-28
Symptom related to work equipment, swing and travel
33 Any of work equipment, swing, and travel does not work. E-36, H-3
34 All of work equipment, swing, and travel mechanism do not lock. E-37
35 Speed or power of all work equipment, swing and travel is low. H-1
36 Engine speed lowers extremely or engine stalls. H-2, S-6
When working mode switch is operated, working mode selection screen is not
37 displayed. E-29
When working mode is changed, setting of engine and hydraulic pump is not
38 changed. E-30
39 Abnormal sound comes out from around hydraulic pump H-4
PC290LC-10 40-49
40 Troubleshooting
Troubleshooting
No. Problem
Index
40 Fine control performance or response is low H-5
Problems related to work equipment
41 Speed or power of boom is low. H-6
42 Speed or power of arm is low. H-7
43 Speed or power of bucket is low H-8
44 Work equipment single operation does not function. H-9
45 Hydraulic drift of boom is large. H-10
46 Hydraulic drift of arm is large. H-11
47 Hydraulic drift of bucket is large. H-12
48 Time lag in work equipment operation is large. H-13
49 When performing hydraulic relief of a work equipment, other work equipment move. H-14
50 Power maximizing function does not work. H-15, E-40
51 Power maximizing function is not reset. E-41
52 When attachment is installed, attachment circuit is not switched to desired one. H-34, E-58
53 Flow rate of attachment circuit cannot be adjusted H-35
Problems related to combined operation
54 Work equipment on large load side moves slower during combined operation H-16
When performing combined operation of swing and boom RAISE , boom RAISE
55 speed is slow. H-17
When performing combined operation of swing and travel , travel speed lowers
56 significantly. H-18
Problems related to travel
57 Machine deviates during travel H-19
58 Travel speed is low H-20
59 Machine is not steered well or steered-travel power is low. H-21
60 Travel speed does not switch or travel speed is too low or high. H-22, E-31, E-32
61 Travel system does not work (only one side) H-23
62 Alarm does not sound during travel. E-42
63 Alarm does not stop sounding while machine is stopped. E-43
Problems related to swing
64 Upper structure swings neither to the right nor left H-24
65 Upper structure does not swing in only one direction H-25
66 Swing acceleration is poor or swing speed is slow in both right and left directions. H-26
Swing acceleration performance is poor or swing speed is slow in only one
67 H-27
direction.
Upper structure overruns excessively when it stops swinging in both right and left
68 H-28
directions.
69 Upper structure overruns excessively when it stops swinging in only one direction. H-29
70 Large shock is made when upper structure stops swinging H-30
71 Large unusual noise is heard when upper structure stops swinging. H-31
72 While swing brake is applied, swing drift on slope is large. H-32
73 While swing brake is released, swing drift on slope is large. H-33
When swing brake cancel switch is set to CANCEL position, machine cannot
74 swing. E-38
When swing brake cancel switch is set to Normal position, swing holding brake
75 does not operate. E-39
Problems related to machine monitor
76 When starting switch is turned to ON position, machine monitor displays nothing E-5
When starting switch is turned to ON position (with engine stopped), engine oil level
77 monitor lights up in red. E-6
When starting switch is turned to ON position (with engine stopped), radiator
78 coolant level monitor lights up in red. E-7
79 Engine coolant temperature monitor lights in white while engine is running. E-8
40-50 PC290LC-10
40 Troubleshooting
Troubleshooting
No. Problem
Index
80 Hydraulic oil temperature monitor lights in white while engine is running. E-9
81 Charge level monitor lights up while engine is running. E-10
82 Fuel level monitor lights up in red while engine is running. E-11
83 Air cleaner clogging monitor lights up in red while engine is running. E-12
84 Water separator monitor lights up while engine is running. E-13
85 Engine coolant temperature monitor lights in red while engine is running. E-14
86 Hydraulic oil temperature monitor lights in red while engine is running. E-15
87 Engine oil pressure monitor lights in red while engine is running. E-16
88 Fuel level gauge keeps indicating minimum or maximum. E-17
Fuel level gauge does not indicate actual fuel level (Indication is not minimum or
89 maximum). E-18
90 Engine coolant temperature gauge keeps indicating minimum or maximum. E-19
Engine coolant temperature gauge does not indicate actual coolant temperature
91 (Indication is not minimum or maximum). E-20
92 Hydraulic oil temperature gauge keeps indicating minimum or maximum. E-21
Hydraulic oil temperature gauge does not indicate actual oil temperature (Indication
93 is not minimum or maximum). E-22
94 Displays on machine monitor are different from those for applicable model. E-23
95 Machine monitor does not display partially. E-24
96 Function switch does not operate E-25
97 Alarm buzzer cannot be canceled E-33
98 When starting switch is in OFF position, service meter is not displayed. E-34
99 Machine monitor cannot be set in service mode E-35
100 Horn does not sound. E-44
101 Horn does not stop sounding. E-45
102 When wiper switch is operated, wiper monitor does not light up or go off. E-46
103 When wiper switch is operated, windshield wiper does not operate. E-47
104 When window washer switch is operated, window washer does not operate. E-48
"Testing and
Air conditioner does not operate normally (including failure code related to air troubleshooting
105 conditioner) procedure" in
Chapter 80
106 Monitoring function does not display lever control signal normally E-49 to E-57
Others
107 KOMTRAX system does not work properly E-59
PC290LC-10 40-51
40 Troubleshooting
Information mentioned in troubleshooting table

(Rev. 2011/01)
a The following information is summarized in the troubleshooting table and the related circuit diagram.
Before performing troubleshooting, understand that information fully.
Action level Failure code
Failure name displayed on the Abnormality Record
Display on Display on Failure
screen of the machine monitor
machine monitor machine monitor
Detail of failure Description of the failure detected by the machine monitor or controller
Action of machine
Action to be taken to protect the system and equipment when the machine monitor or
monitor or
controller detects a trouble
controller
Problem on Problem that appears on machine as result of action (above) taken by machine monitor or
machine controller
Related Information related to the detected failure or troubleshooting
information
Probable cause Procedure, measuring location, criteria and remarks
<Contents of description>
• Procedure
• Measuring location
1 Defective component a "Between A – B" means “Measure voltage or resistance and so on
between A and B".
• Criteria to judge probable causes (normal value)
• Remarks required for judgment
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
Open circuit or short circuit in • If the check result shows no abnormality, and unless otherwise
2 wiring harness
specified, proceed to the next step (next cause item).
• Check that the failure is fixed after a failure was found and repaired.
<Failures in wiring harness>
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not connected to ground circuit contacts the ground wiring
Breaking of harness or machine.
3 (Wire breakage or defective • Hot short circuit
contact of connectors) A harness not connected to the power circuit (24 V) contacts with the
power circuit.
• Short circuit
An independent wire in the harness contacts with other wire.
(poor insulation at connector and others)
Ground fault in harness

4
(Contact with GND circuit)
Hot short circuit

5
(Contact with 24 V circuit)
40-52 PC290LC-10
40 Troubleshooting
PC290LC-10 40-53
40 Troubleshooting

<Precautions for troubleshooting>
1. Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapter as follows unless
otherwise specified.
6 Short-circuiting of harness • When "male" or "female" is not indicated with a connector
number, disconnect the connector, and insert T-adapter between
the male and female connectors.
• When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter only to either
male or female connector.
2. Description sequence of pin number and handling of tester lead
For troubleshooting, connect the positive (+) and negative (-) leads
7 Defective controller as shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.
Circuit diagram related
This is the excerpted circuit diagram related to

troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
• NO: Normally Open
• NC: Normally Closed
40-54 PC290LC-10
40 Troubleshooting
Diagnostic procedure for wiring harness open curcuit of pressure

sensor system
a Since the pressure sensor consists not only of resistors but also “electronic circuits“ such as amplifiers, it
may have the differences among the resistances measured and its own polarities. So troubleshooting
must be performed carefully.
Failure codes that require this diagnosis
• CA123: Boost pressure sensor low error
• CA451: Common rail pressure sensor high error
Procedure
1. Measure and record resistance of the pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the connector on the sensor side.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polarities match those of the sensor.
a If measured value is infinite, measure the resistances with multimeter probes exchanged each
other to reverse their polarities and record the finite value obtained as a measured value.
a Since measured values may disperse, measure several times.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when determining whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine
controller connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on the engine controller side,
and connect T-adapter (4) to the connector on the wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
3. Determining open circuit
If there is an “apparent difference“ between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, determine that "wiring harness is open".
a “Apparent difference“ means a difference of 10 or more times.
PC290LC-10 40-55
40 Troubleshooting
Pressure sensor measuring locations and reference values

Measuring location of Internal resistance of
Sensor sensor pins sensor (reference) Remarks
Boost pressure R2: Between (2) and (4) Approx. 100 z Sensor is common to engine
sensor R1: Between (1) and (4) Approx. 200 z models 107 and 114
R2: Between (3) and (1) Approx. 23 kz Sensor is common to engine
Common rail models 107 and 114
pressure sensor R1: Between (1) (+) and If polarities are inverted,
Approx. 10 Mz
(2) (-) resistance is infinite
*: Other connectors to be disconnected when measuring R2' are shown below. (See circuit diagram related to
each failure code)
• When measuring R2' of boost pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
• When measuring R2' of common rail pressure sensor (CA451):
Connectors of boost pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Note the measurements in the table below. (For measuring locations, see the related circuit diagram
described in the troubleshooting page for the failure code.)
Sensor + Wiring
Sensor unit
harness
(Measuring location ofMeasured value (Measuring location of Measured value
Sensor
pins of sensor side
harness side connector
connector)
of engine controller)
R2': Between (37) and
R2: Between (2) and (4)
Boost pressure (47) (*)
sensor R1': Between (44) and
(47)
R2': Between (37) and
Common rail (47) (*)
pressure sensor R1: Between (1) (+) and R1': Between (47) (+)
(2) (-) and (25) (-)
40-56 PC290LC-10
40 Troubleshooting
Connector list and layout

Number
Connector No. Model Equipment name Address
of pins
A13 DT 2 Intermediate connector (boom working lamp) H1
A15 DT 2 Intermediate connector (rear working lamp) I9
Intermediate connector (camera 1) [rear view
A40 DT 4 camera] K9
A41 DT 4 Intermediate connector (camera 2) S1
A42 DT 4 Intermediate connector (camera 3) S1
A45 DT 4 Camera 1 L8
AB Terminal 2 Alternator (terminal B) AJ8
AC01 YAZAKI 10 Air conditioner unit X5
AC02 SUMITOMO 4 Air conditioner unit X9
Air conditioner compressor electromagnetic
AC03 X 1 AE3
clutch
AMB. AIR Ambient pressure sensor
FRAMATOME 3 AE3
PRESSURE
BOOST Boost pressure & temperature sensor
SUMITOMO 4 AJ4
PRESS. & IMT
CAM SENSOR FRAMATOME 3 Cam (Bkup) speed sensor AE1
CE03 DRC26 60 Engine controller AE2
CK01 070 18 KOMTRAX terminal X7
CK02 070 12 KOMTRAX terminal X7
CM01 070 18 Machine monitor O5
CM02 070 12 Machine monitor O5
CM04 070 8 Machine monitor (for camera connection) O5
COOLANT Coolant temperature sensor
DELPHI 2 AE3
TEMP
CP01 AMP 81 Pump controller V9
CP02 AMP 40 Pump controller W9
CRANK Crankshaft (Ne) speed sensor
FRAMATOME 3 AE1
SENSOR
D01 SWP 8 Diode array M9
D02 SWP 8 Diode array N9
D03 SWP 8 Diode array N9
E01 Terminal 1 Ribbon heater AJ3
E08 DT 2 Intermediate connector (alternator) AJ7
E10 DT 1 Intermediate connector (starting motor) AJ6
E12 SUMITOMO 3 Alternator (terminals IG and L) AJ9
E25 FRAMATOME 4 KDPF pressure sensor AI5
E26 FRAMATOME 4 KDPF temperature sensor AI5
ECM J1[CE01] DRC26 60 Engine controller AI2
ECM J2[CE02] DRC26 60 Engine controller AJ2
EXHAUST
GAS Exhaust temperature sensor
FRAMATOME 2 AG5
TEMPERA-
TURE
EXHAUST Exhaust pressure sensor
FRAMATOME 3 AE5
PRESSURE
F01 ― ― Fuse box T9
F04 L 2 Fusible link (65A) C7
F05 M 2 Fusible link (30A) C9
F11 Terminal 1 Slow-blow fuse C8
F12 Terminal 1 Slow-blow fuse C8
FUEL RAIL Common rail pressure sensor
BOSCH 3 AJ4
PRESS
PC290LC-10 40-57
40 Troubleshooting
Number
of pins
H08 M 4 Intermediate connector (speaker) X4
H09 M 8 Intermediate connector (cab roof) X4
Intermediate connector (R.H. console wiring
H14 S090 22 harness) S9
Intermediate connector (R.H. console wiring
H15 S090 22 harness) U1
Intermediate connector (L.H. console wiring
H16 S090 22 harness) X3
INJECTOR #1 Terminal 2 Injector #1 AE4
INJECTOR #2 Terminal 2 Injector #2 AE5
INJECTOR #3 Terminal 2 Injector #3 AF5
INJECTOR #4 Terminal 2 Injector #4 AG5
INJECTOR #5 Terminal 2 Injector #5 AH5
INJECTOR #6 Terminal 2 Injector #6 AI5
INJECTOR Intermediate connector (injectors #1 and #2)
DT 4 AE4
CYL 1&2
DT 4 AJ4
CYL 3&4
DT 4 AJ5
CYL 5&6
INLET
METERING BOSCH 2 Supply pump solenoid (IMV) AJ3
VALVE
INTER-
DT 12 Intermediate connector AH5
CONNECT
J01 J 20 Junction connector (black) W3
J02 J 20 Junction connector (pink) W2
J03 J 20 Junction connector (orange) V2
J04 J 20 Junction connector (pink) X3
J05 J 20 Junction connector (pink) X6
J06 J 20 Junction connector (orange) X8
K01 M 2 Resistor for PC-EPC valve O8
K02 DT 3 CAN terminating resistor 1 AG1
L01 DT 2 Boom working lamp E8
L02 DT 2 R.H. working lamp F2
L03 M 2 Room lamp S9
L05 SWP 2 Intermediate connector (revolving warning lamp) AC8
L09 DT 2 Rear working lamp J9
L15 DT 2 Revolving warning lamp AB9
L19 DT 2 System operating lamp B7
M01 PA 10 Radio U1
M01A ― 3 Radio (AUX jack) ―
M01B M 3 Intermediate connector (AUX) AD2
M01C ― 3 AUX (audio external input) jack AC1
M02 M 2 L.H. speaker AD8
M03 M 2 R.H. speaker AC9
M04 YAZAKI 2 Cigarette lighter S9
M05 M 6 Front window wiper motor O4
M06 YAZAKI 2 Front window washer motor E2
M07 090 2 Horn (high tone) G1
M08 090 2 Horn (low tone) G1
M09 M 2 Optional power supply connector (1) M5
M10 M 2 Intermediate connector (optional power supply) N5
40-58 PC290LC-10
40 Troubleshooting
Number
of pins
M11 DT 6 DC/DC converter X6
M12 M 2 Optional power supply connector (2) X6
M13A M 2 12 V power supply socket (1) X8

M13B M 2 12 V power supply socket (2) X7
M14 DT 2 Travel alarm K2
Optional power supply connector (continuous
M1A M 2 power supply) [power take-out] M5
M35 DT 2 Air suspension V1
M36 DT 2 Heated seat U1
M40 X 2 Cab L.H. headlamp AB1
M41 X 2 Cab R.H. headlamp Y8
M80 X 3 Bucket quick coupler control box O7
M81 X 2 Bucket quick coupler solenoid valve J2
N08 DT 12 Service connector T9
OEM
CONNECTION FRAMATOME 24 Intermediate connector (engine wiring harness) AI1
[E24]
OIL
PRESSURE FRAMATOME 2 Engine oil pressure switch AE2
SWITCH
P01 AMP 3 Bucket CURL PPC pressure sensor D3
P02 AMP 3 Boom LOWER PPC pressure sensor D3
P03 AMP 3 L.H. swing PPC pressure sensor D2
P04 AMP 3 Arm IN PPC pressure sensor D3
P05 AMP 3 Bucket DUMP PPC pressure sensor D3
P06 AMP 3 Boom RAISE PPC pressure sensor D2
P07 AMP 3 R.H. swing PPC pressure sensor D3
P08 AMP 3 Arm OUT PPC pressure sensor D2
P09 AMP 3 L.H. travel FORWARD PPC pressure sensor P1
P10 AMP 3 L.H. travel REVERSE PPC pressure sensor Q1
P11 AMP 3 R.H. travel FORWARD PPC pressure sensor P1
P12 AMP 3 R.H. travel REVERSE PPC pressure sensor P1
Intermediate connector (service PPC pressure
P13 X 2 switch) O3
R.H. attachment control pedal forward tilt PPC
P14 X 2 pressure switch O3
R.H. attachment control pedal backward tilt PPC
P15 X 2 pressure switch O2
L.H. attachment control pedal forward tilt PPC
P16 X 2 pressure switch Q1
P17 S090 2 Dual pressure switch V2
P18 090 2 Outside air temperature sensor L3
P20 M 3 Fuel control dial P8
P21 DT 2 Fuel level sensor G9
P22 DT 2 Hydraulic oil temperature sensor J9
P23 DT 2 Air cleaner clogging sensor B7
P24 X 2 Coolant level sensor K3
P25 AMP 3 Front pump pressure sensor B3
P26 AMP 3 Rear pump pressure sensor B3
P27 DT 3 Front pump swash plate sensor H9
P28 DT 3 Rear pump swash plate sensor H9
PC290LC-10 40-59
40 Troubleshooting
Number
of pins
L.H. attachment control pedal backward tilt PPC
P30 X 2 pressure switch R1
P31 050 2 Sunlight sensor O6
P44 DT 2 Engine oil level sensor AJ7
P47 DT 2 Water-in-fuel sensor G9
P49 AMP 3 Service pressure sensor G9
P55 FRAMATOME 4 MAF sensor C8
P57 FRAMATOME 3 Crankcase pressure sensor K9
R01 Terminal 1 Battery relay (terminal E) B9
R02 Terminal 1 Battery relay (terminal BR) B9
R03 Terminal 1 Battery relay (terminal M) A9
R04 Terminal 1 Battery relay (terminal B) A9
R05 Relay 5 Lamp relay T9
R06 Relay 5 Starting motor cut-off relay (for PPC lock) V9
R07 Relay 5 Starting motor cut-off relay (for personal code) V9
R08 Relay 5 Horn relay U9
R10 Relay 5 Rear working lamp relay U9
R12 Relay 5 Cab headlamp relay T9
R15 Terminal 1 Ribbon heater relay (coil circuit) C8
R16A Terminal 1 Ribbon heater relay (switch circuit) C7
R16B Terminal 1 Ribbon heater relay (switch circuit) C9
R17 DT 2 Safety relay (terminals S and R) C9
R18 Relay 5 Automatic preheating relay W9
Air conditioner compressor electromagnetic
R21 Relay 5 W9
clutch relay
R28 Terminal 1 Safety relay (terminal C) A8
R29 Terminal 1 Safety relay (terminal B) A8
S01 ― 5 Starting switch P7
S02 SWP 6 Lamp switch P8
S04 SWP 6 Swing lock switch Q8
S07 SWP 6 Revolving warning lamp switch Q8
S10 Y090 2 Horn switch R1
S11 Y090 2 One-touch power max. switch T1

S14 M 3 PPC lock switch U1
S18 SWP 6 Engine shutdown secondary switch T1
S19 DT 2 Seatbelt alarm switch S1
S21 ― 12 Emergency pump drive switch O9
S22 ― 4 Swing brake cancel switch O9
Intermediate connector (emergency operation
S25 090 16 switch) O8
S30 S 8 Model selection connector U9
SB Terminal 2 Starting motor (terminal B) AH6
SC Terminal 1 Starting motor (terminal C) AH5
T01 Terminal 2 Floor frame ground W2
T02 Terminal 1 Cab ground AD2
T03 Terminal 1 Radio ground T1
T04 Terminal 1 Revolving frame ground H1
T05 Terminal 1 Revolving frame ground I1
40-60 PC290LC-10
40 Troubleshooting
Number
of pins
T08 Terminal 1 Revolving frame ground K3
T09 Terminal 1 Revolving frame ground J2
T10 Terminal 1 Revolving frame ground J2
T12 Terminal 1 Engine controller ground L7
TERMINATOR CAN terminating resistor 2
DT 3 AI1
PORT
TOOL PORT DT 3 Communication connector AH1
V01 DT 2 PPC lock solenoid valve C1
V02 DT 2 2-stage relief solenoid valve A1
V03 DT 2 Swing holding brake solenoid valve C2
V04 DT 2 Travel speed increase solenoid valve A2
V05 DT 2 Travel junction solenoid valve C2
V06 DT 2 Swing cut-off solenoid valve A3
V07 DT 2 Attachment selector solenoid valve A2
V11 DT 2 Front pump PC-EPC valve J9
V12 DT 2 Rear pump PC-EPC valve I9
V19 DT 2 LS-EPC valve L9
V23 DT 2 Merge-divider EPC valve (for main spool) B4
V24 DT 2 Merge-divider EPC valve (for LS spool) C4
V25 DT 2 Variable back pressure solenoid valve B3
V30 DT 2 Oil flow adjuster EPC valve for attachment O3
W03 X 2 Window rear limit switch AB9
PC290LC-10 40-61
40 Troubleshooting
Layout of connector (1/6)
40-62 PC290LC-10
40 Troubleshooting
(2/6)
PC290LC-10 40-63
40 Troubleshooting
(3/6)
40-64 PC290LC-10
40 Troubleshooting
(4/6)
PC290LC-10 40-65
40 Troubleshooting
(5/6)
40-66 PC290LC-10
40 Troubleshooting
(6/6)
PC290LC-10 40-67
40 Troubleshooting
Connector contact identification
(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-68 PC290LC-10
40 Troubleshooting
PC290LC-10 40-69
40 Troubleshooting
40-70 PC290LC-10
40 Troubleshooting
PC290LC-10 40-71
40 Troubleshooting
40-72 PC290LC-10
40 Troubleshooting
PC290LC-10 40-73
40 Troubleshooting
40-74 PC290LC-10
40 Troubleshooting
PC290LC-10 40-75
40 Troubleshooting
40-76 PC290LC-10
40 Troubleshooting
PC290LC-10 40-77
40 Troubleshooting
40-78 PC290LC-10
40 Troubleshooting
PC290LC-10 40-79
40 Troubleshooting
40-80 PC290LC-10
40 Troubleshooting
PC290LC-10 40-81
40 Troubleshooting
40-82 PC290LC-10
40 Troubleshooting
PC290LC-10 40-83
40 Troubleshooting
40-84 PC290LC-10
40 Troubleshooting
PC290LC-10 40-85
40 Troubleshooting
40-86 PC290LC-10
40 Troubleshooting
PC290LC-10 40-87
40 Troubleshooting
40-88 PC290LC-10
40 Troubleshooting
PC290LC-10 40-89
40 Troubleshooting
40-90 PC290LC-10
40 Troubleshooting
PC290LC-10 40-91
40 Troubleshooting
40-92 PC290LC-10
40 Troubleshooting
PC290LC-10 40-93
40 Troubleshooting
40-94 PC290LC-10
40 Troubleshooting
PC290LC-10 40-95
40 Troubleshooting
40-96 PC290LC-10
40 Troubleshooting
PC290LC-10 40-97
40 Troubleshooting
40-98 PC290LC-10
40 Troubleshooting
PC290LC-10 40-99
40 Troubleshooting
40-100 PC290LC-10
40 Troubleshooting
PC290LC-10 40-101
40 Troubleshooting
40-102 PC290LC-10
40 Troubleshooting
PC290LC-10 40-103
40 Troubleshooting
40-104 PC290LC-10
40 Troubleshooting
T-branch box and T-branch adapter table

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
799-601- T-box (for ECONO) 21 q q q q q

2600
799-601- T-box (for MS) 37 q
3100
799-601- T-box (for MS) 37 q
3200
799-601- Plate for MS (14-pin) q
3380
799-601- Adapter for BENDIX (MS) 24 MS-24P q
3410
3420
3430
3440
3450
3460
3510
3520
3530
2910
799-601-
Case q
3470
799-601- Adapter for MIC 5 MIC-5P q q q
2710
799-601- Adapter for MIC MIC-
13 q q q
2720 13P
17 q q q q q q
2730 17P
21 q q q q q q
2740 21P
799-601- Adapter for MIC 9 MIC-9P q q q q
2950
799-601- Adapter for ECONO ECONO
2 q q
2750 2P
3 q q
2760 3P
4 q q
2770 4P
PC290LC-10 40-105
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201

8 q q
2780 8P
12 q q
2790 12P
799-601- Adapter for DLI 8 DLI-8P q q
2810
2820
2830
799-601- Extension cable (ECONO type) ECONO
12 q q q
2840 12P
799-601-
Case q
2850
799-601- q
T-box (for DRC60, ECONO) 60
4350
799-601- q
Case
4360
799-601- Adapter for X (T-adapter) 1 q q
7010
799-601- Adapter for X 2 X2P q q q q
7020
7030
7040
799-601- Adapter for SWP 6 SW6P q q q
7050
799-601- Adapter for SWP 8 SW8P q q q
7060
799-601- Adapter for SWP 12 SW12P q
7310
799-601- Adapter for SWP 14 SW14P q q
7070
799-601- Adapter for SWP 16 SW16P q
7320
799-601- Adapter for M (T-adapter) 1 q q
7080
799-601- Adapter for M 2 M2P q q q q
7090
7110
7120
7130
799-601- Adapter for M 8 M8P q
7340
799-601- Adapter for S 8 S8P q q q q
7140
799-601- Adapter for S (White) 10 S10P q q q q
7150
40-106 PC290LC-10
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601- Adapter for S (Blue) 12 S12P q q q

7160
799-601- Adapter for S (Blue) 16 S16P q q q q
7170
799-601- Adapter for S (White) 16 S16PW q
7330
799-601- Adapter for S (White) 12 S12PW q
7350
799-601- Adapter for AMP040 8 A8P q
7180
799-601- Adapter for AMP040 12 A12P q q
7190
799-601- Adapter for AMP040 16 A16P q q q q
7210
799-601- Adapter for AMP040 20 A20P q q q q
7220
799-601-
Short connector for X 2 q q q q
7230
799-601-
Case q q
7240
799-601-
Case q
7270
799-601- Adapter for 070 10 07-10 q
7510
799-601- Adapter for 070 12 07-12 q
7520
799-601- Adapter for 070 14 07-14 q
7530
799-601- Adapter for 070 18 07-18 q
7540
799-601- Adapter for 070 20 07-20 q
7550
799-601- Adapter for relay 5 REL-5P q
7360
799-601- Adapter for relay 6 REL-6P q
7370
799-601- Adapter for JFC 2 q
7380
799-601- q
Adapter for DTM 2 DTM2 q
9010
799-601- q q q
Adapter for DT 2 DT2 q
9020
799-601- q
9030
799-601- q q q
9040
799-601- q
9050
799-601- q
Adapter for DT (gray) 8 DT8GR q
9060
799-601- q
Adapter for DT (black) 8 DT8B q
9070
PC290LC-10 40-107
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601- q
Adapter for DT (green) 8 DT8G q
9080
799-601- q
Adapter for DT (Brown) 8 DT8BR q
9090
799-601- DT12G- q
Adapter for DT (gray) 12 q
9110 R
799-601- q
Adapter for DT (black) 12 DT12B q
9120
799-601- q
Adapter for DT (green) 12 DT12G q
9130
799-601- q
Adapter for DT (Brown) 12 DT12BR q
9140
799-601- Adapter for HD30-18 8 D18-8 q q
9210
9220
9230
9240
9250
9260
9270
9280
9290
799-601- q
Plate for HD30 (24-pin) q q
9310
799-601- q
T-box (for ECONO) 24 q q
9320
799-601-
Case q
9330
799-601-
Case q
9340
799-601- q
Adapter for DRC 40 DRC-40
9350
799-601- q
Adapter for DRC 24 DRC-24
9360
799-601- Socket for engine (CRI-T2) 2 G q
9410*
Adapter for engine (CRI-T2) q q
799-601- Adapter for engine (CRI-T3)
PFUEL 3 A3
9420
Oil pressure sensor
799-601- Socket for engine (CRI-T2) q q
2 P
9430* Socket for engine(CRI-T3) PCV
799-601- Socket for engine (CRI-T2) 1, 2, 3
3 q
9440*
40-108 PC290LC-10
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
795-799- Socket for engine (HPI-T2) 2 S q

5520*
Socket for engine (HPI-T2) q q
795-799- Socket for engine (CRI-T3) 2 C
5530*
Temperature sensor
795-799- Socket for engine (HPI-T2) q q
2 A
5540* Socket for engine(CRI-T3) TIM
795-799- Cable for engine (HPI-T2) 3 q
5460
5470
5480
799-601- q q
Adapter for engine (140-T3) PIM 4 ITT3N
4110
799-601- Adapter for engine (CRI-T3) NE, q q
3 FCIN
4130 CAM
799-601- Adapter for engine (CRI-T3) q q
3 FCIG
4140 Ambient pressure
3 FCIB
4150 POIL
2 4160
4160 Oil pressure switch
3 4180
4180 PEVA
3 1, 2, 3L
4190* Rail pressure
799-601- Socket for engine (CRI-T3) 1, 2, 3, q q
4
4230* Air intake pressure/temperature 4C
3 1, 2, 3A
4240* PAMB
799-601- q q
Socket for engine (CRI-T3) PIM 3 1, 2, 3B
4250*
799-601- 1, 2, 3, q q
Socket for engine (CRI-T3) G 3
4330* G
2 2, PA
4340* Pump actuator
799-601- Socket for engine (CRI-T3)(95) 1, 2, 3,
4 q
4380* Air intake pressure/temperature 4T
799-601- q q
Adapter for controller (ENG) 4 DTP4
4260
799-601- q
Adapter for controller (ENG) 50 DRC50
4211
799-601- q
Adapter for controller (ENG) 60 DRC60
4220
799-601- Socket for controller (95 ENG) 60 q
4390*
799-601- Box for controller (PUMP) 1-
q
4280* 21
PC290LC-10 40-109
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601- Adapter for controller (HST) 16 HST16A q

9720
799-601- Adapter for controller (HST) 16 HST16B q
9710
799-601- Adapter for controller (HST) 26 HST26A q
9730
2,
799-601- Multi-adapter for pins DT2 to 4
3, q
9890 and DTM2
4
*: Shows not T-adapter but socket.
40-110 PC290LC-10
40 Troubleshooting
Fuse list and location

Connection table of fuse box
a This connection table shows the fuse box and the devices which receive the power from the fuse box (the
switched power supply is the power source that supplies power while the starting switch is in ON position
and the continuous power supply is the power source that supplies power while the starting switch is in
OFF and ON positions).
a When performing troubleshooting related to the electrical system, check the fuses and fusible links to see
if the power is supplied properly.
Type of Source for Fuse
power power supply Fuse No. Device
capacity
supply to fuse
Lamp relay, rear lamp relay, and cab lamp relay
PC-EPC (F) solenoid valve, and PC-EPC (R) solenoid
valve
[When emergency pump drive switch is operated]
1 5A Swing holding brake solenoid valve
[When swing brake cancel switch is operated]
Boom RAISE throttle EPC valve
[When emergency boom RAISE throttle cancel switch is
operated]
2 30 A Pump controller (solenoid power supply)
PPC pressure lock solenoid valve
3 5A Starting motor cut-off relay (PPC lock)
Fusible link
Switched F04 (65 A) Starting motor cut-off relay (personal code)
power 4 10 A Window washer motor and cigarette lighter
supply 5 10 A Horn and horn relay
6 5A Heater relay and ribbon heater
7 10 A Revolving warning lamp (if equipped)
Radio, speaker, and left knob switch (pump controller
8 10 A input)
9 20 A Work lamp
10 20 A Air conditioner unit and air conditioner compressor
11 10 A Head lamp
12 10 A Optional power supply (1)
Optional power supply (2), 12 V power supply, and
13 30 A heated air suspension seat
Starting 14 5A Air conditioner controller power supply
switch 15 5A Starting switch and engine shutdown secondary switch
16 10 A Radio backup, room lamp, and system operating lamp
Continu- 17 20 A Machine monitor and pump controller
Fusible link
ous power 18 30 A Engine controller
F05 (30 A)
supply 19 5A Air conditioner controller backup
20 10 A Optional power supply (continuous power supply)
PC290LC-10 40-111
40 Troubleshooting
Locations of fusible links
* Remove the top cover of the air cleaner and remove the battery relay cover, and fusible links (F04) and
(F05) are seen.
Location of fuse box and fuse numbers
40-112 PC290LC-10
40 Troubleshooting
Precautions for cleaning and replacing KDPF (KCSF, KDOC)

1. Related information 2] On machine monitor, check history of
output of “CA2639: Stationary
k Use care not to burn yourself since KDPF regeneration request“ and “CA1921:
and KDOC are heated to 500°C or above. KDPF soot load high error 1“, and
“CA1922: KDPF soot load high error 2“.
• Soot load in KCSF in KDPF is classified into
[Case 1: When replacing KCSF after
eight levels. You can confirm the current soot
removing KDPF]
load by displaying "Diagnostic Tests" from
the machine monitor service menu and then a Since existence of the following condition
selecting "02 Regeneration for service" indicates that the soot load is beyond the
screen from there. regenerable level, you must remove KDPF
2. When cleaning or replacing KCSF and replace KCSF.
1) In periodic cleaning for every 4,500 hours • The time from output of “CA2639: Stationary
1] Check the level of soot load. If the soot regeneration request (L01)“ to output of
load level is displayed, turn on and “CA1921: KDPF soot load high error 1 (L03)“
continue active regeneration for service is >= 300 sec.
until the load becomes zero. and
2] Stop the engine and wait until the • the time from output of “CA1921: KDPF soot
temperature of piping around engine load high error (L03)“ to output of “CA1922:
drops, then remove KDPF and remove KDPF soot load high error 2 (L04)“is >= 300
KCSF, too. sec.
3] Clean KCSF using the ash cleaning [Contents of work]
system, which is used at the specified Case 1-1 Stop the engine and wait until the
maintenance shops and the like. (When temperature of piping around engine drops,
reusing a removed KCSF after cleaning then remove KCSF.
it) Case 1-2 Install another KDPF (new or used
4] Install the cleaned KCSF to the machine. one).
(When reusing a removed KCSF after Case 1-3 Turn starting switch to ON position
cleaning it) and perform KDPF cleaning reset from the
5] Install another KCSF to the machine. KDPF reset screen.
(When replacing a KCSF with new one) If you perform cleaning reset of KDPF, the
6] Turn starting switch to ON position and changes provided in ( ) are reflected.
perform KDPF cleaning reset from the (Soot level: 9 g/l o 8.1 g/l, action level: L04
KDPF reset screen. o L03, failure code: CA1922 o CA1921)
7] Start the engine and warm it up at low Case 1-4 Perform KDPF Change reset from
idle. the KDPF reset screen.
8] Perform active regeneration for service. Case 1-5 Start the engine and warm it up at
2) If cracks or damages are detected low idle.
Case 1-6 Perform active regeneration for
1] Stop the engine and wait until the
service.
temperature of piping around engine
(This active regeneration for service ends
drops, then remove KDPF and remove
when soot load becomes 2 g/l. Therefore,
KCSF, too.
this regeneration may last for two hours or
2] Install another KCSF (new or used
so.))
KCSF) to the machine.
Case 1-7 After the active regeneration for
3] Turn starting switch to ON position and
service is finished, confirm that the failure
perform KDPF cleaning reset from the
code (CA1922, CA1921 and/or CA2639) is
KDPF reset screen.
not output.
4] Perform KDPF Change reset from the
[Case 2: When active regeneration for
KDPF reset screen.
service is performed (removal of KDPF is
5] Start the engine and warm it up at low
unnecessary]
idle.
6] Perform active regeneration for service.
3) KDPF soot load high error 2 (CA1922) is
output
1] Stop the machine and confirm from the
machine monitor that the failure code
(CA1922) is output.
PC290LC-10 40-113
40 Troubleshooting
a When the following condition exists, soot is 4] Stop the engine and wait until the
not actually accumulated (9 g/l or temperature of piping around engine
equivalent). It results from increase in drops, then remove KDOC and check it
differential pressure being caused by for cracks and damages.
troubles such as plugging due to non-uniform [Case 1] When cracks or damages are
accumulation of soot. Since actual soot load detected on KDOC
is not so large as to cause abnormal Case 1-1 Replace KDOC.
combustion when active regeneration is Case 1-2 Perform KDOC reset from the
executed, you do not have to replace KCSF. KDPF reset screen.
If you reduce the soot load by active [Case 2] When cracks or damages are not
regeneration for service, you can use KCSF detected on KDOC
continuously. Case 2-1 Clean KDOC and install it again.
• After making sure through troubleshooting Case 2-2 Perform KDOC reset from the
that a sensor system failure is not present, KDPF reset screen.
execute the active regeneration for service Case 2-3 Perform 40-minute long active
when any of the followings exists. regeneration for service two times. (Fuel is
• The time from output of “CA2639: Stationary injected during regeneration.)
regeneration request (L01)“ to output of a When performing regeneration for service
“CA1921: KDPF soot load high error 1 (L03)“ consecutively, stop the engine once.
is < 300 sec. Case 2-4 Output of CA2637 (KDOC face
or plugging) after the active regeneration for
• the time from output of “CA1921: KDPF soot service indicates that efficiency of KDOC is
load high error (L03)“ to output of “CA1922: degraded. In this case, KDOC must be
KDPF soot load high error 2 (L04)“ is < 300 replaced.
sec.
[Contents of work]
Case 2-1 Start the engine, warm it up at low
idle, then perform KDPF cleaning reset from
the KDPF reset screen.
Case 2-2 Perform active regeneration for
service.
(This active regeneration for service ends
when soot load becomes 2g/l. Therefore,
this regeneration may last for two hours or
so.))
Case 2-3 After the active regeneration for
service is finished, confirm that the failure
code (CA1922, CA1921 and/or CA2639) is
not output.
3. When cleaning or replacing KDOC
1) If cracks or damages are detected
1] If cracks or damages are detected on
KDOC, replace KDOC.
2] Perform KDOC reset from the KDPF
reset screen.
2) When regeneration ineffective (CA1691) is
output
1] Stop the machine and confirm from the
machine monitor that the failure code
(CA1691) is output.
(CA2637 is sometimes output at the
same time.)
2] Check the engine gas color.
3] While CA1691 is output, perform the
active regeneration for service for 40
minutes. (KDOC drying operation: Fuel is
not injected during regeneration.)
40-114 PC290LC-10
40 Troubleshooting
Failure codes table

Failure Action Category
Failure (Displayed on screen) Controller Remarks
code level of history
Failure code [879AKA] A/C Inner sensor Electrical See
879AKA MON ― Chapter 80,
Open Circuit(PAGE 80-52) system
Other items
Failure code [879AKB] A/C Inner sensor Electrical See
879AKB MON ― Chapter 80,
Short Circuit(PAGE 80-53) system
Other items
Failure code [879BKA] A/C Outer sensor Electrical See
879BKA MON ― Chapter 80,
Other items
Failure code [879BKB] A/C Outer sensor Electrical See
879BKB MON ― Chapter 80,
Other items
Failure code [879CKA] Ventilating sensor Electrical See
879CKA MON ― Chapter 80,
Other items
Failure code [879CKB] Ventilating sensor Electrical See
879CKB MON ― Chapter 80,
Other items
Failure code [879DKZ] Sunlight sensor Electrical See
879DKZ MON ― Chapter 80,
Open or Short Circuit(PAGE 80-60) system
Other items
Failure code [879EMC] Ventilating Damper Electrical See
879EMC Abnormality(PAGE 80-62) MON L01 system Chapter 80,
Other items
Failure code [879FMC] Air Mix Damper Electrical See
879FMC Abnormality(PAGE 80-63) MON L01 system Chapter 80,
Other items
Failure code [879GKX] Refrigerant Electrical See
879GKX Abnormality(PAGE 80-64) MON L01 system Chapter 80,
Other items
Failure code [989L00] Engine Controller Electrical
989L00 MON ―
Lock Caution1(PAGE 40-134) system
Failure code [989M00] Engine Controller Electrical
989M00 MON ―
Failure code [989N00] Engine Controller Electrical
989N00 MON ―
Failure code [A1U0N3] HC desorb request1 PUMP/ Electrical
A1U0N3 (PAGE 40-137) L01 system
ENG
Failure code [A1U0N4] HC desorb request2 PUMP/ Electrical
A1U0N4 (PAGE 40-139) L03 system
ENG
Failure code [AA10NX] Air Cleaner Clogging Mechanical
AA10NX (PAGE 40-141) MON L01 system
Failure code [AB00KE] Charge Voltage Low Mechanical
AB00KE (PAGE 40-143) MON L03 system
Failure code [B@BAZG] Engine Oil Mechanical
B@BAZG ENG L03
Pressure Low(PAGE 40-145) system
Failure code [B@BAZK] Eng Oil Level Low Mechanical
B@BAZK MON L01
(PAGE 40-146) system
Failure code [B@BCNS] Engine Coolant Mechanical
B@BCNS ENG L02
Overheat(PAGE 40-147) system
Failure code [B@BCZK] Radiator Coolant Mechanical
B@BCZK MON L01
Level Low(PAGE 40-148) system
Failure code [B@HANS] Hyd Oil Overheat Mechanical
B@HANS PUMP L02
Failure code [CA115] Eng Ne and Bkup Electrical
CA115 Speed Sens Error(PAGE 40-151) ENG L04 system
PC290LC-10 40-115
40 Troubleshooting

Failure code [CA122] Chg Air Press Sensor Electrical
CA122 High Error(PAGE 40-152) ENG L03 system
CA123 Low Error(PAGE 40-154) ENG L03 system
Failure code [CA131] Throttle Sensor High Electrical
CA131 Error(PAGE 40-156) ENG L03 system
Failure code [CA132] Throttle Sensor Low Electrical
Failure code [CA144] Coolant Temp Sens Electrical
Failure code [CA145] Coolant Temp Sens Electrical
Failure code [CA153] Chg Air Temp Sensor Electrical
Failure code [CA154] Chg Air Temp Sensor Electrical
Failure code [CA187] Sensor 2 Supply Volt Electrical
Failure code [CA221] Ambient Press Sensor Electrical
Failure code [CA222] Ambient Press Sensor Electrical
Failure code [CA234] Eng Overspeed(PAGE Electrical
CA234 ENG ―
40-175) system
Failure code [CA238] Ne Speed Sensor Electrical
CA238 Supply Volt Error(PAGE 40-176) ENG L01 system
Failure code [CA239] Ne Speed Sens Electrical
CA239 Supply Volt High Error(PAGE 40-177) ENG L01 system
Failure code [CA271] IMV/PCV1 Short Error Electrical
CA271 (PAGE 40-178) ENG L03 system
Failure code [CA272] IMV/PCV1 Open Error Electrical
Failure code [CA295] Ambient Press Sens In Electrical
CA295 Range Error(PAGE 40-181) ENG L03 system
Failure code [CA322] Inj #1(L#1) Open/Short Electrical


Failure code [CA343] ECM Critical Internal Electrical
CA343 Failure(PAGE 40-194) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
40-116 PC290LC-10
40 Troubleshooting

Failure code [CA356] Mass Air Flow Sensor Electrical
Failure code [CA357] Mass Air Flow Sensor Electrical
Failure code [CA428] Water in Fuel Sensor Electrical
Failure code [CA429] Water in Fuel Sensor Electrical
Failure code [CA435] Eng Oil Press Sw Electrical
Failure code [CA441] Battery Voltage Low Electrical
Failure code [CA442] Battery Voltage High Electrical
Failure code [CA449] Rail Press Very High Electrical
Failure code [CA451] Rail Press Sensor Electrical
Failure code [CA452] Rail Press Sensor Low Electrical
Failure code [CA488] Chg Air Temp High Electrical
CA488 Torque Derate(PAGE 40-215) ENG L03 system
Failure code [CA515] Rail Press Sens Sup Electrical
CA515 Volt High Error(PAGE 40-216) ENG L03 system
Failure code [CA516] Rail Press Sens Sup Electrical
CA516 Volt Low Error(PAGE 40-218) ENG L03 system
Failure code [CA553] Rail Press High Error Electrical
Failure code [CA555] Crankcase Press High Electrical
CA555 Error 1(PAGE 40-221) ENG L01 system
Failure code [CA556] Crankcase Press High Electrical
Failure code [CA559] Rail Press Low Error Electrical
Failure code [CA595] Turbo Speed High Electrical
Failure code [CA687] Turbo Speed Low Electrical
Failure code [CA689] Eng Ne Speed Sensor Electrical
Failure code [CA691] Intake Air Temp Sens Electrical
Failure code [CA692] Intake Air Temp Sens Electrical
Failure code [CA697] ECM Int Temp Sensor Electrical
Failure code [CA698] ECM Int Temp Sensor Electrical
Failure code [CA731] Eng Bkup Speed Sens Electrical
CA731 Phase Error(PAGE 40-236) ENG L01 system
Failure code [CA778] Eng Bkup Speed Electrical
CA778 Sensor Error(PAGE 40-237) ENG L01 system
Failure code [CA1117] Persistent Data Lost Electrical
PC290LC-10 40-117
40 Troubleshooting

Failure code [CA1664] KDOC Malfunction Electrical
Failure code [CA1691] Regeneration Electrical
CA1691 Ineffective(PAGE 40-244) ENG L03 system
Failure code [CA1843] Crankcase Press Electrical
CA1843 Sens High Error(PAGE 40-250) ENG L01 system
CA1844 Sens Low Error(PAGE 40-252) ENG L01 system
Failure code [CA1879] KDPF Delta P Electrical
CA1879 Sensor High Error(PAGE 40-254) ENG L03 system
Failure code [CA1881] KDPF Delta P Electrical
CA1881 Sensor Low Error(PAGE 40-256) ENG L03 system
Failure code [CA1883] KDPF Delta P Sens Electrical
CA1883 In Range Error(PAGE 40-258) ENG L03 system
Failure code [CA1921] KDPF Soot Load Electrical
CA1921 High Error 1(PAGE 40-261) ENG L03 system
Failure code [CA1922] KDPF Soot Load Electrical
CA1942 Sens In Range Error(PAGE 40-268) ENG L01 system
Failure code [CA1993] KDPF Delta Pressure Electrical
Failure code [CA2185] Throt Sensor Sup Electrical

CA2185 Volt High Error(PAGE 40-270) ENG L03 system
Failure code [CA2186] Throt Sensor Sup Electrical

CA2186 Volt Low Error(PAGE 40-271) ENG L03 system
Failure code [CA2249] Rail Press Very Low Electrical

Failure code [CA2271] EGR Valve Pos Sens Electrical
Failure code [CA2272] EGR Valve Pos Sens Electrical
Failure code [CA2288] Turbo Speed High Electrical
Failure code [CA2311] IMV Solenoid Error Electrical
Failure code [CA2349] EGR Valve Solenoid Electrical
CA2349 Open Error(PAGE 40-280) ENG L03 system
Failure code [CA2353] EGR Valve Solenoid Electrical
CA2353 Short Error(PAGE 40-282) ENG L03 system
Failure code [CA2357] EGR Differential Electrical
CA2357 Pressure(PAGE 40-284) ENG L03 system
Failure code [CA2373] Exh Manifold Press. Electrical
CA2373 Sens Volt(PAGE 40-285) ENG L03 system
Failure code [CA2374] Exhaust Manifold Electrical
CA2374 Press Sens Low Error(PAGE 40-287) ENG L03 system
Failure code [CA2375] EGR Orifice Temp Electrical
40-118 PC290LC-10
40 Troubleshooting


Failure code [CA2381] KVGT Pos Sens High Electrical

Failure code [CA2382] KVGT Pos Sens Low Electrical
Failure code [CA2383] KVGT Solenoid Open Electrical
Failure code [CA2386] KVGT Solenoid Short Electrical
Failure code [CA2387] KVGT Servo Error Electrical
Failure code [CA2554] Exh Manifold Press Electrical
Failure code [CA2555] Grid Htr Relay Volt Electrical
Failure code [CA2556] Grid Htr Relay Volt Electrical
Failure code [CA2637] KDOC Face Plugging Electrical
Failure code [CA2639] Manual Stationary Electrical
CA2639 Regeneration Request(PAGE 40-310) ENG L01 system

CA2973 In Range Error(PAGE 40-313) ENG L03 system
Failure code [CA3133] KDPF Outlet Press Electrical

Failure code [CA3251] DOC Inlet Temp High Electrical
Failure code [CA3253] KDOC Temp Error - Electrical
CA3253 Non Regeneration(PAGE 40-324) ENG L03 system
Failure code [CA3254] KDOC Outlet Temp Electrical
Failure code [CA3255] KDPF Temp Error - Electrical
CA3255 Non Regeneration(PAGE 40-328) ENG L03 system
Failure code [CA3256] KDPF Outlet Temp Electrical
Failure code [CA3313] KDOC Inlet Temp Electrical
CA3313 Sensor Low Error(PAGE 40-333) ENG L03 system
PC290LC-10 40-119
40 Troubleshooting

Failure code [CA3419] Mass Air Flow Electrical
CA3419 Sensor Sup Volt High Error(PAGE 40-366) ENG L03 system
Failure code [CA3421] Mass Air Flow Electrical
CA3421 Sensor Sup Volt Low Error(PAGE 40-367) ENG L03 system
Failure code [CA3741] Rail Press Valve Trip Electrical

Failure code [D110KB] Battery Relay Output Electrical

D110KB Voltage(PAGE 40-370) PUMP L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Abnormality(PAGE 40-372) MON L03 system
Failure code [D811MC] KOMTRAX Error Electrical
D811MC KOMTRAX ―
Failure code [D862KA] GPS Antenna Open Electrical
D862KA KOMTRAX ―
Circuit(PAGE 40-376) system
Failure code [D8ALKA] Operating Lamp
Electrical
D8ALKA Open Circuit(KOMTRAX) KOMTRAX ―
system
(PAGE 40-377)
Failure code [D8ALKB] Operating Lamp Electrical
D8ALKB KOMTRAX ―
Short Circuit (KOMTRAX)(PAGE 40-379) system
Failure code [D8AQKR] CAN2 Discon Electrical
D8AQKR MON ―
(KOMTRAX)(PAGE 40-380) system
Failure code [DA20MC] Pump Controller Electrical
DA20MC PUMP ―
Failure code [DA22KK] Pump Solenoid Electrical
DA22KK Power Low Error(PAGE 40-382) PUMP L03 system
Failure code [DA25KP] 5V Sensor 1 Power Electrical
DA25KP PUMP ―
Abnormality(PAGE 40-384) system
Failure code [DA29KQ] Model Selection Electrical
DA29KQ Abnormality(PAGE 40-387) PUMP L01 system
Failure code [DA2LKA] Operating Lamp Electrical
DA2LKA PUMP ―
Open Circuit(Pump Con)(PAGE 40-389) system
Failure code [DA2LKB] Operating Lamp Electrical
DA2LKB PUMP ―
Short Circuit(Pump Con)(PAGE 40-391) system
Failure code [DA2QKR] CAN2 Discon Electrical
DA2QKR (Pump Con)(PAGE 40-392) MON L03 system
Failure code [DA2QKR] CAN1 Discon Electrical
DA2RKR (Pump Con)(PAGE 40-394) MON L04 system
40-120 PC290LC-10
40 Troubleshooting

Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB Abnormality(PAGE 40-395) MON ―
system
Failure code [DAF0MC] Monitor Error(PAGE Electrical
DAF0MC 40-396) MON ―
system
Failure code [DAF8KB] Camera Power Electrical
DAF8KB Supply Short Circuit(PAGE 40-397) MON L03 system
Failure code [DAF9KQ] Model Selection Electrical
DAF9KQ Abnormality(PAGE 40-399) MON L03 system
Failure code [DAFGMC] GPS Module Error Electrical
DAFGMC (PAGE 40-400) KOMTRAX ―
system
Failure code [DAFLKA] Operating Lamp Electrical
DAFLKA Open Circuit(Monitor)(PAGE 40-401) MON ―
system
Failure code [DAFLKB] Operating Lamp Electrical
DAFLKB Short Circuit(Monitor)(PAGE 40-403) MON ―
system
Failure code [DAFQKR] CAN2 Discon Electrical
DAFQKR (Monitor)(PAGE 40-404) KOMTRAX ―
system
Failure code [DAZ9KQ] A/C Model Selection Electrical
DAZ9KQ Abnormality(PAGE 40-405) MON ―
system
Failure code [DAZQKR] CAN2 Discon Electrical
DAZQKR (Aircon ECU)(PAGE 40-406) MON L01 system
Failure code [DB2QKR] CAN2 Discon Electrical
DB2QKR (Engine Con)(PAGE 40-410) MON L03 system
Failure code [DB2RKR] CAN1 Discon Electrical
DB2RKR (Engine Con)(PAGE 40-415) MON L04 system
Failure code [DGH2KB] Hyd Oil Sensor Electrical
DGH2KB Short Circuit(PAGE 40-419) PUMP L01 system
Failure code [DHA4KA] Air Cleaner Clog Electrical
DHA4KA Sensor Open Circuit(PAGE 40-421) MON L01 system
Failure code [DHPAMA] F Pump Press Electrical
DHPAMA Sensor Abnormality(PAGE 40-422) PUMP L01 system
Failure code [DHPBMA] R Pump Press Electrical
DHPBMA Sensor Abnormality(PAGE 40-425) PUMP L01 system
Failure code [DHS3MA] Arm Curl PPC Electrical

DHS3MA Press Sensor Abnormality(PAGE 40-428) PUMP L01 system
Failure code [DHS4MA] Bucket Curl PPC Electrical

Failure code [DHS8MA] Boom Raise PPC Electrical
Failure code [DHS9MA] Boom Lower PPC Electrical
Failure code [DHSAMA] Swing RH PPC Electrical
DHSAMA Press Sensor Abnormality(PAGE 40-439) PUMP L01 system
Failure code [DHSBMA] Swing LH PPC Electrical
DHSBMA Press Sensor Abnormality(PAGE 40-442) PUMP L01 system
Failure code [DHSCMA] Arm Dump PPC Electrical
DHSCMA Press Sensor Abnormality(PAGE 40-445) PUMP L01 system
Failure code [DHSDMA] Bucket Dump PPC Electrical
DHSDMA Press Sensor Abnormality(PAGE 40-448) PUMP L01 system
Failure code [DHSFMA] Travel Fwd LH PPC Electrical
DHSFMA Press Sensor Abnormality(PAGE 40-451) PUMP L01 system
Failure code [DHSGMA] Travel Fwd RH
Electrical
DHSGMA PPC Press Sensor Abnormality(PAGE 40- PUMP L01 system
454)
PC290LC-10 40-121
40 Troubleshooting

Failure code [DHSHMA] Travel Rev LH PPC Electrical
DHSHMA Press Sensor Abnormality(PAGE 40-457) PUMP L01 system
Failure code [DHSJMA] Travel Rev RH PPC Electrical
DHSJMA Press Sensor Abnormality(PAGE 40-460) PUMP L01 system
Failure code [DKR0MA] F Pump Swash Electrical
DKR0MA Plate Sensor Abnormality(PAGE 40-463) PUMP L01 system
Failure code [DKR1MA] R Pump Swash Electrical
DKR1MA Plate Sensor Abnormality(PAGE 40-466) PUMP L01 system
Failure code [DR21KX] Camera 2 Picture Electrical
DR21KX Rev. Drive Abnormality(PAGE 40-469) MON L01 system
Failure code [DR31KX] Camera 3 Picture Electrical
DR31KX Rev. Drive Abnormality(PAGE 40-471) MON L01 system
Failure code [DV20KB] Travel Alarm Short Electrical
DV20KB Circuit(PAGE 40-473) PUMP L01 system
Failure code [DW43KA] Travel Speed Sol Electrical
DW43KA Open Circuit(PAGE 40-475) PUMP L01 system
Failure code [DW43KB] Travel Speed Sol Electrical
DW43KB Short Circuit(PAGE 40-477) PUMP L01 system
Failure code [DW45KA] Swing Brake Sol Electrical
Failure code [DW45KB] Swing Brake Sol Electrical
Failure code [DW91KA] Travel Junction Sol Electrical
Failure code [DW91KB] Travel Junction Sol Electrical
Failure code [DWA2KA] Attachment Sol Electrical
DWA2KA Open Circuit(PAGE 40-489) PUMP L03 system
Failure code [DWA2KB] Attachment Sol Electrical
DWA2KB Short Circuit(PAGE 40-491) PUMP L03 system
Failure code [DWK0KA] 2-Stage Relief Sol Electrical
DWK0KA Open Circuit(PAGE 40-493) PUMP L01 system
Failure code [DWK0KB] 2-Stage Relief Sol Electrical
DWK0KB Short Circuit(PAGE 40-495) PUMP L01 system
Failure code [DWK2KA] Variable Back Press Electrical
DWK2KA Sol Open Circuit(PAGE 40-497) PUMP L01 system
Failure code [DWK2KB] Variable Back Press Electrical
DWK2KB Sol Short Circuit(PAGE 40-499) PUMP L01 system
Failure code [DXA8KA] PC-EPC (F) Sol Electrical
DWK8KA Open Circuit(PAGE 40-505) PUMP L01 system
Failure code [DXA8KB] PC-EPC (F) Sol Electrical
DWK8KB Short Circuit(PAGE 40-507) PUMP L01 system
Failure code [DXA8KA] PC-EPC (F) Sol Electrical
DXA8KA Open Circuit(PAGE 40-505) PUMP L03 system
Failure code [DXA8KB] PC-EPC (F) Sol Electrical
DXA8KB Short Circuit(PAGE 40-507) PUMP L03 system
Failure code [DXA9KA] PC-EPC (R) Sol Electrical
DXA9KA Open Circuit(PAGE 40-509) PUMP L03 system
Failure code [DXA9KB] PC-EPC (R) Sol Electrical

DXA9KB Short Circuit(PAGE 40-511) PUMP L03 system
Failure code [DXE0KA] LS-EPC Sol Open Electrical

DXE0KA Circuit(PAGE 40-513) PUMP L01 system
Failure code [DXE0KB] LS-EPC Sol Short Electrical
DXE0KB Circuit(PAGE 40-515) PUMP L01 system
40-122 PC290LC-10
40 Troubleshooting

Failure code [DXE4KA] Attachment Flow Electrical
DXE4KA PUMP ―
EPC Open Circuit(PAGE 40-517) system
Failure code [DXE4KB] Attachment Flow Electrical
DXE4KB EPC Short Circuit(PAGE 40-519) PUMP ―
system
Failure code [DXE5KA] Merge-divide Main Electrical
DXE5KA Sol Open Circuit(PAGE 40-521) PUMP L01 system
Failure code [DXE5KB] Merge-divide Main Electrical
DXE5KB Sol Short Circuit(PAGE 40-523) PUMP L01 system
Failure code [DXE6KA] Merge-divide LS Sol Electrical
DXE6KA Open Circuit(PAGE 40-525) PUMP L01 system
Failure code [DXE6KB] Merge-divide LS Sol Electrical
DXE6KB Short Circuit(PAGE 40-527) PUMP L01 system
Failure code [DY20KA] Wiper Working Electrical
DY20KA Abnormality(PAGE 40-529) PUMP ―
system
Failure code [DY20MA] Wiper Parking Electrical
DY20MA Abnormality(PAGE 40-531) PUMP ―
system
Failure code [DY2CKB] Washer Drive Short Electrical
DY2CKB Circuit(PAGE 40-533) PUMP ―
system
Failure code [DY2DKB] Wiper Drive (Fwd) Electrical
DY2DKB Short Circuit(PAGE 40-535) PUMP ―
system
Failure code [DY2EKB] Wiper Drive (Rev) Electrical
DY2EKB Short Circuit(PAGE 40-537) PUMP ―
system
PC290LC-10 40-123
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879AKA] A/C Inner Sensor Open Circuit
See ”Failure code [879AKA] A/C Inner Sensor Open
Circuit” of Section 80 Appendix.
a Since connector of inside air temperature sensor
cannot be disconnected while air conditioner is
mounted on machine, air conditioner controller
or air conditioner unit must be replaced.
40-124 PC290LC-10
40 Troubleshooting
Failure code [879AKB] A/C Inner Sensor Short Circuit

See "Failure code [879AKB] A/C Inner Sensor Short
Circuit" of Section 80 Appendix.
a Since connector of inside air temperature sensor
PC290LC-10 40-125
40 Troubleshooting
Failure code [879BKA] A/C Outer Sensor Open Circuit

See "Failure code [879BKA] A/C Outer Sensor
Open Circuit" of Section 80 Appendix.
40-126 PC290LC-10
40 Troubleshooting
Failure code [879BKB] A/C Outer Sensor Short Circuit

See "Failure code [879BKB] A/C Outer Sensor
Short Circuit" of Section 80 Appendix.
PC290LC-10 40-127
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Open Circuit

See Chapter 80, Other items "Failure code
[879CKA] Ventilating Sensor Open Circuit".
a Since connector of ventilating sensor
(evaporator temperature sensor) cannot be
disconnected while air conditioner is mounted
on machine, air conditioner controller or air
conditioner unit must be replaced.
40-128 PC290LC-10
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit

See "Failure code [879CKB] Ventilating Sensor
Short Circuit" of Section 80 Appendix.
a Since connector of ventilating sensor
(evaporator temperature sensor) cannot be
disconnected while air conditioner is mounted
on machine, air conditioner controller or air
conditioner unit must be replaced.
PC290LC-10 40-129
40 Troubleshooting
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit

See "Failure code [879DKZ] Sunlight Sensor Open
or Short Circuit" of Section 80 Appendix.
40-130 PC290LC-10
40 Troubleshooting
Failure code [879EMC] Ventilation Damper Abnormality

See "Failure code [879EMC] Ventilation Damper
Abnormality" of Section 80 Appendix.
a Since connector of vent changeover servomotor
PC290LC-10 40-131
40 Troubleshooting
Failure code [879FMC] Air Mix Damper Abnormality

See "Failure code [879FMC] Air Mix Damper
a Since the connector of air mix servo motor can
not be disconnected as long as it is installed on
the machine, change air conditioner controller or
air conditioner unit.
40-132 PC290LC-10
40 Troubleshooting
Failure code [879GKX] Refrigerant Abnormality

See "Failure code [879GKX] Refrigerant
PC290LC-10 40-133
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution1

Action Engine controller lock caution 1
Failure code
level Failure
- (Machine monitor system)
989L00
Details of • Engine controller is locked (factor 1).
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine cannot be started.
machine
• If this failure code appears after machine monitor is replaced, user password must be
Related changed to one before replacement.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective machine This failure may be caused by replacement of machine monitor.
1
monitor
40-134 PC290LC-10
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution2

Failure code
level Failure
989M00
Details of Engine controller is locked (factor 2).
failure
Problem on • Engine cannot be started.
machine
• If this failure code appears after machine monitor is replaced, user password must be
Related changed to one before replacement.
Defective machine This failure may be caused by replacement of machine monitor.
1
monitor
If this failure code appears while machine monitor is not replaced, machine
Defective machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot
2
monitor be performed.)
PC290LC-10 40-135
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution3

Failure code
level Failure
989N00
Details of • Engine controller is locked (factor 3).
failure
Action of • Tries automatic recovery.
Problem on
machine
Related • Method of reproducing failure code: This failure code cannot be reproduced because of
information automatic recovery.
Defective engine If this failure code appears repeatedly, engine controller may be defective. (Since
1 this is an internal defect, troubleshooting cannot be performed.)
controller
40-136 PC290LC-10
40 Troubleshooting
Failure code [A1U0N3] HC desorb request1

Action KDPF request for drying (HC release)1
Failure code
level Failure
(Engine controller system)
L01 A1U0N3
Details of • Unburned fuel remains in KCSF because engine has run at low idle or with light load for
failure long hours.
Action of • Requests operator to perform manual stationary regeneration (fuel drying) or notifies
controller operator that manual stationary regeneration (fuel drying) is taking place.
Problem on • Machine comes into same state as that in automatic regeneration.
machine (When machine is in safe condition, engine speed is limited approximately to 1000 rpm.)
k Use care not to burn yourself since KDPF and KDOC are heated to 500°C or above.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V)).
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function (Code: 47300 (°C) ).
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• When engine is running at idle (without regenerating KDPF), KDOC inlet temperature,
KDOC outlet temperature and KDPF outlet temperature are all about 100 to 250°C.
Related Temperature differences among them is about 10°C (KDOC inlet temperature > KDOC
information outlet temperature > KDPF outlet temperature).
• KDOC inlet temperature during active regeneration (manual stationary regeneration) is
approx. 250 to 400°C. And KDOC outlet temperature and KDPF outlet temperature are
both approx. 450 to 550°C.
• If you implement manual stationary regeneration according to instruction of machine
monitor when [A1U0N3] or [A1U0N4] is issued, KDOC inlet temperature, KDOC outlet
temperature and KDPF outlet temperature are all go to 250 to 400°C since HC dosing is
not done.
• If remarkable difference is recognized between KDOC inlet temperature and KDOC outlet
temperature when KDPF is sufficiently cooled or engine is running at idle (without
regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet
temperature , whichever is suspected to be defective, referencing KDPF outlet
temperature.
• Connector label "TEMP1" of KDOC inlet temperature sensor is written in black convex
characters on KDPF temperature sensor consolidating box (the same applies to
connector label "TEMP2" for KDOC outlet temperature sensor and connector label
"TEMP3" for KDPF outlet temperature sensor).
• Method of reproducing failure code: Turn starting switch to ON position.
Execution of 1. Perform manual stationary regeneration according to instructions of monitor.
manual stationary If this failure code disappears after regeneration, repair is complete.
1 regeneration
(To dry KCSF)
1. Perform checkup referencing descriptions of wiring harness and connectors in
"c: Electrical equipment"of "Checks before troubleshooting" in "General
Defective wiring information on troubleshooting".
2 2. Turn starting switch to ON position.
harness connector
If this failure code disappears, wiring harness connector is defective.
a If this failure code appears, perform the following.
Defective KDOC If failure code [CA3313], [CA3314], or [CA3315] appears, carry out troubleshooting
3 inlet temperature for it first.
sensor
PC290LC-10 40-137
40 Troubleshooting

1. Turn starting switch to ON position.
2. Monitor signal voltages from KDOC inlet temperature sensor and KDPF outlet
temperature sensor, and record temperatures from respective temperature
sensors in initial state and during manual stationary regeneration (see Related
information).
3. Make sure that machine is in safe condition.
4. From service menu of machine monitor, display "Diagnostic Tests" screen and
Soot accumulation open "02 Regeneration for service" to execute "Manual Stationary
4 in KCSF inside Regeneration" (this operation is ended in about 40 minutes).
KDPF
If this failure code disappears after manual stationary regeneration, cause of
failure is soot accumulation.
a If another failure code appears during manual stationary regeneration, perform
troubleshooting for it first.
a If failure code [CA2639] appears after manual stationary regeneration, perform
troubleshooting for [CA2639] first.
Defective engine When this failure code appears and no failure is found by above checks, engine
5
controller controller is defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
a Turn starting switch to ON position and check that this failure code and failure code [CA2639] are not
displayed.
40-138 PC290LC-10
40 Troubleshooting
Failure code [A1U0N4] HC desorb request2

Action KDPF request for drying (HC discharge)2
Failure code
level Failure
L03 A1U0N4
Details of • Unburned fuel remains in KCSF because engine has run at low idle or with light load for
failure long hours.
Action of • Requests operator to perform manual stationary regeneration (fuel drying) or notifies the
controller operator that manual stationary regeneration (fuel drying) is taking place.
Problem on • Machine comes into same state as that in automatic regeneration.
machine (When machine is in safe condition, engine speed is limited approximately to 1000 rpm.)
• KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature at idle
Related are all about 100 to 250°C. Temperature difference among them is about 10°C (KDOC
information inlet temperature > KDOC outlet temperature > KDPF outlet temperature).
• KDOC inlet temperature during active regeneration (manual stationary regeneration) is
approx. 250 to 400°C. And KDOC outlet temperature and KDPF outlet temperature are
both approx. 450 to 550°C.
• If you implement manual stationary regeneration according to instruction of monitor when
[A1U0N3] or [A1U0N4] is issued, KDOC inlet temperature, KDOC outlet temperature and
KDPF outlet temperature are all go to 250 to 400°C since HC dosing is not done.
• If a remarkable difference is recognized between KDOC inlet temperature and KDOC
outlet temperature when KDPF is sufficiently cooled or with engine at idle (while
regeneration is not taking place), replace the suspected KDOC inlet temperature sensor
or KDOC outlet temperature referencing KDPF outlet temperature.
characters on KDPF temperature sensor consolidating box (the same applies to
connector label "TEMP2" for KDOC outlet temperature sensor and connector label
"TEMP3" for KDPF outlet temperature sensor).
Execution of 1. Perform manual stationary regeneration according to instructions of monitor.
manual stationary If this failure code disappears after regeneration, repair is complete.
1 regeneration
(To dry KCSF)
harness connector
sensor
PC290LC-10 40-139
40 Troubleshooting

2. Monitor signal voltage from KDOC inlet temperature sensor and KDPF outlet
temperature sensor, and record temperatures from respective temperature
sensors in the initial state and during manual stationary regeneration (see
Related information).
4. From the service menu of the machine monitor, display "Diagnostic Tests"
Soot accumulation screen and open "02 Regeneration for service" to execute "Manual Stationary
4 in KCSF inside Regeneration" (this operation is ended in about 40 minutes).
KDPF
If this failure code disappears after manual stationary regeneration, cause of
failure is soot accumulation.
a If another failure code is displayed during manual stationary regeneration,
perform troubleshooting for it first.
a If failure code [CA2639] or [A1U0N3] is displayed after manual stationary
regeneration, perform troubleshooting for [CA2639] or [A1U0N3].
5
performed.)
a Turn starting switch to ON position and check that this failure code and failure codes [CA2639] and
[A1U0N3] do not appear.
40-140 PC290LC-10
40 Troubleshooting
Failure code [AA10NX] Air Cleaner Clogging

Action Air cleaner clogging
Failure code
level Failure
(Machine monitor system)
L01 AA10NX
Details of • Air cleaner clogging switch signal voltage is not below 1 V while engine is running, so
failure machine monitor determines that air cleaner is clogged (switch contact is open).
Action of • Displays air cleaner clogging monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may be damaged.
machine
• Input (ON/OFF) from air cleaner clogging switch can be checked with monitoring function.
Related (Code: 04501 Monitor input 2)
information • Method of reproducing failure code: Start engine.
Clogging of air Air cleaner may be clogged. Check it for clogging and then clean or replace if
cleaner (When clogged.
1 system works
properly)
Defective air 1. Turn starting switch to OFF position.
cleaner clogging 2. Disconnect connector P23 and connect T-adapters to male side.
switch 3. Starting engine.
2 When air cleaner is
(internal open Max. 1 z
circuit in wiring Between P23 normal *1
Resistance (male) (1) and (2) When air cleaner is
harness) Min. 1 Mz
clogged *2
1. Turn starting switch to OFF position.
Open circuit in
2. Disconnect connectors CM02 and P23, and connect T-adapters to each female
wiring harness
side.
3 (wire breakage or
Between CM02 (female) (4) and P23
defective contact of Max. 1 z
connectors) Resistance (female) (1)
Between P23 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine.
Defective machine
4 When air cleaner is
monitor Max. 1 V
Between CM02 (4) normal
Voltage
and CM01 (3) When air cleaner is
clogged 7 to 11 V
• Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
PC290LC-10 40-141
40 Troubleshooting
Circuit diagram related to air cleaner clogging
40-142 PC290LC-10
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low

Action Charging voltage is low
Failure code
level Failure
L03 AB00KE
Details of • While engine is running, machine monitor checks signal voltage from alternator and
failure determines that charge voltage is low (below 7.8 V).
• Displays charge level monitor red on machine monitor.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • If machine is operated as it is, battery may not be charged.
machine
• Signal voltage of alternator can be checked with monitoring function. (Code: 04300
Related Charge voltage)
information • Method of reproducing failure code: Starting engine.
Loose alternator 1. Turn starting switch to OFF position.
1 terminal or open 2. Check terminal.
circuit at terminal
Defective 2. Insert T-adapters into connector E12.
generation by
2 alternator (when a Connector E08 may be used for diagnosis.
system works 3. Starting engine.
properly) Between E12 (1) Engine speed:
Voltage 27.5 to 29.5 V
and ground Medium or higher
Defective wiring 2. Insert T-adapters into connector CM01.
3 harness or machine 3. Start engine.
monitor
Voltage Between CM01 (16) and ground 20 to 30 V
Open circuit in a If no failure is found by check on cause 2, this check is not required.
wiring harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors CM01 and E12, and connect T-adapters to each female
defective contact of side.
connector) Between CM01 (female) (16) and E12
Resistance (female) (1) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.

Ground fault in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors CM01 and E12, and connect T-adapters to either
5 (contact with GND female side.
circuit) Between CM01 (female) (16) and
Resistance ground, or E12 (female) (1) and ground Min. 1 Mz
Defective machine If no failure is found by above checks, machine monitor is defective. (Since this is
6 an internal defect, troubleshooting cannot be performed.)
monitor
PC290LC-10 40-143
40 Troubleshooting
Circuit diagram related to charging
40-144 PC290LC-10
40 Troubleshooting
Failure code [B@BAZG] Engine Oil Pressure Low

Action
Failure code Abnormally low engine oil pressure
level Failure (Engine controller system)
L03 B@BAZG
Details of • While engine is running, engine controller detects engine oil pressure drop (sensor
failure contact is closed) from signal voltage of engine oil pressure switch.
• Displays engine oil pressure monitor yellow on machine monitor.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller • Limits engine output and allows to engine to run.
Problem on • If machine is operated as it is, engine may be damaged.
machine • Engine output decreases.
• Signal from engine oil pressure switch is input to engine controller. If engine oil pressure
Related switch is closed (turned ON) while engine is running, engine controller transmits this
information signal to machine monitor to display this failure code.
• Method of reproducing failure code: Starting engine.
Lowered engine oil Engine oil pressure may be low. Check it and fix if it is low.
pressure (when
1 system works
properly)
If no failure is found by above checks, engine oil pressure monitor system may be
defective. Perform troubleshooting in E-mode.
Defective engine oil • E-14 Coolant temperature monitor lights up in red while engine is running
pressure monitor (PAGE 40-563)
2
system • E-15 Hydraulic oil temperature monitor lights up in red while engine is running
(PAGE 40-564)
• E-16 Engine oil pressure monitor lights up in red while engine is running(PAGE
40-565)
PC290LC-10 40-145
40 Troubleshooting
Failure code [B@BAZK] Eng Oil Level Low

Action Engine oil level is low
Failure code
level Failure
B@BAZK (Machine monitor system)
L01
Details of • While engine is running, signal voltage from engine oil level switch does not remain below
failure 1 V, so machine monitor determines that engine oil level is low (oil level switch is open).
Action of • Displays engine oil level monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Input (ON/OFF) from engine oil level switch can be checked with monitoring function.
Related (Code: 04501 Monitor input 2)
Lowered engine oil Engine oil pressure may be low. Check it and fix if it is low.
1 level (when system
works properly)
Defective engine oil 1. Turn starting switch to OFF position.
level switch 2. Disconnect connector P44.
(internal defect)
Resistance Between P44 (male) (1) and ground Max. 1 z
Open circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapters to each female
3 (wire breakage or side.
defective contact of Between CM02 (female) (2) and P44
connector) Resistance (female) (1) Max. 1 z
If no failure is found by above checks, machine monitor is defective.
• Reference
Defective machine 1. Turn starting switch to OFF position.
4 2. Insert T-adapters into connectors CM01 and CM02.
monitor
Voltage Between CM02 (2) and CM01 (3) Max. 1 V
Circuit diagram related to engine oil level switch
40-146 PC290LC-10
40 Troubleshooting
Failure code [B@BCNS] Engine Coolant Overheat

Action Engine coolant overheats
Failure code
level Failure
B@BCNS (Engine controller system)
L02
Details of • While engine is running, engine controller detects overheating of engine coolant (above
failure approx. 105°C), from signal voltage of engine coolant temperature sensor.
• Displays engine coolant temperature monitor red on machine monitor.
• If cause of failure disappears, machine becomes normal by itself.
Action of • Limits engine output and allows to engine run.
controller • Stops regeneration control.
• Closes EGR valve (depending on coolant temperature).
Problem on • If machine is operated as it is, engine may seize up.
machine
• Signal of engine coolant temperature sensor is input to engine controller and then data is
transmitted to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function.
information (Code: 04107 Engine coolant temperature)
• Method of reproducing failure code: Start engine.
Overheating of Engine coolant may overheat. Check it and remove cause if it overheats.
engine coolant
1 (when system is
normal)
If no failure is found by above checks, engine coolant temperature gauge system
may be defective. Perform the following troubleshooting described in E-mode
Defective engine troubleshooting section.
coolant
2 temperature gauge • E-19 Coolant temperature gauge indicate either Min or Max and does not move
system (PAGE 40-568)
• E-20 Coolant temperature gauge indicates incorrect temperature (indicates
neither Min nor Max)(PAGE 40-569)
PC290LC-10 40-147
40 Troubleshooting
Failure code [B@BCZK] Radiator Coolant Level Low

Action Engine coolant level is low
Failure code
level Failure
B@BCZK (Machine monitor system)
L01
• While starting switch is at ON position (with engine stopped) or engine is running, radiator
Details of coolant level switch signal voltage does not remain below 1 V. So machine monitor
failure determines that engine coolant level is low (sensor contact is open).
Action of • Displays radiator coolant level monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may overheat.
machine
• Input (ON/OFF) from radiator coolant level switch can be checked by using monitoring
Related function.
information (Code: 04500 Monitor input 1)
Lowered radiator Coolant level in radiator sub tank may be low. Check it and add coolant if it is low.
coolant level (when
1 system works
properly)
Defective coolant 2. Disconnect connector P24 and connect T-adapters to male side.
2 level switch Between FULL and
(internal defect) Between P24 Max. 1 z
Resistance LOW lines
(male) (1) and (2)
Below LOW line Min. 1 Mz
Open circuit in 2. Disconnect connectors CM02 and P24, and connect T-adapters to each female
wiring harness side.
3 (wire breakage or
defective contact of a Add coolant.
connector) Between CM02 (female) (3) and P24
• Reference
Defective machine 3. Turn starting switch to ON position.
4
monitor
Between FULL and
Max. 1 V
Between CM02 (3) LOW lines
Voltage
and CM01 (3) Min. 7 to 11 V
Below LOW line
40-148 PC290LC-10
40 Troubleshooting
Circuit diagram related to radiator coolant level switch
PC290LC-10 40-149
40 Troubleshooting
Failure code [B@HANS] Hyd Oil Overheat

Action Hydraulic oil overheat
Failure code
level Failure
B@HANS (Pump controller system)
L02
Details of • While engine is running, pump controller determines that hydraulic oil overheats (above
failure approx. 105°C) from signal voltage of hydraulic oil temperature sensor.
Action of • Displays hydraulic oil temperature monitor red on machine monitor.
Problem on • If machine is operated as it is, hydraulic components may be damaged.
machine
• Signal of hydraulic oil temperature sensor is input to pump controller and then data is
transmitted to machine monitor through CAN communication system.
• Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)
Related • Refer to following troubleshooting described in E mode troubleshooting section.
information • E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move
(PAGE 40-570)
• E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates
Overheating of Hydraulic oil may overheat. Check it and remove cause if it overheats.
hydraulic oil (when
1 system works
properly)
Defective hydraulic If no failure is found by above checks, hydraulic oil temperature gauge system
2 oil temperature may be defective. Perform troubleshooting for failure code [DGH2KB].
gauge system
40-150 PC290LC-10
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error

Action Engine Ne and Bkup speed sensor error
Failure code
level Failure
L04 CA115
Details of • Signals from both engine Ne speed sensor and engine Bkup speed sensor are abnormal.
failure
controller
Problem on • Engine stops.
machine • Engine does not start
Related • Method of reproducing failure code: Start engine.
information
Defective contact of Connectors of Ne speed sensor and Bkup speed sensor may be connected
1 defectively (or to wrong connection). Check them.
sensor connector
Defective Ne speed Perform troubleshooting for failure code [CA689].
2 sensor system
Defective Bkup Perform troubleshooting for failure code [CA778].
3 speed sensor
system
Defective engine If no failure is found by above checks, engine controller is defective. (Since this is
controller
PC290LC-10 40-151
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error

Action Boost pressure sensor high error
Failure code
level Failure
L03 CA122
Details of • High voltage appears in pressure signal circuit of boost pressure & temperature sensor.
failure
• Takes it that boost pressure is at fixed value and allows engine to run.
Action of • Limits engine output and allows to engine to run.
controller • Closes EGR valve.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
• Input voltage from boost pressure sensor can be checked with monitoring function.
(Code: 36501 (V))
• Boost pressure from boost pressure sensor can be checked with monitoring function.
Related
(Code: 36500 (kPa))
information
• If sensor connector is disconnected, code [CA123] for “Low Error“ is displayed, even in
normal condition.
Defective harness information on troubleshooting".
connector
a If this failure appears, implement the following.
Defective sensor If failure code [CA187] or [CA227] is also displayed, perform troubleshooting for it
2 power supply 2 line first.
2. Disconnect connector BOOST PRESS & IMT.
Defective boost 3. Turn starting switch to ON position.
3 pressure & If failure code changes from [CA122] to [CA123] ,boost pressure sensor is
temperature sensor defective.
a Failure code [CA153] for temperature sensor is displayed at the same time.
Ignore this failure code since it appears because of disconnection of sensor.
Short circuit in 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect T-
4 wiring harness adapters to female side of ECM J1.
Resistance Between ECM J1 (female) (15) and (60) Min. 100 kz
Hot short circuit in 2. Disconnect connector BOOST PRESS & IMT, and connect T-adapters to
wiring harness connector ECM J1.
5 (contact with 24 V 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
circuit) disconnected).
Voltage Between ECM J1 (15) and (59) Max. 1 V
controller
40-152 PC290LC-10
40 Troubleshooting
Circuit diagram related to charge pressure sensor
PC290LC-10 40-153
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error

Action Boost pressure sensor low error
Failure code
level Failure
L03 CA123
Details of • Low voltage appears in pressure signal circuit of boost pressure & temperature sensor.
failure
• Takes it that boost pressure is at fixed value and allows engine to run.
machine
• Input voltage from boost pressure sensor can be checked with monitoring function.
(Code: 36501 (V))
• Boost pressure from boost pressure sensor can be checked with monitoring function.
(Code: 36500 (kPa))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Since troubleshooting "socket" for this sensor features female connector alone, it is not
usable for checking open circuit in wiring harness and voltage at sensor connector (not
designed as a T-adapter).
• If sensor connector is disconnected, this failure code appears.
connector
a If this failure appears, implement the following.
Defective power If failure code [CA187] or [CA227] is displayed, carry out troubleshooting for it first.
supply system of
2
boost pressure
sensor
2. Disconnect connectors CAM SENSOR, AMB. AIR PRESSURE, BOOST
Short circuit in PRESS & IMT, and ECM J1.
3 wiring harness 3. Connect T-adapters to female side of ECM J1.
Between ECM J1 (female) (15) and (59) Min. 100 kz
Resistance
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect T-
Ground fault in adapters to female side of ECM J1.
wiring harness
4 (contact with GND Between ECM J1 (female) (15) and
ground Min. 100 kz
circuit) Resistance
Between ECM J1 (female) (60) and
ground Min. 100 kz
Open circuit in If no failure is found by above checks, wiring harness may have open circuit. (*)
5 wiring harness
a If no failure is found by checks on causes 1 to 5 and check result of cause 6 is
Defective boost
abnormal, sensor is defective.
pressure &
temperature sensor 1. Turn starting switch to OFF position.
6 (improper input 2. Insert T-adapter to connector ECM J1.
voltage to engine 3. Turn starting switch to ON position.
controller) Between ECM J1 Min. 0.3 to 4.7 V
Voltage Sensor output
(15) and (59)
controller
40-154 PC290LC-10
40 Troubleshooting
*: *: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
Circuit diagram related to charge pressure sensor
PC290LC-10 40-155
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error

Action Throttle sensor high error
Failure code
level Failure
L03 CA131
Details of • High voltage appears in signal circuit of fuel control dial.
failure
• Uses throttle value obtained before failure detection and allows engine to run if failure is
Action of detected with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after detecting
failure.
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage of fuel control dial can be checked with monitoring function.
Related (Code: 03000 Fuel control dial voltage)
1
harness connector 2. Turn starting switch to ON position.
Defective throttle If failure code [CA2185] or [CA2186] is also displayed simultaneously, perform
2 sensor power troubleshooting for it first.
supply system
Defective fuel 2. Disconnect connector P20 and connect T-adapters to male side.
3 control dial (throttle Between P20 (male)(1) and (3) 4.0 to 6.0 kz
sensor) Resistance Between P20 (male)(2) and (3) 0.25 to 5.0 kz
Between P20 (male)(1) and (2) 0.25 to 5.0 kz
Open circuit or 2. Disconnect connector CE03 and connect T-adapters to female side.
4 short circuit in
wiring harness Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
Resistance
Between CE03 (female) (41) and (51) 0.25 to 5.0 kz
Short circuit in 2. Disconnect connectors CE03 and P20, and connect T-adapters to either
5 wiring harness female side.
Between CE03 (female) (41) and (42), or
Resistance between P20 (female) (1) and (2) Min. 100 kz
Hot short circuit in 1. Turn starting switch to OFF position.

wiring harness 2. Disconnect connector P20 and connect T-adapters to female side.
6 (contact with 24 V 3. Turn starting switch to ON position.
circuit) Voltage Between P20 (female) (2) and ground Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
• Reference
2. Insert T-adapters into connector CE03.
Defective engine 3. Turn starting switch to ON position.
7
controller 4. Operate fuel control dial and perform troubleshooting.
Between CE03 (41)
power supply 4.75 to 5.25 V
and (42)
Voltage
Between CE03 (41)
Sensor output 0.5 to 4.5 V
and (51)
40-156 PC290LC-10
40 Troubleshooting
Circuit diagram related to throttle sensor
PC290LC-10 40-157
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error

Action Throttle sensor low error
Failure code
level Failure
L03 CA132
Details of • Low voltage appears in signal circuit of fuel control dial.
failure
• Uses throttle value obtained before failure detection and allows engine to run if failure is
Action of detected with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after detecting
failure.
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage of fuel control dial can be checked with monitoring function.
Related (Code: 03000 Fuel control dial voltage)
harness connector
Defective throttle If failure code [CA2185] or [CA2186] is also displayed simultaneously, perform
2 sensor power troubleshooting for it first.
supply system
Defective fuel 2. Disconnect connector P20 and connect T-adapters to male side.
3 control dial (throttle Between P20 (male)(1) and (3) 4.0 to 6.0 kz
sensor) Resistance Between P20 (male)(2) and (3) 0.25 to 5.0 kz
Between P20 (male)(1) and (2) 0.25 to 5.0 kz
Open circuit or 2. Disconnect connector CE03 and connect T-adapters to female side.
4 short circuit in
wiring harness Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
Resistance
Between CE03 (female) (41) and (51) 0.25 to 5.0 kz
Open circuit in 2. Disconnect connectors CE03 and P20, and connect T-adapters to each female
5 (wire breakage or Between CE03 (female) (42) and P20
(female) (1) Max. 1 z
defective contact of
connector) Between CE03 (female) (51) and P20
Between CE03 (female) (41) and P20

2. Disconnect connectors CE03 and P20, and connect T-adapters to either
Short circuit in female side.
6 wiring harness Between CE03 (female) (41) and (51), or
between P20 (female) (2) and (3) Min. 100 kz
Resistance
Between CE03 (female) (41) and (42), or Min. 100 kz
between P20 (female) (1) and (3)
40-158 PC290LC-10
40 Troubleshooting

2. Disconnect connectors CE03 and P20, and connect T-adapters to either
Ground fault in female side.
harness Between ground and wiring harness
7 between CE03 (female) (51) and P20 Min. 100 kz
(Contact with GND (female) (2)
circuit) Resistance
Between ground and wiring harness
between CE03 (female) (42) and P20 Min. 100 kz
(female) (1)
• Reference
2. Insert T-adapters into connector CE03.
8
controller 4. Operate fuel control dial and perform troubleshooting.
Between CE03 (41)
power supply 4.75 to 5.25 V
and (42)
Voltage
Between CE03 (41)
Sensor output 0.5 to 4.5 V
and (51)
PC290LC-10 40-159
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error

Action Engine coolant temperature sensor high error
Failure code
level Failure
L01 CA144 (Engine controller system)
Details of • High voltage appears in engine coolant temperature sensor signal circuit.
failure
Action of • Takes it that coolant temperature is at fixed value (100°C) and allows engine to run.
controller
Problem on • Engine does not start easily at low temperatures.
machine • Overheat prevention function does not work.
• Input voltage from engine coolant temperature sensor can be checked with monitoring
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
information • This failure code appears if temperature sensor connector is disconnected.
• Because troubleshooting "socket" for this sensor features female connector alone, it is
not connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed as a T-adapter).

connector
If this failure code disappear, wiring harness connector is defective.
a If this failure code appears, implement the following.
2. Disconnect connector COOLANT TEMP and connect socket to male side.
a When coolant temperature is 0°C or higher, if coolant temperature sensor
resistance is between 700 z and 37 kz, regard coolant temperature sensor as
Defective coolant normal.
2 temperature sensor 0°C 30 to 37 kz
COOLANT TEMP
25°C 9.3 to 10.7 kz
(male)
Resistance 50°C 3.2 to 3.8 kz
Between (A) and
(B) 80°C 1.0 to 1.3 kz
95°C 700 to 800 z
2. Disconnect connector ECM J1 and connect T-adapters to female side.
Open circuit or Between ECM J1 (female) (13) and (14)
short circuit in (coolant temperature: Min. 0°C)
3
wiring harness Resistance a Use "Coolant temperature- 700 z to 37 kz
Resistance characteristics" table for
check on cause 2 shown above as
resistance criteria.
controller
40-160 PC290LC-10
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
PC290LC-10 40-161
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error

Action Engine coolant temperature sensor low error
Failure code
level Failure
L01 CA145
Details of • Low voltage appears in engine coolant temperature sensor signal circuit.
failure
Action of • Takes it that coolant temperature is at fixed value (100°C) and allows engine to run.
controller
• Input voltage from engine coolant temperature sensor can be checked with monitoring
function.
(Code: 04105 (V))
• Temperature sensed by engine coolant temperature sensor can be checked with
Related monitoring function.
information (Code: 04107°C )
• If temperature sensor connector is disconnected, this failure code is not generated but
failure code [CA144] for "High Error" is generated.
connector
If this failure code disappear, wiring harness connector is defective.
2. Disconnect connector COOLANT TEMP and connect socket to male side.
a When coolant temperature is 0°C or higher, if coolant temperature sensor
resistance is between 700 z and 37 kz, regard coolant temperature sensor as
normal.
0°C 30 to 37 kz
Defective coolant Between 25°C 9.3 to 10.7 kz
2 temperature sensor COOLANT TEMP 50°C 3.2 to 3.8 kz
(male) (A) and (B) 80°C 1.0 to 1.3 kz
Resistance 95°C 700 to 800 z
Between
COOLANT TEMP
Whole range Min. 100 kz
(male) (B) and
ground
Between ECM J1 (female) (13) and (14)
Short circuit in (coolant temperature: Min. 0°C)
3 wiring harness
Resistance a Use "Coolant temperature- 700 z to 37 kz
Resistance characteristics" table for
check on cause 2 shown above as
resistance criteria.
Ground fault in
2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect T-
wiring harness
4 adapters to female side of ECM J1.
(contact with GND
circuit) Between ECM J1 (female) (13) and
Resistance ground Min. 100 kz
controller
40-162 PC290LC-10
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
PC290LC-10 40-163
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error

Action Boost temperature sensor high error
Failure code
level Failure
L03 CA153
Details of • High voltage appears in temperature signal circuit of boost pressure & temperature
failure sensor.
• Takes it that boost temperature is at fixed value and allows engine to run.
Problem on • Engine protection function based on boost temperature does not work.
• Input voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
• Temperature sensed by boost temperature sensor can be checked with monitoring
function. (Code: 18500 °C)
information • Because troubleshooting "socket" for this sensor features female connector alone, it is
not connectable to female connector of sensor wiring harness, and thus not usable for
• This failure code is generated if temperature sensor connector is disconnected.
harness connector
If this failure code does not appear, wiring harness connector is defective.
a If this failure code is displayed, perform the following.
1. Be ready with starting switch at OFF position, then perform troubleshooting
without turning starting switch to ON position.
2. Disconnect connector BOOST PRESS & IMT and connect socket to male side.
-40°C 41 to 48 kz
-20°C 14 to 16 kz
BOOST PRESS & 0°C 5.4 to 6.1 kz
Defective boost IMT (male) 30°C 1.6 to 1.8 kz
2 temperature sensor Between (3) and (4) 60°C 560 to 600 z
130°C 80 to 90 z
BOOST PRESS &
IMT (male)
Between(3) and
ground
Open circuit or Between ECM J1 (female) (5) and (59)
3 short circuit in
wiring harness a Use "Boost temperature-Resistance
Resistance characteristics" table for check on 80 z to 48 kz
cause 2 shown above as resistance
criteria.
controller
40-164 PC290LC-10
40 Troubleshooting
Circuit diagram related to charge temperature sensor
PC290LC-10 40-165
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error

Action Boost temperature sensor low error
Failure code
level Failure
L03 CA154
Details of • Low voltage appears in temperature signal circuit of boost pressure & temperature
failure sensor.
• Takes it that boost temperature is at fixed value and allows engine to run.
Problem on • Engine protection function based on boost temperature does not work.
• Input voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
Related function.
information (Code: 18500 °C)
• If temperature sensor connector is disconnected, this failure code is not generated but
failure code [CA153] for "High Error" is generated.
harness connector
a If this failure code is displayed, perform the following.
1. Be ready with starting switch at OFF position, then perform troubleshooting
without turning starting switch to ON position.
2. Disconnect connector BOOST PRESS & IMT and connect socket to male side.
-40°C 41 to 48 kz
-20°C 14 to 16 kz
BOOST PRESS & 0°C 5.4 to 6.1 kz
Defective boost IMT (male) 30°C 1.6 to 1.8 kz
2 temperature sensor Between (3) and (4) 60°C 560 to 600 z
130°C 80 to 90 z
BOOST PRESS &
IMT (male)
Between(3) and
ground
Short circuit in Between ECM J1 (female) (5) and (59)
3 wiring harness a Use "Boost temperature-Resistance
Resistance characteristics" table for check on 80 z to 48 kz
cause 2 shown above as resistance
criteria.
harness 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect T-
4
(Contact with GND adapters to female side of ECM J1.
controller
40-166 PC290LC-10
40 Troubleshooting
Circuit diagram related to charge temperature sensor
PC290LC-10 40-167
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Volt Low Error

Action Sensor power supply 2 low error
Failure code
level Failure
L03 CA187
Details of • Voltage drop is detected in sensor power supply 2 circuit.
failure
• Takes it that boost pressure is at calculated value and allows engine to run.
• Limits engine output and allows engine to run.
• Takes it that crankcase pressure is at fixed value (to about 0 MPa) and allows engine to
run.
Action of • Closes EGR valve.
controller • Stops KDPF regeneration control.
• Takes it that ambient pressure is at fixed value (52.4 MPa) and allows engine to run.
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
machine • Engine starting performance becomes deteriorated.
information
1. Perform checkup referencing the descriptions of wiring harness and
connectors in "c: Electrical equipment"of "Checks before troubleshooting" in
Defective wiring "General information on troubleshooting".
harness connector
a If this failure code is displayed, implement the following.
2. Disconnect connector BOOST PRESS & IMT and turn starting switch to ON
Defective boost position.
2 pressure & If this failure code is not displayed, sensor is defective.
temperature sensor
a Many other failure codes appear at same time because of disconnection of
connector. Ignore failure codes other than [CA187] .
2. Disconnect connector AMB AIR PRESSURE and turn starting switch to ON
Defective ambient position.
3 pressure sensor If this failure code does not appear, sensor is defective.
Defective Bkup 2. Disconnect connector CAM SENSOR, and turn starting switch to ON position.
4 (cam) speed If this failure code is not displayed, sensor is defective.
sensor a Many other failure codes appear at same time because of disconnection of
Defective 2. Disconnect connector P57 and turn starting switch to ON position.
5 crankcase pressure If this failure code is not displayed, sensor is defective.
sensor a Many other failure codes appear at same time because of disconnection of
2. Disconnect wiring harness connector ECM J1 and turn starting switch to ON
Defective engine position.
6 wiring harness If this failure code is not displayed, engine wiring harness is defective.
40-168 PC290LC-10
40 Troubleshooting

Defective engine 2. Disconnect connector ECM J1 and connect T-adapters to male side.
7 3. Turn starting switch to ON position with connector ECM J1 disconnected.
controller
Voltage Between ECM J1 (male) (59) and (60) 4.75 to 5.25V
Circuit diagram related to sensor power supply 2
PC290LC-10 40-169
40 Troubleshooting
Failure code [CA221] Ambient Press Sensor High Error

Action Ambient pressure sensor high error
Failure code
level Failure
L03 CA221
Details of • High voltage appears in ambient pressure sensor signal circuit .
failure
• Takes it that ambient pressure is at fixed value (52.44 kPa) and allows engine to run.
machine
• Input voltage from ambient pressure sensor can be checked with the monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
harness connector
Defective sensor If failure code [CA187] or [CA227] is displayed simultaneously, perform
2 power supply 1 line troubleshooting for it first.
Defective ambient 2. Disconnect connector AMB.AIR PRESSURE.
3 pressure sensor 3. Turn starting switch to ON position.
If failure code [CA221] changes to [CA222], sensor is defective.
2. Disconnect connectors ECM J1 and AMB AIR PRESSURE, and connect T-
Short circuit in adapters to female side of either of them.
4 wiring harness Between ECM J1 (60) and (16), or
Resistance between AMB. AIR PRESSURE Min. 100 kz
(female) (1) and (3)
2. Disconnect connector AMB. AIR PRESSURE.
3. Connect T-adapters to female side of connector AMB. AIR PRESSURE or
Hot short circuit in
insert T-adapters in connector ECM J1.
wiring harness
5 4. Turn starting switch to ON position (with connector AMB AIR PRESSURE
(contact with 24 V
disconnected).
circuit)
Between ECM J1 (16) and (59), or
Voltage between AMB. AIR PRESSURE Max. 1 V
controller
40-170 PC290LC-10
40 Troubleshooting
Circuit diagram related to ambient pressure sensor
PC290LC-10 40-171
40 Troubleshooting
Failure code [CA222] Ambient Press Sensor Low Error

Action Ambient pressure sensor low error
Failure code
level Failure
L03 CA222
Details of • Low voltage appears in ambient pressure sensor signal circuit .
failure
Action of • Takes it that ambient pressure is at fixed value (52.44 kPa) and allows engine to run.
controller
machine
• Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
Related function.
information (Code: 37400 (kPa))
• If sensor connector is disconnected, this failure code is generated.
harness connector
Defective power If failure code [CA187] or [CA227] is displayed simultaneously, perform
supply line of troubleshooting for it first.
2
ambient pressure
sensor
2. Disconnect connector AMB. AIR PRESSURE and connect T-adapters to
Defective power female side.
supply line of 3. Turn starting switch to ON position.
3
ambient pressure
sensor Between AMB. AIR
Voltage PRESSURE Power supply input 4.75 to 5.25 V
2. Disconnect connectors AMB AIR PRESSURE and ECM J1, and connect T-
adapters to each female side.
a If power supply input is normal in
check on cause 3, this check is not
required. Max. 10 z
Open circuit in Between ECM J1 (female) (60) and
wiring harness AMB. AIR PRESSURE (female) (1)
4 (wire breakage or
defective contact of a If power supply input is normal in
connector) Resistance check on cause 3, this check is not
required. Max. 10 z
AMB. AIR PRESSURE (female) (2)
AMB. AIR PRESSURE (female) (3) Max. 10 z
(Sensor output)
40-172 PC290LC-10
40 Troubleshooting

2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and connect T-
Ground fault in adapters to female side of either of them.
wiring harness
5 (contact with GND Between ECM J1 (female) (16) or AMB.
AIR PRESSURE (female) (3) Min. 100 kz
circuit) Resistance
Between ECM J1 (female) (60) or AMB.
AIR PRESSURE (female) (1) Min. 100 kz

2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and connect T-
Short circuit in adapters to female side of either of them.
6 wiring harness Between ECM J1 (16) and (60), or
Resistance between AMB. AIR PRESSURE Min. 100 kz
a If any failure is found by above checks, sensor is defective.
Defective ambient 2. Insert T-adapters to connector ECM J1.
Between ECM J1
Voltage Sensor output 0.5 to 4.5 V
(16) and (60)
controller
Circuit diagram related to ambient pressure sensor
PC290LC-10 40-173
40 Troubleshooting
Failure code [CA227] Sensor 2 Supply Volt High Error

Action Sensor power supply 2 high error
Failure code
level Failure
L03 CA227
Details of • High voltage is detected in sensor power supply 2 circuit.
failure
• Takes it that boost pressure is at calculated value and allows engine to run.
• Takes it that crankcase pressure is at fixed about 0 MPa and allows engine to run.
• Takes it that ambient pressure is at fixed value (52.4 MPa) and allows engine to run.
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
machine • Engine startability becomes poor.
information
High voltage of Perform troubleshooting for failure code [CA187].
1 sensor power
supply 2
40-174 PC290LC-10
40 Troubleshooting
Failure code [CA234] Eng Overspeed

Action Engine overspeed
Failure code
level Failure
L02 CA234
Details of • Engine speed is over the operating range.
failure
Action of • Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem on • Engine speed fluctuates.
machine
• Engine speed can be checked with monitoring function.
Related (Code: 01002 Engine speed)
information • Method of reproducing failure code: Start the engine and run at high idle.
Use of improper Fuel used may be improper. Check it.
1
fuel
Defect in related If another failure code is displayed, carry out troubleshooting for it.
2 system
3 Improper fuel Machine may be used improperly. Instruct operator on proper way to use.
controller
PC290LC-10 40-175
40 Troubleshooting
Failure code [CA238] Ne Speed Sensor Supply Volt Error

Action Ne speed sensor supply voltage error
Failure code
level Failure
L01 CA238
Details of • Low voltage appeared in power supply circuit of engine Ne speed sensor.
failure
Action of • Controls the engine with signal from engine Bkup speed sensor.
controller
• Running engine stops (when Bkup speed sensor is also defective).
Problem on • Stopped engine cannot be started (when Bkup speed sensor is also defective).
• Engine hunts.
information
1
2. Disconnect connector CRANK SENSOR, and turn starting switch to ON
position.
2 Defective sensor If this failure code is not displayed, crank sensor is defective.
connector. Ignore failure codes other than [CA238].
2. Disconnect wiring harness connector ECM J1 and turn starting switch to ON
Defective wiring position.
3 If this failure code is not displayed, engine wiring harness is defective.
harness
2. Disconnect connector ECM J1 and connect T-adapters to male side.
Defective engine
4 3. Turn starting switch to ON position with engine wiring harness connector
controller
disconnected.
Voltage Between ECM J1 (male) (36) and (37) 4.75 to 5.25 V
Circuit diagram related to Ne speed sensor
40-176 PC290LC-10
40 Troubleshooting
Failure code [CA239] Ne Speed Sens Supply Volt High Error

Action Ne speed sensor supply voltage high error
Failure code
level Failure
L01 CA239
Details of • High voltage appears in power supply circuit of engine Ne speed sensor.
failure
Action of • Controls engine with signal from engine Bkup speed sensor.
controller
• Engine hunts.
information
1
2. Disconnect connector CRANK SENSOR, and turn starting switch to ON
2 Defective sensor
position.
If this failure code is not displayed, sensor is defective.
2. Disconnect wiring harness ECM J1 and turn starting switch to ON position.
Defective wiring If this failure code is not displayed, engine wiring harness is defective.
3
harness
Defective engine
controller
disconnected.
Circuit diagram related to Ne speed sensor
PC290LC-10 40-177
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error

Action Short circuit in IMV/PCV1
Failure code
level Failure
L03 CA271
Details of • Short circuit is detected in drive circuit of supply pump actuator (IMV).
failure
controller
• Engine speed does not increase from low idle.
Problem on • Engine output lowers.
machine • Common rail fuel pressure rises above command value.
Related • Method of reproducing failure code: Starting switch: ON
information
1. See descriptions of wirings harness and connectors in "c: Electrical equipment"
in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check them.
1 2. Starting switch: ON
harness connector
If this failure code does not appear, the wiring harness connector is defective.
1. Starting switch: OFF
2. Disconnect connector ECM J1.
Defective supply
2 Between ECM J1 (female) (30) and (40) 1-5z
pump actuator
Resistance Between ECM J1 (female) (40) and
ground Min. 100 kz

Short circuit or 2. Disconnect connector ECM J1 and connect T-adapter to the female side.
3 ground fault in Between ECM J1 (female) (30) and (40) 1-5z
wiring harness Resistance Between ECM J1 (female) (2) and
ground Min. 100 kz
a If no failure is found by check cause 3, this check is not required.

Short circuit in 1. Starting switch: OFF
4 wiring harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and connect
T-adapter to female side of ECM J1.
a If no failure is found by checks cause 3, this check is not required.
Ground fault in 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and connect
wiring harness T-adapter to female side of ECM J1.
5
(contact with Between ECM J1 (female) (30) and
ground circuit) ground Min. 100 kz
Resistance
ground Min. 100 kz
controller
40-178 PC290LC-10
40 Troubleshooting
Circuit diagram related to lMV／PCV1
PC290LC-10 40-179
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error

Action Open circuit in IMV/PCV1
Failure code
level Failure
L03 CA272
Details of • Open circuit is detected in drive circuit of supply pump actuator (IMV).
failure
Action of None in particular
controller
Problem on • Engine runs but its speed does not stabilize.
machine • Common rail fuel pressure rises above command value.
• Method of reproducing failure code: Starting switch: ON
Related • Because troubleshooting "socket" for this sensor features female connector alone, it is
information not connectable to female connector of sensor wiring harness, and thus not usable for
harness connector
Defective supply 2. Disconnect connector INLET METERING VALVE.
2 pump actuator Between INLET METERING VALVE
Resistance (male) (1) and (2) 5 z Max.
Open or short 1. Starting switch: OFF

3 circuit in wiring 2. Disconnect connector ECM J1 and connect T-adapter to female side.
harness Resistance Between ECM J1 (female) (30) and (40) 5 z Max.
2. Disconnect connector CP3 INLET METERING VALVE.
Hot short circuit in 3. Insert T-adapter to connector ECM J1.
wiring harness 4. Turn starting switch to ON position and perform troubleshooting after one
4
(contact with 24 V minute or longer (with connector CP3 INLET METERING VALV disconnected).
circuit)
a Average voltage is displayed because of PWM.
Voltage Between ECM J1 (30) and (40) Max. 3 V
controller
Circuit diagram related to lMV／PCV1
40-180 PC290LC-10
40 Troubleshooting
Failure code [CA295] Ambient Press Sens In Range Error

Action Ambient pressure sensor in range error
Failure code
level Failure
L03 CA295
Details of • Output from ambient pressure sensor is out of normal range.
failure
Action of • Takes it that ambient pressure is at fixed value (52.44 kPa) and allows engine to run.
controller
machine
• Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function.
(Code: 37400 (kPa))
Defective ambient Perform troubleshooting for failure codes [CA221] and [CA222].
1 pressure sensor
system
PC290LC-10 40-181
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error

Action Open or short circuit in injector #1 (L#1)
Failure code
level Failure
L03 CA322
Details of • Open or short circuit occurs in drive circuit of No. 1 injector.
failure
controller
Problem on • Combustion becomes irregular or engine hunts.
Related • While engine is running normally, pulse voltage of approx. 65 V is applied to injector (+)
information side but cannot be measured by using multimeter because it cannot measure pulse
voltages.
harness connector
2. Disconnect connector INJECTOR CYL 1&2 and connect T-adapters to male
side.
Defective No. 1
2 Between INJECTOR CYL 1&2 (male) (3)
injector Max. 2 z
and (4)
Resistance
Between INJECTOR CYL 1&2 (male) (3)
and ground Min. 100 kz

Open circuit or 2. Disconnect connector ECM J1 and connect T-adapters to female side.
3 ground fault in Between ECM J1 (female) (48) and (58) Max. 2 z
ground Min. 100 kz

wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1&2, and connect T-
4 (wire breakage or adapters each female side.
defective contact of Between ECM J1 (female) (48) and
INJECTOR CYL 1&2 (female) (3) Max. 2 z
connector)
Resistance

5 (contact with GND adapters to either female side.
circuit)
Between ground and ECM J1 (female) Min. 100 kz
Resistance (48) or INJECTOR CYL 1&2 (female) (3)
40-182 PC290LC-10
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL 1&2, and connect T-
adapters female side of ECM J1.
Short circuit in a Check by using multimeter in continuity mode.
6 wiring harness Between ECM J1 (female) (48) and No continuity (no
each pin other than (48) sound is heard.)
Continuity
Between ECM J1 (female) (58) and No continuity (no
Defective injector of If failure codes for other injectors is also displayed, perform troubleshooting for
7 other cylinder them, too.
Defective injector If failure code for other injectors is also displayed, perform troubleshooting for it
8 harness of other first.
cylinder
controller
Circuit diagram related to No. 1 injector
PC290LC-10 40-183
40 Troubleshooting

Action Open or short circuit in injector #5 (L/B #5)
Failure code
level Failure
L03 CA323
failure
controller
voltages.
harness connector
side.
Defective No. 5
injector Max. 2 z
and (4)
Resistance

Open circuit or 2. Disconnect connector ECM J1 and connect T-adapter to female side.
ground Min. 100 kz

4 (wire breakage or adapters to each female side.
connector)
Resistance

circuit) Between ground and ECM J1 (female)
(44) or between INJECTOR CYL 5&6 Min. 100 kz
Resistance
(female) (3)
40-184 PC290LC-10
40 Troubleshooting

adapters to female side of ECM J1.
Continuity
Defective injectors If failure code for other injector is also displayed, perform troubleshooting for it first.
7 of other cylinder
Defective injector If failure code for other injector is also displayed, perform troubleshooting for it first.
8 wiring harness of
other cylinder
controller
PC290LC-10 40-185
40 Troubleshooting

Failure code
level Failure
L03 CA324
failure
controller
voltages.
harness connector
side.
Defective No. 3
injector Max. 2 z
and (4)
Resistance

ground Min. 100 kz

connector)
Resistance

circuit)
40-186 PC290LC-10
40 Troubleshooting

Continuity
Defective injector of If failure code for other injector is also displayed, perform troubleshooting for it first.
7 other cylinder
8 wiring harness of
other cylinder
controller
PC290LC-10 40-187
40 Troubleshooting

Failure code
level Failure
L03 CA325
failure
controller
voltages.
harness connector
side.
Defective injector
No. 6 Max. 2 z
and (2)
Resistance

ground Min. 100 kz

connector)
Resistance

circuit)
40-188 PC290LC-10
40 Troubleshooting

Short circuit in a Check by using multimeter tester in continuity mode.
Continuity
7 other cylinder
8 wiring harness of
other cylinder
controller
PC290LC-10 40-189
40 Troubleshooting

Action Open or short circuit in injector #2 (L#2)
Failure code
level Failure
L03 CA331
failure
controller
voltages.
harness connector
side.
Defective No. 2
injector Max. 2 z
and (2)
Resistance

ground Min. 100 kz

connector)
Resistance

circuit)
40-190 PC290LC-10
40 Troubleshooting

Continuity
Defective injector of If failure codes for other injectors are displayed, perform troubleshooting for them,
7 other cylinder too.
Defective injector If failure codes for other injector is also displayed, perform troubleshooting for it
8 wiring harness of first.
other cylinder
controller
PC290LC-10 40-191
40 Troubleshooting

Action Open or short circuit in injector #4 (L/B #4 )
Failure code
level Failure
L03 CA332
failure
controller
voltages.
harness connector
side.
Defective No. 4
injector Max. 2 z
and (2)
Resistance

ground Min. 100 kz

connector) INJECTOR CYL 3&4 (female) (2) Max. 2 z
Resistance
a If no abnormality is found by check on cause 3, this check is not required.

Ground fault in
5 (contact with GND 2. Disconnect connectors ECM J1 and INJECTOR CYL 3&4, and connect T-
circuit) adapters to either female side.
40-192 PC290LC-10
40 Troubleshooting

adapter to female side of ECM J1.
Short-circuiting of a Check by using multimeter in continuity mode.
6
harness Between ECM J1 (female) (43) and No continuity (no
Continuity
7 other cylinder
8 wiring harness of
other cylinder
controller
PC290LC-10 40-193
40 Troubleshooting
Failure code [CA343] ECM Critical Internal Failure

Action ECM critical internal failure
Failure code
level Failure
L04 CA343
Details of • Memory or power supply circuit in engine controller is defective.
failure
controller
Problem on • Engine may stop during operation or may not be able to start.
machine
• Power supply voltage of engine controller can be checked with monitoring function.
Related (Code: 03203 Battery Voltage)
information • Method of reproduc failure code: Starting engine.
Defective related If another failure code is displayed, perform troubleshooting for it, too.
1 system
Internal defect of Perform troubleshooting for failure code [CA441].
2 engine controller
40-194 PC290LC-10
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error

Action Injector drive circuit error
Failure code
level Failure
L03 CA351
Details of • There is error in drive power circuit of injector.
failure
Action of • Limits engine output and allows engine to run.
controller
• Exhaust gas becomes black.
Problem on • Combustion becomes irregular.
• Stopped engine cannot be started.
Related • Power supply voltage of engine controller can be checked by using monitoring function.
information (Code: 03203 (V))
1 system
Defective power Perform troubleshooting for failure code [CA441].
2 supply voltage
system
PC290LC-10 40-195
40 Troubleshooting

Action Sensor power supply 1 low error
Failure code
level Failure
L03 CA352
Details of • Voltage drop is detected in sensor power supply 1 circuit.
failure
• Controls EGR valve lift sensor to close EGR valve and allows engine to run with output
limited.
Action of • Controls KVGT position sensor to close EGR valve and allows engine to run with output
controller limited.
• Controls exhaust manifold pressure sensor to close EGR valve and allows engine to run
with output limited.
machine
information
harness connector
2. Disconnect connector EXHAUST PRESSURE and turn starting switch to ON
Defective exhaust position.
2 manifold pressure If this failure code is not displayed, sensor is defective.
sensor
a Many other failure codes are displayed because of disconnection of connector.
Ignore failure codes other than [CA352].
2. Disconnect connector SEGR and turn starting switch to ON position.
Defective EGR If this failure code is not displayed, sensor is defective.
3
valve lift sensor
2. Disconnect connector SVGT and turn starting switch to ON position.
Defective KVGT If this failure code is not displayed, sensor is defective.
4 position sensor
2. Disconnect wiring harness ECM J2 and turn starting switch to ON position.
Defective engine If this failure code is not displayed, engine wiring harness is defective.
5 wiring harness
Defective engine
controller
disconnected.
40-196 PC290LC-10
40 Troubleshooting
Circuit diagram related to sensor power supply 1
PC290LC-10 40-197
40 Troubleshooting
Failure code [CA356] Mass Air Flow Sensor High Error

Action Mass air flow sensor high error
Failure code
level Failure
L03 CA356
Details of • High-frequency voltage appears in mass air flow signal circuit.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
• Air flow rate sensed by mass air flow sensor can be checked with monitoring function.
(Code: 48200 (kg/sec)
Related • Sensor output is pulse voltage of about 5 V, so it cannot be measured by using
information multimeter.
• Mass air flow sensor and intake temperature sensor are integrated.
harness connector
Defective sensor If failure code [CA3419] or [CA3421] is also displayed, perform troubleshooting for
2 power supply first.
system
Defective mass air 2. Disconnect connector P55.
3 flow sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code changes to failure code [CA357], mass air flow sensor is
defective.
Defective sensor 2. Disconnect connector P55 and connect T-adapters to female side.
4 power supply 3. Turn starting switch to ON position.
system Between P55
Voltage power supply Approx. 12 V
Open circuit in a If no failure is found by check on cause 4, this check is not required.
5 (wire breakage or 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to each
defective contact of female side.
connectors) Between ECM J1 (female) (22) and P55

Short circuit in 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to female
wiring harness side of ECM J1.
6 (between wiring a Check by using multimeter tester in continuity mode.
harnesses)
Resistance each pin other than (23) Min. 100 kz
controller
40-198 PC290LC-10
40 Troubleshooting
Circuit diagram related to mass air flow sensor
PC290LC-10 40-199
40 Troubleshooting
Failure code [CA357] Mass Air Flow Sensor Low Error

Action Mass air flow sensor low error
Failure code
level Failure
L03 CA357
Details of • Low-frequency voltage appears in mass air flow signal circuit.
failure
• Takes it that mass air flow is at fixed value (10 kg/min).
machine
• Air flow rate sensed by mass air flow sensor can be checked with monitoring function.
(Code: 48200 (kg/sec)
• Sensor output is pulse voltage of about 5 V, so it cannot be measured by using
Related multimeter.
information • Mass air flow sensor and intake temperature sensor are integrated.
• If sensor connector is disconnected, this failure code and failure code [CA691] are
displayed at same time.
1
system
Defective mass air 1. Turn starting switch to OFF position.

flow sensor 2. Replace mass air flow sensor.
3
(internal defect) 3. Turn starting switch to ON position.
If this failure code is not displayed, original mass air flow sensor is defective.
system Between P55
Voltage power supply Approx. 12 V
2. Disconnect connectors ECM J1 and P55, and connect T-adapters to each
female side.
a If no failure is found by check on
Open circuit in cause 4, this check is not required. Max. 10 z
wiring harness Between ECM J1 (female) (21) and P55
5 (wire breakage or (female) (2)
connectors) Resistance a If no failure is found by check on
cause 4, this check is not required. Max. 10 z
Between ECM J1 (female) (22) and P55
(female) (3)
Between ECM J1 (female) (23) and P55 Max. 10 z
(female) (1)
40-200 PC290LC-10
40 Troubleshooting

Ground fault in 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to either
wiring harness female side.
6 (contact with GND Between ECM J1 (female) (23) and
circuit) Resistance ground, or between P55 (female) (1) and Min. 100 kz
ground
7 (between wiring a Check by using multimeter in continuity mode.
harnesses)
Resistance each pin other than (23) Min. 100 kz

Hot short circuit in 2. Disconnect connector P55 and connect T-adapters to female side.
wiring harness 3. Turn starting switch to ON position.
8 (contact with 24 V
circuit) a Ignore displayed failure code.
Voltage Between P55 (female) (1) and (3) Max. 1 V
controller
PC290LC-10 40-201
40 Troubleshooting

Action Sensor power supply 1 high error
Failure code
level Failure
L03 CA386
Details of • High voltage is detected in sensor power supply 1 circuit.
failure
• Controls EGR stroke sensor to close EGR valve and allows engine to run with output
limited.
Action of • Controls KVGT stroke sensor to close EGR valve and allows engine to run with output
controller limited.
• Controls exhaust manifold sensor to close EGR valve and allows engine to run with
output limited.
machine
information
High sensor power Perform troubleshooting for failure code [CA352].
1 supply voltage
40-202 PC290LC-10
40 Troubleshooting
Failure code [CA428] Water in Fuel Sensor High Error

Action Water-in-fuel sensor high error
Failure code
level Failure
L01 CA428
Details of • High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function.
Related (Code: 18800)
harness connector
Defective water-in- 1. Turn starting switch to OFF position.
fuel sensor 2. Disconnect connector P47 and connect T-adapters to female side.
2
installed to fuel pre- a If water is in water separator, drain it.
filter Between P47 (female) (1) and (2)
Resistance Min. 10 to 100 kz
3 short circuit in
wiring harness Between ECM J1 (female) (24) and (32)
Resistance Min. 10 to 100 kz
(Resistance of water-in-fuel sensor)
wiring harness 2. Disconnect connectors ECM J1 and P47, and connect T-adapters to ECM J1
4 (wire breakage or (female) and P47 (male).
defective contact of Between ECM J1 (female connector)
(32) and P47 (female connector) (1) Max. 10 z
connector)
Resistance
Between ECM J1 (male) (24) and P47
(male) (2) Max. 10 z

2. Disconnect connectors ECM J1 and P47, and connect T-adapters to female
Short circuit in side of ECM J1.
5 wiring harness a Check by using multimeter in continuity mode.
Continuity
controller
PC290LC-10 40-203
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-204 PC290LC-10
40 Troubleshooting
Failure code [CA429] Water in Fuel Sensor Low Error

Action Water-in-fuel sensor low error
Failure code
level Failure
L01 CA429
Details of • Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor can be checked with monitoring function.
Related (Code: 18800)
harness connector
Defective water-in- 2. Disconnect connector P47 and connect T-adapters to female side.
fuel sensor
2
installed to fuel pre- a If water is in water separator, drain it.
filter Between P47 (female) (1) and (2) Min. 10 to 100 kz
Resistance
Between P47 (female) (1) and ground Min. 100 kz
Short circuit or Between ECM J1 (female) (24) and (32)
3 ground fault in Min. 10 to 100 kz
harness (Resistance of water-in-fuel sensor)
Resistance
ground Min. 100 kz

2. Disconnect connectors ECM J1 and P47, and connect T-adapters to female
Short circuit in side of ECM J1.
Continuity
wiring harness 2. Disconnect connectors ECM J1 and P47, and connect T-adapters to either
5 (contact with GND ECM J1 (female connector) or P47 (male connector).
circuit)
Between ground and ECM J1 (female)
Resistance (24) or P47 (male) 2 Min. 100 kz
controller
PC290LC-10 40-205
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-206 PC290LC-10
40 Troubleshooting
Failure code [CA435] Eng Oil Press Sw Error

Action Engine oil pressure switch error
Failure code
level Failure
L01 CA435
Details of • Abnormality is detected in signal circuit of engine oil pressure switch.
failure
controller
Problem on • Engine protection function based on engine oil pressure does not work.
machine • Engine oil pressure monitor is not displayed correctly.
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is closed (turned ON) when oil pressure is low (when engine is
stopped), but is opened (turned OFF) when high (when engine is running).
Related • To generate this failure code, engine controller checks if engine oil pressure switch is
information closed (ON), that is, if signal voltage is zero only when engine is stopped.
• When engine is running, failure of engine oil pressure switch is shown by failure code
[B@BAZG].
1
Defective engine oil 2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapters to
2 pressure switch male side.
Between OIL PRESSURE SWITCH
Resistance (male) (1) and ground Max. 10 z

Open circuit or
3 short circuit in
wiring harness Between ECM J1 (female) (31) and
Resistance ground Max. 10 z
controller
Circuit diagram related to engine oil pressure switch
PC290LC-10 40-207
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error

Action Battery voltage low error
Failure code
level Failure
L04 CA441
Details of • Low voltage appears in controller power supply circuit.
failure
Action of • Takes power voltage to be at fixed value (24 V) and allows engine to run.
controller
Problem on • Engine stops.
machine • Engine startability is poor
Related • Power supply voltage of engine controller can be checked with moniitoring funtion.
information (Code: 03203(V))
Loose or corroded Battery cable terminal may be loose or corroded. Check it.
1 battery terminal
Loose terminal or 1. Starting switch: OFF
2 partial open circuit Check terminals of alternator, battery relay, ground terminal (T12), etc.
at terminal
See descriptions of wirings harness and connectors in "c: Electrical equipment" in
Defective wiring
3 "Checks before troubleshooting" of "General information on troubleshooting", and
harness connector
check them.
Improper battery 2. Perform troubleshooting with starting switch at OFF position and at engine
4 voltage cranking.
Voltage Between battery terminals (+) and (-). 20 - 30 V
2. Insert T-adapter into connector E12.
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Voltage Between E12 (1) and ground 27.5 - 29.5 V
controller
40-208 PC290LC-10
40 Troubleshooting
Circuit diagram related to engine controller power supply
PC290LC-10 40-209
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error

Action Battery voltage high error
Failure code
level Failure
L04 CA442
Details of • High voltage (about 36 V or higher) appears in controller power supply circuit.
failure
Action of • Takes it that power supply voltage is at fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart.
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03203 (V))
High battery Perform troubleshooting for failure code [CA441].
1 voltage
40-210 PC290LC-10
40 Troubleshooting
Failure code [CA449] Rail Press Very High Error

Action Common rail pressure sensor very high error 2
Failure code
level Failure
L03 CA449
Details of • High pressure error (2) appears in common rail circuit.
failure
Action of • Runs engine with engine output limited.
controller
Problem on • Engine sound becomes large without load or with light load.
• Common rail pressure can be checked with monitoring function.
Related (Code: 36400 Common rail pressure)
1 system
Air may be in low-pressure fuel circuit. Check it according to following procedure.
Air in low-pressure 1. Remove fuel pressure pickup port plug (outlet side) of fuel main filter.
2
fuel circuit 2. Operate feed pump of fuel pre-filter.
3. Check leakage level of fuel and air from pressure pickup plug hole.
a For check of pressure in fuel return circuit, see Testing and adjusting, "Testing
Defective fuel fuel pressure".
3 return circuit parts Fuel return circuit Max. 18.6 MPa
Engine at low idle or cranking
pressure {Max. 0.19 kg/cm2}
Defective common Perform troubleshooting for failure codes [CA451] and [CA452].
4 rail pressure sensor
system
a For check of leakage from pressure limiter, see Testing and adjusting,
Defective pressure "Checking fuel return rate and leakage".
5
limiter Leakage from
Engine at low idle (for 30 seconds) Max. 8 cc
pressure limiter
Defective supply If no failure is found by above checks, supply pump may be defective.
6 pump
PC290LC-10 40-211
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error

Action Common rail pressure sensor high error
Failure code
level Failure
L03 CA451
Details of • High voltage appears in signal circuit of common rail pressure sensor.
failure
controller
Problem on • Engine speed or output lowers.
machine • Engine does not restart
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
Related • This failure code is generated if common rail pressure sensor connector is disconnected.
information • Since troubleshooting "socket" for this sensor features female connector alone, it is not
usable for checking open circuit in wiring harness and voltage at sensor connector (not
designed as a T-adapter).
harness connector
Defective common If failure code [CA515] or [CA516] is displayed simultaneously, perform
2 rail pressure sensor troubleshooting for it first.
power supply line
Short circuit in 2. Disconnect connectors FUEL RAIL PRESS and ECM J2.
2. Disconnect connector FUEL RAIL PRESS and connect T-adapters to
Hot short circuit in connector ECM J2.
wiring harness 3. Turn starting switch to ON position (with connector FUEL RAIL PRESS
4 (contact with 24 V disconnected).
circuit)
a Pin (31) of ECM J2 is connected to 5 V line via resistor inside engine controller.
Voltage Between ECM J2 (21) and (44) 4.75 to 5.25 V
Open circuit in If no failure is found by above checks, wiring harness may have open circuit. (*)
5 wiring harness
a If no failure is found by checks on causes 1 to 5 and any failure is found by
Defective common check on cause 6, sensor is defective.
rail pressure sensor 1. Turn starting switch to OFF position.
6 (improper input 2. Insert T-adapters to connector ECM J2.
voltage to engine 3. Turn starting switch to ON position.
controller) Sensor output
Between ECM J2 (21) and (44) 0.2 to 4.8 V
voltage
controller
40-212 PC290LC-10
40 Troubleshooting
Circuit diagram related to common rail pressure sensor
PC290LC-10 40-213
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error

Action Common rail pressure sensor low error
Failure code
level Failure
L03 CA452
Details of • Low voltage appears in signal circuit of common rail pressure sensor.
failure
controller
Problem on • Engine speed or output lowers.
machine • Engine does not restart
• Signal voltage of common rail pressure sensor can be checked with monitoring function.
(Code: 36401 Common rail pressure sensor volt)
information • If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is displayed.
harness connector
Defective common If failure code [CA515] or [CA516] is displayed simultaneously, perform
2 rail pressure sensor troubleshooting for it first.
power supply line
Defective common 2. Disconnect connector FUEL RAIL PRESS.
3 rail pressure sensor 3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451] , sensor is defective.
Ground fault in
2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and connect T-
wiring harness
4 adapters to female side of ECM J2.
(contact with GND

Short circuit in 2. Disconnect connectors FUEL RAIL PRESS and ECM J2.
controller
40-214 PC290LC-10
40 Troubleshooting
Failure code [CA488] Chg Air Temp High Torque Derate

Action Boost temperature high error
Failure code
level Failure
L03 CA488
Details of • Temperature signal from boost pressure & temperature sensor exceeds upper limit of
failure control temperature.
controller
machine
• Boost temperature can be checked with monitoring function.
Related (Code: 18500 Boost temperature)
Cooling performance of aftercooler may degrade. Check following points:
Lowered cooling
performance of • Looseness and damage of fan belt
1
aftercooler • Insufficient cooling air
• Clogging of aftercooler fins
Abnormal rise of Outlet temperature of turbocharger may be abnormally high. Check related parts.
2 turbocharger outlet
temperature
Defective boost Perform troubleshooting for failure codes [CA153] and [CA154].
3 temperature sensor
PC290LC-10 40-215
40 Troubleshooting
Failure code [CA515] Rail Press Sens Sup Volt High Error
Action Common rail pressure sensor power supply voltage high
Failure code
level Failure error
Details of • High voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
controller
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function.
(Code: 36401 (V))
Related • Pressure sensed by common rail pressure sensor can be checked with monitoring
(Code: 36400 (MPa))
1
2. Disconnect connector FUEL RAIL PRESS.
Defective common
If this failure code does not appear, sensor is defective.
(internal defect)
a Many failure codes are also displayed because of disconnection of connector.
Ignore them other than this failure code.
Defective wiring If this failure code is not displayed, wiring harness may be defective. Perform
3
harness following troubleshooting.
wiring harness 2. Disconnect connector FUEL RAIL PRESS and connect T-adapters to female
4 (contact with 24 V side.
circuit) 3. Turn starting switch to ON position.
Between FUEL RAIL PRESS (female)
(3) and (1)
2. Disconnect connector ECM J2 and connect T-adapters.
5
controller Voltage Between ECM J2 (male) (31) and (21) 4.75 to 5.25 V
40-216 PC290LC-10
40 Troubleshooting
PC290LC-10 40-217
40 Troubleshooting
Failure code [CA516] Rail Press Sens Sup Volt Low Error
Action Common rail pressure sensor power supply voltage low
Failure code
level Failure error
Details of • Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
controller
machine
information
1
2. Disconnect connector FUEL RAIL PRESS.
Defective common
If this failure code does not appear, sensor is defective.
(internal defect)
Defective wiring If this failure code is not displayed, wiring harness may be defective. Perform
3
harness following troubleshooting.
Ground fault in 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and connect T-
wiring harness adapters to female side.
4 (contact with GND Between ground and ECM J2 (female)
circuit) (31) or FUEL RAIL PRESS (female) (1) Min. 100 kz
Resistance
(44) , or FUEL RAIL PRESS (female) (3) Min. 100 kz

2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and connect T-
Ground fault in adapters to either female side.
wiring harness Between ECM J2 (female) (21) and (44),
5 (contact with GND or between FUEL RAIL PRESS (female) Min. 100 kz
circuit) (3) and (2)
Resistance
Between ECM J2 (female) (21) and (31),
or between FUEL RAIL PRESS (female) Min. 100 kz
(1) and (2)
40-218 PC290LC-10
40 Troubleshooting

2. Disconnect connector ECM J2 and connect T-adapters.
6
controller Voltage Between ECM J2 (male) (31) and (21) 4.75 to 5.25 V
PC290LC-10 40-219
40 Troubleshooting
Failure code [CA553] Rail Press High Error

Action Common rail pressure high error 1
Failure code
level Failure
L01 CA553
Details of • High pressure error (1) appears in common rail circuit.
failure
controller
Problem on • Engine sound becomes large without load or with light load.
1 system
Cable connection to ground terminal may be incorrect. Check following terminals.
Defective • Ground terminal of machine ((-) terminal of battery)
2 connection of • Ground terminal of engine
ground terminal • Ground terminal of engine controller
• Ground terminal of starting motor
Damaged O-ring of O-ring of supply pump actuator may be damaged. Check it.
3 supply pump
actuator
system
40-220 PC290LC-10
40 Troubleshooting
Failure code [CA555] Crankcase Press High Error 1

Action Crankcase pressure high error 1
Failure code
level Failure
L01 CA555
Details of • Crankcase pressure high error (level 1) is detected.
failure
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401 (V))
Related • Pressure from crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
Clogged KCCV Replace KCCV filter.
1
filter
When KCCV filter is replaced, if this failure code does not disappear and emulsion
Blocked KCCV gas
2 is recognized inside KCCV, blowby gas piping of KCCV may be clogged with
piping
emulsion. Perform troubleshooting for coolant leakage.
Defective Sensor system may be defective. Perform troubleshooting for failure codes
3 crankcase pressure [CA1843] and [CA1844].
sensor
PC290LC-10 40-221
40 Troubleshooting
Failure code [CA556] Crankcase Press High Error 2

Action Crankcase pressure high error 2
Failure code
level Failure
L03 CA556
Details of • Crankcase pressure high error (level 2) is detected.
failure
controller
machine
(Code: 48401 (V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
1
filter
Blocked KCCV gas
piping
sensor
When KCCV filter is replaced, if failure code crankcase pressure high error does
Increase of blowby not disappear and failure code of crankcase pressure high errors is displayed in
4 gas short period, engine may be seized or turbocharger may have trouble. Perform
troubleshooting for mechanical system.
40-222 PC290LC-10
40 Troubleshooting
Failure code [CA559] Rail Press Low Error

Action Supply pump pressure low error 1
Failure code
level Failure
L01 CA559
Details of • Low pressure (1) appears in common rail circuit.
failure
controller
• Engine does not start at all or does not start easily.
Problem on • Exhaust gas becomes black.
1 Improper fuel Fuel used may be improper. Check it.
Fuel leakage to Fuel may leak to outside. Check it (check visually while running engine at low idle).
2
outside
a For more information on troubleshooting, see Note 1.
a For check of fuel pressure in low-pressure circuit, see Testing and adjusting,
"Testing fuel pressure".
Negative pressure
at fuel supply pump Max. -40.7 kPa
Defective parts in Engine at high idle
3 inlet (outlet side of {Max. -305 mmHg}
low-pressure circuit fuel pre-filter)
207 to 500 kPa
During cranking
{2.11 to 5.1 kg/cm2}
Inlet pressure of
207 to 650 kPa
fuel main filter
Engine at high idle {2.11 to 6.63 kg/
cm2}
a For check of leakage rate from pressure limiter, see Testing and adjusting,
Defective pressure "Checking fuel delivery, return rate and leakage".
4
limiter Leakage from
Engine at low idle (30 seconds) Max. 8 ml
pressure limiter
Defective injector a For check of return rate from injector, see Testing and adjusting, "Checking fuel
delivery, return rate and leakage".
5 (including high-
During cranking
pressure piping in Return rate from Max. 45 ml
cylinder head) (Min.150 rpm and for 30 seconds)
injector
a For check of return rate from supply pump, see Testing and adjusting,
"Checking fuel delivery, return rate and leakage".
Defective supply
6 pump During cranking
Return rate from Max. 575 ml
(Min.150 rpm and for 30 seconds)
supply pump
system
Note 1: Check low-pressure line parts for the following
1) Fuel level
2) Clogging of fuel tank breather
3) Leakage from or clogging of low-pressure fuel piping
4) Clogging of fuel pre-filter
5) Clogging of fuel main filter
PC290LC-10 40-223
40 Troubleshooting
6) Replace fuel filter if failure is not fixed by clearing clog.
40-224 PC290LC-10
40 Troubleshooting
Failure code [CA595] Turbo Speed High Error 2

Action Turbocharger speed high error 2
Failure code
level Failure
L01 CA595
Details of • Turbocharger speed is too high.
failure
controller
machine
• Speed detected by turbocharger speed sensor can be checked with monitoring function.
Related (Code: 48100 (rpm))
Increase in Turbocharger speed may be high. Check it.
1 turbocharger speed
Defective Check turbocharger since it may have trouble.
2 turbocharger
Defective If no failure is found by check on cause 1, turbocharger speed sensor system may
3 turbocharger speed be defective. Perform troubleshooting for failure code [CA687].
sensor
PC290LC-10 40-225
40 Troubleshooting
Failure code [CA687] Turbo Speed Low Error

Action Turbocharger speed low error
Failure code
level Failure
L01 CA687
Details of • Turbocharger speed is too low.
failure
Action of • Takes it that turbocharger speed is at calculated value and allows engine to run.
controller
Problem on
machine
1 turbocharger
harness connector
Defective 1. Turn starting switch to OFF position.
turbocharger speed 2. Disconnect connector VGT_REV and connect T-adapters to female side.
3 sensor
(internal defect) Resistance Between VGT_REV (female) (1) and (2) 600 to 1600 z
Open circuit or 1. Turn starting switch to OFF position.
short circuit in 2. Disconnect connector ECM J2 and connect T-adapters to female side.
wiring harness
4 (short circuit, open
circuit or defective Resistance Between ECM J2 (female) (32) and (33) 600 to 1600 z
contact of
connector)
2. Disconnect connectors ECM J2 and VGT_REV, and connect T-adapters to
Ground fault in
either female side.
wiring harness
(32) or VGT_REV (female) (1) Min. 100 kz
circuit) Resistance
(33) or VGT_REV (female) (2) Min. 100 kz

Ground fault in 2. Disconnect connectors ECM J2 and VGT_REV, and connect T-adapters to
wiring harness either female side.
6 (contact with GND Between ECM J2 (female) (32) and (33),
circuit) Resistance or between VGT_REV (female) (1) and Min. 100 kz
(2)
Improper Turbocharger speed sensor may be improperly installed (loosened) or speed-
installation of detection parts (parts in KVGT) may be defective (deformation due to heat). Check
7 sensor or defective them.
speed-detection
parts
controller
40-226 PC290LC-10
40 Troubleshooting
Circuit diagram related to turbo speed sensor
PC290LC-10 40-227
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error

Action Engine Ne speed sensor error
Failure code
level Failure
L01 CA689
Details of • Signal from engine Ne speed sensor is abnormal.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
machine • Engine startability becomes is poor.
• Engine hunts.
• Since inside of speed sensor is not composed of coil but Hall sensor and electronic
circuit, speed sensor cannot be determined to be normal by measuring its resistance by
Related using multimeter.
information • Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be
measured by using multimeter.
• Speed sensor senses passing slotted hole in speed sensing wheel that is installed on
inside of crankshaft vibration damper and rotated by crankshaft.
1
Defective Ne speed If failure codes [CA238] and [CA239] are also displayed, perform troubleshooting
2 sensor power for them first.
supply line
Breakage or Engine Ne speed sensor may be broken or may have improper installation
improper (looseness). Check it.
installation
3
(looseness) of
engine Ne speed
sensor
2. Disconnect connector CRANK SENSOR and connect T-adapters to female
Defective Ne speed
side.
4 sensor power
supply input
Power supply input Between CRANK SENSOR (female) (1)
voltage and (2) 4.75 to 5.25 V

2. Disconnect connectors ECM J1 and CRANK SENSOR.
Open circuit in Between ECM J1 (female) (36) and
wiring harness CRANK SENSOR (female) (1)
5 (wire breakage or
defective contact of Resistance a If no failure is found by check on
connector) cause 4, this check is not required. Max. 10 z
CRANK SENSOR (female) (2)
Between ECM J1 (female) (26) and Max. 10 z
CRANK SENSOR (female) (3)
40-228 PC290LC-10
40 Troubleshooting

2. Disconnect connectors ECM J1 and CRANK SENSOR.
Short circuit in Between ECM J1 (female) (26) and (36)
6 wiring harness Min. 100 kz
or CRANK SENSOR (female) (1) and (3)
Resistance
or CRANK SENSOR (female) (2) and (3) Min. 100 kz
wiring harness 2. Disconnect connectors ECM J1 and CRANK SENSOR.
circuit) Resistance (26) or CRANK SENSOR (female) (3) Min. 100 kz

2. Disconnect connector CRANK SENSOR.
wiring harness
(contact with 24 V
circuit) Between CRANK SENSOR (female) (3)
Voltage Max. 1 V
and ground
Damaged or loose Check speed sensing wheel.
9 wheel for speed
sensing
Defective Ne speed If no failure is found by above checks, Ne speed sensor is defective. (Since this is
sensor
controller
Circuit diagram related to engine Ne speed sensor
PC290LC-10 40-229
40 Troubleshooting
Failure code [CA691] Intake Air Temp Sens High Error

Action Intake temperature sensor high error
Failure code
level Failure
L01 CA691
Details of • High voltage appears in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake temperature is at fixed value (25°C) and allows engine to run.
controller
Problem on
machine
• Signal voltage from intake temperature sensor can be checked with monitoring function.
(Code: 18401 (V))
• Temperature sensed by intake temperature sensor can be checked with monitoring
function.
Related (Code: 18400 (°C))
information • Mass air flow sensor and intake temperature sensor are integrated.
• If sensor connector is disconnected, this failure code and failure code [CA357] are
displayed at the same time.
harness connector
2. Disconnect connector P55 and connect T-adapter to male side.
-30°C 25 to 28 kz
0°C 5.5 to 6.1 kz
Defective intake Between P55
(male) (3) and (4) 25°C 1.9 to 2.1 kz
40°C 1.1 to 1.2 kz
(internal defect) Resistance 100°C 180 to 185 z
Between P55
(male) (3) and
Whole range Min. 1 Mz
ground (sensor
body)
wiring harness
Resistance Between ECM J1 (female) (6) and (22) 180 z to 28 kz
3 (Short circuit, open
circuit or defective
contact of a Use Intake temperature-Resistance characteristics table prepared for check on
connector) cause 2 as resistance criteria.

Hot short circuit in 2. Disconnect connector P55.
wiring harness 3. Insert T-adapters into connector ECM J1 or connect T-adapters to female side
4
(Contact with 24 V of connector P55.
circuit) Between ECM J1 (6) and (22), or
Voltage Max. 5.25 V
between P55 (female) (1) and (3)
40-230 PC290LC-10
40 Troubleshooting

harnesses)
Between ECM J1 (female) (6) and each
Resistance pin other than (6) Min. 100 kz
controller
Circuit diagram related to intake air temperature sensor
PC290LC-10 40-231
40 Troubleshooting
Failure code [CA692] Intake Air Temp Sens Low Error

Action Intake temperature sensor low error
Failure code
level Failure
L01 CA692
Details of • Low voltage appears in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake temperature is at fixed value (25°C) and allows engine to run.
controller
Problem on
machine
• Signal voltage from intake temperature sensor can be checked with monitoring function.
(Code: 18401 (V))
• Temperature sensed by intake temperature sensor can be checked with monitoring
Related function.
information (Code: 18400 (°C))
• Mass air flow sensor and intake temperature sensor are integrated.
harness connector
Defective intake 1. Turn starting switch to OFF position.
2 temperature sensor 2. Disconnect connector P55.
(internal defect)
If this failure code changes to failure code [CA691], sensor is defective.
-30°C 25 to 28 kz
0°C 5.5 to 6.1 kz
Defective intake Between P55
(male) (3) and (4) 25°C 1.9 to 2.1 kz
40°C 1.1 to 1.2 kz
(internal defect) Resistance 100°C 180 to 185 z
Between P55
(male) (3) and
Whole range Min. 1 Mz
ground (sensor
body)
wiring harness
Resistance Between ECM J1 (female) (6) and (22) 180 z to 28 kz
4 (Short circuit, open
contact of a Use Intake temperature-Resistance characteristics table prepared for check on
connector) cause 2 as resistance criteria.

wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to either
Resistance (6) or between P55 (female) (4) Min. 1 Mz
40-232 PC290LC-10
40 Troubleshooting

harnesses)
Between ECM J1 (female) (6) and each
controller
Circuit diagram related to intake air temperature sensor
PC290LC-10 40-233
40 Troubleshooting
Failure code [CA697] ECM Int Temp Sensor High Error

Action ECM internal temperature sensor high error
Failure code
level Failure
L01 CA697
Details of • High voltage appears in signal circuit of engine controller internal temperature sensor.
failure
controller
Problem on
machine
• Temperature sensed by internal temperature sensor of engine controller can be checked
Related with monitoring function.
Unsuitable use of Check whether controller is used in a high-temperature environment.
1
controller
controller
40-234 PC290LC-10
40 Troubleshooting
Failure code [CA698] ECM Int Temp Sensor Low Error

Action ECM internal temperature sensor low error
Failure code
level Failure
L01 CA698
Details of • Low voltage appears in signal circuit of engine controller internal temperature sensor.
failure
controller
Problem on
machine
• Temperature sensed by internal temperature sensor of engine controller can be checked
Related with monitoring function.
Unsuitable use of Check whether controller is used in a low-temperature environment.
1
controller
controller
PC290LC-10 40-235
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error

Action Engine Bkup speed sensor phase error
Failure code
level Failure
L01 CA731
Details of • Phase error occurs between signals from engine Ne speed sensor and engine Bkup
failure speed sensor
Action of • Continues to control engine by using signal from engine Ne speed sensor.
controller
• Engine does not start at all or does not start easily.
Problem on • Idle speed is unstable.
machine • Exhaust gas becomes black.
information
Breakage of engine Engine Ne speed sensor may be broken. Check it.
1 Ne speed sensor
Breakage of engine Engine Bkup speed sensor may be broken. Check it.
2 Bkup speed sensor
Speed sensing wheel on crankshaft side may be installed defectively or broken.
Defective
Check it according to following procedure.
installation or
3 breakage of wheel 1. Align paint mark (M1) on damper with oil pan mounting bolt (M2).
for speed sensing a Do not align with mark of No. 1 cylinder compression top dead center
on crankshaft side (approximately 76 to 88 deg. before compression top dead center).
Speed sensing ring on camshaft side may be installed defectively or broken.
Defective Check it according to the following procedure.
installation or
1. Set No.1 piston at compression top dead center (match stamped mark).
4 breakage of ring for
2. Remove Bkup speed sensor.
speed sensing on
camshaft side 3. If you can see double-slot part (with one crest) (B) on speed sensing ring
through sensor mounting hole (H), speed sensing ring is installed correctly.
Defective timing of Timing of crankshaft and camshaft may be defective. Check it.
5 crankshaft and
camshaft
Cable connection to ground terminal may be incorrect. Check following terminals.
Defective • Ground terminal of machine ((-) terminal of battery)
6 connection of • Ground terminal of engine
ground terminal • Ground terminal of engine controller
• Ground terminal of starting motor
40-236 PC290LC-10
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error

Action Engine Bkup speed (cam) sensor error
Failure code
level Failure
L01 CA778
Details of • Signal from engine Bkup speed (cam) sensor is abnormal.
failure
Action of • Continues to control engine by using signal from engine Ne speed sensor.
controller
Problem on • Engine startability becomes poor.
machine • Engine output lowers.
• Since inside of speed sensor is not composed of coil but Hall sensor and electronic
circuit, speed sensor cannot be determined to be normal by measuring its resistance by
Related using multimeter.
information • Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be
measured by using multimeter.
• Speed sensor detects rotating slot of ring for speed sensing mounted on camshaft.
1 wiring connector 2. Turn starting switch to ON position.
Defective sensor If failure code [CA187] or [CA227] is displayed simultaneously, perform
2 power supply 2 line troubleshooting for it first.
Damage or Check engine Bkup speed (cam) sensor as it may be damaged or incorrectly
incorrect (loose) (loosely) installed.
3 installation of
engine Bkup speed
(cam) sensor
2. Disconnect connector CAM SENSOR and connect T-adapters to female side.
4 Bkup speed sensor Between CAM SENSOR (female) (1)
power supply input power supply 4.75 to 5.25 V
and (2)
Between CAM SENSOR (female) (1)
and (2)
2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-adapters
Open circuit in to each female side.
CAM SENSOR (female) (1) Max. 10 z
5 (wire breakage or
connector) Resistance CAM SENSOR (female) (2) Max. 10 z
Between ECM J1 (female) (9) and CAM
SENSOR (female) (3) Max. 10 z

2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-adapters
to either female side.
Short circuit in
6 wiring harness Between ECM J1 (female) (9) and (60)
or CAM SENSOR (female) (1) and (3) Min. 100 kz
Resistance
or CAM SENSOR (female) (2) and (3)
PC290LC-10 40-237
40 Troubleshooting

wiring harness 2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-adapters
7 (contact with GND to either female side.
Resistance (9) , or CAM SENSOR (female) (3) Min. 100 kz

2. Disconnect connector CAM SENSOR and connect T-adapters to female side.
wiring harness
(contact with 24 V
circuit) Between CAM SENSOR (female) (3)
Voltage Max. 1 V
and ground
Loosening of cam Remove engine Bkup speed (cam) sensor, and check ring through hole (H).
9 shaft speed a If ring (B) for camshaft speed sensing is loosely mounted, follow instructions
sensing ring given in "Reference".
Defective engine If no failure is found by above checks, engine Bkup speed (cam) sensor is
10 Bkup speed (cam) defective. (Since this is an internal defect, troubleshooting cannot be performed.)
sensor
controller
Circuit diagram related to engine Bkup speed sensor
40-238 PC290LC-10
40 Troubleshooting
Checking camshaft ring for loose installation

Remove the front cover and check the camshaft ring for looseness.
a See Disassembly and assembly, "Removal and installation of engine front oil seal(PAGE 50-70)".
a Keep the front seal, liquid gasket LG-7 and front seal tool (795–799–6400) on hand.
Removal
1. Remove the fan and fan belt. For detail, see Disassembly and assembly, "Removal and installation of
engine rear oil seal(PAGE 50-74)".
2. Remove damper assembly (1).
(DP): Dowel pin
3. Remove front cover (2).

4. Remove front seal (3).
(RING): Ring
5. Check mounting bolt (4) of camshaft ring (5) for looseness.

3 Mounting bolt (4):
10 ± 2 Nm {0.98 ± 0.2 kgm}
(DP) : Dowel pin
PC290LC-10 40-239
40 Troubleshooting
Connection
a See the figures in "Removal".
1. Install front cover (2).
2 Front cover: Liquid gasket (LG-7)
2. See Disassembly and assembly, "Removal and installation of engine front oil seal(PAGE 50-70)" and
perform the following.
1) Install front seal (3).
2) Install dowel pin (DP), and install the damper assembly.
3) Install fan belt, and install the fan.
4) Install the cooling system assembly.
40-240 PC290LC-10
40 Troubleshooting
Failure code [CA1117] Persistent Data Lost Error

Action Partial data loss error
Failure code
level Failure
L04 CA1117
Details of
• Internal failure is detected in controller.
failure
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on start.
machine • Engine controller is not capable of storing internal data appropriately.
Related • Internal data of engine controller (those related to KDPF) might be lost. After recovery
information from this error is completed, you must implement appropriate measures.
Defective power Electric power supply circuit system may be defective. Perform troubleshooting for
1 supply circuit failure code [CA441].
system
Improper operation Battery disconnect switch may be operated improperly.
2 of battery
disconnect switch
For actions to take after resetting error, see "Procedure for active regeneration for service".
PC290LC-10 40-241
40 Troubleshooting
Failure code [CA1664] KDOC Malfunction

Action Defective KDOC function
Failure code
level Failure
L03 CA1664
Details of • KDOC inlet temperature sensor and KDOC outlet temperature sensor indicate similar
failure values during KDPF regeneration.
• Closes EGR valve.
machine
Related • While engine is running at idle (non-regeneration), KDOC inlet temperature, KDOC outlet
information temperature and KDPF outlet temperature are all about 100 to 250°C. Temperature
difference among them is about 10°C (KDOC inlet temperature > KDOC outlet
temperature > KDPF outlet temperature).
• During active regeneration (manual stationary regeneration), KDOC inlet temperature is
about 250 to 400°C. And KDOC outlet temperature and KDPF outlet temperature are
both about 450 to 550°C.
• Active regeneration (manual stationary regeneration) takes about 40 minutes.
characters on KDPF temperature sensor consolidating box (same applies to connector
label "TEMP2" for KDOC outlet temperature sensor and connector label "TEMP3" for
KDPF outlet temperature sensor).
<Method of resetting failure code>
• Repeat work equipment pump relief operation and running engine at high idle in turn with
fuel control dial at FULL for about 15 minutes in total.
(However, operate so that machine is in PO mode during running engine at high idle.)
sensor
Defective KDOC If failure code [CA3316], [CA3317], or [CA3318] is displayed, carry out
2 outlet temperature troubleshooting for it first.
sensor
Malfunction of 1. Check that KDPF is installed to exhaust system.
3
KDOC 2. Check that KDOC is installed to KDPF.
harness connector
40-242 PC290LC-10
40 Troubleshooting

temperature sensor, and record signal voltages from respective temperature
sensors in the initial state (see Related information).
4. Disconnect either connector TEMP1 or TEMP2.
Short circuit in
wiring harness
temperature sensor, and record 2nd signal voltages from respective
temperature sensors (see Related information).
If 2nd signal voltages from KDPF outlet temperature sensor are almost same as
those in initial state respectively, wiring harness is short circuited (perform
troubleshooting for failure codes [CA3315] and [CA3322]).
a Start and run engine at high idle for 15 minutes, and then check that this failure code is not displayed.
Circuit diagram related to KDOC temperature sensor
PC290LC-10 40-243
40 Troubleshooting
Failure code [CA1691] Regeneration Ineffective

Action Defective regeneration by KDPF
Failure code
level Failure
L03 CA1691
• Efficiency (catalytic action) of KDOC is degraded. (KDOC inlet temperature and KDOC
Details of outlet temperature during regeneration are normally 250 to 400°C and 450 to 550°C
failure respectively. In this case, KDOC outlet temperature does not rise enough, so soot
trapped in KCSF cannot be burnt normally.)
Action of • Limits engine output and allows to engine run.
machine
function (Code: 47300(°C)).
• KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature are all
about 100 to 250°C. Temperature difference among them is about 10°C (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature).
• KDOC inlet temperature is about 250 to 400°C. And KDOC outlet temperature and KDPF
Related outlet temperature are both about 450 to 550°C.
information • KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature are all
about 250 to 400°C.
characters on KDPF temperature sensor integration box (the same applies to connector
• Procedure for implementing manual stationary regeneration from "Regeneration for
service" menu
a When soot level is 3 or below, manual stationary regeneration is available only from
"Regeneration for service" menu.
1. Start engine.
3. From Service screen of machine monitor, display "Diagnostic Tests" screen and open "02
Regeneration for service" to execute "Manual Stationary Regeneration" (this operation is
ended in about 40 minutes).
• Failure code "[CA2637] FDOC Face Plugging" may also appear. Perform troubleshooting
for this failure code, however.
• If noticeable difference is recognized between KDOC outlet temperature and
Defective KDOC KDOC inlet temperature or KDPF outlet temperature when KDPF is sufficiently
1 outlet temperature cooled or engine is running at idle (non-regeneration), replace KDOC outlet
sensor temperature sensor.
40-244 PC290LC-10
40 Troubleshooting

1. Accelerate engine abruptly two times from low idle to high idle, then keep
speed running at high idle for five seconds.
Defective exhaust • If black smokes are recognized at acceleration or during running at high
2 gas color idle, perform troubleshooting for "S-9 KDPF is plugged soon."
a It does not matter that black smoke powders are emitted at engine acceleration
if they are not emitted with engine running at high idle.
a Dry KDOC.
2. Monitor and record signal voltages from KDOC inlet temperature sensor and
Malfunction of KDPF outlet temperature sensor with KDPF in initial state and during manual
3 KDOC stationary regeneration. Check them to see if KDOC outlet temperature sensor
(Drying of KDOC) is normal (see Related information).
3. Perform manual stationary regeneration (see Related information).
a Since purpose of this operation is to dry KDOC, fuel for regeneration is not
injected during regeneration.
k Start your work after KDPF and KDOC are sufficiently cooled down.
Defective KDOC 1. Remove KDPF.

2. Remove KDOC.
4 (Stains, cracks or 3. Blow air from outlet side of KDOC to eliminate stains on ceramic surface inside
damages on KDOC KDOC.
surface) 4. Check ceramic in KDOC for cracks.
If cracks are found on KDOC, KDOC is defective (replace KDOC).
a Perform the following even when you do not replace KDOC.
1. 1. Install KDOC and KDPF.
3. From service screen of machine monitor, display "Diagnostic Tests" screen and
open "03 KDPF Memory Reset" to execute "03 KDOC Change (reset
procedure for KDOC Change)".
If you execute “KDOC Change”, failure codes [CA1691] and [CA2637] do not
Reset procedure appear on the screen.
5 for KDOC Change At this point, dozing of fuel for regeneration starts, which was stopped when this
failure code appeared.
a Check that reset procedure for KDOC Change is completed successfully
(number of resets). If not, perform troubleshooting again.
a When you have replaced KDOC, execute manual stationary regeneration one
more time and check that no failure code appears to finish troubleshooting.
a Execute this troubleshooting when KDOC is not replaced.
2. Monitor and record signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor with KDPF in initial state and during manual
stationary regeneration. Check them to see if KDOC outlet temperature sensor
Malfunction of is normal (see Related information).
KDOC 3. Perform manual stationary regeneration (see Related information).
6 (Degradation in 5. Start engine and execute manual stationary regeneration again.
catalytic action of
KDOC) a Check that no failure code appears to finish troubleshooting.
a If failure code [CA2637] appears after manual stationary regeneration, KDOC
malfunctions (replace KDOC since its catalytic action is degraded).
a When you have replaced KDOC, execute troubleshooting for cause 5 again
and perform manual stationary regeneration one more time. Check that no
failure code appears to finish troubleshooting.
PC290LC-10 40-245
40 Troubleshooting

Action
Failure code
level Failure Sensor power supply 5 low error
L03 CA1695
Details of • Low voltage appears in 5 V power supply for KDPF differential pressure sensor and
failure KDPF outlet pressure sensor.
• Takes it that KDPF outlet pressure sensor is at fixed value (0 kPa {0 kg/cm 2}) and allows
engine to run.
• Takes it that KDPF delta pressure sensor value is at recommended value (or at 0 kPa {0
Action of kg/cm2}).
• Limits engine output and allows engine run.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
harness connector
Defective KDPF
2. Disconnect connector E25.
delta pressure
2 (outlet pressure)
sensor a Ignore displayed failure codes other than this one.
(internal defect) If this failure code does not appear, KDPF delta pressure (outlet pressure) sensor
is defective.
wiring harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to either
circuit) Between CE03 ground and (female) (52)
Resistance or E25 (female) (4) Min. 100 kz

Short circuit in 2. Disconnect connectors CE03 and E25, and connect T-adapters to female side
4 wiring harness of connector CE03.
Between CE03 (female) (52) and each

3. Insert T-adapters into connector CE03 or connect T-adapters to female side of
Defective engine connector E25.
5
controller 4. Turn starting switch to ON position.
Between CE03 (52) and (43), or
between E25 (female) (4) and (1)
40-246 PC290LC-10
40 Troubleshooting
Circuit diagram related to KDPF differential pressure sensor and KDPF

outlet pressure sensor
PC290LC-10 40-247
40 Troubleshooting

Action
Failure code
level Failure Sensor power supply 5 high error
L03 CA1696
Details of • High voltage appears in 5 V power supply for KDPF delta pressure sensor and KDPF
failure outlet pressure sensor.
• Takes it that KDPF outlet pressure sensor is at fixed value (0 kPa {0 kg/cm 2}) and allows
engine to run.
• Takes it that KDPF delta pressure sensor value is at recommended value (or at 0 kPa {0
Action of kg/cm2}) and allows engine to run.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
harness connector
Defective KDPF
delta pressure
2 (outlet pressure)
sensor a Ignore displayed failure codes other than this one.
(internal defect) If this failure code does not appear, KDPF delta pressure (outlet pressure) sensor
is defective.
Short circuit in 2. Disconnect connectors CE03 and E25, and connect T-adapters to female side

3. Insert T-adapters into connector CE03 or connect T-adapters to female side of
Defective engine connector E25.
4
Between CE03 (52) and (43), or
between E25 (female) (4) and (1)
40-248 PC290LC-10
40 Troubleshooting
Circuit diagram related to KDPF differential pressure sensor and KDPF

outlet pressure sensor
PC290LC-10 40-249
40 Troubleshooting
Failure code [CA1843] Crankcase Press Sens High Error

Action Crankcase pressure sensor high error
Failure code
level Failure
L01 CA1843
Details of • High voltage appears in signal circuit of crankcase pressure sensor.
failure
Action of • Takes it that crankcase pressure is at fixed value (0 kPa {0 kg/cm2}) and allows engine to
controller run.
Problem on
machine
(Code: 48401 (V))
1
system
crankcase pressure 2. Disconnect connector P57.
3 sensor 3. Turn starting switch to ON position.
(internal defect) If failure code changes from [CA1843] to [CA1844], crankcase pressure sensor is
defective.
Open circuit in 2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each
4 (wire breakage or
defective contact of a Open circuit of GND line
connector) Between ECM J1 (female) (59) and P57

Short circuit in 2. Disconnect connectors ECM J1 and P57, and connect T-adapters to either
Resistance or between P57 (female) (1) and (3) Min. 100 kz

circuit) Voltage Between P57 (female) (3) and (2) Max. 1 V
controller
40-250 PC290LC-10
40 Troubleshooting
Circuit diagram related to crankcase pressure sensor
PC290LC-10 40-251
40 Troubleshooting
Failure code [CA1844] Crankcase Press Sens Low Error

Action Crankcase pressure sensor low error
Failure code
level Failure
L01 CA1844
Details of • Low voltage appears in signal circuit of crankcase pressure sensor.
failure
Action of • Takes it that crankcase pressure is at fixed value (0 kPa {0 kg/cm2}) and allows engine to
controller run.
Problem on
machine
(Code: 48401 (V))
harness connector
system
system Between P57
Voltage power supply 4.75 to 5.25 V
2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each
female side.
a If any failure is found on wiring harness, disconnect connector OEM
CONNECTION, too, and check likewise to determine which is defective,
engine side wiring harness or chassis side wiring harness.
Open circuit in
wiring harness a If no failure is found by check on
4 (wire breakage or cause 3, this check is not required. Max. 10 z
defective contact of Between ECM J1 (female) (60) and P57
connector) (female) (1)
Resistance a If no failure is found by check on
(female) (2)

2. Disconnect connectors ECM J1 and P57, and connect T-adapters to either
Ground fault in female side.
wiring harness a If any failure is found on wiring harness, disconnect connector OEM
5 (contact with GND CONNECTION, too, and check likewise to determine which is defective,
circuit) namely engine side wiring harness or chassis side wiring harness.
Resistance (3) or P57 (female) (3)
40-252 PC290LC-10
40 Troubleshooting

2. Disconnect connectors ECM J1 and P57, and connect T-adapters to either
female side.
Short circuit in
6 Between ECM J1 (female) (3) and (59),
wiring harness Min. 100 kz
or between P57 (female) (2) and (3)
Resistance
or between P57 (female) (1) and (2) Min. 100 kz

crankcase pressure 2. Insert T-adapters into connector P57.
(internal defect) Between P57
• Reference
Defective engine 1. Turn starting switch to OFF position.
8 2. Insert T-adapters to connector ECM J1.
controller
Between ECM J1
(3) and (59)
Circuit diagram related to crankcase pressure sensor
PC290LC-10 40-253
40 Troubleshooting
Failure code [CA1879] KDPF Delta P Sensor High Error

Action KDPF delta pressure sensor high error
Failure code
level Failure
L03 CA1879
Details of • High voltage appears in KDPF delta pressure sensor signal circuit.
failure
• Takes it that KDPF delta pressure sensor is at recommended value and allows engine to
run.
Action of (If another failure code appears at the same time, 0 kPa {0 kg/cm 2 value may be used).
• Limits engine output and allows to engine to run.
machine
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1695] is not displayed but failure code [CA3133] is on screen, open
Related circuit of GND line (defective connector contact) may occur.
information • Signal voltage from KDPF delta pressure sensor can be checked with monitoring
• Differential pressure from KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47101 (MPa))
1
Defective sensor If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for it
2 power supply line first.
Defective sensor 2. Disconnect connector E25 and connect T-adapters to female side.
3 power supply line 3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
Defective KDPF 3. Turn starting switch to ON position.
4 delta pressure If failure code switches to [CA1881] , KDPF delta pressure sensor is defective.
sensor
a If this failure still remains, wiring harness or engine controller is defective.
a Ignore other displayed failure codes.
Open circuit in 1. Starting switch: OFF
wiring harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to each female
defective contact of a Open circuit in GND line
connector)
Between CE03 (female) (43) and E25 10 z Max.
Resistance (female) (1)
40-254 PC290LC-10
40 Troubleshooting

2. Disconnect connectors CE03 and E25, and connect T-adapters to female side
Short circuit in of connector CE03.
Between CE03 (female) (55) and each No continuity
Continuity
pin other than (55) (No sound is heard)
7
performed.)
Circuit diagram related to KDPF differential pressure sensor
PC290LC-10 40-255
40 Troubleshooting
Failure code [CA1881] KDPF Delta P Sensor Low Error

Action KDPF delta pressure sensor low error
Failure code
level Failure
L03 CA1881
Details of • Low voltage appears in KDPF delta pressure sensor signal circuit.
failure
• Takes it that KDPF delta pressure sensor value is at recommended value and allows
Action of engine to run.
controller • (If another failure code appears at the same time, value of 0 kPa {0 kg/cm 2 may be used).
• Close EGR valve, runs engine with limited output, and stops KDPF regeneration control.
machine
• If failure code [CA1696] is not displayed but failure code [CA3134] is on the screen,
sensor connector may be disconnected or open circuit (defective connector contact) may
Related occur in 5 V circuit.
information • This failure code is generated if sensor connector is disconnected.
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring
1
2. Disconnect connectors CE03 and E25, and connect T-adapters to each female
side.
wiring harness Between CE03 (female) (43) and E25
connector) Resistance a If no failure is found by check on
Between CE03 (female) (52) and E25
(female) (4)

circuit) Between ground and CE03 (female) (55) Min. 100 kz
Resistance or between E25 (female) (2)
40-256 PC290LC-10
40 Troubleshooting

Continuity
Defective KDPF 2. Insert T-adapters into connector E25.
7 delta pressure 3. Turn starting switch to ON position.
sensor
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
8
performed.)
PC290LC-10 40-257
40 Troubleshooting
Failure code [CA1883] KDPF Delta P Sens In Range Error

Action KDPF delta pressure sensor in range error
Failure code
level Failure
L03 CA1883
Details of • Signal voltage from KDPF delta pressure sensor does not indicate the correct value
failure (signal voltage is within the normal range).
• Takes it that KDPF delta pressure sensor value is at recommended value and allows
engine to run..
Action of (If another failure code appears at the same time, value of 0 kPa {0 kg/cm 2 may be used).
Problem on Engine output decreases.
machine
• Signal voltage from KDPF delta pressure sensor can be checked by using monitoring
• Differential pressure from KDPF delta pressure sensor can be checked by using
Related monitoring function. (Code: 47101 (MPa))
information • Method of reproducing failure code: Turn starting switch to ON position (wait and see for 1
minute)
[How to clear the failure code]
1. Start engine (make sure it is stopped now)
2. After warm-up operation, set fuel dial to FULL position and relieve work equipment pump
circuit for 30 seconds.
Repeat steps 1 and 2 several times. If this failure code is cancelled, repair is complete.
1.Remove KDPF delta pressure sensor tube.
2.Clean KDPF delta pressure sensor tube to eliminate plugging.
3.Check KDPF delta pressure sensor tube for cracking and damage.
4.Connect both ends of tube securely and install KDPF delta pressure sensor
tube.
Defective KDPF • Reference
1 delta pressure How to check KDPF delta pressure sensor tube for clogging
sensor tube 1. Turn starting switch to ON position.
2. Monitor differential pressure sensed by KDPF delta pressure sensor on
monitoring screen of machine monitor.
• Code: 47101 (MPa)
Differential
0 ± 0.003 (MPa)
pressure
harness connector
40-258 PC290LC-10
40 Troubleshooting

Defective wiring
5 harness or engine If failure code [CA1881] is not displayed, wiring harness or engine controller is
controller defective.
a Perform check on cause 2 again.
2. Disconnect connector E25 and connect short connector to female side.
a Connect 5 V line to signal line (short pin (4) to (2) of connector E25).
Defective wiring 3. Turn starting switch to ON position.
6 harness or engine If failure code [CA1879] is not displayed, wiring harness or engine controller is
a Perform check on cause 2 again.
Defective KDPF
7 a If no failure is found by check on checks on cause 5, KDPF delta pressure
delta pressure
sensor is defective.
sensor
side.
connector) Resistance a If no failure is found by check on
(female) (4)

circuit) Between ground and CE03 (female) (55)
Resistance or between E25 (female) (2) Min. 100 kz

10 wiring harness
a Check by using multimeter in continuity mode.
Continuity
1. Turn starting switch to ON position and wait for approximately one minutes
(recheck of error at key-ON).
2. If this failure code is displayed, perform [Clearing failure codes] in "Related
Defective engine
11 information".
controller
When this failure code remains displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)
a If this failure code is still displayed and does not disappear even after performing "How to clear the failure
code" in Related information, repeat the troubleshooting.
PC290LC-10 40-259
40 Troubleshooting
40-260 PC290LC-10
40 Troubleshooting
Failure code [CA1921] KDPF Soot Load High Error 1

Action KDPF soot load high error 1
Failure code
level Failure
L03 CA1921
• Soot load in KDPF reaches level 6 or 7 and KDPF regeneration is required for elimination
Details of of soot (request for regeneration to operator).
failure (if soot load reaches level 8, KDPF must be replaced.)
controller • Disables automatic active regeneration while allows manual stationary regeneration.
machine
a Duration of manual stationary regeneration depends on the soot load in KCSF. Roughly
speaking, if the soot load is at level 6 or 7, duration is 2 to 3 hours (1 to 2 hours for level
5).
• Soot load in KDPF is classified into eight levels. You can check current soot load by
displaying "02 Regeneration for service" screen of machine monitor.
• Manual stationary regeneration is available for eliminating soot when the soot load is at
level 7 or below.
• Failure code [CA1922] is displayed when the soot load reaches level 8, and indicates that
KDPF is completely plugged with soot, requiring inspection, cleaning, and replacement of
KDPF.
Possible causes of accumulation of soot
1. Engine is running within light load range where engine cannot keep exhaust temperature
high enough to burn soot in KDPF.
• Low temperature of gas entering aftertreatment system (KDPF) can cause
accumulation of a large volume of soot.
• Running engine with high load is required to prevent accumulation of soot in KDPF.
2. Engine has trouble that causes excessive emission of black smoke.
• While failure code [CA1921] is displayed, if "Error 2777" is also displayed, sooth load is at
level 4 or higher level and automatic regeneration is disabled.
a Procedure for resetting prohibition of automatic regeneration
From service menu of machine monitor, display "Diagnostic Tests" screen and open "02
Related Regeneration for service" and cancel "Regeneration Disable" (prohibition of automatic
information regeneration) (regeneration is automatically executed as engine load goes high).
function (Code: 47300 °C ).
function (Code: 47400 °C ).
characters on KDPF temperature sensor integration box ( same applies to connector
a If another failure code is displayed (including during manual stationary regeneration),
perform troubleshooting for it first.
a While failure code [CA1921] is displayed, if "Error 2777" is also displayed, automatic
regeneration is disabled but manual stationary regeneration can be performed.
PC290LC-10 40-261
40 Troubleshooting
a If failure code [CA1922] has been displayed from the first, it changes to [CA1921] during
its troubleshooting process. In this case, see troubleshooting for failure code [CA1922].
Method of reproducing failure code: Turn starting switch to ON position.
• Perform manual stationary regeneration.
1.Start engine.
2.Check that machine is in safe condition.
3.Perform manual stationary regeneration (manual stationary regeneration is
available from user mode of machine monitor).
• While manual stationary regeneration is continued, failure code [CA2639] is
Soot load in KDPF displayed on machine monitor but it does not matter (manual stationary
1 (KCSF) regeneration is completed in about 2 to 3 hours and failure code [CA2639]
disappears).
a If failure code [CA2639] remains on machine monitor for 3 hours after manual
stationary regeneration is completed, perform troubleshooting for failure code
[CA2639].
a Check that this failure code is not displayed after manual stationary
regeneration.
a Perform this troubleshooting when failure code [CA1921] or [CA2639] is
displayed after manual stationary regeneration.
1. Accelerate engine abruptly two times from low idle to high idle, then maintain
engine speed at high idle for five seconds.
Defective exhaust • If black smokes are emitted at engine acceleration or during running engine at
2 gas color high idle, perform troubleshooting for "S-9 KDPF is plugged soon."
a If powders of black smokes that were generated at acceleration disappear at
high idle, the condition is normal.
a Check that no failure code appears.
40-262 PC290LC-10
40 Troubleshooting
Failure code [CA1922] KDPF Soot Load High Error 2

Action KDPF soot load high error 2
Failure code
level Failure
L04 CA1922
• Soot load in KDPF reaches above normal level and KDPF must be regenerated to
Details of eliminate soot (request for regeneration to operator).
failure • Soot load is at level 8 (KDPF is completely plugged).
controller • Disables automatic active regeneration while allows manual stationary regeneration.
machine
• Soot load in KDPF is classified into eight levels. You can check current soot load by
displaying "Diagnostic Tests" from machine monitor service menu and then selecting "02
Regeneration for service" screen.
• This failure code is displayed when soot load reaches level 8 (soot load level 8 means
that KDPF is completely plugged with soot, requiring inspection, cleaning, and
replacement of KDPF.
• Manual stationary regeneration is available for eliminating soot when soot load is at level
7 or below.
a If you can reduce soot load to level 7 or below by performing reset procedure for KDPF
Change (if failure code changes from [CA1922] to [CA1921]), you can perform manual
stationary regeneration eliminating need of KDPF replacement.
a Duration of manual stationary regeneration depends on soot load in KCSF. Roughly
speaking, if soot load is at level 6 or 7, duration is 2 to 3 hours.
• Low temperature of gas entering aftertreatment system (KDPF) can cause accumulation
of large volume of soot. Running engine with high load is required to prevent
Related accumulation of soot in KDPF.
information • If failure code [CA1922] appears while failure code [CA1921] and error code 2777 remain
active in abnormality record, automatic regeneration is disabled. You must cancel
prohibition.
a Procedure for resetting prohibition of automatic regeneration
Regeneration for service" and cancel "Regeneration Disable" (prohibition of automatic
regeneration). (regeneration is automatically executed as engine load goes high).
Possible causes of accumulation of soot
1. Engine is running within light load range where engine cannot keep exhaust temperature
high enough to burn soot in KDPF.
• Low temperature of gas entering aftertreatment system (KDPF) can cause
accumulation of large volume of soot.
• Running engine with high loadOperation of high engine load is required to prevent
accumulation of soot in KDPF.
2. Engine has trouble that causes excessive emission of black smoke.
PC290LC-10 40-263
40 Troubleshooting
function (Code: 47300 (°C)).
• While engine is running at high idle, KDOC inlet temperature, KDOC outlet temperature
and KDPF outlet temperature are all about 100 to 250°C. Temperature difference among
them is about 10°C (KDOC inlet temperature > KDOC outlet temperature > KDPF outlet
temperature).
characters on KDPF temperature sensor integration box ( same applies to connector
• Procedure for executing manual stationary regeneration from “Regeneration for service”
a When soot load is level 3 or below, manual stationary regeneration is available only from
"Regeneration for service".
1) Start engine.
2) Check that machine is in safe condition.
3) From service menu of machine monitor, display "Diagnostic Tests" screen and open "02
Regeneration for service" to execute "Manual Stationary Regeneration".
a Reset procedure for KDPF Cleaning
KDPF Memory Reset" to execute "02 KDPF Cleaning" (reset procedure for KDPF
Change).
a Reset procedure for KDPF Change
KDPF Memory Reset" to execute "01 KDPF Change (resetting of replacement of KDPF)".
a When you have replaced KCSF of KDPF, be sure to execute reset procedures for KDPF
Cleaning and KDPF Change and then perform manual stationary regeneration from the
forced regeneration for service to eliminate humidity of KCSF.
• Check failure code generation record on abnormality record screen.
Defective KDPF 2. On abnormality record screen of machine monitor, check generation record of
(KCSF) failure codes [CA2639], [CA1921] and [CA1922].
1
(Replace KCSF) Time interval from generation of [CA2639] to generation of [CA1921] ≧ 300 sec.
and
Time interval from generationof [CA1921]. to generation of [CA1922] ≧ 300 sec.
40-264 PC290LC-10
40 Troubleshooting

When above condition is satisfied, a large volume of soot is accumulated. Remove
KDPF, replace KCSF and perform checks on causes 3 to 8.
a If above conditions is not satisfied, actual soot load is less than indicated level.
After checking that sensors are functioning normally, perform troubleshooting
for cause 2. If you can change, failure code [CA1922] to [CA1921], manual
stationary regeneration is available.
PC290LC-10 40-265
40 Troubleshooting
• Reset procedure for KDPF Cleaning

2. Perform reset procedure for KDPF Cleaning (see Related information).
3. If failure code changes from [CA1922] to [CA1921], perform manual stationary
regeneration after checking that machine is in safe condition.
(Manual stationary regeneration is available from "User mode" of machine
monitor, too).
Defective KDPF
a If failure code [CA1922] remains unchanged, remove KDPF, replace KCSF and
(KCSF)
perform troubleshooting for causes 3 and after.
(Perform manual • While manual stationary regeneration is continued, failure code [CA2639] is
2 stationary displayed on machine monitor. But this does not mean any problem (manual
regeneration to stationary regeneration is completed in about 2 to 3 hours and failure code
eliminate [CA2639] disappears at the same time).
accumulated soot)
a If this failure code remains on machine monitor for 3 hours after manual
stationary regeneration is completed, perform following troubleshooting for
failure code [CA2639].
a Check that no failure code appears after manual stationary regeneration.
a When failure code [CA1922], [CA1921] or [CA2639] is displayed after manual
stationary regeneration, perform troubleshooting for cause 10.
• Reset procedure for KDPF Cleaning
2. Perform reset procedure for KDPF Cleaning (see Related information).
a Check that failure code changes from [CA1922] to [CA1921].
Reset of KDPF
3 (KCSF) a If failure code [CA1922] remains, perform reset procedure for KDPF
Cleaning again.
• Reset procedure for KDPF Change
3. Perform reset procedure for KDPF Change (see Related information).
a Perform troubleshooting for causes 4 and after.
sensor
sensor
Defective KDPF If failure code [CA3319], [CA3321], or [CA3322] is displayed, carry out
sensor
Defective KDPF 1. Turn starting switch to ON position.
delta pressure 2. Monitor differential pressure sensed by KDPF delta pressure sensor that is
sensor displayed on monitoring screen of machine monitor.
7
• Code: 47101 (MPa)
(Including sensor
tube) Differential
0 ± 0.003 (MPa)
pressure
a Execute this troubleshooting when differential pressure is out of above range.
1. Remove KDPF delta pressure sensor tube.
Defective KDPF 2. Clean KDPF delta pressure sensor tube to eliminate plugging.
delta pressure
8 sensor a Execute the following when KDPF delta pressure sensor tube is free from
plugging.
(Including sensor
tube) 1. Perform troubleshooting on cause "Short circuit in wiring harness" described in
troubleshooting page of failure code [CA1881] or [CA1883] (if short circuit is
not found, replace KDPF delta pressure sensor).
40-266 PC290LC-10
40 Troubleshooting

1. Perform manual stationary regeneration from "Regeneration for service" menu
(see Related information).
Execution of • While manual stationary regeneration is continued, failure code [CA2639] is
manual stationary displayed on machine monitor. But it does not mean any problem (manual
9 regeneration stationary regeneration is completed in about 2 to 3 hours and failure code
[CA2639] disappears).
(To dry KCSF)
[CA2639].
a Perform this troubleshooting when failure code [CA1922], [CA1921] or
[CA2639] is displayed after manual stationary regeneration.
1. Accelerate engine abruptly two times from low idle to high idle, then keep
Defective exhaust engine speed at high idle for five seconds.
10 gas color
• If black smokes are emitted at engine acceleration or during running engine at
high idle, perform troubleshooting for "S-9 KDPF is plugged soon."
a It does not matter that black smoke powders are emitted at engine acceleration
if they are not emitted during running engine at high idle.
a Check that no failure code appears.
PC290LC-10 40-267
40 Troubleshooting
Failure code [CA1942] Crankcase Press Sens In Range Error

Action Crankcase pressure sensor in range error
Failure code
level Failure
L01 CA1942
Details of • Signal voltage from crankcase pressure sensor is out of normal range.
failure
controller
Problem on
machine
(Code: 48401 (V))
sensor
2
filter
Blocked KCCV gas
piping
When KCCV filter is replaced, if failure code crankcase pressure high error does
Increase of blowby not disappear and failure code of crankcase pressure high errors is displayed in
4 gas short period, engine may be seized or turbocharger may have trouble. Perform
troubleshooting for mechanical system.
40-268 PC290LC-10
40 Troubleshooting
Failure code [CA1993] KDPF Delta Pressure Low Error

Action KDPF delta pressure low error
Failure code
level Failure
L03 CA1993
Details of • Signal voltage from KDPF delta pressure sensor is below threshold value.
failure
machine
Related • Differential pressure from KDPF delta pressure sensor can be checked with monitoring
information function. (Code: 47101 (MPa))
[How to clear failure code]
In order to prevent an error during operation, relieve work equipment pump circuit for 30
seconds after starting and warming up engine. Repeat this hydraulic stall several times. If
this failure code is cancelled, repair is complete.
Defective KDPF If failure code [CA1879], [CA1881], or [CA1883] is displayed, perform
1 delta pressure troubleshooting for it.
sensor
Malfunction of Check that KDPF is installed to exhaust system and is not clogged with foreign
2
KDPF matters.
Check the following .
Defective KDPF 1. KDPF delta pressure sensor tube is installed.
3 delta pressure 2. KDPF delta pressure sensor tube is connected correctly.
sensor tube 3. Remove KDPF delta pressure sensor tube and check it for cracks and
damages.
4. KDPF delta pressure sensor tube is not loosened at its both ends?
Defective engine
4 information".
controller
a If this failure code is still displayed and does not disappear even after performing "How to clear the failure
code" in the related information, repeat the troubleshooting.
PC290LC-10 40-269
40 Troubleshooting
Failure code [CA2185] Throt Sensor Sup Volt High Error

Action Throttle sensor power supply voltage high error
Failure code
level Failure
L03 CA2185
Details of • High voltage appears in throttle sensor power supply (5 V) circuit.
failure
Action of • Sets throttle angle by using signal other than throttle sensor signal and allows engine to
controller run.
Problem on • Engine speed cannot be controlled with fuel control dial.
machine
information
1
Defective throttle 2. Disconnect connector P20, and turn starting switch to ON position.
2 sensor (fuel control If this failure code is not displayed, throttle sensor is defective.
dial) a Other failure codes are also displayed because of disconnection of connector.
Short circuit in 2. Disconnect connectors CE03 and P20, and connect T-adapter to female side

circuit) Voltage Between P20 (female) (1) and ground 4.75 to 5.25 V
Defective engine 2. Disconnect connector CE03, and connect T-adapters to male side.
5 3. Turn starting switch to ON position with wiring harness disconnected.
controller
Voltage Between CE03 (male) (41) and (42) 4.75 - 5.25 V
40-270 PC290LC-10
40 Troubleshooting
Failure code [CA2186] Throt Sensor Sup Volt Low Error

Action Throttle sensor power supply voltage low error
Failure code
level Failure
L03 CA2186
Details of • Low voltage was detected in throttle sensor power supply (5 V) circuit.
failure
Action of • Sets throttle position by using signals other than throttle sensor signals and allows engine
controller to run.
Problem on • Engine speed cannot be controlled by fuel control dial.
machine
information
1
Defective throttle 2. Disconnect connector P20, and turn starting switch to ON position.
2 sensor (fuel control If this failure code is not displayed, throttle sensor is defective.
dial) a Other failure codes are displayed at the same time. This is because connector
is disconnected. Ignore failure codes other than [CA2186].
Ground fault in 1. Starting switch: OFF
wiring harness 2. Disconnect connectors CE02 and P20, and connect T-adapter to either female
3 side.
(contact with
Between CE03 (female) (42) or P20
ground circuit) Resistance Min. 100 kz
(female) (1) and ground
2. Disconnect connectors CE03 and P20, and connect T-adapter to female side
4 wiring harness 3. Starting switch: ON
Resistance other pin Min. 100 kz

Defective engine 2. Disconnect connector CE03, and connect T-adapters to male side.
5 3. Turn starting switch to ON position with wiring harness disconnected.
controller
Voltage Between CE03 (male) (41) and (42) 4.75 - 5.25 V
PC290LC-10 40-271
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error

Action Supply pump pressure low error 2
Failure code
level Failure
L03 CA2249
Details of • Low pressure (2) appears in common rail circuit.
failure
controller
• Engine startability becomes poor.
Problem on • Exhaust gas becomes black.
Supply pump Perform troubleshooting for failure code [CA559].
1 pressure low error
2
40-272 PC290LC-10
40 Troubleshooting
Failure code [CA2271] EGR Valve Pos Sens High Error

Action EGR valve lift sensor high error
Failure code
level Failure
L03 CA2271
Details of • High voltage error is detected in signal circuit of EGR valve lift sensor.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 (V))
Related • Valve position sensed by EGR valve lift sensor can be checked with monitoring function.
information (Code: 18100 (mm))
1
system
Defective EGR 2. Disconnect connector SEGR.
3 valve lift sensor 3. Turn starting switch to ON position.
(internal defect) If failure code changes from [CA2271] to [CA2272], EGR valve lift sensor is
defective.
2. Disconnect connector INTER-CONNECT.
Defective 3. Turn starting switch to ON position.
connector box If failure code changes from [CA2271] to [CA2272], connector box is defective.
4 (internal open
a EGR solenoid failure code [CA2349], KVGT sensor failure code [CA2382], and
circuit)
KVGT solenoid failure code [CA2383] are also displayed. Ignore those failure
codes since they are displayed because of disconnection of connector INTER-
CONNECT.
connector box 2. Disconnect connector INTER-CONNECT and SEGR, and connect T-adapters.
5 (wire breakage or a Open circuit of GND line
defective contact of Between INTER-CONNECT (male) (4)
connectors) Resistance and SEGR (female) (B) Max. 10 z

2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-
Open circuit in
wiring harness
6 (wire breakage or a Open circuit of GND line
connector) a If no failure is found by check on cause 2, this check is not required.
Between ECM J2 (female) (47) and Max. 10 z
Resistance INTER-CONNECT (female) (4)
PC290LC-10 40-273
40 Troubleshooting

Short circuit in adapters to either female side.
7 wiring harness Between ECM J2 (female) (30) and (59),
Resistance or between INTER-CONNECT (female) Min. 100 kz
(3) and (5)
2. Disconnect connectors INTER-CONNECT and connect T-adapters to female
wiring harness
8 side.
(contact with 24 V
circuit)
Voltage Between SEGR (female) (C) and (B) Max. 1 V
• Reference
Defective engine 2. Insert T-adapters to connector ECM J2.
9
Between ECM J2
Voltage (female) (59) and Sensor output 1.0 to 4.0 V
(47)
Circuit diagram related to EGR valve lift sensor
40-274 PC290LC-10
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error

Action EGR valve lift sensor low error
Failure code
level Failure
L03 CA2272
Details of • Low voltage appears in signal circuit of EGR valve lift sensor.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 (V))
Related • Valve position sensed by EGR valve lift sensor can be checked with monitoring function.
1
system
Defective sensor 2. Disconnect connector SEGR and connect T-adapters to female side.
system Between SEGR
(female) (A) and (B)
2. Disconnect connector INTER-CONNECT and SEGR, and connect T-adapter.
causes 2 and 3, this check is not
required. Max. 10 z
Open circuit in
connector box Between INTER-CONNECT (male) (3)
and SEGR (female) (A)
4 (wire breakage or
defective contact of Resistance a If no failure is found by check on
connectors) causes 2 and 3, this check is not
required. Max. 10 z
Between INTER-CONNECT (male) (4)
and SEGR (female) (B)
and SEGR (female) (C) Max. 10 z

Ground fault in 2. Disconnect connector INTER-CONNECT and SEGR, and connect T-adapters.
connector box Between ground and INTER-CONNECT
5 Min. 100 kz
(contact with GND (male) (5) and SEGR (female) (C)
circuit) Resistance
Between ground and INTER-CONNECT Min. 100 kz
(male) (3) and SEGR (female) (A)
PC290LC-10 40-275
40 Troubleshooting

2. Disconnect connector INTER-CONNECT and SEGR, and connect T-adapters.
Short circuit in Between INTER-CONNECT (male) (4)
connector box and (5), or between SEGR (female) (B) Min. 100 kz
6
(internal open and (C)
circuit) Resistance
and (4), or between SEGR (female) (A) Min. 100 kz
and (B)
a If no failure is found by checks on
Open circuit in required. Max. 10 z
7 (wire breakage or INTER-CONNECT (female) (3)
connector) Resistance a If no failure is found by checks on
required. Max. 10 z
INTER-CONNECT (female) (4)
INTER-CONNECT (female) (5) Max. 10 z

Ground fault in adapters to each female side.
wiring harness
(59) and INTER-CONNECT (female) (5) Min. 100 kz
circuit) Resistance
(30) and INTER-CONNECT (female) (3) Min. 100 kz

Short circuit in Between ECM J2 (female) (47) and (59),
9 wiring harness or between INTER-CONNECT (female) Min. 100 kz
(4) and (5)
Resistance
or between INTER-CONNECT (female) Min. 100 kz
(3) and (4)
2. Insert T-adapters to connector SEGR.
Defective EGR Between SEGR
10 valve lift sensor Voltage (female) (C) and Sensor output 1.0 to 4.0 V
(internal defect) (B)
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check whether wiring harness connector is normal, and then make
judgement.
controller
40-276 PC290LC-10
40 Troubleshooting
Circuit diagram related to EGR valve lift sensor
PC290LC-10 40-277
40 Troubleshooting
Failure code [CA2288] Turbo Speed High Error 1

Action Turbocharger speed high error 1
Failure code
level Failure
L01 CA2288
Details of • Turbocharger speed is excessively high.
failure
Action of
controller
machine
Increase in Turbocharger speed may be high. Check it.
1 turbocharger speed
2 turbocharger
Defective If no failure is found by check on cause 1, turbocharger speed sensor system may
3 turbocharger speed be defective. Perform troubleshooting for failure code [CA687].
sensor
40-278 PC290LC-10
40 Troubleshooting
Failure code [CA2311] IMV Solenoid Error

Action IMV solenoid error
Failure code
level Failure
L03 CA2311
Details of • Resistance of supply pump actuator circuit is abnormally high or low.
failure
controller
machine
information
Malfunction of IMV Perform troubleshooting for failure codes [CA271] and [CA272].
1
solenoid
PC290LC-10 40-279
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Error

Action EGR Valve Sol Current Low Error
Failure code
level Failure
L03 CA2349
Details of • Open circuit is in EGR valve solenoid drive circuit.
failure
controller • Stops regeneration control by KDPF.
machine
• Signal current to EGR valve lift solenoid can be checked with monitoring function.
Related (Code: 48600 (mA))
harness connector
Defective EGR 1. Turn starting switch to OFF position.
valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male side.
2
(Internal open
circuit) Resistance Between EGR-SOL (male) (1) and (2) 5 to 10 z
3 short circuit in
wiring harness a Resistance of EGR valve solenoid
Resistance Between ECM J2 (female) (6) and (16) 5 to 10 z
Ground fault in 2. Disconnect connectors ECM J2 and EGR-SOL, and connect T-adapters to
4
(Contact with GND Between ECM J2 (female) (6) and
circuit) Resistance ground, or between EGR-SOL (female) Min. 100 kz
(1) and ground
connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT, and connect T-
5 (Wire breakage or adapter.
and EGR-SOL (female) (1) Max. 10 z
connectors)
Resistance
and EGR-SOL (female) (2) Max. 10 z

Ground fault on 1. Turn starting switch to OFF position.
6
(Contact with GND adapter.
circuit) Between ground and INTER-CONNECT Min. 100 kz
Resistance (male) (1) and EGR-SOL (female) (1)
40-280 PC290LC-10
40 Troubleshooting

Breaking of 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-adapter
7 (Wire breakage or to female side.
connectors) Resistance

harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-
8 adapters to each female side.
(Contact with GND
Resistance ground, or between INTER-CONNECT Min. 100 kz
Hot short-circuiting 2. Disconnect connector EGR-SOL and connect T-adapter to female side.
of harness 3. Turn starting switch to ON position.
9 Between EGR-SOL (female) (1) and
(Contact with 24 V Max. 1 V
ground
circuit) Voltage
Between EGR-SOL (female) (2) and
ground Max. 1 V
controller
Circuit diagram related to EGR valve solenoid
PC290LC-10 40-281
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Error

Action EGR Valve Sol Current High Error
Failure code
level Failure
L03 CA2353
Details of
• Short circuit is in EGR valve solenoid drive circuit.
failure
machine
• Signal current to EGR valve lift solenoid can be checked with monitoring function.
harness connector
valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male side.
2
(Internal open
circuit) Resistance Between EGR-SOL (male) (1) and (2) 5 to 10 z
3 short circuit in
wiring harness a Resistance of EGR valve solenoid
Ground fault in 2. Disconnect connectors ECM J2 and EGR-SOL, and connect T-adapters to
4
circuit) Resistance ground, or between EGR-SOL (female) Min. 100 kz
(1) and ground
5
circuit) Between ground and INTER-CONNECT
Resistance (male) (1) and EGR-SOL (female) (1) Min. 100 kz

(Contact with GND
40-282 PC290LC-10
40 Troubleshooting

Hot short-circuiting 2. Disconnect connector EGR-SOL and connect T-adapter to female side.
7
(Contact with 24 V Between EGR-SOL (female) (1) and (2) Max. 1 V
circuit) Voltage Between EGR-SOL (female) (2) and
ground Max. 1 V
controller
Circuit diagram related to EGR valve solenoid
PC290LC-10 40-283
40 Troubleshooting
Failure code [CA2357] EGR Differential Pressure

Action EGR Valve servo error
Failure code
level Failure
L03 CA2357
Details of
• EGR valve has servo error.
failure
machine
information
1 system
Improper EGR
a For measurement of EGR valve drive oil pressure, see Testing and adjusting,
2 valve drive
"Measuring EGR valve and KVGT drive oil pressure".
pressure
a For check of engine oil pressure, see Testing and adjusting, "Testing engine oil
Defective engine oil pressure".
3 system (main If engine oil pressure is not normal, preform troubleshooting (S mode) for
circuit) mechanical system.
(S-14 Oil pressure lowers.)
Defective oil pump Oil pump relief valve for EGR valve circuit may be defective. Check it directly.
4
for EGR valve
Defective oil pipe Oil pipe for EGR valve circuit may be defective. Check it directly .
5
for EGR valve
Defective oil return Oil return pipe for EGR valve circuit may be defective. Check it directly.
6 pipe for EGR valve
Defective EGR EGR valve may be defective. Check it directly.
7
valve
Defective EGR Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
valve lift sensor
controller
40-284 PC290LC-10
40 Troubleshooting
Failure code [CA2373] Exh Manifold Press. Sens Volt

Action Exhaust manifold pressure sensor high error
Failure code
level Failure
L03 CA2373
Details of • High voltage error is detected in signal circuit of exhaust manifold pressure sensor.
failure
Action of • Runs engine by setting the exhaust manifold pressure to the calculated value.
controller
machine
• Signal voltage from exhaust manifold pressure sensor can be checked using monitoring
function.
(Code: 48301 (V))
Related • Pressure sensed by exhaust manifold pressure sensor can be checked using monitoring
(Code: 48300 (MPa))
harness connector
2 power supply [CA352] or [CA386] first.
system
Defective charge 2. Disconnect connector EXHAUST PRESSURE.
(internal defect) If failure code [CA2373] changes to [CA2374], exhaust manifold pressure sensor
is defective.
Short-circuiting of 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and connect T-
adapter to female side.
4 (short circuit
between Between ECM J2 (female) (34) and (30),
harnesses) Resistance or between EXHAUST PRESSURE Min. 100 kz
Hot short-circuiting 2. Disconnect connector EXHAUST PRESSURE and connect T-adapter to
of harness female side.
(Contact with 24 V
circuit) Between EXHAUST PRESSURE
Voltage Max. 1 V
If no abnormality is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
Defective engine 2. Insert T-adapter to connector ECM J2.
6
Between ECM J2
Voltage (female) (34) and Sensor output 0.2 to 4.7 V
(47)
PC290LC-10 40-285
40 Troubleshooting
Circuit diagram related to exhaust manifold pressure sensor
40-286 PC290LC-10
40 Troubleshooting
Failure code [CA2374] Exhaust Manifold Press Sens Low Error

Action Exhaust manifold pressure low error
Failure code
level Failure
L03 CA2374
Details of • Low voltage error is detected in signal circuit of exhaust manifold pressure sensor.
failure
Action of • Runs engine by setting the exhaust manifold pressure to the calculated value.
controller
machine
• Signal voltage from exhaust manifold pressure sensor can be checked using monitoring
function.
(Code: 48301 (V))
Related • Pressure sensed by exhaust manifold pressure sensor can be checked using monitoring
(Code: 48300 (MPa))
harness connector
2 power supply [CA352] or [CA386] first.
system
2. Disconnect connector EXHAUST PRESSURE and connect T-adapter to
female side.
Defective sensor
2 power supply
system Between
EXHAUST
PRESSURE
2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and connect T-
Breaking of adapter to female side.
harness Between ECM J2 (female) (30) and
EXHAUST PRESSURE (female) (1) Max. 10 z
3 (Open circuit or
defective contact in Between ECM J2 (female) (47) and
connector) Resistance EXHAUST PRESSURE (female) (2) Max. 10 z
EXHAUST PRESSURE (female) (3) Max. 10 z

2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and connect T-
Ground fault in adapters to either female side.
harness Between ground and ECM J2 (female)
4 (34) and EXHAUST PRESSURE Min. 100 kz
(Contact with GND
(female) (3)
circuit) Resistance
(30) and EXHAUST PRESSURE Min. 100 kz
(female) (1)
PC290LC-10 40-287
40 Troubleshooting

harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and connect T-
adapters to either female side.
5 (short circuit
between Between ECM J2 (female) (34) and (47),
harnesses) Resistance or between EXHAUST PRESSURE Min. 100 z
Defective exhaust 1. Turn starting switch to OFF position.
manifold pressure 2. Disconnect connector ECM J2 and connect T-adapter to female side.
(internal defect) Between EXHAUST PRESSURE
controller
Circuit diagram related to exhaust manifold pressure sensor
40-288 PC290LC-10
40 Troubleshooting
Failure code [CA2375] EGR Orifice Temp Sens High Error

Action EGR orifice temperature sensor high error
Failure code
level Failure
L03 CA2375
Details of • High voltage appears in signal circuit of EGR orifice temperature sensor.
failure
Action of • Takes it that EGR orifice temperature is at calculated value and allows engine to run.
controller
• Voltage sensed by EGR orifice temperature sensor can be checked with monitoring
function.
(Code: 48501 (V))
Related • Temperature sensed by EGR orifice temperature sensor can be checked with monitoring
(Code: 48500 (°C))
• This failure code is generated if sensor connector is disconnected.
See descriptions of harness and connectors in "c: Electrical equipment" of
Defective wiring
1 "Checks before troubleshooting" in "General information on troubleshooting", and
harness connector
check them.
2. Disconnect connector EXHAUST GAS TEMPERATURE and connect T-
adapters to male side.
-30°C 760 to 880 kz
EXHAUST GAS
0°C 380 to 515 kz
TEMPERATURE
(Male) 25°C 155 to 225 kz
Defective EGR 80°C 21 to 29 kz
Between (1) and (2)
orifice temperature 200°C 900 to 1050 z
2 sensor a Temperature- 300°C 150 to 200 z
Resistance
(internal defect) Resistance characteristics 400°C 40 to 56 z
500°C 15 to 22 z
EXHAUST GAS
TEMPERATURE
(Male)
Between (2) and
ground (sensor
body)
Open circuit or 1. 1. Turn starting switch to OFF position.
short circuit in 2. Disconnect connector ECM J2 and connect T-adapter to female side.
wiring harness
3
(short circuit, open a Use Temperature-Resistance characteristics for check of EGR orifice
temperature sensor as resistance criteria.
connector contact) Resistance Between ECM J2 (female) (18) and (48) 15 z to 880 kz
wiring harness
4 adapters to female side.
(contact with 24 V
circuit) Between EXHAUST GAS
Voltage Max. 5 V
TEMPERATURE (female) (1) and (2)
controller
PC290LC-10 40-289
40 Troubleshooting
Circuit diagram related to EGR orifice temperature sensor
40-290 PC290LC-10
40 Troubleshooting
Failure code [CA2376] EGR Orifice Temp Sens Low Error

Action EGR orifice temperature sensor low error
Failure code
level Failure
L03 CA2376
Details of • Low voltage error is detected in EGR orifice temperature sensor signal circuit.
failure
• Runs engine by setting EGR orifice temperature to the calculated value.
• Stops regeneration control by KDPF.
machine
• Voltage sensed by EGR orifice temperature sensor can be checked using monitoring
function.
(Code: 48501 (V))
Related • Temperature sensed by EGR orifice temperature sensor can be checked using
information monitoring function.
(Code: 48500 (°C))
See descriptions of harness and connectors in "c: Electrical equipment" of
Defective wiring
1 "Checks before troubleshooting" in "General information on troubleshooting", and
harness connector
check them.
orifice temperature 2. Disconnect connector EXHAUST GAS TEMPERATURE.
(internal defect) If this failure code changes to failure code [CA2375], EGR orifice temperature
• Reference
adapter to male side.
-30°C 760 to 880 kz
0°C 380 to 515 kz
Between 25°C 155 to 225 kz
Defective EGR EXHAUST GAS 80°C 21 to 29 kz
orifice temperature TEMPERATURE 200°C 900 to 1050 z
3 sensor (male) (1) and (2) 300°C 150 to 200 z
(internal defect) 400°C 40 to 56 z
Resistance
500°C 15 to 22 z
Between
EXHAUST GAS
TEMPERATURE
(male) (2) and
ground (sensor
body)
short circuit in 2. Disconnect connector ECM J2 and connect T-adapter to female side.
wiring harness
4 a Resistance is the same as that given in temperature-resistance characteristics
(short circuit, open
table of EGR orifice temperature sensor that has bee used to check cause 3.
connector contact) Resistance Between ECM J2 (female) (18) and (48) 15 z to 880 kz
PC290LC-10 40-291
40 Troubleshooting

Ground fault in 2. Disconnect connectors ECM J2 and EXHAUST GAS TEMPERATURE, and
harness connect T-adapters to either female side.
5 Between ECM J2 (female) (48) and
(Contact with GND
circuit) ground, or between EXHAUST GAS
Resistance TEMPERATURE (female) (2) and Min. 100 kz
ground
controller
Circuit diagram related to EGR orifice temperature sensor
40-292 PC290LC-10
40 Troubleshooting
Failure code [CA2381] KVGT Pos Sens High Error

Action KVGT position sensor high error
Failure code
level Failure
L03 CA2381
Details of • High voltage appears in KVGT position sensor signal circuit.
failure
• EGR valve is closed and KVGT is fully opened.
Action of • Limits engine output and allows engine to run
controller • Disables KDPF of its regeneration control.
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position sensed by the KVGT position sensor can be checked with monitoring function.
1
harness connector 2. Starting switch: ON
Defective sensor If failure code [CA352] or [CA386] is displayed at the same time, carry out
2 power supply line troubleshooting for it first.
Defective KVGT 2. Disconnect connector SVGT.
3 position sensor 3. Starting switch: ON
(internal defect) a If failure code [CA2381] changes to [CA2382], KVGT position sensor is
defective.
2. Disconnect connector INTER-CONNECT.
Defective 3. Starting switch: ON
connector box If failure code [CA2381] changes to [CA2382], connector box is defective.
4
(internal short a Failure codes for defective EGR solenoid [CA2349], EGR sensor [CA2272],
circuit) and KVGT solenoid [CA2383] are also displayed at the same time.
Ignore these codes since they appear because of disconnection of connector
INTER-CONNECT.
connector box 2. Disconnect connectors INTER-CONNECT and SVGT, and connect T-adapters.
5 (wire breakage or a Open circuit in GND line
connector) Resistance and SVGT (female) (B) 10 z Max.

wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-
connector)
Between ECM J2 (female) (47) and 10 z Max.
Resistance INTER-CONNECT (female) (9)
PC290LC-10 40-293
40 Troubleshooting

Short circuit in 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-
wiring harness adapters to either female side.
7
(Short circuit with Between ECM J2 (female) (30) and (38)
GND circuit) Resistance or between INTER-CONNECT (female) Min. 100 kz
(8) and (10)
Hot short circuit in 1. Starting switch: OFF
wiring harness 2. Disconnect connector SVGT and connect T-adapter to female side.
(contact with 24 V
circuit) Voltage Between SVGT (female) (C) and (B) Max. 1 V
If no problem is found by above checks, engine controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed.)
• Reference
Defective engine 2. Insert T-adapter into connector ECM J2.
9
controller 3. Starting switch: ON
Between ECM J2
Voltage (female) (38) and Sensor output 1.0 - 4.0 V
(47)
Circuit diagram related to KVGT position sensor
40-294 PC290LC-10
40 Troubleshooting
Failure code [CA2382] KVGT Pos Sens Low Error

Action KVGT position sensor low error
Failure code
level Failure
L03 CA2382
Details of • Low voltage appears in KVGT position sensor signal circuit.
failure
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position sensed by the KVGT position sensor can be checked with monitoring function.
1
Defective sensor If failure code [CA352] or [CA386] is displayed at the same time, carry out
2 power supply line troubleshooting for it first.
2. Disconnect connector SVGT and connect T-adapter to female side.
Defective sensor
power supply line
Between SVGT
Voltage Power supply 4.75 - 5.25 V
a If no abnormality is found in checks on causes 2 and 3, this check is not
required.
connector box 2. Disconnect connectors INTER-CONNECT and SVGT, and connect T-adapters.
4 (wire breakage or Between INTER-CONNECT (male) (8)
and SVGT (female) (A) 10 z Max.
connector) Between INTER-CONNECT (male) (9)
Resistance and SVGT (female) (B) 10 z Max.
and SVGT (female) (C) 10 z Max.

Ground fault in 2. Disconnect connectors INTER-CONNECT and SVGT, and connect T-adapters.
connector box Between INTER-CONNECT (male) (10)
5 Min. 100 kz
(contact with and SVGT (female) (C) and ground
ground circuit) Resistance
and SVGT (female) (A) and ground Min. 100 kz

2. Disconnect connectors INTER-CONNECT and SVGT, and connect T-adapters.
Short circuit in Between INTER-CONNECT (male) (9)
connector box and (10) or between SVGT (female) (B) Min. 100 kz
6
(internal short and (C)
circuit) Resistance
and (9) or between SVGT (female) (A) Min. 100 kz
and (B)
PC290LC-10 40-295
40 Troubleshooting

required.
Open circuit in 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-
wiring harness adapters to each female side.
7 (wire breakage or Between ECM J2 (female) (30) and
defective contact of INTER-CONNECT (female) (8) 10 z Max.
connector) Between ECM J2 (female) (47) and
Resistance INTER-CONNECT (female) (9) 10 z Max.
INTER-CONNECT (female) (10) 10 z Max.

Ground fault in adapters to each female side.
8 INTER-CONNECT (female) (10) and Min. 100 kz
(contact with
ground
ground circuit) Resistance
INTER-CONNECT (female) (8) and Min. 100 kz
ground
2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-adapter
Short circuit in to either female side.
wiring harness Between ECM J2 (female) (47) and (38)
9 or between INTER-CONNECT (female) Min. 100 kz
(Short circuit with (9) and (10)
GND circuit) Resistance
or between INTER-CONNECT (female) Min. 100 kz
(8) and (9)
2. Insert T-adapter in connector, SVGT
3. Starting switch: ON
Defective KVGT Between SVGT
10 position sensor Voltage (female) (C) and Sensor output 1.0 - 4.0 V
(internal defect) (B)
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage
is abnormal, check wiring harness and controller, too, for another cause of trouble,
and then judge.
controller
Circuit diagram related to KVGT position sensor
40-296 PC290LC-10
40 Troubleshooting
Failure code [CA2383] KVGT Solenoid Open Error

Action KVGT solenoid open error
Failure code
level Failure
L03 CA2383
Details of • Open error is detected in KVGT solenoid drive circuit.
failure
• Closes EGR valve and fully opens KVGT.
machine
• Signal current to KVGT solenoid can be checked using monitoring function (Code: .48800
Related (mA)).
harness connector
Defective KVGT 1. Turn starting switch to OFF position.
solenoid valve 2. Disconnect connector VGT-SOL and connect T-adapter to male side.
2
(Internal open
circuit) Resistance Between VGT-SOL (male) (1) and (2) 5 to 10 z
3 short circuit in
wiring harness a Resistance of KVGT valve solenoid
Ground fault in 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapters to
4
circuit) Resistance ground, or between VGT-SOL (female) Min. 100 kz
(1) and ground
connector box 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and connect T-
5 (Open circuit or adapter.
defective contact in Between INTER-CONNECT (male) (6)
and VGT-SOL (female) (1) Max. 10 z
connector)
Resistance
and VGT-SOL (female) (2) Max. 10 z

6
circuit) Between ground and INTER-CONNECT Min. 100 kz
Resistance (male) (6) and VGT-SOL (female) (1)
PC290LC-10 40-297
40 Troubleshooting

harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-adapter
7 (Open circuit or to female side.
defective contact in Between ECM J2 (female) (10) and
connector) Resistance

(Contact with GND
Hot short-circuiting 2. Disconnect connector VGT-SOL and connect T-adapter to female side.
9 Between VGT-SOL (female) (1) and
(Contact with 24 V Max. 1 V
ground
circuit) Voltage
Between VGT-SOL (female) (2) and
ground Max. 1 V
controller
Circuit diagram related to KVGT solenoid
40-298 PC290LC-10
40 Troubleshooting
Failure code [CA2386] KVGT Solenoid Short Error

Action KVGT solenoid short error
Failure code
level Failure
L03 CA2386
Details of
• Short circuit error is detected in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked using monitoring function.
harness connector
Defective KVGT 1. Turn starting switch to OFF position.
solenoid valve 2. Disconnect connector VGT-SOL and connect T-adapter to male side.
2
(Internal open
circuit) Resistance Between VGT-SOL (male) (1) and (2) 5 to 10 z
3 short circuit in
wiring harness a Resistance of KVGT valve solenoid
Ground fault in 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapters to
4
circuit) Resistance ground, or between VGT-SOL (female) Min. 100 kz
(1) and ground
5
circuit) Between ground and INTER-CONNECT
Resistance (male) (6) and VGT-SOL (female) (1) Min. 100 kz

(Contact with GND
PC290LC-10 40-299
40 Troubleshooting

Hot short-circuiting 2. Disconnect connector VGT-SOL and connect T-adapter to female side.
7
(Contact with 24 V Between VGT-SOL (female) (1) and (2) Max. 1 V
circuit) Voltage Between VGT-SOL (female) (2) and
ground Max. 1 V
controller
Circuit diagram related to KVGT solenoid
40-300 PC290LC-10
40 Troubleshooting
Failure code [CA2387] KVGT Servo Error

Action KVGT servo error
Failure code
level Failure
L03 CA2387
Details of • KVGT servo error has occurred
failure (Response from KVGT position sensor differs from KVGT opening command.)
machine
information
Defect in related If another failure code is indicated, carry out troubleshooting for it.
1 system
KVGT drive oil a For testing of KVGT drive pressure, see Testing and adjusting, "Testing EGR
2 pressure abnormal valve, KVGT oil pressure".
KVGT control a For testing of KVGT control pressure, see Testing and adjusting, "Testing EGR
3 pressure abnormal valve, KVGT oil pressure".
If KVGT control oil pressure is abnormal, replace EPC valve.
Defective engine oil a For check of engine oil pressure, see Testing and adjusting,"Measuring engine
oil pressure(PAGE 30-21)".
4 pressure system
(main circuit) If engine oil pressure is not normal, perform troubleshooting (S mode).
(S-14 Oil pressure drops)
Defective oil pump Oil pump relief valve for the KVGT circuit may be defective. Check it.
5
for KVGT
Defective oil supply Oil supply pipe for the KVGT circuit may be defective. Check it.
6 pipe for KVGT
Defective oil return Oil return pipe for KVGT circuit may be defective. Check it.
7 pipe for KVGT
8 Defective KVGT. KVGT may be defective. Check it.
Defective KVGT Carry out troubleshooting for failure codes [CA2381] and [CA2382].
9 position sensor
controller
PC290LC-10 40-301
40 Troubleshooting
Failure code [CA2554] Exh Manifold Press Sens In Range Error

Action Exhaust manifold pressure sensor in-range error
Failure code
level Failure
L03 CA2554
Details of • Exhaust manifold pressure sensor output value displayed is out of normal range.
failure
Action of • Fixes exhaust manifold pressure to a calculated value and continues operation.
controller
machine
• Signal voltage from the exhaust manifold pressure sensor can be checked with
monitoring function.
(Code: 48301 (V))
Related • Pressure sensed by the exhaust manifold pressure sensor can be checked with
(Code: 48300 (MPa)
Blocked exhaust Exhaust manifold pressure sensor pipe may be blocked. Perform troubleshooting
1 manifold pressure for blockage.
sensor
Defective exhaust Exhaust manifold pressure sensor system may be defective. Carry out
2 manifold pressure troubleshooting for failure codes [CA2373] and [CA2374].
sensor
40-302 PC290LC-10
40 Troubleshooting
Failure code [CA2555] Grid Htr Relay Volt Low Error

Action Intake air heater relay voltage high error
Failure code
level Failure
L01 CA2555
Details of • Open circuit is detected in drive circuit (primary circuit) of preheat relay.
failure
controller
Problem on • Intake air heater does not work in auto preheating (degraded starting performance at low
machine temperature and emission of white smokes)
function.
(Code: 18500 Boost temperature)
• Method of reproducing failure code: Turn starting switch to ON position (charge
temperature: lower than -4°C).
Related • Troubleshooting for this failure code covers circuit starting from engine controller to
information primary (coil) side of preheater relay R18.
• For troubleshooting related to heater relay and secondary side of preheater relay R18,
see E-mode below.
• E-2 Manual preheating system does not work(PAGE 40-545)
• E-3 Automatic preheating system does not work(PAGE 40-548)
• E-4 Preheating monitor does not light up when preheater is operated(PAGE 40-550)
harness connector
Defective preheater
2 2. Disconnect relay R18, and connect T-adapter to male side.
relay R18
Resistance Between R18 (male) (1) and (2) 200 - 400 z
Defective preheater 2. Replace relay R18 with another one.
3 relay R18 3. Starting switch: ON
If this failure code disappears, original preheater relay R18 is defective.
Open or short 2. Disconnect connector CE03, and connect T-adapter to female side.
4 circuit in wiring Between CE03 (female) (4) and (13)
harness Resistance 200 - 400 z
a Preheater relay R18 coil resistance
2. Disconnect connector CE03 and relay R18, and connect T-adapters to each
Open circuit in female side.
5 wiring harness Between CE03 (female) (4) and R18
(female) (1) 1 z Max.
Resistance
Between R18 (female) (2) and CE03
(13) 1 z Max.
PC290LC-10 40-303
40 Troubleshooting

2. Disconnect connector CE03 and relay R18, and connect T-adapter to female
Short circuit in side of CE03.
Continuity
other pin (No sound is heard)
controller
40-304 PC290LC-10
40 Troubleshooting
Circuit diagram related to intake air heater relay
PC290LC-10 40-305
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Volt High Error

Action Intake air heater relay short circuit error
Failure code
level Failure
L01 CA2556
Details of • Short circuit is detected in drive circuit (primary circuit) of preheater relay.
failure
controller
Problem on • Intake air heater does not work in auto preheating (degraded starting performance at low
machine temperature and emission of white smokes)
function.
(Code: 18500 )
• Method of reproducing failure code: Turn starting switch to ON position (charge
temperature: lower than -4°C).
Related • Troubleshooting for this failure code covers circuit starting from engine controller to
information primary (coil) side of preheater relay R18.
• For troubleshooting related to heater relay and secondary side of preheater relay R18,
see E-mode below.
• E-2 Manual preheating system does not work(PAGE 40-545)
• E-3 Automatic preheating system does not work(PAGE 40-548)
• E-4 Preheating monitor does not light up when preheater is operated(PAGE 40-550)
harness connector
Defective preheater
2 2. Disconnect relay R18, and connect T-adapter to male side.
relay R18
Resistance Between R18 (male) (1) and (2) 200 - 400 z
Defective preheater 2. Replace relay R18 with another one.
3 relay R18 3. Starting switch: ON
If this failure code disappears, original preheater relay R18 is defective.
Ground fault in 2. Disconnect connector CE03 and relay R18, and connect T-adapter to either
Between CE03 (female) (4) or R18
Resistance (female) (1) and ground Min. 1 Mz

2. Disconnect connector CE03 and relay R18, and connect T-adapter to female
Short circuit in side of CE03.
Continuity
controller
40-306 PC290LC-10
40 Troubleshooting
Circuit diagram related to intake air heater relay
PC290LC-10 40-307
40 Troubleshooting
Failure code [CA2637] KDOC Face Plugging

Action KDOC face plugging
Failure code
level Failure
L01 CA2637
• KDOC face is plugged.
1. KDOC surface becomes dirty and catalyst efficiency is lowered due to bad operating
Details of conditions (cleaning of KDOC).
failure 2. Deterioration of KDOC by high temperature, efficiency drop by sticking foreign matter,
efficiency drop by breakage, deterioration (replacement of KDOC with new one or
used one)
machine
k Use care not to burn yourself since turbocharger exhaust connector, KDPF, and
KDOC are heated to 500°C or above.
a When you have replaced KDOC of KDPF, be sure to perform reset procedure for KDOC
Change and then perform manual stationary regeneration from "Regeneration for service"
menu to eliminate humidity of KDOC.
• Procedure for performing manual stationary regeneration from "Regeneration for service"
menu
Related a When soot load is level 3 or below, manual stationary regeneration is available only from
information "Regeneration for service" menu.
1) Start engine.
2) Make sure that machine is in safe condition.
3) From service menu of machine monitor, display "Diagnostic Tests" screen and open "02
• If KDOC efficiency remains at low level, this failure code [CA2637] is displayed
repeatedly and then failure code [CA1691] Regeneration Ineffective may be displayed.
[How to clear failure code]
• Start engine, perform warm-up operation, and then run engine normally for about 3 hours.
(If exhaust temperature is high, time before clearing failure code is shortened.)
1 Defective KVGT If failure code [CA238*] is displayed, perform troubleshooting for it first.
Defective EGR If failure code [CA227*] or [CA23**] is displayed simultaneously, perform
2 troubleshooting for first.
valve
Malfunction of 1. Remove turbocharger exhaust connector.

3 turbocharger 2. Check inside of turbocharger exhaust connector for adhesion of oil and fuel.
exhaust connector • If adhesion is recognized, perform troubleshooting failure codes [CA227*] and
[CA23**] that relate to EGR valve and KVGT .
Exhaust connector Inspect exhaust system between turbocharger and KDPF, and also check
4 and duct to KDPF connector and duct for damage and wear.
error
• If excessive black smokes are emitted during running at high idle, perform
Defective exhaust
5 troubleshooting for "S-9 KDPF is plugged soon."
gas color
a It does not matter that powders of black smokes are emitted at engine
acceleration if they are not emitted during engine running at high idle.
40-308 PC290LC-10
40 Troubleshooting

1. Remove KDPF.
2. Remove KDOC.
Malfunction of • Check KDOC for cracks (replace KDOC, if they are found).
6 • Check KDOC to determine whether 50% or more of its inlet surface is
KDOC
plugged with soot (clean KDOC).
a When you have replaced KDOC, perform troubleshooting for causes 7 and 8.
1. Install KDOC and KDPF.
3. From service screen of machine monitor, display "Diagnostic Tests" screen and
Reset procedure open "03 KDPF Memory Reset" to execute "03 KDOC Change (reset
7 for KDOC Change procedure for KDOC Change)".
a Check that reset procedure for KDOC Change successfully completed (number
of resets). If not try troubleshooting again.
1. Perform manual stationary regeneration two times from "Regeneration for
service" menu(see relevant information).
• When perform consecutive 'regeneration for service', stop engine once.
• When failure code [CA2637] KDOC Face Plugging is displayed after
'regeneration for service' is performed.
Execution of Replace KDOC since efficiency of KDOC is degraded.
manual stationary
8 regeneration • While manual stationary regeneration is continued, failure code [CA2639] is
displayed on machine monitor, but it does not mean any trouble (manual
(To dry KCSF) stationary regeneration is completed in about 40 minutes and failure code
[CA2639] disappears at the same time).
[CA2639].
a Perform work for about 3 hours, and then check that this code is not displayed.
PC290LC-10 40-309
40 Troubleshooting
Failure code [CA2639] Manual Stationary Regeneration Request

Action Manual stationary regeneration request
Failure code
level Failure
L01 CA2639
Manual Stationary Regeneration Request asks user to execute "manual stationary
regeneration" that can eliminate soot more efficiently since soot load in KCSF of KDPF
Details of exceeds level that allows for automatic regeneration.
failure • Soot load is at level 4 or 5.
• It does not matter that this failure code appears on machine monitor as long as manual
stationary regeneration is continued.
Action of • Continues engine normally.
controller
Problem on
• No
machine
a If KDOC inlet temperature remains at about 250°C or below after manual stationary
regeneration is started by controller, fuel dosing is stopped. Thus, regeneration is
essentially not started.
• KVGT solenoid current can be checked with monitoring function (Code: .48800 (mA)).
• KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature at idle
are all about 100 to 250°C. Temperature difference among them is about 10°C (KDOC
Related inlet temperature > KDOC outlet temperature > KDPF outlet temperature).
information • During active regeneration (manual stationary regeneration), KDOC inlet temperature is
characters on KDPF temperature sensor consolidating box (same applies to connector
• - Manual stationary regeneration implementation procedure
1. Start engine.
2. Check that machine is in safe condition.
3. From service menu of machine monitor, display "Diagnostic Tests" screen and open "02
a Duration of manual stationary regeneration depends on soot load in KCSF. Duration is
roughly as shown below.
• When soot load is level 4: About 40 minutes to 1 hour
• When soot load is level 5: About 1 to 2 hours
a If soot load reaches level 6 or 7, failure code [CA1921] is generated.
a If soot load reaches level 8, failure code [CA1922] is generated.
a If this failure code remains on machine monitor for hours after manual stationary
regeneration is completed, perform following troubleshooting.
40-310 PC290LC-10
40 Troubleshooting
a If another failure code is displayed (including while manual stationary regeneration is

taking place), perform troubleshooting for it first.
• If noticeable difference is recognized between KDOC inlet temperature and
Defective KDOC KDOC outlet temperature or KDPF outlet temperature when KDPF is
1 inlet temperature sufficiently cooled or engine is running at idle (non-regeneration), replace the
sensor KDOC inlet temperature sensor.
If KDOC inlet temperature is below about 250°C and KVGT solenoid current is
2 Defective KVGT. kept at about 1,000 mA for many hours during manual stationary regeneration,
KVGT is defective.
Defective KDPF 1. Perform troubleshooting for "S-22" of S-mode.
3 (KDOC, KCSF) 2. Remove KDOC and KCSF in KDPF and clean KDOC and KCSF.
a Perform this troubleshooting when failure code [CA2639] is displayed after
manual stationary regeneration.
Defective exhaust • If black smokes are emitted at engine acceleration or during running engine
4 gas color high idle, perform troubleshooting for "S-9 KDPF is plugged soon."
a It does not matter that powders of black smokes are emitted at engine
acceleration if they are not emitted during running engine at high idle.
a Check that the failure code is not displayed.
5
performed.)
PC290LC-10 40-311
40 Troubleshooting
Failure code [CA2961] EGR Orifice Temp High Error 1

Action EGR orifice temperature high error 1
Failure code
level Failure
L03 CA2961
Details of • Output signals from the EGR temperature sensor exceeds upper temperature control limit
failure and indicates a value out of normal range.
controller
machine
• Signal voltage of EGR orifice temperature sensor can be checked with monitoring
function.
(Code: 48501 (V)
Related • Temperature sensed by the EGR orifice temperature sensor can be checked with
(Code: 48500 (°C))
• This failure code is displayed if the sensor connector is disconnected.
Defect in related If another failure code is indicated, carry out troubleshooting for it.
1 system
EGR gas EGR gas temperature may be abnormally high. Perform troubleshooting.
2 temperature rise
Defective EGR EGR orifice temperature sensor system may be defective. Carry out
3 orifice temperature troubleshooting for failure codes [CA2375] and [CA2376].
sensor
40-312 PC290LC-10
40 Troubleshooting
Failure code [CA2973] Chg Air Press Sensor In Range Error

Action Charge pressure sensor in-range error
Failure code
level Failure
L03 CA2973
Details of • Charge pressure (boost pressure) sensor output value displayed is out of normal range.
failure
• Fixes charge pressure (boost pressure) to a calculated value and continues operation.
controller • Limits engine output and allows engine to run
• Disables KDPF of its regeneration control.
machine
• Signal of charge pressure (boost pressure) sensor can be checked by using monitoring
function.
(Code: 36501 (V))
Related • Pressure sensed by the charge pressure (boost pressure) sensor can be checked by
information using monitoring function.
(Code: 36500 (MPa)
Defective charge Charge pressure sensor system may be defective. Carry out troubleshooting for
1 pressure sensor failure codes [CA122] and [CA123].
PC290LC-10 40-313
40 Troubleshooting
Failure code [CA3133] KDPF Outlet Press Sens High Error

Action KDPF outlet pressure sensor high error
Failure code
level Failure
L03 CA3133
Details of • High voltage error has occurred in the KDPF outlet pressure sensor signal circuit.
failure
• Sets KDPF outlet pressure to a recommended value (gauge pressure) and continues
Action of operation.
controller (If another failure code is also displayed, the machine may be operated at 0 kPa {0 kg/
cm2} (gauge pressure).)
Problem on
machine
k Since the temperature of the KDPF and KDOC will become higher than 500°C, take
care not to get burn injury.
• The outlet pressure sensor and KDPF outlet pressure sensor are integrated.
Related • If failure code [CA1695] is not displayed but failure code [CA1879] is displayed, an open
information circuit (poor connection in connector) is suspected in the GND line.
• Signal voltage from the KDPF outlet pressure sensor can be checked by using monitoring
function. (Code: 3004(V))
• Outlet pressure sensed by the KDPF outlet pressure sensor can be checked by using
monitoring function. (Code: 3003 (MPa))
harness connector
Defective sensor If failure code [CA1695] or [CA1696] is displayed, carry out troubleshooting for it
Defective sensor 2. Disconnect connector E25 and connect T-adapter to female side.
3 power supply line 3. Starting switch: ON
Voltage Between E25 (female) (4) and (1) 4.75 - 5.25 V
Defective KDPF
4 outlet pressure If failure code changes to [CA3134], KDPF outlet pressure sensor is defective.
sensor a If this failure code is still displayed, the wiring harness or engine controller is
defective.
connector)
Between CE03 (female) (43) and E25 10 z Max.
40-314 PC290LC-10
40 Troubleshooting

2. Disconnect connectors CE03 and E25, and connect T-adapter to female side
Continuity
7
performed.)
Circuit diagram related to KDPF outlet pressure sensor
PC290LC-10 40-315
40 Troubleshooting
Failure code [CA3134] KDPF Outlet Press Sens Low Error

Action KDPF outlet pressure sensor low error
Failure code
level Failure
L03 CA3134
Details of • Low voltage error has occurred in the KDPF outlet pressure sensor signal circuit.
failure
Action of operation (operates at 0 kPa {0 kg/cm2} (gauge pressure) if other failure codes are
controller generated at the same time).
Problem on
machine
• The KDPF outlet pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1696] is not displayed but failure code [CA1881] is displayed, the
Related sensor connector may be disconnected or an open circuit (poor connection in connector)
information is suspected in the 5 V line.
• Outlet pressure sensed by the KDPF outlet pressure sensor can be checked by using
monitoring function. (Code: 3003 (MPa))
harness connector
side.
a If no failure is found by checks cause
Open circuit in 2, this check is not required. 10 z Max.
connector) Resistance a If no failure is found by checks cause
2, this check is not required. 10 z Max.
(female) (4)

wiring harness 2. Disconnect connectors CE03 and E25, and connect T-adapter to either female
5 (contact with GND side.
circuit) Between CE03 (female) (58) or E25 Min. 100 kz
Resistance (female) (3) and ground
40-316 PC290LC-10
40 Troubleshooting

Continuity
Defective KDPF 2. Insert T-adapter into connector E25.
7 outlet pressure 3. Starting switch: ON
sensor
Voltage Between E25 (3) and (1) 0.5 - 4.5 V
8
performed.)
PC290LC-10 40-317
40 Troubleshooting
Failure code [CA3135] KDPF Outlet Press Sens In Range Error

Action KDPF outlet pressure sensor in-range error
Failure code
level Failure
L03 CA3135
Details of • Signals from KDPF outlet pressure sensor indicate a value higher than normal (signal
failure voltage is within noraml range).
Action of operation.
controller (If another failure code is also displayed, the machine may be operated at 0 kPa {0 kg/
cm2} (gauge pressure).)
Problem on
machine
• The KDPF delta sensor and KDPF outlet pressure sensor are integrated.
Related • Differential pressure sensed by the KDPF outlet pressure sensor can be checked by
information using monitoring function. (Code: 3003 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position (observe for one
minute).
[Clearing failure codes]
1. Start the engine (from stopped state).
2. When warm-up operation is complete, set fuel dial to Full and put the work equipment
pump in relief condition for 30 seconds.
Repeat step 1 and 2 several times. If this failure code is cleared, repair is complete.
1.Remove the KDPF delta pressure sensor tube.
2.Clean the KDPF delta pressure sensor tube and remove any clogging.
3.Check the KDPF delta pressure sensor tube for cracks and damages.
4.Install the KDPF delta pressure sensor tube by securely connecting both ends
of the tube.
Defective KDPF • Reference
1 delta pressure Check the KDPF delta pressure sensor tube for clogging.
sensor tube 1. Starting switch: ON
2. Monitor the outlet pressure sensed by the KDPF outlet pressure sensor on
the monitoring screen of the machine monitor.
• Code: 3003 (MPa)
Differential
0 ± 0.0015 (MPa)
pressure
2
40-318 PC290LC-10
40 Troubleshooting

Defective wiring
5 harness or engine If failure code [CA3134] is not displayed, the wiring harness or engine controller is
a Carry out troubleshooting for cause 2 again.
2. Disconnect connector E25 and connect a short connector to female side.
a Connect a source of 5 V to signal line (connect E25 pins (4) and (2) with a
Defective wiring jumper wire).
6 harness or engine 3. Starting switch: ON
controller If failure code [CA3133] is not displayed, the wiring harness or engine controller is
defective.
a Perform troubleshooting for cause 2 again.
Defective KDPF
7 a If no failure is found by check on checks on cause 5, KDPF delta pressure
delta pressure
sensor
side.
a If no failure is found by checks on
Open circuit in cause 3, this check is not required. 10 z Max.
wiring harness Between CE03 (female) (43) and
8 (wire breakage or E25 (female) (1)
connector) Resistance a If no failure is found by checks on
cause 3, this check is not required. 10 z Max.
Between CE03 (female) (52) and
E25 (female) (4)

wiring harness 2. Disconnect connectors CE03 and E25, and connect T-adapter to either female
9 (contact with GND side.
circuit) Between CE03 (female) (58) or E25
Resistance (female) (3) and ground Min. 100 kz

10 wiring harness
Continuity
Defective engine
11 information".
controller
a If this failure code is still displayed, even after [Clearing failure codes] in "Related information" is carried
out, redo troubleshooting.
PC290LC-10 40-319
40 Troubleshooting
40-320 PC290LC-10
40 Troubleshooting
Failure code [CA3251] DOC Inlet Temp High Error

Action KDOC inlet temperature high error
Failure code
level Failure
L03 CA3251
Details of • The KDOC inlet temperature is continuously high.
failure
controller • A default value (250°C) is is substituted for the KDOC inlet temperature.
machine
• Signal voltage from the KDOC inlet temperature sensor can be checked by using
monitoring function. (Code: 47301(V))
• Temperature sensed by the KDOC inlet temperature sensor can be checked by using
• Signal voltage from the KDOC outlet temperature sensor can be checked by using
• Temperature sensed by the KDOC outlet temperature sensor can be checked by using
• Signal voltage from the KDPF outlet temperature sensor can be checked by using
Related monitoring function. (Code: 47201(V))
information • Temperature sensed by the KDPF outlet temperature sensor can be checked by using
• The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature at
idle (not regenerating) will all be approx. 100– 250°C and the difference between these
temperatures will be approx. 10°C (KDOC inlet temperature > KDOC outlet temperature >
KDPF outlet temperature).
• If misfire occurs at the injector,
1) the combustion is impaired causing high exhaust temperature.
2) When there is a problem in any of the cylinders, fuel injection at other cylinders may be
increased to compensate for the torque drop, causing high exhaust temperature.
• Start the engine and run at low idle for approximately 10 minutes.
• If an error code is displayed, run the engine at high idle for two more minutes.
harness connector
sensor
2. Disconnect connectors CE03 and TEMP1 (KDOC intlet temperature sensor),
and connect T-adapter to female side of connector CE03.
Short circuit in
No continuity
Continuity (No sound is heard)
other pin
PC290LC-10 40-321
40 Troubleshooting

2. Display the signal voltage and temperature of the KDOC inlet temperature
sensor, KDOC outlet temperature sensor, and KDPF outlet temperature sensor
by using the monitoring function.
3. Run the engine at idle for 10 minutes.
4. Note down the temperature values (confirm that they are at normal
Defective KDOC temperatures)
4 inlet temperature 5. Monitor the temperature of each sensor.
sensor If any of the temperature sensor values has changed for more than 24°C, the
temperature sensor is considered to be defective.
a If none of the temperature sensor values has changed for more than 24°C, the
problem is not in the sensors.“Perform troubleshooting for cause 5“ and after.
a If another failure code is displayed during idling, carry out troubleshooting for it
first.
Abnormality in Check the intake system hoses, clamps, and tubes for damages and loosening.
5 intake system Repair as necessary (repair air leaks).
There is a cylinder that causes no speed change when operated in cylinder cut-out
6 Defective injector
test mode. (See Testing and adjusting “Cylinder cut-out test mode“.)
1. Remove turbocharger exhaust connector.
2. Check for oil or fuel inside the turbocharger exhaust connector.
• If oil or fuel is found, visually check for oil leaks from the turbocharger. Repair if
Oil leakage from any abnormality is found.
7 turbocharger
a Wipe off oil and fuel from the piping.
a If a trace of oil or fuel leakage into the KDPF is found, check the KDPF. Clean
or replace as necessary.
Check the exhaust system between the turbocharger and exhaust manifold for oil
leaks or fuel leaks.
Oil leakage from • Wipe off oil or fuel if found.
8
EGR valve
2. If this failure code is displayed, carry out [Clearing failure codes] in "Related
Defective engine information".
9
controller If this failure code is still displayed and no problem is found by above checks,
40-322 PC290LC-10
40 Troubleshooting
Circuit diagram related to KDOC and KDPF temperature sensor
PC290LC-10 40-323
40 Troubleshooting
Failure code [CA3253] KDOC Temp Error - Non Regeneration

Action KDOC temperature error - Non regeneration
Failure code
level Failure
L03 CA3253
Details of • KDOC outlet temperature is maintained at a high level while active regeneration is not
failure executed.
• Regards KDOC outlet temperature as a default value (250°C).
machine
k Exercise care not to burn yourself since KDPF and KDOC are heated to 500°C or
above.
• Signal voltage from KDOC inlet temperature sensor can be checked using monitoring
• Temperature sensed by KDOC inlet temperature sensor can be checked using monitoring
• Signal voltage from KDOC outlet temperature sensor can be checked using monitoring
• Temperature sensed by KDOC outlet temperature sensor can be checked using
monitoring function (Code: 47400(°C)).
Related • Signal voltage from KDPF outlet temperature sensor can be checked using monitoring
information function (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked using
monitoring function (Code: 47200(°C)).
• Misfire on injector can induce the following phenomena.
1) Increase in exhaust gas temperature due to degraded combustion.
2) KDOC inlet temperature high error due to relative increase in engine exhaust gas
temperature that results when other cylinders try to compensate shortfall in torque of the
failed cylinder by increasing volume of fuel injection.
[How to clear the failure code]
• Starts the engine and runs it at low idle for approximately 10 minutes.
• If display of the failure code remains, the controller runs the engine further for three
minutes at high idle.
Defective KDOC Perform troubleshooting for cause 5 of failure code [CA3251].
1 inlet temperature
sensor
Defective KDOC Perform troubleshooting for cause 5 of failure code [CA3254].
2 outlet temperature
sensor
1. Remove the KDPF.
2. Remove the KDOC.
• Check for cracks in the KDOC (replace KDOC if cracks are found).
Malfunction of a When the KDOC of KDPF is changed, always perform the resetting procedure
3 for KDOC change, and then perform manual stationary regeneration from
KDOC
"Regeneration for service" to eliminate moist from the KDOC. (See
troubleshooting for failure code [CA2637], causes 7 and 8.)
• Check if more than 50% of the KDOC inlet face is plugged with soot or not.
(KDOC cleaning)
4
40-324 PC290LC-10
40 Troubleshooting
Failure code [CA3254] KDOC Outlet Temp High Error 1

Action KDOC outlet temperature high error 1
Failure code
level Failure
L01 CA3254
Details of • The KDOC outlet temperature is continuously high.
failure
Action of
controller
Problem on
machine
• The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature at
idle (not regenerating) will all be approx. 100– 250°C and the difference between these
temperatures will be approx. 10°C (KDOC inlet temperature > KDOC outlet temperature >
KDPF outlet temperature).
• If misfire occurs at the injector,
1) the combustion is impaired causing high exhaust temperature.
2) When there is a problem in any of the cylinders, fuel injection at other cylinders may be
increased to compensate for the torque drop, causing high exhaust temperature.
• If an error code is displayed, run the engine at high idle for two more minutes.
harness connector
sensor
2. Disconnect connectors CE03 and TEMP2 (KDOC outlet temperature sensor),
and connect T-adapter to female side of connector CE03.
Short circuit in
No continuity
other pin
PC290LC-10 40-325
40 Troubleshooting

Defective KDOC temperatures)
4 outlet temperature 5. Monitor the temperature of each sensor.
first.
6 Defective injector
test mode. (See Testing and adjusting “Cylinder cut-out test mode“.)
7 turbocharger
8
EGR valve
1. Remove the KDPF.
2. Remove the KDOC.
KDOC
(KDOC cleaning)
10
40-326 PC290LC-10
40 Troubleshooting
PC290LC-10 40-327
40 Troubleshooting
Failure code [CA3255] KDPF Temp Error - Non Regeneration

Action KDPF temperature error in non regeneration state
Failure code
level Failure
L03 CA3255
Details of • The KDPF outlet temperature is continuously extremely high when active regeneration is
failure not performed.
machine
Related
information • Method of reproducing failure code: Starting switch: ON
• If a failure code is displayed, run the engine at high idle for three more minutes.
1 KDPF system error Carry out troubleshooting for failure code [CA3312].
40-328 PC290LC-10
40 Troubleshooting
Failure code [CA3256] KDPF Outlet Temp High Error 1

Action KDPF outlet temperature high error 1
Failure code
level Failure
L01 CA3256
Details of • The KDPF outlet temperature is continuously high.
failure
Action of
controller
Problem on
machine
Related
information • Method of reproducing failure code: Starting switch: ON
• Start the engine and run at low idle for approximately 1 minute.
Defective KDPF Carry out troubleshooting for failure code [CA3312].
1 system
PC290LC-10 40-329
40 Troubleshooting
Failure code [CA3311] KDOC Outlet Temp High Error 2

Action KDOC outlet temperature high error 2
Failure code
level Failure
L03 CA3311
Details of • The KDOC outlet temperature compared to the KDOC inlet temperature is continuously
failure extremely high.
machine
Related care not to get burn injury.
information
1 KDOC system error Carry out troubleshooting for failure code [CA3254].
40-330 PC290LC-10
40 Troubleshooting
Failure code [CA3312] KDPF Outlet Temp High Error 2

Action KDPF outlet temperature high error 2
Failure code
level Failure
L03 CA3312
Details of • The KDPF outlet temperature is continuously extremely high.
failure
machine
k Since the temperature of the KDOC and KDPF will become higher than 500°C, take
information • Temperature sensed by the KDOC inlet temperature sensor can be checked by using
harness connector
If this failure code does not appear, the harness connector is defective.
Defective KDPF If failure code [CA3319], [CA3321], or [CA3322] is displayed, carry out
sensor
2. Disconnect connectors CE03 and TEMP3 (KDOC outlet temperature sensor),
Short circuit in and connect T-adapter to female side of connector CE03.
Continuity
Defective KDPF temperatures)
4 outlet temperature 5. Monitor the temperature of each sensor.
first.
6 Defective injector test mode. (See Testing and adjusting “Cylinder cut-out test mode“.)
PC290LC-10 40-331
40 Troubleshooting

7 turbocharger
8
EGR valve
1. Remove the KDPF.
2. Remove the KDOC.
KDOC
(KDOC cleaning)
10
40-332 PC290LC-10
40 Troubleshooting
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error

Action KDOC inlet temperature sensor low error
Failure code
level Failure
L03 CA3313
Details of • Low voltage has appeared in the KDOC inlet temperature sensor circuit.
failure
• KDOC outlet temperature is substituted for KDOC inlet temperature to continue
operation.
(If the KDOC outlet temperature sensor is also abnormal, the default value (250°C) is
Action of taken as KDOC inlet temperature to continue operation.)
• Limits engine output and allows engine to run
machine
Related • Signal voltage from the KDPF outlet temperature sensor can be checked by using
information monitoring function. (Code: 47201(V))
• Temperature sensed by the KDPF outlet temperature sensor can be checked by using
• If the sensor connector is disconnected or an open circuit occurs, this failure code is not
generated but failure code [CA3314] for "High Error" is generated.
• The KDOC inlet temperature sensor connecter label "TEMP1" is indicated on the KDPF
temperature sensor integrated box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
Since there is a possibility of error occurring during operation, start the engine and run at low
idle for approximately one minute. If this failure code is cleared, repair is complete.
troubleshooting", and check them.
Defective wiring 2. Starting switch: ON
1
harness connector If this failure code does not appear, the wiring harness connector is defective.
PC290LC-10 40-333
40 Troubleshooting

2. Disconnect TEMP1 (KDOC inlet temperature sensor).
If this failure code changes to [CA3314], KDOC inlet temperature sensor is
defective.
a If this failure code is still displayed, the wiring harness or engine controller is
defective.
• Reference
Defective KDOC 1. Starting switch: OFF
2 inlet temperature 2. Disconnect connector TEMP1 and connect T-adapter to female side.
sensor -10 °C 33 – 65 k z
0 °C 25 – 47 k z
Between TEMP1 50 °C 7.8 – 12.2 k z
(female) (1) and (2) 100 °C 3.2 – 4.5 k z
Resistance 400 °C 200 - 240 z
700 °C 64 - 69 z
Between TEMP1
(female) (1) and Whole range Min. 100 kz
ground
wiring harness 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to either
(contact with female side of CE03 or male side of TEMP1.
ground circuit)
3
(including inside of Between CE03 (female) (45) or TEMP1
KDPF temperature Resistance (male) (1) and ground Min. 100 kz
sensors integrated
box)
wiring harness 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to female
side of connector CE03.
4 (including inside of
KDPF temperature a Check by using multimeter in continuity mode.
sensors integrated Between CE03 (female) (45) and each No continuity
box) Continuity
required.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
KDPF temperature
a If no failure is found by check cause
5 sensors integrated
3, this check is not required. Min. 100 kz
box abnormal
Between E26 (male) (3) and ground
Resistance
4, this check is not required.
Min. 100 kz
Between E26 (male) (3) and each
other pin
Ground fault in
wiring harness
6 2. Disconnect connectors CE03 and E26, and connect T-adapter to either female
(contact with side.
ground circuit) Between CE03 (female) (45) or E26 Min. 100 kz
40-334 PC290LC-10
40 Troubleshooting

7 wiring harness
Continuity
8
PC290LC-10 40-335
40 Troubleshooting
Failure code [CA3314] KDOC Inlet Temp Sens High Error

Action KDOC inlet temperature sensor high error
Failure code
level Failure
L03 CA3314
Details of • High voltage has appeared in the KDOC inlet temperature sensor circuit.
failure
operation.
machine
• If failure codes [CA3317] and [CA3319] are also displayed, the KDPF temperature
sensors integrated box connector is disconnected, or an open circuit (poor connection in
connector) is suspected in the GND line.
"TEMP3").
1
harness connector If this failure code does not appear, the wiring harness connector is defective.
40-336 PC290LC-10
40 Troubleshooting

2. Disconnect KDOC inlet temperature sensor (connectorTEMP1) and connect T-
adapter to male side.
3. Connect T-box to T-adapter and connect T-box pins (1) and (2) using a jumper
wire.
a Connect signal wire to ground.
If this failure code changes to [CA3313], KDOC inlet temperature sensor is
defective.
Defective KDOC
2 inlet temperature a If this failure code is still displayed, the wiring harness or engine controller is
sensor defective.
• Reference
2. Disconnect connector TEMP1 and connect T-adapter to female side.
-10 °C 33 – 65 k z
0 °C 25 – 47 k z
Resistance (female) (1) and (2) 100 °C 3.2 – 4.5 k z
400 °C 200 – 240 z
700 °C 64 – 69 z
circuit in wiring 2. Disconnect connector CE03, and connect T-adapter to female side.
harness
Between CE03 (female) (45) and (19)
KDPF temperature Resistance a Resistance accords with value in the 64 z - 65 kz
sensors integrated above Temperature-Resistance
box) characteristics table.
Open circuit in
wiring harness
system 1. Starting switch: OFF
2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to female
(wire breakage or
side of CE03 and male side of TEMP1.
4 connector) Between CE03 (female) (45) and
TEMP1 (male) (1) 10 z Max.
(including inside of
KDPF temperature Resistance
sensors integrated TEMP1 (male) (2) 10 z Max.
box)
Short circuit in 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to female
wiring harness side of connector CE03.
sensors integrated No continuity
box) Continuity (No sound is heard)
other pin
PC290LC-10 40-337
40 Troubleshooting

a If no abnormality is found in checks on causes 3 to 5, this check is not required.
3. Disconnect connectors TEMP1, TEMP2, TEMP3, and connect T-adapter to
male side of TEMP1.
a If no abnormality is found in checks
on causes 3 or 4, this check is not
required. 10 z Max.
KDPF temperature Between E26 (male) (2) and TEMP1
6 sensors integrated (female) (2)
box abnormal
Resistance on causes 3 or 4, this check is not
required. 10 z Max.
Between E26 (male) (3) and TEMP1
(female) (1)
Between E26 (male) (3) and each other
pin
a If no abnormality is found in checks on causes 3 or 4, this check is not required.
defective contact of Between CE03 (female) (45) and E26

8 wiring harness
Continuity
9
40-338 PC290LC-10
40 Troubleshooting
PC290LC-10 40-339
40 Troubleshooting
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error

Action KDOC inlet temperature sensor in-range error
Failure code
level Failure
L03 CA3315
Details of • Temperatures sensed by KDOC inlet temperature sensor and KDOC outlet temperature
failure sensor deviate from estimated values (signal voltages are in normal range).
operation.
machine
"TEMP3").
Defective KDOC If failure code [CA3313] or [CA3314] is displayed, carry out troubleshooting for it
1 inlet temperature first.
sensor
2
2. Disconnect TEMP1 (KDOC inlet temperature sensor).
40-340 PC290LC-10
40 Troubleshooting

2. Disconnect TEMP1 and connect T-adapter to male side.
wire.
Defective wiring
4 harness or engine a Connect signal wire to ground.
If failure code [CA3313] is not displayed, the wiring harness or engine controller is
defective.
a If no abnormality is found in checks on causes 3 and 4, KDOC inlet
temperature sensor is defective.
• Reference
Defective KDOC 2. Disconnect connectorTEMP1 and connect T-adapter to male side.
5 inlet temperature -10 °C 33 – 65k z
sensor 0 °C 25 – 47k z
Resistance (female) (1) and (2) 100 °C 3.2 – 4.5k z
400 °C 200 - 240 z
700 °C 64 - 69 z
harness
Open circuit in
wiring harness
(wire breakage or
box)
ground circuit)
8
sensors integrated
box)
9
other pin
PC290LC-10 40-341
40 Troubleshooting

male side of TEMP1.
required. 10 z Max.
(female) (2)
KDPF temperature
10 sensors integrated a If no abnormality is found in checks
box abnormal on causes 6 or 7, this check is not
required. 10 z Max.
Resistance Between E26 (male) (3) and TEMP1
(female) (1)
pin

Ground fault in Starting switch: OFF
wiring harness
12 Disconnect connectors CE03 and E26, and connect T-adapter to either female
(contact with side.
ground circuit) Between CE03 (female) (45) or E26

13 wiring harness
Continuity
1. Remove the KDPF.
Malfunction of 2. Remove the KDOC.
14 • Check for cracks in the KDOC (replace KDOC if cracks are found).
KDOC
• Check if more than 50% of the KDOC inlet face is plugged with soot or not
(KDOC cleaning).
15
40-342 PC290LC-10
40 Troubleshooting
PC290LC-10 40-343
40 Troubleshooting
Failure code [CA3316] KDOC Outlet Temp Sens Low Error

Action KDOC outlet temperature sensor error
Failure code
level Failure
L03 CA3316
Details of • Low voltage has appeared in the KDOC outlet temperature sensor circuit.
failure
• KDOC inlet temperature is substituted for KDOC outlet temperature to continue operation
(if the KDOC inlet temperature sensor is also abnormal, the default value (250°C) is taken
Action of as KDOC outlet temperature to continue operation.)
machine
"TEMP3").
1
harness connector
40-344 PC290LC-10
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).
If failure code changes to [CA3317], KDOC outlet temperature sensor is defective.
defective.
• Reference
Defective KDOC
outlet temperature -10 °C 33 – 65 k z
2
sensor Between TEMP2 0 °C 25 – 47 k z
(female) (1) and (2) 50 °C 7.8 – 12.2 k z
100 °C 3.2 – 4.5 k z
Between TEMP
Resistance (female) (1) and (2) 400 °C 200 - 240 z
Between TEMP2
(female) (1) and (2) 700 °C 64 - 69 z
Between TEMP2
(male) (1) and Whole range 100 kz
ground
ground circuit)
3
sensors integrated
box)
4
box) Continuity
required.
KDPF temperature
5 sensors integrated a If no failure is found by check cause
box abnormal 3, this check is not required. Min. 100 kz
Resistance
pin
PC290LC-10 40-345
40 Troubleshooting

Ground fault in
wiring harness
(contact with side.

7 wiring harness
Continuity
8
controller If this failure code is displayed and no problem is found by above checks, engine
controller is defective. (Since this is an internal defect, troubleshooting cannot be
performed.)
40-346 PC290LC-10
40 Troubleshooting
Failure code [CA3317] KDOC Outlet Temp Sens High Error

Action KDOC outlet temperature sensor high error
Failure code
level Failure
L03 CA3317
Details of • High voltage has appeared in the KDOC outlet temperature sensor circuit.
failure
• KDOC inlet temperature is substituted for KDOC outlet temperature to continue
operation.
(If the KDOC inlet temperature sensor is also abnormal, the default value (250°C) is taken
machine
"TEMP3").
1
harness connector
PC290LC-10 40-347
40 Troubleshooting

2. Disconnect KDOC outlet temperature sensor (connectorTEMP2) and connect
T-adapter to female side.
wire.
If failure code changes to [CA3316], KDOC outlet temperature sensor is defective.
Defective KDOC a If this failure code is still displayed, the wiring harness or engine controller is
2 outlet temperature defective.
sensor • Reference
-10 °C 33 – 65 kz
0 °C 25 – 47 kz
Between TEMP2 50 °C 7.8 – 12.2 kz
Resistance (female) (1) and (2) 100 °C 3.2 – 4.5 kz
400 °C 200 - 240 z
700 °C 64 - 69 z
harness
Open circuit in
wiring harness
(wire breakage or
box)
other pin
40-348 PC290LC-10
40 Troubleshooting

male side of TEMP2.
required. 10 z Max.
6 sensors integrated (male) (2)
box abnormal
required. 10 z Max.
(male) (1)
5, this check is not required. Min. 1 Mz
pin

8 wiring harness
Continuity
9
performed.)
PC290LC-10 40-349
40 Troubleshooting
40-350 PC290LC-10
40 Troubleshooting
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error

Action KDOC outlet temperature sensor in-range error
Failure code
level Failure
L03 CA3318
Details of • Temperatures sensed by KDOC outlet temperature sensor and KDOC inlet temperature
failure sensor deviate from estimated values.
• KDOC inlet temperature is substituted for KDOC outlet temperature to continue
operation.
(If the KDOC inlet temperature sensor is also abnormal, the default value (250°C) is taken
machine
"TEMP3").
Defective KDOC If failure code [CA3316] or [CA3317] is displayed, carry out troubleshooting for it
1 outlet temperature first.
sensor
harness connector
2. Disconnect TEMP2 (KDOC outlet temperature sensor).
PC290LC-10 40-351
40 Troubleshooting

2. Disconnect TEMP2 and connect T-adapter to male side.
wire.
Defective wiring
4 harness or engine a Connect signal wire to ground.
defective.
a If no abnormality is found in checks on cause 3, KDOC outlet temperature
• Reference
Defective KDOC 2. Disconnect connector TEMP2 and connect T-adapter to female side.
5 outlet temperature -10 °C 33 – 65 kz
sensor 0 °C 25 – 47 kz
400 °C 200 - 240 z
700 °C 64 - 69 z
harness
Open circuit in
wiring harness
(wire breakage or
box)
ground circuit)
8
(including inside of Between CE03 (female) (48) or TEMP2 Min. 100 kz
KDPF temperature Resistance (male) (1) and ground
sensors integrated
box)
40-352 PC290LC-10
40 Troubleshooting

9
box) Continuity
male side of TEMP2.
required. 10 z Max.
(male) (2)
KDPF temperature
required. 10 z Max.
(male) (1)
pin

Ground fault in
wiring harness
(contact with side.

13 wiring harness
No continuity
other pin
PC290LC-10 40-353
40 Troubleshooting

1. Remove the KDPF.
Malfunction of 2. Remove the KDOC.
14 • Check for cracks in the KDOC (replace KDOC if cracks are found).
KDOC
• Check if more than 50% of the KDOC inlet face is plugged with soot or not
(KDOC cleaning).
15
performed.)
40-354 PC290LC-10
40 Troubleshooting
Failure code [CA3319] KDPF Outlet Temp Sens High Error

Action KDPF outlet temperature sensor high error
Failure code
level Failure
L03 CA3319
Details of • High voltage has appeared in the KDPF outlet temperature sensor circuit.
failure
• KDOC outlet temperature is substituted for KDPF outlet temperature to continue
operation.
Action of taken as KDPF outlet temperature to continue operation.)
machine
"TEMP3").
1
harness connector
PC290LC-10 40-355
40 Troubleshooting

2. Disconnect KDPF outlet temperature sensor (connectorTEMP3) and connect
T-adapter to male side.
wire.
If failure code changes to [CA3321], KDPF outlet temperature sensor is defective.
Defective KDPF a If this failure code is still displayed, the wiring harness or engine controller is
2 outlet temperature defective.
sensor • Reference
-10 °C 33 – 65 kz
0 °C 25 – 47 kz
400 °C 200 - 240 z
700 °C 64 - 69 z
harness
Open circuit in
wiring harness
(wire breakage or
box)
other pin
40-356 PC290LC-10
40 Troubleshooting

male side of TEMP3.
required. 10 z Max.
6 sensors integrated (male) (2)
box abnormal
required. 10 z Max.
(male) (1)
pin

8 wiring harness
Continuity
9
performed.)
PC290LC-10 40-357
40 Troubleshooting
40-358 PC290LC-10
40 Troubleshooting
Failure code [CA3321] KDPF Outlet Temp Sens Low Error

Action KDPF outlet temperature sensor low error
Failure code
level Failure
L03 CA3321
Details of • Low voltage has appeared in the KDPF outlet temperature sensor circuit.
failure
operation.
Action of taken as KDPF outlet temperature to continue operation.)
machine
"TEMP3").
1
harness connector
PC290LC-10 40-359
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).
If failure code changes to [CA3319], KDPF outlet temperature sensor is defective.
defective.
• Reference
Defective KDPF 2. Disconnect connector TEMP3 and connect T-adapter to female side.
2 outlet temperature
sensor -10 °C 33 – 65 kz
0 °C 25 – 47 kz
(female) (1) and (2) 100 °C 3.2 – 4.5 kz
Resistance 400 °C 200 - 240 z
700 °C 64 - 69 z
Between TEMP3
(female) (1) and Whole range Min. 1 Mz
ground
ground circuit)
3
KDPF temperature Resistance (male) (1) and ground Min. 1 Mz
sensors integrated
box)
4
box) Continuity
required.
KDPF temperature
5 sensors integrated a If no failure is found by check cause
box abnormal 3, this check is not required. Min. 1 Mz
Resistance
pin
Ground fault in
wiring harness
(contact with side.
ground circuit) Between CE03 (female) (54) or E26 Min. 1 Mz
40-360 PC290LC-10
40 Troubleshooting

7 wiring harness
Continuity
8
performed.)
PC290LC-10 40-361
40 Troubleshooting
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error

Action KDPF outlet temperature sensor in-range error
Failure code
level Failure
L03 CA3322
Details of • Temperatures sensed by KDPF outlet temperature sensor deviate from estimated values.
failure
operation (if the KDOC outlet temperature sensor is also abnormal, the default value
Action of (250°C) is taken as KDPF outlet temperature to continue operation.)
machine
Related
information • Signal voltage from the KDPF outlet temperature sensor can be checked by using
"TEMP3").
Since there is a possibility of error occurring during operation, start the engine and run at high
idle for 15 minutes. If this failure code is cleared, repair is complete.
Defective KDPF If failure code [CA3319] or [CA3321] is displayed, carry out troubleshooting for it
1 outlet temperature first.
sensor
2
harness connector
40-362 PC290LC-10
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).
If failure code [CA3319] is not displayed, the harness or engine controller is
defective.
Defective harness 1. Starting switch: OFF

3 or engine controller 2. Disconnect TEMP3 and connect T-adapter to female side.
wire.
defective.
a If no abnormality is found in checks on cause 3, KDPF outlet temperature
• Reference
Defective KDPF 2. Disconnect connector TEMP3 and connect T-adapter to female side.
4 outlet temperature -10 °C 33 – 65 kz
sensor 0 °C 25 – 47 kz
400 °C 200 - 240 z
700 °C 64 - 69 z
harness
Open circuit in
wiring harness
(wire breakage or
box)
ground circuit)
7
(including inside of Between CE03 (female) (54) or TEMP3 Min. 1 Mz
KDPF temperature Resistance (male) (1) and ground
sensors integrated
box)
PC290LC-10 40-363
40 Troubleshooting

8
box) Continuity
male side of TEMP3.
required. 10 z Max.
(male) (2)
KDPF temperature
required. 10 z Max.
(male) (1)
pin

Ground fault in
wiring harness
(contact with side.

12 wiring harness
Continuity
13
performed.)
40-364 PC290LC-10
40 Troubleshooting
PC290LC-10 40-365
40 Troubleshooting
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Action Mass air flow sensor power high error
Failure code
level Failure
L03 CA3419
Details of • High voltage appears in mass air flow sensor power supply 1 (12 V) circuit.
failure
• Sets mass air flow to a fixed value (10 kg/min) and continues operation.
machine
information
1
2. Disconnect connector P55.
Defective sensor 3. Starting switch: ON
2 If this failure code does not appear, the mass air flow sensor is defective.
(internal defect)
a Other failure codes are displayed at the same time. This is because connector
is disconnected. Ignore failure codes other than this one.
3 If this failure code does not appear, the wiring harness is defective.
harness
2. Disconnect connector ECM J1 and connect T-adapter to male side.
Defective engine 3. Starting switch: ON
4
controller Voltage Between ECM J1 (male) (21) and (22) Approx. 12 V
40-366 PC290LC-10
40 Troubleshooting
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Action Mass air flow sensor power low error
Failure code
level Failure
L03 CA3421
Details of • Low voltage appears in mass air flow sensor power supply (12 V) circuit.
failure
• Sets mass air flow to a fixed value (10 kg/min) and continues operation.
machine
information
1
Defective sensor 3. Starting switch: ON
2 If this failure code does not appear, the mass air flow sensor is defective.
(internal defect)
Defective harness 3. Starting switch: ON
3 If this failure code does not appear, the wiring harness is defective.
or connector

wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
circuit) Between ECM J1 (female) (21) of P55
Resistance (female ) (2) and ground Min. 1 Mz

wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
5 (between wiring female side.
harnesses) Between ECM J1 (female) (21) and (22),
Resistance or between P55 (female) (2) and (3) Min. 1 Mz

2. Disconnect connector ECM J1 and connect T-adapter to male side.
Defective engine 3. Starting switch: ON
6
controller Voltage Between ECM J1 (male) (21) and (22) Approx. 12 V
PC290LC-10 40-367
40 Troubleshooting
40-368 PC290LC-10
40 Troubleshooting
Failure code [CA3741] Rail Press Valve Trip Error

Action Common rail pressure limiter valve open
Failure code
level Failure
L03 CA3741
Details of • Engine controller determined that the common rail pressure limiter has opened.
failure
Action of
controller
Problem on • Engine output drops or engine does not start in some cases.
machine
• Signal voltage from the common rail pressure sensor can be checked with monitoring
function.
(Code: 36401 (V))
Related • Pressure sensed by the common rail pressure sensor can be checked with monitoring
(Code: 36400 (MPa)
Common rail Carry out troubleshooting for failure Code [CA449].
1 pressure limiter
valve open
PC290LC-10 40-369
40 Troubleshooting
Failure code [D110KB] Battery Relay Output Voltage

Action Short circuit in battery relay output circuit
Failure code
level Failure
(Pump controller system)
L01 D110KB
Details of • Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
failure
• Stops 24 V output to battery relay primary circuit (coil side).
Problem on • Writing data into ROM (non-volatile memory) of each controller may fail.
machine
• As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
be measured at pump controller connector.
Related • Output state (ON/OFF) to battery relay can be checked with monitoring function.
information (Code: 03700 Controller output 1)
• Method of reproducing failure code: For 0.5 seconds after turning starting switch from ON
to OFF position.
Defective battery 1. Turn starting switch to OFF position.
relay
1
(internal open Continuity Between terminal RE and terminal BR Continuity
circuit)
2. Disconnect negative battery cable (in order to prevent short circuit).
3. Disconnect terminals R01 and R02, and connectors D01, H15 and CP02.
Ground fault in
Between terminal R02 (BR) and ground Min. 1 Mz
wiring harness
2 (contact with GND Between ground and terminal R02
circuit) (harness side), D01 (female) (1), or D01 Min. 1 Mz
Between ground and CP02 (female)
(108) or between D01 (female) (5) Min. 1 Mz
If no failure is found by above checks, pump controller is defective.
• Reference
Pump controller 2. Insert T-adapters into connector D01.
defective.
4. Measure voltage during 4 to 7 seconds after turning starting switch from ON to
OFF position
Voltage Between D01 (5) and ground 20 to 30 V
40-370 PC290LC-10
40 Troubleshooting
Circuit diagram related to battery relay
PC290LC-10 40-371
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality

Action Personal code relay malfunction
Failure code
level Failure
(KOMTRAX system in machine monitor)
L03 D19JKZ
Details of • Open circuit or short circuit is in primary (coil) circuit of personal code relay.
failure
• None in particular (for open circuit ).
• Stops output to personal code relay (for short circuit ).
Action of • If cause of failure disappears, machine becomes normal by itself (for open circuit ).
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (for short circuit ).
Problem on
machine
• This failure code is displayed only when engine lock function is enabled.
• Method of reproducing failure code: Turn starting switch to ON position (for open circuit).
Related Trouble cannot be reproduced on machine (for short circuit).
information • Troubleshooting for this failure code covers circuit starting from No. 3 of fuse F01, through
primary (coil) circuit of personal code relay R07, to machine monitor.
Blown No. 3 of fuse When fuse is blown, ground fault may occur in circuit.
1
F01
Defective personal
2 2. Disconnect relay R07 and connect T-adapters to male side.
code relay R07
Resistance Between R07 (male) (1) and (2) 100 to 500 z
Defective personal 2. Replace relay R07 with another one.
3 code relay R07 3. Turn starting switch to ON position.
If this failure code disappears, original personal code relay R07 is defective.
2. Remove fuse No. 3 of fuse box F01.
Open circuit, short 3. Disconnect connector CM01 and connect T-adapter to female side.
4 circuit, or ground
Between F01-3 and CM01 (female) (6) 100 to 500 z
fault in harness
Resistance Between ground and F01-3 or CM01
(female) (6) Min. 1 Mz

wiring harness 2. Remove fuse No. 3 of fuse box F01.
5 (wire breakage or 3. Disconnect connector CM01 and relay R07, and connect T-adapters to each
defective contact of female side.
connector) Between F01-3 and R07 (female) (1) Max. 1 z
Resistance Between R07 (female) (2) and CM01

Ground fault in 3. Disconnect connector CM01 and relay R07, and connect T-adapters to either
Between ground and F01-3 or R07
(female) (1) Min. 1 Mz
Resistance
Between ground and R07 (female) (2) or Min. 1 Mz
between CM01 (female) (6)
40-372 PC290LC-10
40 Troubleshooting

3. Disconnect connectors CM01 and relay R07, and connect T-adapters to
Short circuit in female side of connector CM01.
7 wiring harness
Between CM01 (female) (6) and each No continuity
Continuity
pin other than pin (6) (No sound is heard)
Defective machine If no failure is found by above checks, machine monitor (KOMTRAX portion) is
8 monitor defective. (Since this is an internal defect, troubleshooting cannot be performed.)
(KOMTRAX)
PC290LC-10 40-373
40 Troubleshooting
Circuit diagram related to personal code relay
40-374 PC290LC-10
40 Troubleshooting
Failure code [D811MC] KOMTRAX Error

Action KOMTRAX malfunctions.
Failure code
level Failure
— (KOMTRAX system)
D811MC
Details of
• Malfunction of KOMTRAX
failure
Action of
controller
Problem on • KOMTRAX system does not work properly
machine
information
Malfunction of Defective KOMTRAX (Since this is an internal defect, troubleshooting cannot be
1 performed.)
KOMTRAX
PC290LC-10 40-375
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit

Action GPS Antenna Open Circuit
Failure code
level Failure
－ (KOMTRAX system in machine monitor)
D862KA
Details of • Open circuit is in GPS antenna circuit.
failure
Problem on • GPS positioning cannot work.
machine
Related • Method of reproducing failure code: Turn starting switch to On position.
information
Defective GPS Probable causes are defective GPS antenna, open circuit or short circuit in
1 antenna or antenna antenna cable, and defective connection of antenna cable connector (GPS).
cable
Figure of structure
40-376 PC290LC-10
40 Troubleshooting

Action Open circuit in system operating lamp
Failure code
level Failure
― (KOMTRAX system)
D8ALKA
• KOMTRAX determines that system operating lamp circuit is open because voltage of
Details of lamp output line remains at about 5 V or below for about 3 seconds after starting switch is
failure turned to ON position during which KOMTRAX outputs no signal to lamp.
controller
• While system operating lamp lights up, battery disconnect switch must not be turned to
Problem on
OFF position. Turning battery disconnect switch to OFF position can destroy memory
machine
data on KOMTRAX.
• Although KOMTRAX is not able to light system operating lamp, no trouble will result
Related unless battery disconnect switch is turned to OFF position.
information • As long as system operating lamp is lit, its output voltage remains at Low level.
• Output to system operating lamp is not made from any controller for about 3 seconds
after starting switch is turned to ON position. Therefore, open circuit becomes detectable.
Defective fuse No. a If room lamp is lit, this check is not required.
1
16 in fuse box F01 If fuse is blown, ground fault may occur.
Open circuit in 2. Remove fuse No. 16 of fuse box F01.
wiring harness 3. Disconnect connectors CK01 and connect T-adapters to female side.
2 (wire breakage or 4. Disconnect connectors L19 and connect T-adapters to female side.
defective contact of Between L19 (female) (1) and F01-16 Max. 1 z
connector) Resistance Between CK01 (female) (8) and L19

Ground fault in
wiring harness
3 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19, and connect T-
(contact with GND
adapter to female side of CM01.
circuit)
Resistance Between CK01 (female) (15) and ground Min. 1 Mz
Defective If no failure is detected by above checks, KOMTRAX terminal is defective.
4
KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.)
PC290LC-10 40-377
40 Troubleshooting
Circuit diagram related to system operating lamp
40-378 PC290LC-10
40 Troubleshooting
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)

Action Short circuit of system operating lamp
Failure code
level Failure
― (KOMTRAX system)
D8ALKB
Details of • KOMTRAX determines that system operating lamp circuit shorts because output voltage
failure does not become Low level while KOMTRAX outputs signals to system operating lamp.
controller
Problem on
OFF position. Turning battery disconnect switch to OFF position can destroy the memory
machine
data on KOMTRAX.
Related • Although KOMTRAX is not able to light system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
• As long as system operating lamp is lit, its output voltage remains at Low level.
Short circuit in
wiring harness
adapters to female side of L19.
Resistance Between L19 (female) (1) and (2) Min. 1 Mz
2
PC290LC-10 40-379
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)

Action CAN communication-2 line of KOMTRAX terminal is
Failure code
level Failuredisabled
- D8AQKR (Detected by machine monitor) (Machine monitor system)
Details of • Machine monitor does not recognize KOMTRAX terminal through CAN communication-2
failure line (KOMNET/c).
Action of
controller
Problem on
machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Machine monitor uses five different failure codes, [DA2QKR], [DB2QKR], [D8AQKR],
[DAZQKR] and [DAFQKR], to indicate CAN communication failure through CAN 2 line.
When all of these five failure codes are displayed, ground fault, short circuit or hot short
circuit in wiring harness (CAN communication line). Since air conditioner is also operated
Related through CAN communication, you must, in such case, check from air conditioner screen
information whether air conditioner is operable (ON/OFF and air flow of air conditioner).
a Even when this failure code is displayed on monitor screen, air conditioner may remain
operable. If air conditioner is operable, there is no possibility of ground fault, short circuit
or hot short circuit in wiring harness (CAN communication line)
• Since power to each controller and machine monitor is supplied directly from battery, they
receive power even while starting switch is at OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
Defective power Perform troubleshooting for "E-59" of E-mode.
1 supply to
KOMTRAX terminal
Defective CAN Perform checks on causes 4 to 9 of troubleshooting for [DB2QKR].
2 communication 2
line
3
40-380 PC290LC-10
40 Troubleshooting
Failure code [DA20MC] Pump Controller

Action Malfunction of pump controller
Failure code
level Failure
- (Pump controller system)
DA20MC
Details of • Malfunction of pump controller
failure
Action of
controller
Problem on • Pump controller does not operate normally
machine
information
Malfunction of If machine operates normally, replacement is not necessary.
1 pump controller
PC290LC-10 40-381
40 Troubleshooting
Failure code [DA22KK] Pump Solenoid Power Low Error

Action Pump solenoid power supply voltage low error
Failure code
level Failure
L03 DA22KK
Details of • Solenoid power supply voltage of controller is below 20 V.
failure
• Stops generation of failure codes (open circuit and short circuit) for all solenoid systems
Action of while this failure code is active.
controller • If cause of failure disappears, machine become normal by itself.
Problem on • No solenoid valve is energized properly, so machine does not work properly.
machine
Related be measured at pump controller connector.
information • If failure code [D110KB] is displayed, perform troubleshooting for it first.
Defective fusible If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 5.)
1 link F04 or fuse No.
2 of fuse box F01
Dropped battery
2 2. After measuring voltage, measure it again when starting engine.
voltage
Voltage Between battery (+) and ground 20 to 30 V
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connector CP02 and connect T-adapters to female side.
Defective wiring 3. Connect ground cable and turn starting switch to ON position.
3
harness
Between ground and each of CP02
Voltage 20 to 30 V
(116), (118) and (121)
Open circuit in 2. Remove fusible link F04 and fuse (2) in fuse box F01.
wiring harness 3. Disconnect connector CP02 and connect T-adapters to female side.
4 (wire breakage or Between F01-2 and each of CP02
defective contact of (female) (116), (118) and (121) Max. 1 z
connector)
Resistance Between F01-1A and F04 (male) (2) Max. 1 z
Between F04 (male) (1) and terminal
Max. 1 z
R03
2. Remove fusible link F04 and fuse (2) in fuse box F01.
Ground fault in 3. Disconnect connector CP02 and connect T-adapters to female side.
wiring harness Between ground and each of CP02
5 (female) (116), (118) and (121), or F01-2 Min. 1 Mz
(contact with GND
circuit) and ground
Resistance Between ground and F01-1A or F04
(male) (2) Min. 1 Mz
Between ground and F04 (male) (1) or
Min. 1 Mz
terminal R03
Defective pump If no falure is found by above checks, pump controller is defective. (Since this is an
6 internal defect, troubleshooting cannot be performed.)
controller.
40-382 PC290LC-10
40 Troubleshooting
Circuit diagram related to solenoid power supply
PC290LC-10 40-383
40 Troubleshooting
Failure code [DA25KP] 5V Sensor 1 Power Abnormality

Action 5 V sensor power supply output 1 abnormality
Failure code
level Failure
－ (Pump controller system)
DA25KP
Details of • Voltage of 5 V sensor power output 1 circuit is below 2.5 V or above 6.0 V.
failure
• Stops output of 5 V sensor power supply output 1.
• Automatic travel speed selector function does not work (pump pressure sensor system).
Problem on • Auto-decelerator keeps working and is not canceled or fine control performance of work
machine equipment is lowered (PPC pressure sensor system).
Defective bucket 1. Turn starting switch to OFF position.
CURL PPC 2. Disconnect connector P01 and turn starting switch to ON position.
1 pressure sensor
(Internal open a If this failure code is not displayed any more, the sensor is defective.
circuit)
Defective bucket 1. Turn starting switch to OFF position.
DUMP PPC 2. Disconnect connector P05 and turn starting switch to ON position.
2 pressure sensor
a If this failure code is not displayed any more, the sensor is defective.
(Internal open
circuit)
Defective arm IN 1. Turn starting switch to OFF position.
PPC pressure 2. Disconnect connector P04 and turn starting switch to ON position.
3 sensor
(Internal open
circuit)
Defective arm OUT 1. Turn starting switch to OFF position.
PPC pressure 2. Disconnect connector P08 and turn starting switch to ON position.
4 sensor
(Internal open
circuit)
Boom RAISE PPC 1. Turn starting switch to OFF position.
pressure sensor 2. Disconnect connector P06 and turn starting switch to ON position.
5
(Internal open
circuit)
Defective boom 1. Turn starting switch to OFF position.
LOWER PPC 2. Disconnect connector P02 and turn starting switch to ON position.
6 pressure sensor
(Internal open
circuit)
Defective swing 1. Turn starting switch to OFF position.
right PPC pressure 2. Disconnect connector P07 and turn starting switch to ON position.
7 sensor
(Internal open
circuit)
LEFT PPC 2. Disconnect connector P03 and turn starting switch to ON position.
8 pressure sensor
(Internal open
circuit)
40-384 PC290LC-10
40 Troubleshooting

Defective F pump 1. Turn starting switch to OFF position.
pressure sensor 2. Disconnect connector P25 and turn starting switch to ON position.
9
(Internal open
circuit) a If this failure code is not displayed any more, the sensor is defective.
Defective R pump 1. Turn starting switch to OFF position.
pressure sensor 2. Disconnect connector P26, and turn starting switch to ON position.
10
(Internal open
circuit)
Defective R.H. 1. Turn starting switch to OFF position.
travel FORWARD 2. Disconnect connector P11 and turn starting switch to ON position.
PPC pressure
11 sensor a If this failure code is not displayed any more, the sensor is defective.
(Internal open
circuit)
Defective R.H. 1. Turn starting switch to OFF position.
travel REVERSE 2. Disconnect connector P12, and turn starting switch to ON position.
PPC pressure
(Internal open
circuit)
Defective L.H. 1. Turn starting switch to OFF position.
travel FORWARD 2. Disconnect connector P09 and turn starting switch to ON position.
PPC pressure
(Internal open
circuit)
Defective L.H. 1. Turn starting switch to OFF position.
travel REVERSE 2. Disconnect connector P10, and turn starting switch to ON position.
PPC pressure
(Internal open
circuit)
swash plate sensor 2. Disconnect connector P27, and turn starting switch to ON position.
15
(Internal open
circuit)
swash plate sensor 2. Disconnect connector P28 and turn starting switch to ON position.
16
(Internal open
circuit) a If this failure code is not displayed any more, the sensor is defective.
a Measure voltage before controller stops output.

Hot short-circuiting 2. Disconnect connectors P01 to P12, P25, and P26.
of harness 3. Connect T-adapter to female side of either of disconnected connectors (e.g.
17
(Contact with 24 V P07).
circuit) 4. Turn starting switch to ON position (with connectors P01 to P12, P25, and P26
disconnected).
Voltage Between P07 (female) (3) and ground 4.5 to 5.5 V
harness 2. Disconnect connectors CP01, P01 to P12, P25, and P26.
18 3. Connect T-adapter to female side of connector CP01.
(Contact with GND
circuit) Resistance Between CP01 (female) (6) and ground Min. 1 Mz
Defective pump If no failure is found by above checks, pump controller is defective. (Since this is
controller
PC290LC-10 40-385
40 Troubleshooting
Circuit diagram related to 5V sensor power supply output 1
40-386 PC290LC-10
40 Troubleshooting
Failure code [DA29KQ] Model Selection Abnormality

Action Model selection error
Failure code
level Failure
DA29KQ (Pump controller system)
L01
Details of • Model code signal other than signals for codes registered in controller is input.
failure
• Changes input model code to code of default model (PC200) and continues control.
Problem on • Because pump controller recognizes machine as "PC200", no particular problem occurs.
machine
• Condition of model selection signal can be checked by using monitoring function.
(Code: 02201 Switch Input 2)
Model select 1 = OFF
Related Model select 2 = ON
information Model select 3 = ON
Model select 4 = ON
Defective model 2. Disconnect connector S30 and connect T-adapter to female side.
selection connector Between S30 (female) (1) and (8) Min. 1 Mz
1 (open circuit or Between S30 (female) (2) and (8) Min. 1 z
short circuit in Resistance Between S30 (female) (3) and (8) Min. 1 z
internal wiring) Between S30 (female) (4) and (8) Max. 1 z
Between S30 (female) (7) and (8) Max. 1 Mz
2. Disconnect connectors CP01 and connect T-adopters to each female side.
Breaking of Between CP01 (female) (21) and ground
2 Max. 1 z
harness
Resistance Between CP01 (female) (40) and ground Max. 1 z
Between CP01 (female) (77) and ground Max. 1 z
Short-circuiting of 2. Disconnect connectors CP01 and connect T-adopters to each female side.
3
harness Between CP01 (female) (59) and (21) Min. 1 Mz
Resistance
Between CP01 (female) (58) and (21) Min. 1 Mz
harness 2. Disconnect connectors CP01 and connect T-adopters to each female side.
4
(Contact with GND Between CP01 (female) (59) and ground Min. 1 Mz
circuit) Resistance
Between CP01 (female) (58) and ground Min. 1 Mz
controller
PC290LC-10 40-387
40 Troubleshooting
Circuit diagram related to model selection abnormality
40-388 PC290LC-10
40 Troubleshooting
Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con)

Action Open circuit in system operating lamp
Failure code
level Failure
― (Pump controller system)
DA2LKA
• Pump controller determines that system operating lamp circuit is open because voltage of
Details of lamp output line remains at about 5 V or below for about 3 seconds after starting switch is
failure turned to ON position during which pump controller outputs no signal to lamp.
controller
Problem on OFF position. Turning battery disconnect switch to OFF position can destroy the memory
machine data on pump controller.
• Although pump controller is not able to light system operating lamp, no trouble will result
1
connector) Resistance Between CP02 (female) (100) and L19

Ground fault in 2. Remove fuse No. 16 of fuse box F01.
wiring harness 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19, and connect T-
3 (contact with GND adapter to female side of CP02.
circuit) Between CP02 (female) (100) and
Resistance ground Min. 1 Mz
controller
PC290LC-10 40-389
40 Troubleshooting
40-390 PC290LC-10
40 Troubleshooting
Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con)

Action Short circuit in system operating lamp
Failure code
level Failure
― (Pump controller system)
DA2LKB
• Pump controller determines that system operating lamp circuit shorts because output
Details of voltage does not become Low level while pump controller outputs signals to system
failure operating lamp.
controller
Problem on OFF position. Turning battery disconnect switch to OFF position can destroy the memory
machine data on pump controller.
Related • Although pump controller is not able to light system operating lamp, no trouble will result
Short circuit in
wiring harness
controller
PC290LC-10 40-391
40 Troubleshooting
Failure code [DA2QKR] CAN2 Discon (Pump Con)

Action CAN communication-2 line of pump controller is disabled
Failure code
level Failure
DA2QKR (Detected by machine monitor) (Machine monitor system)
L03
Details of • Machine monitor does not recognize pump controller through CAN communication-2 line.
failure (KOMNET/c).
Action of
• Holds information at failure occurrence.
controller
• Information obtained from pump controller is not displayed or special function that uses
Problem on information from pump controller does not work. Or update of received data is stopped
machine (failure codes, monitoring codes, etc. transmitted from pump controller)
switch is received.
circuit in wiring harness (CAN communication line) may occur. Since air conditioner is
also operated through CAN communication, you must, in such case, check from air
Related conditioner screen whether air conditioner is operable (ON/OFF and air flow of air
information conditioner).
a Even when this failure code is displayed on monitor screen, air conditioner may remain
using multimeter.
Defective fusible 2. Disconnect fusible link F05 and connect T-adapters to female side.
1
link F05 a If fusible link is blown, ground fault may occur.
Resistance Between F05 (female) (1) and (2) Max. 1 z
Defective fuse No. 1. Turn starting switch to OFF position.

2 2. Remove fuse No. 17 of fuse box F01.
17 in fuse box F01
If fuse is blown, ground fault may occur.
a Check ground terminal T04 for looseness and rust.
Defective power 1. Turn starting switch to OFF position.
3 supply to pump 2. Disconnect connectors CP01 and connect T-adopters to each female side.
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
Between CP01 (female) (4) and (5) 20 to 30 V
1. Turn starting switch to OFF position and disconnect battery ground cable.
wiring harness 3. Disconnect connectors F05 and CP01, and connect T-adapters to each female
(wire breakage or side.
4
defective contact of Between R04 terminal and F05 (female)
(1) Max. 1 z
connector)
Resistance Between F05 (male) (2) and F01-16D Max. 1 z
Between F01-17 and CP01 (female) (1) Max. 1 z
Between F01-17 and CP01 (female) (4) Max. 1 z
Defective CAN Perform checks on causes 4 to 9 of troubleshooting for [DB2QKR].
5 communication 2
line
40-392 PC290LC-10
40 Troubleshooting

controller
monitor
Circuit diagram related to pump controller power supply
PC290LC-10 40-393
40 Troubleshooting
Failure code [DA2QKR] CAN1 Discon (Pump Con)

Action CAN communication-1 line of pump controller is disabled
Failure code
level Failure
(Detected by machine monitor) (Machine monitor system)
L04 DA2RKR
Details of • Machine monitor does not recognize pump controller over CAN communication-1 line
failure (KOMNET/r).
• Working mode is maintained.
• Presence/absence of auto-deceleration is maintained.
Action of
• This error occurs even while pump controller is OFF.
controller
• Travel speed (Hi/Lo) is held.
• Information at occurrence of the failure is held.
• Information or special function obtained from pump controller is not displayed or operable.
Or update of received data is stopped.
• Pump cannot be controlled.
Problem on • Gauge pointer for hydraulic oil temperature disappears from machine monitor.
machine • Windshield wiper cannot be operated
• Window washer cannot be operated
• Flow in attachment hydraulic line cannot be controlled
• Method of reproducing failure code: Turn starting switch ON position.
switch is received.
• [DB2RKR] is used for defective CAN communication by CAN1 when it is detected by
machine monitor. When failure code [DB2RKR] is also displayed, ground fault, short
circuit or hot short circuit in wiring harness (CAN communication line) can be suspected.
Related • Cab side terminating resistor of CAN1 is provided in machine monitor and connector
information "Terminal port" is provided on engine side (CAN communication-1 line (KOMNET/r) is not
provided. It is led from connector "ECM J2").
• Since power to each controller and machine monitor is connected to battery directly, they
using multimeter.
Defective power Perform troubleshooting for causes 1 to 4 of failure code [DA2QKR].
1 supply to pump
controller
Defective CAN Perform troubleshooting for causes 2 to 9 of failure code [DB2RKR].
2 communication 1
system
controller
monitor
40-394 PC290LC-10
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality

Action Monitor internal memory (ROM) error
Failure code
level Failure
― (Machine monitor system)
DAF0MB
Details of • Program of machine monitor is rewritten (program error).
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Defective machine Machine monitor is defective.(Since this is an internal defect, troubleshooting
1 cannot be performed.)
monitor
PC290LC-10 40-395
40 Troubleshooting
Failure code [DAF0MC] Monitor Error

Action Monitor malfunctions
Failure code
level Failure
DAF0MC
Details of
• Machine monitor malfunctions.
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Replacement of Machine monitor is defective.(Since this is an internal defect, troubleshooting
machine monitor
40-396 PC290LC-10
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit

Action Short circuit in camera power supply
Failure code
level Failure
L03 DAF8KB
Details of • Output power supply voltage (rating: 8 V) from machine monitor to camera is below 6.0 V
failure or above 10 V.
• Stops output power supply voltage (rating: 8 V) to camera.
Problem on • Camera image is not displayed on monitor screen.
machine
information
Defective camera 1. Turn starting switch to OFF position.
2. Disconnect camera connector(s), and turn starting switch to ON position.
1 (internal open
Disconnect camera connectors and perform failure reproduction operation. If
circuit)
failure code disappears at this time, camera has an internal defect.
2. Disconnect connector CM04.
Defective machine 3. Connect T-adapters to male side of connector CM04.
2
monitor 4. Turn starting switch to ON position.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
wiring harness 2. Disconnect connector CM04 and camera connector(s).
3 (contact with GND 3. Connect T-adapters to female side of connector CM04.
circuit) Resistance Between CM04 (female) (1) and ground Min. 1 Mz
2. Disconnect camera connector(s).
3. Insert T-adapters into connector CM04.
wiring harness
(contact with 24 V
(Disconnect camera connector(s) and check that camera is not defective in
circuit)
advance.)
Voltage Between CM04 (1) and (7) Max. 10 V
PC290LC-10 40-397
40 Troubleshooting
Circuit diagram related to camera power supply
40-398 PC290LC-10
40 Troubleshooting
Failure code [DAF9KQ] Model Selection Abnormality

Action Model selection error
Failure code
level Failure
DAF9KQ (Machine monitor system)
L03
• Machine model in machine monitor program is different from that in pump controller
Details of program
failure (Replaced machine monitor or pump controller has wrong part No.)
Action of
controller
Problem on • Machine does not operate normally
machine
• Condition of model selection signal can be checked by using monitoring function.
(Code: 02201 Switch Input 2)
Related Model select 2 = ON
information Model select 3 = ON
Model select 4 = ON
Defective machine Machine monitor is defective (wrong model is programmed).
1
monitor
Defective pump Defective pump controller (programming is done on an untended model)
2
controller
PC290LC-10 40-399
40 Troubleshooting
Failure code [DAFGMC] GPS Module Error

Action GPS module malfunction
Failure code
level Failure
- (KOMTRAX system in machine monitor)
DAFGMC
Details of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX
failure communication modem in 50 seconds after KOMTRAX started.
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (a least 50
information seconds after starting switch is turned to ON position).
Defective machine GPS module of machine monitor may be defective. (Since this is an internal
1 defect, troubleshooting cannot be performed.)
monitor
40-400 PC290LC-10
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor)

Action Open circuit of system operating lamp
Failure code
level Failure
DAFLKA
• Machine monitor determines that system operating lamp circuit is open because voltage
Details of of lamp output line remains at about 5 V or below for about 3 seconds after starting switch
failure is turned to ON position during which machine monitor outputs no signal to lamp.
controller
Problem on
machine
data on machine monitor.
• Although machine monitor is not able to light system operating lamp, no trouble will result
1
wiring harness 3. Disconnect connector CM01 and connect T-adapters to female side.
connector) Resistance Between CM01 (female) (8) and L19

Ground fault in
wiring harness
(contact with GND
adapters to female side of CM01.
circuit)
Resistance Between CM01 (female) (8) and ground Min. 1 Mz
monitor
PC290LC-10 40-401
40 Troubleshooting
40-402 PC290LC-10
40 Troubleshooting
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor)

Action Short circuit of system operating lamp
Failure code
level Failure
DAFLKB
• Machine monitor determines that system operating lamp circuit shorts because output
Details of voltage does not become Low level while machine monitor outputs signals to system
failure operating lamp.
controller
Problem on
machine
data on machine monitor.
Related • Although machine monitor is not able to light system operating lamp, no trouble will result
Short circuit in
wiring harness
monitor
PC290LC-10 40-403
40 Troubleshooting
Failure code [DAFQKR] CAN2 Discon (Monitor)

Action CAN communication-2 line of machine monitor is disabled
Failure code
level Failure
— DAFQKR (KOMTRAX terminal detected it) (KOMTRAX system)
Details of • KOMTRAX terminal does not recognize machine monitor through CAN communication-2
failure line.
Action of
controller
Problem on • System sometimes does not work properly.K
machine
switch is received.
• Since a failure code is displayed on machine monitor through CAN communication, this
Related failure code [DAFQKR] does not appear if CAN communication of machine monitor fails.
information Therefore, the code becomes recognizable over KOMTRAX system alone.
receive power even while starting switch is in OFF position.
using multimeter.
Defective power Perform troubleshooting for "E-3" of E-mode.
1 supply to machine
monitor
Defective CAN Perform check on cause 5 of troubleshooting for failure code [DB2QKR].
2
communication
40-404 PC290LC-10
40 Troubleshooting
Failure code [DAZ9KQ] A/C Model Selection Abnormality

Action Mismatching of air conditioner model selection signals
Failure code
level Failure
― DAZ9KQ (Machine monitor system)
• Machine model in machine monitor program is different from that in air conditioner
Details of controller program
failure (Replaced machine monitor or air conditioner controller has wrong part No.)
Action of
controller
Problem on • Machine does not operate normally
machine
• Model codes registered in air conditioner controller cannot be checked with monitoring
function.
Related • Model codes registered in machine monitor can be checked with monitoring function
information (Code: 00500)
Defective machine Machine monitor is defective (wrong model is programmed).
1
monitor
Defective air Air conditioner controller is defective (wrong model is programmed).
2 conditioner
controller
PC290LC-10 40-405
40 Troubleshooting
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)

Action CAN communication-2 line of air conditioner controller is
Failure code
level Failuredisabled
L01 DAZQKR (Detected by machine monitor) (Machine monitor system)
Details of • Machine monitor does not recognize air conditioner controller through CAN
failure communication-2 line (KOMNET/c).
Action of
controller
• Information obtained from air conditioner controller is not displayed.
Problem on • Operation of air conditioner is disabled (air does not come out)
machine (Air conditioner control screen is not displayed correctly on machine monitor.)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective due to
cause 2.
Related • Machine monitor uses five different failure codes, [DA2QKR], [DB2QKR], [D8AQKR],
information [DAZQKR] and [DAFQKR], to indicate CAN communication failure through CAN 2 line.
circuit in wiring harness (CAN communication line) may occur.
using multimeter.
Improper power Perform "Troubleshooting for electric power supply system" in Section 80
supply to air
1
conditioner
controller
Defective CAN 1. Turn starting switch to OFF position.
terminating resistor 2. Disconnect connectors CM02 and K02, and connect T-adapters to each male
2 (open circuit or side.
short circuit in Between K02 (male) (A) and (B) 120 ± 12 z
internal wiring) Resistance
Between CM02 (male) (8) and (9) 120 ± 12 z
• CAN communication line
a CAN communication terminating resistor of 120 z is provided in machine
monitor, too. Since 120 z resistors are connected in parallel, if combined
resistance measured at connector of controller other than machine monitor is
60 z, there is no open circuit in wiring harness.
2. Disconnect related connectors and insert T-adapters into connector to be
measured.
Open circuit or a When short circuit occurs (1 z or less between terminals), disconnect every
3 short circuit in CAN communication connector of controllers. Then, check where short circuit
wiring harness occurs, namely between wiring harnesses or within controller.
Between CM02 (female) (8) and (9) Approx. 120 z
Between CE03 (female) (17) and (18) Approx. 60 z
Between CP01 (female) (45) and (64) Approx. 60 z
Between AC01 (female) (1) and (2) Approx. 60 z
Resistance
Between CK01 (female) (10) and (11) Approx. 60 z
Between CC01 (female) (3) and (9) Approx. 60 z
Between K02 (female) (A) and (B) Approx. 120 z
40-406 PC290LC-10
40 Troubleshooting

• ACC signal from starting switch (start of CAN communication is not identifiable)
2. Disconnect connector to be measured and insert T-adapters into connector.
3. Connect ground cable and turn starting switch to ON position.
Open circuit in
wiring harness Between CM01 (10) and (3) 20 to 30 V
4 (wire breakage or Between CE03 (3) and (21) 20 to 30 V
defective contact of Between CP01 (2) and each of CP01
(24), (43) and (80) 20 to 30 V
connector) Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
Between CC01 (female) (2) and (7) 20 to 30 V
2. Disconnect related connectors, and connect T-adapters to female side of
connector to be measured.
Between CM02 (female) (8) and CP01
Between CM02 (female) (8) and CE03
Open circuit in
wiring harness Between CM02 (female) (8) and AC01
5 (wire breakage or
defective contact of Between CM02 (female) (9) and AC01
Between CM02 (female) (8) and CK01
Between CM02 (female) (8) and CC01
Between CE03 (female) (17) and K02
(female) (A) Max. 1 z
(female) (B) Max. 1 z
a If no failure is found by checks on cause 2 (no open circuit), measure voltage at

one connector.
Ground fault in 2. Disconnect all related connector and connect T-adapters to each female side
wiring harness to be measured.
6 (contact with GND Between ground and any of CP01
circuit) (female) (45), CM02 (female) (7), (8) or Min. 1 Mz
CE03 (female) (17)
Resistance
Between ground and any of CP01
(female) (64), CM02 (female) (9) or Min. 1 Mz
CE03 (female) (18)
PC290LC-10 40-407
40 Troubleshooting

a If no failure is found by check on cause 2 (no open circuit), measure at only one
place each.
3. Connect battery ground cable.
Short circuit or hot
short circuit in a Since voltages of CAN_H and CAN_L lines are normally 2.5±1 V including
wiring harness during communication, regards lines as normal if their voltages are between 1
7
(contact with 24 V and 4 V.
circuit) Between ground and any of CM02
(female) (8), CP01 (female) (45), CK01
(female) (10), AC01 (female) (2), CC01 1 to 4 V
(female) (3) or CE03 (female) (17)
Voltage
Between ground and any of CM02
• When all five failure codes of [DA2QKR], [DB2QKR], [D8AQKR], [DAZQKR],
and [DAFQKR] are displayed
a Identify which controller fails by repeating following Steps 1 to 3 and
disconnecting them one by one from CAN communication.
Defective engine 2. Disconnect CAN communication connectors of engine controller (connector
controller, pump CE03), pump controller (connector CP01), air conditioner unit (connector
controller, air AC01), ID controller (connector CC01), and KOMTRAX terminal (connector
8
conditioner unit, ID CK01) in order one by one.
controller, or 3. Connect battery ground cable, turn starting switch to ON position and perform
KOMTRAX terminal troubleshooting.
4. Return to Step 1 and check the next controller.
If YES, the
disconnected Is number of displayed failure codes less than 5?
controller is
defective.
Defective air If no failure is found by above checks, air conditioner controller is defective. (Since
9 conditioner this is an internal defect, troubleshooting cannot be performed.)
controller
monitor
40-408 PC290LC-10
40 Troubleshooting
Circuit diagram related to CAN communication line 2
PC290LC-10 40-409
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con)

Action CAN communication-2 line of engine controller is disabled
Failure code
level Failure
DB2QKR (Detected by machine monitor) (Machine monitor system)
L03
Details of • Machine monitor does not recognize engine controller through CAN communication-2 line
failure (KOMNET/c).
Action of
• Information at occurrence of the failure is held.
controller
• Information obtained from engine controller is not displayed or special function that uses
Problem on information from engine controller does not work. Or update of received data is stopped
machine (failure codes, monitoring codes, etc. transmitted from engine controller)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective due to
cause 2.
circuit in wiring harness (CAN communication line) may occur. Since air conditioner is
Related also operated through CAN communication, you must, in such case, check from air
information conditioner screen whether air conditioner is operable (ON/OFF and air flow of air
conditioner).
a Even when a failure code is displayed on monitor screen, air conditioner may remain
using multimeter.
Defective fuses 1. Turn starting switch to OFF position.
1 Nos. 15 and 18 in 2. Remove fuse Nos 15 and 18 of fuse box F01.
fuse box F01 If fuse is blown, short circuit may occur in engine controller.
a If fuse is not blown, this check is not required.
Defective engine 1. Turn starting switch to OFF position.
2 2. Disconnect connector EC03 and connect T-adapters to male side.
controller
Between CE03 (male) (1) and (21) Min. 10 z
Resistance
Between CE03 (male) (11) and (31) Min. 10 z
a Check ground terminal T12 for looseness and rust.
Improper power 1. Turn starting switch to OFF position.
3 supply to engine 2. Disconnect connector CE03 and connect T-adapters to female side.
Between CE03 (female) (1) and (21) 20 to 30 V
Voltage
Between CE03 (female) (11) and (31) 20 to 30 V
Improper power Perform troubleshooting for failure code [CA441].
4 supply to engine
controller
terminating resistor 2. Disconnect connectors CM02 and K02, and connect T-adapters to each male
side.
5 (open circuit or
Between K02 (male) (A) and (B) 120 ± 12 z
short circuit in
internal wiring) Resistance 120 ± 12 z
Between CM02 (male) (8) and (9)
40-410 PC290LC-10
40 Troubleshooting

2. Disconnect related connectors and insert T-adapters into connector to be
measured.
Open circuit or
a When short circuit occurs (1 z or less between terminals), disconnect every
6 short circuit in
CAN communication connector of controllers. Then, check where short circuit
wiring harness
occurs, namely between wiring harnesses or within controller.
Between CE03 (female) (17) and (18) Approx. 60 z
Resistance Between AC01 (female) (1) and (2) Approx. 60 z
Between CK01 (female) (10) and (11) Approx. 60 z
Between CC01 (female) (3) and (9) Approx. 60 z
Between K02 (female) (A) and (B) Approx. 120 z
3. Connect ground cable and turn starting switch to ON position.
Open circuit in Between CM01 (10) and (3) 20 to 30 V
wiring harness
Between CE03 (3) and (21) 20 to 30 V
7 (wire breakage or
Between CP01 (2) and each of CP01
defective contact of 20 to 30 V
(24), (43) and (80)
connector) Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
Between CC01 (female) (2) and (7) 20 to 30 V
PC290LC-10 40-411
40 Troubleshooting

2. Disconnect related connectors, and connect T-adapters to female side of
connectors to be measured.
Open circuit in
wiring harness Between CM02 (female) (8) and AC01
8 (wire breakage or
defective contact of Between CM02 (female) (9) and AC01
(female) (A) Max. 1 z
(female) (B) Max. 1 z
a If no failure is found by check on cause 5 (no open circuit), conduct

measurement at only one place.
Ground fault in 2. Disconnect related connectors, and connect T-adapters to female side of
wiring harness connectors to be measured.
9 (contact with GND Between ground and any of CP01
circuit) (female) (45), CM02 (female) (7), (8) or Min. 1 Mz
CE03 (female) (17)
Resistance
Between ground and of CP01 (female)
(64), CM02 (female) (9) or CE03 Min. 1 Mz
(female) (18)
40-412 PC290LC-10
40 Troubleshooting

place each.
Short circuit or hot
short circuit in a Since voltages of CAN_H and CAN_L lines are normally 2.5±1 V including
during communication, they should regard lines as normal if their voltages are
10 wiring harness
(contact with 24 V between 1 and 4 V.
circuit) Between ground and any of CM02
Voltage
Between ground and any of CM02
• When all five failure codes of [DA2QKR], [DB2QKR], [D8AQKR], [DAZQKR],
and [DAFQKR] are displayed
a Identify which controller fails by repeating following Steps 1 to 3 and
Defective engine 2. Disconnect CAN communication connectors of engine controller (connector
controller, pump CE03), pump controller (connector CP01), air conditioner unit (connector
controller, air AC01), ID controller (connector CC01), and KOMTRAX terminal (connector
11
conditioner unit, ID CK01) in order one by one.
controller, or 3. Connect battery ground cable, turn starting switch to ON position and perform
KOMTRAX terminal troubleshooting.
4. Return to Step 1 and check the next controller.
If YES, the
disconnected Is number of displayed failure codes less than 5?
controller is
defective.
controller
monitor
PC290LC-10 40-413
40 Troubleshooting
40-414 PC290LC-10
40 Troubleshooting
Failure code [DB2RKR] CAN1 Discon (Engine Con)

Action CAN communication-1 line of engine controller is disabled
Failure code
level Failure
(Detected by machine monitor) (Machine monitor system)
L04 DB2RKR
Details of • Machine monitor does not recognize engine controller through CAN communication-1 line
failure (KOMNET/r).
• Holds current working mode.
Action of
• Holds current selection of auto-deceleration.
controller
• Information obtained from engine controller is not displayed or special function that uses
information from engine controller does not work. Or update of received data is stopped.
Problem on • Engine is uncontrollable.
machine • Engine speed and coolant temperature are undetectable.
• Gauge pointers for engine coolant temperature and hydraulic oil temperature disappear
from machine monitor.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller system may be defective
due to cause 1.
• Machine monitor uses failure code [DA2RKR] to indicate CAN communication failure
through CAN 1 line. When failure code [DA2RKR] is also displayed, ground fault, short
Related circuit or hot short circuit in wiring harness (CAN communication line) may occur.
information • Terminating resistor of CAN1 on cab side is inside machine monitor, and that on engine
side is connector "B_RES". (Connector "B_RES" is not on CAN communication 1 line but
connected to it via connector "J2").
using multimeter.
Defective engine Perform checks on causes 1 to 3 of troubleshooting for [DB2QKR].
1 controller system
terminating resistor 2. Disconnect connector CM02 and terminal port, and connect T-adapters to each
2 (open circuit or male sides of side them.
short circuit in Between terminal port (male) (A) and (B) 120 ± 12 z
internal wiring) Resistance
Between CM02 (male) (10) and (12) 120 ± 12 z
2. Disconnect connectors CM02, CP01, ECM J1, ECM J2 and Terminal port one
by one, and connect T-adapters to each female side.
Open circuit or
3 short circuit in a When short circuit occurs (1 z or less between terminals), disconnect every
wiring harness CAN communication connector of controllers. Then, check where short circuit
occurs, namely between wiring harnesses or within the controller.
Between Terminal port (female) (A) and
Approx. 120 z
Resistance (B)
Between ECM J1 (female) (8) and (18) Approx. 120 z
Between ECM J2 (female) (24) and (25) Approx. 120 z
PC290LC-10 40-415
40 Troubleshooting

Open circuit in 2. Disconnect connectors CM01, CP01, and CE03, and insert T-adapters.
wiring harness 3. Connect ground cable and turn starting switch to ON position.
4 (wire breakage or Between CM01 (10) and (3) 20 to 30 V
Between CE03 (3) and (21) 20 to 30 V
connector) Voltage
Between CP01 (2) and each of CP01
(24), (43), (80) and (2) 20 to 30 V

2. Disconnect connectors CM02, CP01, ECM J1, ECM J2, and Terminal port, and
connect T-adapters to any female side.
Open circuit in
wiring harness Between CM02 (female) (12) and CP01
5 (wire breakage or
defective contact of Between CM02 (female) (11) and ECM
J1 (female) (8) Max. 1 z
connector)
Resistance
Between CM02 (female) (12) and ECM
J1 (female) (18) Max. 1 z
Terminal port (female) (A) Max. 1 z
Terminal port (female) (B) Max. 1 z
2. Disconnect connectors CM02, CP01, ECM J1, ECM J2, and Terminal port, and
connect T-adapters to any female side.
(female) (7), CM02 (female) (10), (11) or Min. 1 Mz
Ground fault in ECM J1 (female) (8)
wiring harness Between ground and ECM J2 (female)
6 (contact with GND Min. 1 Mz
(24) or Terminal port (female) (A)
circuit) Resistance Between ground and any of CP01
(female) (26), CM02 (female) (12) or Min. 1 Mz
ECM J1 (female) (18)
Between ground and any of ECM J2
(female) (25) or Terminal port (female) Min. 1 Mz
(B)
place each.
2. Disconnect either connector CM02, CP01 or Terminal port, and connect T-
adapters to female side.
Short circuit or hot 4. Turn starting switch to ON position.
short circuit in
7 wiring harness a Measurement is not conducted on ECM J1 and ECM J2.
(contact with 24 V a Since voltages of CAN_H and CAN_L lines normally 2.5±1 V including during
circuit) communication, regard lines as normal if their voltages are between 1 and 4 V.
(female) (7), CM02 (female) (10), (11) or 1 to 4 V
Terminal port (female) (A)
Voltage
(female) (26), CM02 (female) (12) or 1 to 4 V
Terminal port (female) (B)
40-416 PC290LC-10
40 Troubleshooting

• When failure code [DA2RKR] is also displayed
a Identify which of pump controller and engine controller fails by disconnecting
them one by one from CAN communication.
Defective pump 1. Turn starting switch to OFF position and disconnect battery ground cable.
8 2. Disconnect pump controller (connector CP01).
controller
3. Connect the ground cable and turn starting switch to ON position.
If YES, pump Does any or both of failure codes [DA2RKR] and [DB2RKR]
controller is for CAN1 communication failure disappear?
defective.
• When failure code [DA2RKR] is also displayed
a Identify which of pump controller and engine controller has failed by
Defective engine 1. Turn starting switch to OFF position and disconnect battery ground cable.
9 2. Disconnect engine controller (connector ECM J1).
controller
3. Connect the ground cable and turn the starting switch to ON position.
If YES, engine Does any or both of failure codes [DA2RKR] and [DB2RKR]
controller is for CAN1 communication failure disappear?
defective.
controller
monitor
PC290LC-10 40-417
40 Troubleshooting
40-418 PC290LC-10
40 Troubleshooting
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit

Action Short circuit in hydraulic oil temperature sensor
Failure code
level Failure
L01 DGH2KB
Details of • Signal voltage of hydraulic oil temperature sensor circuit is below 1 V and ground fault is
failure detected.
controller
Problem on • While hydraulic oil temperature rises to normal operating temperature, hydraulic oil
machine temperature gauge keeps indicating top of white range (bottom of green range).
• Signal voltage from hydraulic oil temperature sensor can be checked with monitoring
Related function.
information (Code: 04402 Hydraulic oil temperature sensor voltage)
2. Disconnect connector P22 and connect T-adapters to male side.
Between P22 10°C Approx. 90 kz
Defective hydraulic (male) (1) and (2) 30°C Approx. 35 kz
oil temperature
a Temperature- 80°C Approx. 6.5 kz
1 sensor
Resistance
(internal open or Resistance characteristics
short circuit) of oil 100°C Approx. 3.5 kz
temperature
sensor
Between P22 (male) (2) and ground Min. 1 Mz
2. Disconnect connector P22 and connect T-adapters to female side.
Open circuit or 3. Turn starting switch to ON position.
short circuit or
a If voltage is 0 V, wiring harness has open circuit, ground fault, or short circuit,
2 ground fault or hot
and if voltage is 24 V, wiring harness has hot short circuit.
short circuit in
wiring harness a Voltage of approximately 5 V is applied to temperature sensor signal lines
through resistor in pump controller.
Voltage Between P22 (female) (1) and (2) Approx. 5 V
2. Disconnect connectors CP01 and connect T-adopters to each female side.
a Use temperature-resistance characteristics table for troubleshooting on cause
Short circuit or 1.
3 ground fault in
harness a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is
below 1 z, wiring harness has short circuit.
Between CP01 (female) (28) and (46) 3.5 to 90 kz
Resistance
wiring harness 2. Disconnect connectors CP01 and P22, and connect T-adapters to either
Resistance ground, or between P22 (female) (2) and Min. 1 Mz
ground
controller
PC290LC-10 40-419
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-420 PC290LC-10
40 Troubleshooting
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit

Action Open circuit in air cleaner clogging sensor
Failure code
level Failure
L01 DHA4KA
Details of • Air cleaner clogging switch signal voltage is not below 1 V while engine is stopped, so
failure machine monitor determines that air cleaner is clogged (switch contact is open).
Action of • Displays system abnormality monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may be broken.
machine
• Input state (ON/OFF) from air cleaner clogging switch can be checked with monitoring
Related function.
information (Code: 04501 Monitor input: 2)
Defective air 1. Turn starting switch to OFF position.
cleaner clogging 2. Disconnect connector P23 and connect T-adapters to male side.
switch 3. Turn starting switch to ON position.
1
(internal open
circuit in wiring Between P23 When air cleaner is
Resistance (male) (1) and (2) Max. 1 z
harness) normal *1
Open circuit in
2. Disconnect connectors CM02 and P23, and connect T-adapters to each female
wiring harness
side.
2 (wire breakage or
Between CM02 (female) (4) and P23
connectors)
Between P23 (female) (2) and ground Max. 1 z
Defective machine 3. Turn starting switch to ON position.
3
monitor
Between CM02 (4) When air cleaner is
Voltage Max. 1 V
and CM01 (3) normal
• Air cleaner suction resistance
*1: Max. -3,430 Pa {-350 mmH2O}
Circuit diagram related to air cleaner clogging
PC290LC-10 40-421
40 Troubleshooting
Failure code [DHPAMA] F Pump Press Sensor Abnormality

Action Front pump pressure sensor malfunction
Failure code
level Failure
L01 DHPAMA
Details of • Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that front pump pressure is 0 MPa {0 kg/cm 2}.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse
polarities, pressure sensor is damaged. Accordingly, take extreme care when checking.
Related • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
information be measured at pump controller connector.
• Front pump pressure can be checked with monitoring function.
(Code: 01100 F pump pressure).
Defective 5 V If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1 sensor power
supply 1 line
Defective 5 V 3. Turn starting switch to ON position.
2 sensor power
supply 1 line a If power supply voltage is abnormal, proceed to check on cause 4.
Between P25
2. Insert T-adapters into connector P25.
Between P25 (2)
and (1)
a If power supply voltage is normal and sensor output voltage is abnormal, it is
Defective front difficult to judge whether cause is defective sensor, ground fault or hot short
pump pressure circuit ofwiring harness. Check as followings.
3 sensor
(internal defect) 2. Replace connector P25 with connector P26 of R pump PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record" screen of
electrical system on machine monitor.
4. If E mark is not displayed for this failure code, front pump pressure sensor is
defective.
a After finishing test, restore connector.
40-422 PC290LC-10
40 Troubleshooting

2. Disconnect connectors CP01 and P25, and connect T-adapters to each female
side.
a If power supply voltage in check on
cause 2 is normal, this check is not
wiring harness Between CP01 (female) (18) and P25
defective contact of Between CP01 (female) (11) and P25

required. Max. 1 z
Between CP01 (female) (6) and P25
(female) (3)

circuit) Between ground and CP01 (female) (11)
Resistance or P25 (female) (2) Min. 1 Mz

wiring harness
6 3. Connect T-adapters to female side of connector P25.
(contact with 24 V
circuit)
Voltage Between P25 (female) (2) and ground Max. 1 V
controller
PC290LC-10 40-423
40 Troubleshooting
Circuit diagram related to front pump pressure sensor
40-424 PC290LC-10
40 Troubleshooting
Failure code [DHPBMA] R Pump Press Sensor Abnormality

Action Rear pump pressure sensor malfunction
Failure code
level Failure
L01 DHPBMA
Details of • Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that rear pump pressure is 0 MPa {0 kg/cm2}.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
• Rear pump pressure can be checked with monitoring function.
(Code: 01101 R pump pressure).
1 sensor power
supply 1 line
2 sensor power
Between P26
2. Insert T-adapters to connector P26.
Between P26 (2)
and (1)
Defective rear difficult to judge whether cause is defective sensor, ground fault or hot short
pump pressure circuit of wiring harness. Check as followings.
3 sensor 1. Turn starting switch to OFF position.
(internal defect) 2. Replace connector P26 with connector P25 of front pump PPC pressure
sensor.
4. If E mark is not displayed for this failure code, rear pump pressure sensor is
defective.
PC290LC-10 40-425
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
Ground fault in 2. Disconnect connectors CP01 and P26, and connect T-adapters to either
5
(contact with GND Between CP01 (female) (30) and
circuit) Resistance ground, or between P26 (female) (2) and Min. 1 Mz
ground
wiring harness 2. Disconnect connector P26.
(contact with 24 V 4. Turn starting switch to ON position.
circuit)
controller
40-426 PC290LC-10
40 Troubleshooting
Circuit diagram related to rear pump pressure sensor
PC290LC-10 40-427
40 Troubleshooting
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality

Action Arm IN PPC sensor alfunction
Failure code
level Failure
L01 DHS3MA
Details of • Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that arm IN PPC pressure is 0 MPa {0 kg/cm 2}.
Problem on • Automatic deceleration cannot be canceled.
machine • Arm IN performance lowers.
• Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P04
2. Insert T-adapters into connector P04
Between P04 (2)
and (1)
Defective arm IN difficult to judge whether cause is defective sensor, ground fault or hot short
PPC pressure circuit of harness. Check as followings.
3 sensor
(internal defect) 2. Replace connector P04 with connector of other PPC pressure sensor.
4. If E mark is not displayed for this failure code, arm IN PPC pressure sensor is
defective.
40-428 PC290LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
Between ground and CP01 (female) (14)
circuit) Resistance Min. 1 Mz
or P04 (female) (2)
circuit)
controller
Circuit diagram related to arm CURL (arm IN) PPC pressure sensor
PC290LC-10 40-429
40 Troubleshooting
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality

Action Bucket CURL PPC pressure sensor malfunction
Failure code
level Failure
L01 DHS4MA
Details of • Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that bucket CURL PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Bucket CURL performance lowers.
• Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P01
2. Insert T-adapter into connector P01.
Between P01 (2)
and (1)
Defective bucket difficult to judge whether cause is defective sensor, ground fault or hot short
CURL PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed for this failure code, bucket CURL PPC pressure
40-430 PC290LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P01 (female) (2)
circuit)
controller
PC290LC-10 40-431
40 Troubleshooting
Circuit diagram related to bucket CURL PPC pressure sensor
40-432 PC290LC-10
40 Troubleshooting
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality

Action Boom RAISE PPC pressure sensor malfunction
Failure code
level Failure
L01 DHS8MA
Details of • Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that boom RAISE PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Boom RAISE performance lowers.
• Boom RAISE PPC pressure can be checked with monitoring function.
(Code: 07400 Boom RAISE PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P06
2. Insert T-adapters in connector P06.
Between P06 (2)
and (1)
Defective boom difficult to judge whether cause is defective sensor, ground fault or hot short
RAISE PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed for this failure code, boom RAISE PPC pressure
PC290LC-10 40-433
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P06 (female) (2)
circuit)
controller
40-434 PC290LC-10
40 Troubleshooting
Circuit diagram related to boom RAISE PPC pressure sensor
PC290LC-10 40-435
40 Troubleshooting
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality

Action Boom LOWER PPC pressure sensor malfunction
Failure code
level Failure
L01 DHS9MA
Details of • Signal voltage of boom LOWER PPC pressure sensor circuit is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that boom LOWER PPC pressure is 0 MPa {0 kg/cm2}.
machine • Boom LOWER performance lowers.
If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse polarities,
pressure sensor is damaged. Accordingly, take extreme care when checking.
Related • As T-adapter for pump controller connector is “socket-type box“, operating voltage cannot
• Boom LOWER PPC pressure can be checked with monitoring function.
(code: 07500 Boom LOWER PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P02 (2)
and (1)
Between P02 (2)
and (1)
Defective boom difficult to judge whether cause is defective sensor, ground fault or hot short
LOWER PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed for this failure code, boom LOWER PPC pressure
40-436 PC290LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
Between ground and C01 (female) (13)
or P02 (female) (2)
circuit)
controller
PC290LC-10 40-437
40 Troubleshooting
Circuit diagram related to boom LOWER PPC pressure sensor
40-438 PC290LC-10
40 Troubleshooting
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality

Action Swing RIGHT PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSAMA
Details of • Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that swing RIGHT PPC pressure is 0 MPa {0 kg/cm2}.
machine • Poor operability of right swing operation
• Swing RIGHT PPC pressure can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P07
2. Connect T-adapters to connector P07.
Between P07 (2)
and (1)
Defective swing difficult to judge whether cause is defective sensor, ground fault or hot short
RIGHT PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed for this failure code, swing RIGHT PPC pressure
PC290LC-10 40-439
40 Troubleshooting

side.
connectors) Resistance (female) (2) Max. 1 z

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P07 (female) (2)
(contact with 5 V or 4. Turn starting switch to ON position.
24 V circuit)
controller
40-440 PC290LC-10
40 Troubleshooting
Circuit diagram related to swing RIGHT PPC pressure sensor
PC290LC-10 40-441
40 Troubleshooting
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality

Action Swing LEFT PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSBMA
Details of • Signal voltage of swing LEFT PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that swing LEFT PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Swing LEFT performance lowers.
• Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P03
Between P03 (2)
and (1)
Defective swing difficult to judge whether cause is defective sensor, ground fault or hot short
LEFT PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E-mark for this failure code is not displayed, swing LEFT PPC pressure
40-442 PC290LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P03 (female) (2)
24 V circuit)
controller
PC290LC-10 40-443
40 Troubleshooting
Circuit diagram related to swing LEFT PPC pressure sensor
40-444 PC290LC-10
40 Troubleshooting
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality

Action Arm OUT PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSCMA
Details of • Signal voltage of arm OUT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that arm OUT PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Arm OUT performance lowers.
• Arm OUT PPC pressure can be checked with monitoring function.
(Code 07600: Arm OUT PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P08
Between P08 (2)
and (1)
Defective arm OUT difficult to judge whether cause is defective sensor, ground fault or hot short
PPC pressure circuit of harness. Check as followings.
3 sensor
4. If E mark is not displayed in this failure code column, arm dump PPC pressure
PC290LC-10 40-445
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P08 (female) (2)
circuit)
controller
40-446 PC290LC-10
40 Troubleshooting
Circuit diagram related to arm DUMP (arm OUT) PPC pressure sensor
PC290LC-10 40-447
40 Troubleshooting
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

Action Bucket DUMP PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSDMA
Details of • Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that bucket DUMP PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Bucket dump performance lowers.
• Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P05 (3)
and (1)
Between P05 (2)
and (1)
Defective bucket difficult to judge whether cause is defective sensor, ground fault or hot short
DUMP PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed in this failure code column, bucket DUMP PPC
pressure sensor is defective.
40-448 PC290LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
harness 2. Disconnect connectors CP01 and P05, and connect T-adapters to either
5 female side.
(Contact with GND
or P05 (female) (2)
circuit)
controller
PC290LC-10 40-449
40 Troubleshooting
Circuit diagram related to bucket DUMP PPC pressure sensor
40-450 PC290LC-10
40 Troubleshooting
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality

Action Left travel FORWARD PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSFMA
Details of • Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Travel performance lowers.
• Left travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07102 Left travel FORWARD PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P09
Between P09 (2)
and (1)
Defective left travel difficult to judge whether cause is defective sensor, ground fault or hot short
FORWARD PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed in this failure code column, left travel FORWARD
PPC pressure sensor is defective.
PC290LC-10 40-451
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P09 (female) (2)
24 V circuit)
controller
40-452 PC290LC-10
40 Troubleshooting
Circuit diagram related to travel PPC pressure sensor
PC290LC-10 40-453
40 Troubleshooting
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality

Action Right travel FORWARD PPC pressure sensor abnormality
Failure code
level Failure
L01 DHSGMA
Details of • Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above
failure 4.5 V.
Action of • Controls machine taking it that right travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Travel performance is poor.
• Right travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07103 Right travel FORWARD PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P11
Between P11 (2)
and (1)
Defective right a If power supply voltage is normal and sensor output voltage is abnormal, it is
travel FORWARD difficult to judge whether cause is defective sensor, ground fault or hot short
3 PPC pressure circuit of harness. Check as followings.
sensor 1. Turn starting switch to OFF position.
4. If E mark is not displayed in this failure code column, right travel FORWARD
40-454 PC290LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P11 (female) (2)
24 V circuit)
controller
PC290LC-10 40-455
40 Troubleshooting
40-456 PC290LC-10
40 Troubleshooting
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality

Action Left travel REVERSE PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSHMA
Details of • Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Travel performance lowers.
• Left travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07104 Travel left reverse PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P10
Between P10 (2)
and (1)
Defective left travel difficult to judge whether cause is defective sensor, ground fault or hot short
REVERSE PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed in this failure code column, left travel REVERSE PPC
pressure sensor is defective.
PC290LC-10 40-457
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P10 (female) (2)
24 V circuit)
controller
40-458 PC290LC-10
40 Troubleshooting
PC290LC-10 40-459
40 Troubleshooting
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality

Action Right travel REVERSE PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSJMA
Details of • Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking right it that travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Travel performance is poor.
• Right travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07105 Travel right reverse PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P12
Between P12 (2)
and (1)
Defective right a If power supply voltage is normal and sensor output voltage is abnormal, it is
travel REVERSE difficult to judge whether cause is defective sensor, ground fault or hot short
3 PPC pressure circuit of harness. Check as followings.
sensor 1. Turn starting switch to OFF position.
4. If E mark is not displayed in this failure code column, right travel REVERSE
a After finishing test, return connector to condition as it was.
40-460 PC290LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P12 (female) (2)
24 V circuit)
controller
PC290LC-10 40-461
40 Troubleshooting
40-462 PC290LC-10
40 Troubleshooting
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality

Action F pump swash plate sensor malfunction
Failure code
level Failure
L01 DKR0MA
Details of • Signal voltage of F pump swash plate sensor circuit is below 0.5 V or above 4.5 V.
failure
controller
Problem on • Low-load matching function that lowers engine speed when load on engine is low does
machine not work.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will be broken. Accordingly, take extreme care when checking.
• Voltage from front pump swash plate sensor can be checked with monitoring function.
(Code: 01138 F pump swash plate sensor voltage)
1 sensor power
supply 1 line
2 sensor power
Between P27
Defective F pump
swash plate sensor Between P27 (male) (A) and (B) Approx. 6 kz
3
Between P27 (female) (B) and (C) Approx. 6 kz
(internal defect) Resistance
Between P27 (female) (A) and (C) Approx. 170 z
Between P27 (male) (C) and ground Min. 1 Mz
Defective F pump 2. Insert T-adapters into connector P27.
4 swash plate sensor 3. Turn starting switch to ON position.
(internal defect) Between P27 (C)
Voltage Sensor output Approx. 3 V
and (B)
Defective F pump 3. Starting engine.
5 swash plate sensor a Position all control levers in NEUTRAL position to set swash plate of pump at
(internal defect) its minimum angle.
Between P27 (C) Approx. 1.4 V
and (B)
PC290LC-10 40-463
40 Troubleshooting

difficult to judge whether cause is defective sensor, ground fault or hot short
circuit of harness. Check as followings.
swash plate sensor 2. Replace connector P27 with connector P28.
6
(internal defect)
4. If E mark is not displayed in this failure code column, F pump swash plate
side.
7 (wire breakage or (female) (A)
connector) Resistance a If power supply voltage in check on
required. Max. 1 z
(female) (B)
(female) (C) Max. 1 z

8 female side.
(contact with GND
or P27 (female) (C)
circuit)
Voltage Between P27 (female) (C) and ground Max. 1 V
controller
40-464 PC290LC-10
40 Troubleshooting
Circuit diagram related to F and R pump swash plate sensor
PC290LC-10 40-465
40 Troubleshooting
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality

Action R pump swash plate sensor malfunction
Failure code
level Failure
L01 DKR1MA
Details of • Signal voltage of R pump swash plate sensor circuit is below 0.5 V or above 4.5 V.
failure
controller
Problem on • Low-load matching function that lowers engine speed when load on engine is low does
machine not work.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will be broken. Accordingly, take extreme care when checking.
• Voltage from rear pump swash plate sensor can be checked with monitoring function.
(Code: 01140 R pump swash plate sensor voltage)
1 sensor power
supply 1 line
2 sensor power
Between P28
Defective R pump
swash plate sensor Between P28 (male) (A) and (B) Approx. 6 kz
3
Between P28 (female) (B) and (C) Approx. 6 kz
(internal defect) Resistance
Between P28 (female) (A) and (C) Approx. 170 z
Between P28 (male) (C) and ground Min. 1 Mz
Defective R pump 2. Insert T-adapters into connector P28
4 swash plate sensor 3. Turn starting switch to ON position.
(internal defect) Between P28 (C)
Voltage Sensor output Approx. 3 V
and (B)
2. Insert T-adapters into connector P28
Defective R pump 3. Starting engine.
5 swash plate sensor a Position all control levers in NEUTRAL position to set swash plate of pump at
(internal defect) its minimum angle.
Between P28 (C) Approx. 1.4 V
and (B)
40-466 PC290LC-10
40 Troubleshooting

difficult to judge whether cause is defective sensor, ground fault or hot short
circuit of harness. Check as followings.
swash plate sensor 2. Replace connector P28 with connector P27.
6
(internal defect)
4. If E mark is not displayed in this failure code column, R pump swash plate
side.
7 (wire breakage or (female) (A)
connector) Resistance a If power supply voltage in check on
required. Max. 1 z
(female) (B)
(female) (C) Max. 1 z

8 female side.
(contact with GND
or P28 (female) (C)
circuit)
Voltage Between P28 (female) (C) and ground Max. 1 V
controller
PC290LC-10 40-467
40 Troubleshooting
Circuit diagram related to F and R pump swash plate sensor
40-468 PC290LC-10
40 Troubleshooting
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality

Action Camera 2 image reverse drive malfunction
Failure code
level Failure
L01 DR21KX
Details of • Output voltage of camera 2 image reverse drive line (pin 6 of connector CM04) differs
failure from command voltage output from machine monitor.
Action of • Does not display image of camera 2.
controller
Problem on • Image of camera 2 is not displayed.
machine
• When output voltage of camera 2 image reverse drive line (pin 6 of connect CM04) is 0 V,
original image is sent. When it is 8 V, mirror image is sent (since power supply voltage of
Related camera is 8 V, 8 V is used as command voltage to sent mirror image).
information • Since two or more connector A46 may be provided, you must check connector A41 to
identify which camera is assigned to camera 2.
Open circuit in 2. Disconnect connectors CM04 and A46, and connect T-adapters to each female
1 (wire breakage or Between CM04 (female) (6) and A46
Between CM04 (female) (8) and A46

wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapters to either
circuit) Between ground and CM04 (female) (6)
Resistance or A46 (female) (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector A46 and connect T-adapters to female side.
3
(contact with 24 V a Check that camera 2 is set for original images.
circuit) Between A46 (female) (3) and (4), or
Voltage Max. 1 V
between A46 (female) (3) and ground
Short circuit in 2. Disconnect connector CM04 and connect T-adapters to female side.
4 wiring harness Between CM04 (female) (6) and each
Resistance pin other than (6) Min. 1 Mz
If no failure is found by above checks, camera 2 is defective. (Since this is an
5 Defective camera 2 internal defect, troubleshooting cannot be performed.)
monitor
PC290LC-10 40-469
40 Troubleshooting
Circuit diagram related to camera
40-470 PC290LC-10
40 Troubleshooting
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality

Action Camera 3 image reverse drive malfunction
Failure code
level Failure
L01 DR31KX
Details of • Output voltage of camera 3 image reverse drive line (pin 7 of connector CM04) differs
failure from command voltage output from machine monitor.
Action of • Does not display image of camera 3.
controller
Problem on • Image of camera 3 is not displayed.
machine
• When output voltage of camera 3 image reverse drive line (pin 7 of connect CM04) is 0 V,
original image is sent. When it is 8 V, mirror image is sent (since power supply voltage of
Related camera is 8 V, 8 V is used as command voltage to sent mirror image).
information • Since two or more connector A46 may be provided, you must check connector A42 to
identify which camera is assigned to camera 3.
Open circuit in 2. Disconnect connectors CM04 and A46, and connect T-adapters to each female
1 (wire breakage or Between CM04 (female) (7) and A46
Between CM04 (female) (8) and A46

wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapters to either
circuit) Between ground and CM04 (female) (7)
Resistance or A46 (female) (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector A46 and connect T-adapters to female side.
3
(contact with 24 V a Check that camera 3 is set for original images.
circuit) Between A46 (female) (3) and (4) or
Voltage Max. 1 V
ground
Short circuit in 2. Disconnect connector CM04 and connect T-adapter to female side.
4 wiring harness Between CM04 (female) (7) and each
Resistance pin other than (7) Min. 1 Mz
If no failure is found by above checks, camera 3 is defective. (Since this is an
5 Defective camera 3 internal defect, troubleshooting cannot be performed.)
monitor
PC290LC-10 40-471
40 Troubleshooting
Circuit diagram related to camera
40-472 PC290LC-10
40 Troubleshooting
Failure code [DV20KB] Travel Alarm Short Circuit

Action Short circuit in travel alarm circuit
Failure code
level Failure
L01 DV20KB
Details of • Abnormal current flows when drive current is output to travel alarm circuit.
failure
• Stops output to travel alarm circuit.
Problem on
• Travel alarm does not sound.
machine
2. Disconnect connector M14 and connect T-adapters to female side.
4. Operate travel lever to perform troubleshooting.
Defective travel Travel lever:
alarm Max. 1 V
1 Between M14 NEUTRAL
(internal defect) Voltage Travel lever:
FORWARD or 20 to 30 V
REVERSE
a If above voltage is normal but travel alarm does not sound, travel alarm is
defective.
wiring harness 2. Disconnect connectors CP02 and M14, and connect T-adapters to either
2 female side.
(contact with GND
(107) or M14 (female) (1)
2. Insert T-adapters into connector M14.
4. Operate travel lever to perform troubleshooting.
Defective pump
3 Travel lever:
controller Max. 1 V
Between M14 (1) NEUTRAL
Voltage Travel lever:
and (2)
FORWARD or 20 to 30 V
REVERSE
PC290LC-10 40-473
40 Troubleshooting
Circuit diagram related to travel alarm
40-474 PC290LC-10
40 Troubleshooting
Failure code [DW43KA] Travel Speed Sol Open Circuit

Action Open circuit in travel speed Hi/Lo selector solenoid circuit
Failure code
level Failure
L01 DW43KA
Details of • Voltage at controller output terminal exceeds standard value when controller does not
failure output signal voltage to travel speed selector solenoid.
Action of • None in particular (Since no current flows, solenoid is not energized.)
Problem on • Actual travel speed at "Hi" setting is slow. (Although "Hi" speed is displayed on machine
machine monitor, actual travel speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (If controller sends solenoid ON command, monitoring display is ON
Related even if solenoid is not switched to ON due to open circuit.)
information (Code: 02300 Solenoid 1)
Defective travel 1. Turn starting switch to OFF position.
speed selector 2. Disconnect connector V04 and connect T-adapters to male side.
1 solenoid
(internal open Resistance Between V04 (female) (1) and (2) 20 to 60 z
circuit)
2 (wire breakage or
defective contact of Between CP02 (female) (93) and each
Resistance of CP02 (female) (115), (117) and (120) 20 to 60 z
connector)
a If no failure is found by above checks, this check is not required.
wiring harness 2. Disconnect connectors CP02 and V04, and connect T-adapters to either
2 (wire breakage or female side.
defective contact of Between CP02 (female) (93) and V04
Between V04 (female) (2) and each of
CP02 (female) (115), (117) and (120) Max. 1 z
controller
PC290LC-10 40-475
40 Troubleshooting
Circuit diagram related to travel speed solenoid
40-476 PC290LC-10
40 Troubleshooting
Failure code [DW43KB] Travel Speed Sol Short Circuit

Action Travel speed solenoid short circuit
Failure code
level Failure
L01 DW43KB
Details of • When output current to travel speed selector solenoid is turned off, voltage at controller
failure output terminal was detected to be above the standard value.
• Stops output to travel speed selector solenoid.
Problem on • "Hi" travel speed is slow. (Although "Hi" speed is displayed on machine monitor, travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
Related even if solenoid is not switched ON due to short circuit.)
speed selector 2. Disconnect connector V04, and connect T-adapter to male side.
solenoid
1 Between V04 (female) (1) and (2) 20 to 60 z
(internal short
circuit or ground Resistance
Between V04 (male) (1) and ground Min. 1 Mz
fault)
Short circuit or 2. Disconnect connector CP02 and connect T-adapter to female side.
2 ground fault in Between CP02 (female) (93) and each
harness of CP02 (female) (115), (117) and (120) 20 to 60 z
Resistance
a If no abnormality is found in check on cause 2, this check is not required.
harness 2. Disconnect connectors CP02 and V04, and connect T-adapters to either
3 female side.
(Contact with GND
Resistance ground, or between V04 (female) (1) and Min. 1 Mz
ground
Hot short-circuiting 1. Turn starting switch to OFF position.
of harness 2. Disconnect connector V04.
4 3. Connect T-adapter to female side of connector V04.
(Contact with 24 V 4. Turn starting switch to ON position.
circuit)
Voltage Between V04 (female) (1) and ground Max. 1 V
controller
PC290LC-10 40-477
40 Troubleshooting
40-478 PC290LC-10
40 Troubleshooting
Failure code [DW45KA] Swing Brake Sol Open Circuit

Action Open circuit in swing holding brake circuit
Failure code
level Failure
L03 DW45KA
Details of • Controller output voltage to swing holding brake solenoid exceeds standard value when it
failure stops outputting drive current to swing holding brake solenoid.
• None in particular (Since no current flows, solenoid is not energized. Namely, swing
Action of holding brake remains applied.)
Problem on • Upper structure cannot swing (swing holding brake is not released).
machine
• If solenoid and wiring harness are normal, operator can swing upper structure by setting
swing brake cancel switch to RELEASE position (however, swing holding brake is not
released when upper structure stops). Namely, swing holding brake remains applied.)
• Both swing lock switch and swing holding brake cancel switch must be turned to OFF
position during troubleshooting.
Related • Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information monitoring function. (If controller sends solenoid ON command, monitoring display is ON
even if solenoid is not switched to ON due to open circuit.)
(Code: 02300 Solenoid 1)
• Swing holding brake solenoid is powered from pin (101) of pump controller connector
CP02 or pin (1) of fuse box F01.
Blown No. 1 of fuse If fuse is blown, see troubleshooting for [DW45KB].
1 F01 (right top fuse)
2 holding brake 2. Disconnect connector V03 and connect T-adapters to male side.
solenoid Resistance Between V03 (male) (1) and (2) 20 to 60 z
2. Remove diode array D01 and connect T-adapters to male side.
Defective diode
3 array D01 a Check by using multimeter in diode range.
Between D01 (male) (3) (+) and (7) (-) No continuity
Continuity
Between D01 (male) (7) (+) and (3) (-) Continuity
Defective diode
Continuity
2. Remove diode D01.
Open circuit in 3. Disconnect connectors CP02 and connect T-adapters to each female side.
wiring harness
5 (wire breakage or a Set swing lock switch to OFF position.
defective contact of Between CP02 (female) (101) and D01
connector)
Resistance
Between D01 (female) (3) and CP02
(female) (115) 20 to 60 z
PC290LC-10 40-479
40 Troubleshooting

wiring harness 2. Disconnect connectors D01, CP02, and V03, and connect T-adapters to each
6 (wire breakage or female side.
defective contact of Between D01 (female) (3) and V03
controller
40-480 PC290LC-10
40 Troubleshooting
Circuit diagram related to swing holding brake solenoid
PC290LC-10 40-481
40 Troubleshooting
Failure code [DW45KB] Swing Brake Sol Short Circuit

Action swing holding brake solenoid system short circuit
Failure code
level Failure
L03 DW45KB
Details of • When outputting current to swing holding brake solenoid, abnormal current flows in circuit
failure and short circuit is detected.
• Stops output to swing holding brake solenoid.
Problem on • Swing operation cannot be performed (swing holding brake is not released).
machine
• If solenoid and harness are normal, operator can swing upper structure by setting swing
brake cancel switch in release position (swing holding brake does not work, however,
when performing stop operation of upper strueture. Namely, swing holding brake remains
applied.)
• Both swing lock switch and swing brake cancel switch must be turned to OFF position as
long as troubleshooting is continued.
Related • Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information monitoring function. (If controller sends solenoid ON command, monitoring display is ON
even if solenoid is not switched ON due to short circuit.)
(Code: 02300 Solenoid 1)
• Method of reproducing failure code: Start engine and operate boom, arm, or bucket or
swing upper structure.
• Power of swing holding brake solenoid circuit is fed from pin (101) of pump controller
connector CP02 or pin (1) of fuse box F01.
Blown No. 1 of fuse Even if fuse is blown, perform troubleshooting according to following steps to
1 F01 (right top fuse) identify cause.
Defective swing 2. Disconnect connector V03, and connect T-adapter to male side.
2 holding brake
Between V03 (male) (1) and (2) 20 to 60 z
solenoid Resistance
Defective diode
Continuity
Defective diode
Continuity
Ground fault in 2. Remove No. 1 of fuse F01 (right top fuse, 5 A) and diode D01.
harness 3. Disconnect connectors CP02 and V03.
5 4. Connect T-adapters to female sides of connectors CP02 and D01.
(Contact with GND
Between CP02 (female) (101) and
circuit) Min. 1 Mz
Resistance ground
Between D01 (female) (3) and ground Min. 1 Mz
2. Remove No. 1 of fuse F01 (right top fuse, 5 A) and diode D01.
Short-circuiting of 3. Disconnect connector CP02.
6 4. Connect T-adapters to female sides of connectors D01 and CP02.
harness
Between D01 (female) (3) and each of 20 to 60 z
Resistance CP02 (female) (115), (117) and (120)
40-482 PC290LC-10
40 Troubleshooting

circuit)
controller
PC290LC-10 40-483
40 Troubleshooting
40-484 PC290LC-10
40 Troubleshooting
Failure code [DW91KA] Travel Junction Sol Open Circuit

Action Open circuit in travel junction solenoid circuit
Failure code
level Failure
L01 DW91KA
Details of • Controller output voltage to travel junction solenoid exceeds standard value when it stops
failure outputting drive current to travel junction solenoid.
Action of • None in particular (Since no current flows, solenoid does not operate.)
Problem on • Machine cannot turn easily during traveling.
machine
• Controller's command (ON/OFF) to travel junction valve solenoid can be checked with
Defective junction 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V05 and connect T-adapters to male side.
1
(internal open
circuit) Resistance Between V05 (male) (1) and (2) 20 to 60 z
Open circuit or
2 short circuit in
wiring harness Between CP02 (female) (85) and each

wiring harness 2. Disconnect connectors CP02 and V05, and connect T-adapters to each female
controller
PC290LC-10 40-485
40 Troubleshooting
Circuit diagram related to travel interconnection valve solenoid
40-486 PC290LC-10
40 Troubleshooting
Failure code [DW91KB] Travel Junction Sol Short Circuit

Action Travel interconnection solenoid short circuit
Failure code
level Failure
L01 DW91KB
Details of • When outputting current to travel interconnection valve solenoid, abnormal current flows
failure in circuit and short circuit is detected.
• Stop outputting current to travel junction solenoid.
Problem on • Machine is not steered easily during travel.
machine
• Controller's command (ON/OFF) to travel junction valve solenoid can be checked with
Related even if solenoid is not switched ON due to short circuit.)
interconnection 2. Disconnect connector V05, and connect T-adapter to male side.
solenoid
1 Between V05 (male) (1) and (2) 20 to 60 z
(internal short
fault)
Resistance
3 female side.
(Contact with GND
ground
circuit)
controller
PC290LC-10 40-487
40 Troubleshooting
Circuit diagram related to travel interconnection valve solenoid
40-488 PC290LC-10
40 Troubleshooting
Failure code [DWA2KA] Attachment Sol Open Circuit

Action Open circuit in ATT 1-way/2-way selector solenoid circuit
Failure code
level Failure
L03 DWA2KA
Details of • Controller output voltage to ATT return selector solenoid exceeds standard value when it
failure stops outputting drive current to ATT return selector solenoid.
Problem on • Hydraulic circuit for attachment does not change to single-acting circuit.
machine
• Command of controller (ON/OFF) to ATT return selector solenoid can be checked with
monitoring function. (even if solenoid is not switched to ON due to open circuit, display on
Related monitor is ON when ON command is sent from controller).
• Method of reproducing failure code: Turn starting switch ON and set machine in mode
other than breaker mode (B).
attachment return 2. Disconnect connector V07, and connect T-adapters to male side.
1 selector solenoid
(internal open Resistance Between V07 (male) (1) and (2) 20 to 60 z
circuit)
Open circuit or 2. Disconnect connector CP02 and connect T-adapters to female side.
wiring harness of CP02 (female )(115), (117) and (120) 20 to 60 z
Resistance
a If no failure is found in check on cause 2, this check is not required.
controller
PC290LC-10 40-489
40 Troubleshooting
Circuit diagram related to ATT single/multiple selector solenoid
40-490 PC290LC-10
40 Troubleshooting
Failure code [DWA2KB] Attachment Sol Short Circuit

Action Attachment single/double selector solenoid short circuit
Failure code
level Failure
L03 DWA2KB
Details of • When outputting current to attachment return selector solenoid, abnormal current flows in
failure circuit and short circuit is detected.
• Stops outputting current to attachment return selector solenoid.
Problem on • Hydraulic circuit for attachment does not change to single-acting circuit.
machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (If controller sends solenoid ON command, monitoring display is
Related ON even if solenoid is not switched ON due to short circuit.)
• Method of reproducing failure code: Turn starting switch to ON position and set machine
in breaker mode (B).
attachment return 2. Disconnect connector V07, and connect T-adapter to male side.
1 selector solenoid
(Internal short Resistance
circuit, ground fault) Between V07 (male) (1) and ground Min. 1 Mz
2 ground fault in
harness Between CP02 (female) (86) and each

Ground fault in
harness
3 2. Disconnect connectors CP02 and V07, and connect T-adapters to either
(Contact with GND female side.
circuit) Between CP02 (female) (86) or V07

circuit)
controller
PC290LC-10 40-491
40 Troubleshooting
Circuit diagram related to ATT single/multiple selector solenoid
40-492 PC290LC-10
40 Troubleshooting
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit

Action 2-stage relief solenoid system open circuit
Failure code
level Failure
L01 DWK0KA
Details of • When stop outputting current to 2-stage relief solenoid circuit, controller solenoid output
failure voltage is above standard value and open circuit is detected.
Problem on • Travel power is low (The main relief valve is not set in the HIGH-PRESSURE position)
machine • Power maximizing function does not work.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
even if solenoid is not switched ON due to open circuit.)
Related (Code: 02300 Solenoid 1)
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
• Controller detects open circuit if output to solenoid is OFF.
Defective 2-stage 1. Turn starting switch to OFF position.
relief solenoid 2. Disconnect connector V02, and connect T-adapter to male side.
1
(internal open
circuit in harness) Resistance Between V02 (male) (1) and (2) 20 to 60 z
2. Disconnect connector CP02 and connect T-adapter to female side.
Open circuit or
2 short circuit in a If resistance is above 1 Mz, harness has open circuit. If resistance is below 1
wiring harness z, harness has short circuit.
Between CP02 (female) (109) and each
a If cause 2 is not the cause for the trouble, this check is not required.
harness 2. Disconnect connectors CP02 and V02, and connect T-adapters to each female
3 (Wire breakage or side.
controller
PC290LC-10 40-493
40 Troubleshooting
Circuit diagram related to 2-stage relief solenoid
40-494 PC290LC-10
40 Troubleshooting
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit

Action 2-stage relief solenoid system short circuit
Failure code
level Failure
L01 DWK0KB
Details of • When outputting current to drive 2-stage relief solenoid circuit, abnormal current flows in
• Stops the power supply to 2-stage relief solenoid circuit.
Problem on • Travel power is low (The main relief valve is not set in the HIGH-PRESSURE position)
machine • Power maximizing function does not work.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
even if solenoid is not switched ON due to short circuit.)
Related (Code: 02300 Solenoid 1)
• Controller detects open circuit if output to solenoid is OFF.
Defective 2-stage 1. Turn starting switch to OFF position.
1 (internal short Between V02 (male) (1) and (2) 20 to 60 z
fault) Between V02 (female) (1) and ground Min. 1 Mz
Ground fault in 2. Disconnect connectors CP02 and V02, and connect T-adapters to female sides
harness of V02.
2
(Contact with GND Between CP02 (female) (109) and
circuit) Resistance ground, or between V02 (female) (1) and Min. 1 Mz
ground
Short-circuiting of 2. Disconnect connectors CP02 and V02, and connect T-adapters to female side
3
harness of V02.
Resistance Between V02 (female) (1) and (2) Min. 1 Mz
circuit)
controller
PC290LC-10 40-495
40 Troubleshooting
40-496 PC290LC-10
40 Troubleshooting
Failure code [DWK2KA] Variable Back Press Sol Open Circuit

Action Open circuit invariable back-pressure solenoid circuit
Failure code
level Failure
L01 DWK2KA
Details of • Controller output voltage to variable back-pressure solenoid exceeds standard value
failure when it stops outputting drive current to variable back-pressure solenoid.
Problem on • Set pressure of back-pressure valve cannot be changed
machine
• Controller's command (ON/OFF) to variable back-pressure solenoid can be checked with
Defective variable 1. Turn starting switch to OFF position.
back pressure 2. Disconnect connector V25 and connect T-adapters to male side.
1 solenoid
circuit)
Open circuit or
2 ground fault in
a If no failure is found in check on cause 2, this check is not required.

controller
PC290LC-10 40-497
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
40-498 PC290LC-10
40 Troubleshooting
Failure code [DWK2KB] Variable Back Press Sol Short Circuit

Action Short circuit in variable back pressure solenoid valve
Failure code
level Failure
L01 DWK2KB
Details of • When outputting current to variable back pressure solenoid, abnormal current flows in
• Stop output to variable back pressure solenoid.
Problem on • Set pressure of back pressure valve cannot be changed
machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked by
using monitoring function. (If controller sends solenoid ON command, monitoring display
Related is ON even if solenoid is not switched ON due to short circuit.)
Defective variable 1. Turn starting switch to OFF position.
back pressure 2. Disconnect connector V25, and connect T-adapter to male side.
solenoid
(internal short
fault)
Short circuit or
2 ground fault in 20 to 60 z
of CP02 (female) (115), (117) and (120)
harness Resistance
ground Min. 1 Mz

3 female side.
(Contact with GND
ground
circuit)
controller
PC290LC-10 40-499
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
40-500 PC290LC-10
40 Troubleshooting
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit

Action Open circuit of swing C/O solenoid system
Failure code
level Failure
L01 DWK8KA
Details of • When the output to swing C/O solenoid is OFF, open circuit is detected due to excessive
failure output voltage of controller solenoid above standard value.
Problem on • Swing motor relief pressure remains Lo
machine
• Command (ON/OFF) to swing C/O solenoid by controller can be checked with monitoring
function. (Even if solenoid is not ON due to open circuit, if controller command is ON,
Related monitoring display is ON.)
information (Code: 02301 solenoid 2)
cut-off solenoid 2. Disconnect connector V06, and connect T-adapter to male side.
1
(internal open
Open circuit or
2 ground fault of

wiring harness 2. Disconnect connector CP02 and V06, then connect T-adaptors to each female
3 (Wire breakage or side.
CP02 (female) (115), (117) and (120) 1 Max. 1 z
controller
PC290LC-10 40-501
40 Troubleshooting
Circuit diagram related to swing cut-off solenoid
40-502 PC290LC-10
40 Troubleshooting
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit

Action Short circuit of swing C/O solenoid system
Failure code
level Failure
L01 DWK8KB
Details of • When output to swing C/O solenoid is ON, short circuit is detected due to abnormal
failure current in circuit.
• Output to swing C/O solenoid is turned to OFF position.
Problem on • Swing motor relief pressure remains Lo
machine
• Command (ON/OFF) to swing C/O solenoid by controller can be checked with monitoring
function.
Related (Code: 02301 solenoid 2)
information • Method of reproducing failure code: Engine start + Hoist swing only operation (Do not
operate arm.)
cut-off solenoid 2. Disconnect connector V06, and connect T-adapter to male side.
1 (internal short Between V06 (male) (1) and (2) 20 to 60z
fault) Between V06 (male) (1) and ground Min. 1 Mz
Short circuit or
of CP02 (female) (115), (117) and (120)
harness Resistance
ground Min. 1 Mz

Ground fault in
wiring harness
3 2. Disconnect connectors CP02 and V06, then connect T-adaptors to either
(Contact with female side.
ground circuit) Between ground and CP02 (female) (94)
Resistance or V06 (female) (1) Min. 1 Mz

wiring harness 2. Disconnect connector V06.
4 3. Connect T-adaptor to female side of connector V06.
circuit)
controller
PC290LC-10 40-503
40 Troubleshooting
Circuit diagram related to swing cut-off solenoid
40-504 PC290LC-10
40 Troubleshooting
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit

Action Open circuit in F-PC-EPC solenoid circuit
Failure code
level Failure
L03 DXA8KA
Details of • When F-PC-EPC solenoid is driven, no current flows.
failure
Problem on • If pump load increases, engine speed decreases sharply and engine may stall.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stalling by
turning emergency pump drive switch to ON.
Related • Drive current of F-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC solenoid current (F))
Incorrect operation Set emergency pump drive switch to normal position (lower side).
1 of emergency
pump drive switch
Defective F-PC- 1. Turn starting switch to OFF position.
EPC solenoid 2. Disconnect connector V11 and connect T-adapters to male side.
2
(internal open
2. Disconnect connector S25 and connect T-adapters to female side.
Defective Switch position:
emergency pump Max. 1 z
Between S25 Normal
drive switch (male) (3) and (2) Switch position:
3 Min. 1 Mz
(internal open Emergency
circuit in wiring Resistance
Switch position:
harness) Max. 1 z
Between S25 Normal
(male) (6) and (5) Switch position:
Emergency Min. 1 Mz

4 short circuit in a Check that emergency pump drive switch is at normal position (lower side).
wiring harness

2. Disconnect connectors CP02, S25, and V11, and connect T-adapters to each
wiring harness Between CP02 (female) (96) and S25
5 (wire breakage or
defective contact of Between S25 (female) (2) and V11
Between S25 (female) (6) and each of
Between S25 (female) (5) and V11
controller
PC290LC-10 40-505
40 Troubleshooting
Circuit diagram related to PC-EPC solenoid
40-506 PC290LC-10
40 Troubleshooting
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit

Action Short circuit in F-PC-EPC solenoid circuit
Failure code
level Failure
L03 DXA8KB
Details of • When F-PC-EPC solenoid is driven, abnormal current flows in circuit.
failure
Action of • Stops outputting current to F-PC-EPC solenoid.
machine
Related • Drive current of F-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC solenoid current (F))
Defective service 1. Turn starting switch to OFF position.
PC-EPC (F) 2. Disconnect connector V11 and connect T-adapters to male side.
solenoid
(internal short
fault)
Defective 2. Disconnect connector S25 and connect T-adapters to female side.
emergency pump Between S25
drive switch (male) (5) and each Switch position: Min. 1 Mz
2 Normal
(internal short of (2) and (3)
Between ground
fault) and S25 (male) (2) Switch position:
Min. 1 Mz
or (3) Normal

Short circuit or
3 ground fault in a Check that emergency pump drive switch is at normal position (lower side).
of CP02 (female) (115), (117) and (120) 3 to 14 z
Resistance
Ground fault in 2. Disconnect connectors CP02, S25, and V11, and connect T-adapters to either
4
(contact with GND Between ground and CP02 (female) (96)
circuit) or S25 (female) (3) Min. 1 Mz
Resistance
Between ground and S25 (female) (5) or
V11 (female) (2) Min. 1 Mz
controller
PC290LC-10 40-507
40 Troubleshooting
40-508 PC290LC-10
40 Troubleshooting
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit

Action Open circuit R-PC-EPC solenoid circuit
Failure code
level Failure
L03 DXA9KA
Details of • When R-PC-EPC solenoid is driven, no current flows.
failure
Action of • None in particular (Since no current flows, solenoid.)
machine
Related • Drive current of R-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC solenoid current (R))
Incorrect operation Set emergency pump drive switch to normal position (lower side).
1 of emergency
pump drive switch
Defective R-PC- 1. Turn starting switch to OFF position.
2
(internal open
2. Disconnect connector S25 and connect T-adapters to female side.
Defective Switch position:
Max. 1 z
emergency pump Between S25 Normal
drive switch (male) (9) and (8) Switch position:
3 Min. 1 Mz
Emergency
(internal open Resistance
circuit) Switch position:
Max. 1 z
Between S25 Normal
(male) (12) and (11) Switch position:
Emergency Min. 1 Mz

4 short circuit in a Check that emergency pump drive switch is at normal position (lower side).
wiring harness

2. Disconnect connectors CP02, S25, and V12, and connect T-adapters to each
wiring harness Between CP02 (female) (104) and S25
5 (wire breakage or
defective contact of Between S25 (female) (8) and V12
connector)
Resistance
Between S25 (female) (12) and each of
Between S25 (female) (11) and V12
controller
PC290LC-10 40-509
40 Troubleshooting
40-510 PC290LC-10
40 Troubleshooting
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit

Action Short circuit in R-PC-EPC solenoid circuit
Failure code
level Failure
L03 DXA9KB
Details of • When R-PC-EPC solenoid is driven, abnormal current flows.
failure
• Stops outputting current to R-PC-EPC solenoid.
machine
Related • Drive current of R-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC solenoid current (R))
Defective R-PC- 1. Turn starting switch to OFF position.
Defective 2. Disconnect connector S25 and connect T-adapters to female side.
emergency pump Between S25
drive switch (male) (8), (9) to Switch position:
2 Min. 1 Mz
(internal short (11) Normal
Between ground
fault) and S25 (male) (8) Switch position:
Min. 1 Mz
or (9) Normal

Short circuit or a Check that emergency pump drive switch is at normal position (lower side).
Resistance
ground Min. 1 Mz

Ground fault in 2. Disconnect connectors CP02, S25, and V12, and connect T-adapter to either
4 (contact with GND Between ground and CP02 (female)
circuit) (104) or between S25 (female) (9) Min. 1 Mz
Resistance
Between ground and S25 (female) (11)
or between V12 (female) (2) Min. 1 Mz
controller
PC290LC-10 40-511
40 Troubleshooting
40-512 PC290LC-10
40 Troubleshooting
Failure code [DXE0KA] LS-EPC Sol Open Circuit

Action Open circuit in LS-EPC solenoid circuit
Failure code
level Failure
L01 DXE0KA
Details of • When LS-EPC solenoid is driven, no current flows.
failure
Problem on • Travel speed at Lo and Mi speed setting is high.
machine • Work equipment speed and swing speed are high in fine control mode (L).
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500 LS-EPC solenoid current)
Defective LS-EPC 1. Turn starting switch to OFF position.
1
(internal open
Open circuit or
2 short circuit in

connector)
Resistance
controller
PC290LC-10 40-513
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
40-514 PC290LC-10
40 Troubleshooting
Failure code [DXE0KB] LS-EPC Sol Short Circuit

Action Short circuit in LS-EPC solenoid circuit
Failure code
level Failure
L01 DXE0KB
Details of • When LS-EPC solenoid is driven, abnormal current flows.
failure
• Stops outputting current to LS-EPC solenoid.
Problem on • Travel speed at Lo and Mi setting is high.
machine • Work equipment speed and swing speed are high in fine control mode (L).
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500 LS-EPC solenoid current)
Defective LS-EPC 1. Turn starting switch to OFF position.
Short circuit or 2. Disconnect connector CP02 and connect T-adapters to female side.
Resistance
Resistance , or V19 (female) (1) Min. 1 Mz
controller
PC290LC-10 40-515
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
40-516 PC290LC-10
40 Troubleshooting
Failure code [DXE4KA] Attachment Flow EPC Open Circuit

Action Open circuit in Attachment flow throttle EPC circuit
Failure code
level Failure
DXE4KA
Details of • When attachment flow throttle EPC solenoid is driven, no current flows.
failure
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow throttle EPC solenoid can be checked with monitoring
function.
Related (Code: 01700 Service solenoid current)
information • Method of reproducing failure code: Turn starting switch to ON position and set machine
in breaker mode (B).
attachment flow 2. Disconnect connector V30, and connect T-adapters to male side.
throttle EPC
1 solenoid
circuit)
Open circuit or
2 short circuit in

connector)
Resistance
controller
PC290LC-10 40-517
40 Troubleshooting
Circuit diagram related to service flow throttle EPC
40-518 PC290LC-10
40 Troubleshooting
Failure code [DXE4KB] Attachment Flow EPC Short Circuit

Action Short circuit in attachment flow throttle EPC solenoid circuit
Failure code
level Failure
DXE4KB
Details of • When attachment flow throttle EPC solenoid is driven, abnormal current flows.
failure
• Stops outputting current to attachment flow throttle EPC solenoid.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow throttle EPC solenoid can be checked with monitoring
function.
Related (Code: 01700 Service solenoid current)
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B).
attachment flow 2. Disconnect connector V30, and connect T-adapters to male side.
throttle EPC
1 solenoid
(internal short Resistance
circuit or ground Between V30 (male) (1) and ground Min. 1 Mz
fault)
Resistance
circuit) Between ground and CP02 (female)
Resistance (97), or V30 (female) (1) Min. 1 Mz
controller
PC290LC-10 40-519
40 Troubleshooting
Circuit diagram related to service flow throttle EPC
40-520 PC290LC-10
40 Troubleshooting
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit

Action Open circuit in pump merge-divider main solenoid circuit
Failure code
level Failure
L01 DXE5KA
Details of • When pump merge-divider (main) EPC solenoid is driven, no current flows.
failure
• None in particular (Solenoid is not energized because no current flows to it. Pump merge-
Action of divider LS solenoid, too, is not energized since no current flows to it.)
is turned to OFF position.
Problem on • Single operation speed of work equipment and swing is high in fine control mode (L).
machine • Machine cannot turn easily during traveling.
• Drive current of pump merge-divider main EPC solenoid can be checked with monitoring
function.
Related (Code: 08000 Merge-divider (main) solenoid current)
information • Method of reproducing failure code: Turn starting switch to ON position, start engine, and
then drive machine without operating work equipment and swinging.
Defective merge- 1. Turn starting switch to OFF position.
divider main EPC 2. Disconnect connector V23 and connect T-adapters to male side.
1 solenoid
circuit)
Open circuit or
2 short circuit in

connector)
Resistance
CP02 (115), (117) and (120) Max. 1 z
controller
PC290LC-10 40-521
40 Troubleshooting
Circuit diagram related to pump merge-divider main solenoid
40-522 PC290LC-10
40 Troubleshooting
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit

Action Short circuit in pump merge-divider main solenoid circuit
Failure code
level Failure
L01 DXE5KB
Details of • When pump merge-divider (main) EPC solenoid is driven, abnormal current flows.
failure
• Stops outputting current to pump merge-divider (main) EPC solenoid. (Since no current
Action of flows, pump merge-divider LS solenoid is not energized, either.)
• Drive current of pump merge-divider main EPC solenoid can be checked with monitoring
function.
Related (Code: 08000 Merge-divider (main) solenoid current)
divider main EPC 2. Disconnect connector V23 and connect T-adapters to male side.
solenoid
(internal short
fault)
Short circuit or
of CP02 (female) (115), (117) and (120)
harness Resistance
ground Min. 1 Mz

circuit) Between ground and CP02 (female)
Resistance (112) or between V23 (female) (1) Min. 1 Mz
controller
PC290LC-10 40-523
40 Troubleshooting
Circuit diagram related to pump merge-divider main solenoid
40-524 PC290LC-10
40 Troubleshooting
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit

Action Open circuit in pump merge-divider LS solenoid open circuit
Failure code
level Failure
L01 DXE6KA
Details of • When pump merge-divider (LS) EPC solenoid is driven, no current flows.
failure
• None in particular (Solenoid is not energized because no current flows to it. Pump merge-
Action of divider main solenoid, too, is not energized since no current flows to it.)
• Drive current of pump merge-divider LS EPC solenoid can be checked with monitoring
function.
Related (Code: 08001 Merge-divider (LS) solenoid current)
divider LS EPC 2. Disconnect connector V24 and connect T-adapters to male side.
1 solenoid
circuit)
Open circuit or
2 short circuit in

connector)
Resistance
controller
PC290LC-10 40-525
40 Troubleshooting
Circuit diagram related to merge-divider LS solenoid
40-526 PC290LC-10
40 Troubleshooting
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit

Action Short circuit in pump merge-divider LS solenoid circuit
Failure code
level Failure
L01 DXE6KB
Details of • When pump merge-divider (LS) EPC solenoid is driven, abnormal current flows.
failure
• Stops outputting current to pump merge-divider (LS) EPC solenoid. (Since no current
Action of flows, merge-divider main solenoid is not energized, either.)
• Drive current of pump merge-divider LS EPC solenoid can be checked with monitoring
function.
Related (Code: 08001 Merge-divider (LS) solenoid current)
divider LS EPC 2. Disconnect connector V24 and connect T-adapters to male side.
solenoid
(internal short
fault)
Resistance
Resistance or between V24 (female) (1) Min. 1 Mz
controller
PC290LC-10 40-527
40 Troubleshooting
Circuit diagram related to merge-divider LS solenoid
40-528 PC290LC-10
40 Troubleshooting
Failure code [DY20KA] Wiper Working Abnormality

Action Wiper operation malfunction
Failure code
level Failure
DY20KA
Details of • When windshield wiper is turned on, W signal to indicate that wiper blade reaches end of
failure cleaning area is not input.
Action of • Stops output of actuating signal to wiper motor.
Problem on • Wiper motor does not operate.
machine
• Signal input (ON/OFF) of W contact signal to indicate that wiper blade reaches end of
cleaning area can be checked with monitoring function.
(Code: 02204 Switch input 5)
• Method of reproducing failure code: Turn starting switch to ON position and set wiper
switch to INT or ON position.
Wiper position:
Defective wiper Both ends of Max. 1 z
motor cleaning area
Between M05
1 Wiper position:
(internal open (female) (6) and (5)
circuit) Resistance Other than both
Min. 1 Mz
ends of cleaning
area
Between M05 Wiper position:
(female) (1) and (3) Max. 20 z
Whole area
2. Disconnect connectors CP01 and CP02, and connect T-adapters to each
female side.
Wiper position:
Both ends of Max. 1 z
Open circuit or Between CP01 cleaning area
2 short circuit in (female) (56) and Wiper position:
wiring harness ground Other than both
Resistance Min. 1 Mz
ends of cleaning
area
Between CP02
(female) (114) and Wiper position:
Max. 20 z
(119) Whole area

2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connector CP01 and CP02 and male
Open circuit in side of M05.
wiring harness Between CP01 (female) (56) and M05
3 (wire breakage or (male) (6) Max. 1 z
defective contact of Between M05 (male) (5) and ground
connector) (T01) Max. 1 z
Resistance
Between CP02 (female) (114) and M05
(male) (1) Max. 1 z
(male) (3) Max. 1 z
controller
PC290LC-10 40-529
40 Troubleshooting
Circuit diagram related to wiper
40-530 PC290LC-10
40 Troubleshooting
Failure code [DY20MA] Wiper Parking Abnormality

Action Wiper resting malfunction
Failure code
level Failure
DY20MA
Details of • When windshield wiper rests, P signal to indicate that wiper blade is in rest area is not
failure input.
Action of • Stops output of signal for resting wiper to wiper motor.
Problem on • Wiper motor does not rest wiper blade.
machine
• Condition of P contact signal to indicate that wiper blade is in area can be checked with
monitoring function.
• Method of reproducing failure code: Turn starting switch to ON position, set wiper switch
to INT or ON position, and then set it to OFF position.
Defective wiper Wiper position:
motor Max. 1 z
Between M05 Rest area
1
(internal open (female) (4) and (5) Wiper position:
circuit) Resistance Cleaning area Min. 1 Mz
Between M05 Wiper position:
Whole area
2. Disconnect connectors CP01 and CP02, and connect T-adapters to each
female side.
Wiper position:
Open circuit or Between CP01 Max. 1 z
Rest area
2 short circuit in (female) (75) and
wiring harness Wiper position:
ground Min. 1 Mz
Resistance Cleaning area
Between CP02
(female) (114) and Wiper position:
Max. 20 z
(119) Whole area

2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connector CP01 and CP02 and male
Open circuit in side of M05.
wiring harness Between CP01 (female) (75) and M05
3 (wire breakage or (male) (4) Max. 1 z
defective contact of Between M05 (male) (5) and ground
connector) (T01) Max. 1 z
Resistance
(male) (1) Max. 1 z
(male) (3) Max. 1 z
controller
PC290LC-10 40-531
40 Troubleshooting
40-532 PC290LC-10
40 Troubleshooting
Failure code [DY2CKB] Washer Drive Short Circuit

Action Short circuit in washer drive circuit
Failure code
level Failure
DY2CKB
Details of • Abnormal current flows when activating window washer motor drive.
failure
• Stops output of activating signal to washer motor.
Problem on • Window washer does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position and turn washer
information switch to ON position.
1 Defective fuse No.4 If the fuse is broken, the circuit probably has a ground fault, etc. (See Cause 5.)
Defective washer 1. Turn starting switch to OFF position.
motor 2. Disconnect connector M06 and connect T-adapters to male side.
2 (internal open Between M06 (male) (1) and (2) 5 to 20 z
circuit or ground Resistance Between ground and each of M06
fault) (male) (1) and (2) Min. 1 Mz

Defective diode 2. Disconnect diode array D02 and connect T-adapters to mail side.
array D02
3 a Check by using multimeter in diode range.
(internal open
circuit) Between D02 (male) (6) (+) and (2) (-) Continuity
Continuity
4 short circuit in 2. Disconnect connectors CP01 and connect T-adopters to each female side.
wiring harness Voltage Between CP01 (female) (3) and ground 20 to 30 V
Ground fault in 2. Remove fuse F01 (4).
wiring harness 3. Disconnect connectors M06, CP01, and D02, and connect T-adapters to any
circuit) Between ground and F01 (4), M06
(female) (2), or D02 (female) (2) Min. 1 Mz
Resistance
Between ground and CP01 (female) (3),
M06 (female) (1), or D02 (female) (6) Min. 1 Mz

wiring harness 2. Disconnect connectors CP01 and M06, and connect T-adapters to female side
6 of CP01.
(contact with 24 V
3. Remove fuse No. 4.
circuit)
Voltage Between CP01 (female) (3) and ground Max. 1V
controller
PC290LC-10 40-533
40 Troubleshooting
Circuit diagram related to window washer motor
40-534 PC290LC-10
40 Troubleshooting
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit

Action Short circuit in wiper motor drive (normal rotation) circuit
Failure code
level Failure
DY2DKB
Details of • Abnormal current flows when activating wiper motor drive (normal rotation side).
failure
• Stops output of activating signal to wiper motor drive (normal rotation side).
Problem on • Windshild wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
Defective wiper 1. Turn starting switch to OFF position.
motor 2. Disconnect connector M05 and connect T-adapters to female side.
1 (internal short Continuity Between M05 (female) (1) and (3) Continuity
circuit or ground
fault) Resistance Between M05 (female) (3) and ground Min. 1 Mz
Short circuit in 2. Disconnect connectors CP02 and M05 and connect T-adapters to either
2 wiring harness harness side.
Between CP02 (female) (119) and (114),
Resistance or between M05 (male) (1) and (3) Min. 1 Mz

wiring harness 2. Disconnect connectors CP02 and M05, and connect T-adapter to either
3 harness side.
(contact with GND
(119) or M05 (male) (3)
If no failure is found by above checks, pump controller is defective. (Since this is
• Reference
Defective pump 3. Turn starting switch to ON position.
4
controller 4. Set wiper switch to ON and OFF to perform troubleshooting.
Wiper switch: OFF Max. 3 V
Between M05 (3) Pulse of voltages
Voltage
and (5) Wiper switch: ON below 3 V and
above 20 V
PC290LC-10 40-535
40 Troubleshooting
40-536 PC290LC-10
40 Troubleshooting
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit

Action Short circuit in wiper motor drive (reverse rotation) circuit
Failure code
level Failure
DY2EKB
Details of • Abnormal current flows when activating wiper motor drive (reverse rotation side).
failure
• Stops of activating signal to wiper motor drive (reverse rotation side).
Problem on • Windshild wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
Defective wiper 1. Turn starting switch to OFF position.
motor 2. Disconnect connector M05 and connect T-adapters to female side.
1 (internal short Continuity Between M05 (female) (1) and (3) Continuity
circuit or ground
fault) Resistance Between M05 (female) (1) and ground Min. 1 Mz
Short circuit in 2. Disconnect connectors CP02 and M05 and connect T-adapters to either
2 wiring harness harness side.
Between CP02 (female) (119) and (114),
Resistance or between M05 (male) (1) and (3) Min. 1 Mz

wiring harness 2. Disconnect connectors CP02 and M05, and connect T-adapters to either
3 harness side.
(contact with GND
(114) or M05 (male) (1)
If no failure is found by above checks, pump controller is defective. (Since this is
• Reference
Defective pump 3. Turn starting switch to ON position.
4
controller 4. Turn wiper switch ON and OFF to perform troubleshooting.
Wiper switch: OFF Max. 3 V
Between M05 (3) Pulse of voltages
Voltage
and (5) Wiper switch: ON below 3 V and
above 20 V
PC290LC-10 40-537
40 Troubleshooting
40-538 PC290LC-10
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not rotate)

Failure • Engine does not start (Engine does not crank).
• Engine starting circuit has following two start lock mechanisms.
Related 1. Start lock by using password of machine monitor
information 2. Start lock by using lock lever
• In the case of "Battery relay does not make operating sound" when the starting switch is
turned to ON position, perform trouble shooting for E-1 also.
Defective fusible
1 2. Remove fusible links F04 and F05
link F04
Resistance Between terminals F04 and F05 Max. 1 z
Defective fusible
2 2. Remove fusible links F04 and F05
link F05
Resistance Between terminals F04 and F05 Max. 1 z
Defective fuse No. If fuse is broken, circuit probably has a grounding fault. (See Cause 19.)
3
3 in fuse box F01
Defective fuse No. If fuse is broken, circuit probably has a grounding fault. (See Cause 19.)
4
17 in fuse box F01
Loose terminal or 1. Turn starting switch to OFF position.
5 open circuit at Check terminals of starting motor, alternator, battery relay, grounds T04 and T08,
terminal etc.
Between battery relay terminal R01 and
Defective contact ground
(grounding)
6 between battery a Check grounding at machine frame.
Resistance Max. 1 z
relay and frame a Loosened or rusted terminal T08
a Rusted contact faces of battery
bracket and frame
a Be ready with starting switch at OFF, then perform troubleshooting without
turning starting switch to ON position.
Low charge level of Battery voltage (2
7 battery Min. 24 V
pieces)
Electrolyte specific
gravity (one piece) Min. 1.26
Failure codes [DA2RMC] and [DAFRMC] indicate failures in engine controller
Defective engine
8 power supply and ACC signal respectively. If these codes are displayed, perform
controller system
troubleshooting for them first.
2. Disconnect connector H15 and connect T-adapter to male side.
3. After troubleshooting, turn starting switch to ON/START position and perform
troubleshooting again.
Starting switch at
Between H15 Min. 1 Mz
OFF
Defective starting (male) (1) and (2) Starting switch at
switch Max. 1 z
9 ON
(internal open Starting switch at
circuit) Between H15 Min. 1 Mz
OFF
Resistance (male) (1) and (5) Starting switch at
Max. 1 z
ON
Starting switch at
Between H15 Min. 1 Mz
OFF
(male) (1) and (4) Starting switch at
Max. 1 z
START
PC290LC-10 40-539
40 Troubleshooting

Defective lock lever 1. Turn starting switch to OFF position.
switch 2. Disconnect connector S14 and connect T-adapters to female side.
10
(internal open Between S14 Lock lever at FREE Min. 1 Mz
circuit) Resistance (female) (1) and (3) Lock lever at LOCK Max. 1 z
Defective starting 1. Turn starting switch to OFF position.
motor cut-off relay 2. Disconnect connector R06 and connect T-adapters to male side.
R06
11 Between R06 (male) (1) and (2) 200 to 600 z
(internal open Between R06 (male) (3) and (4)
Resistance Max. 1 z
circuit or short
circuit) Between R06 (male) (3) and (5) Min. 1 Mz
Defective personal 1. Turn starting switch to OFF position.
code relay R07 2. Disconnect connector R07 and connect T-adapters to male side.
12 (internal open Between R07 (male) (1) and (2) 200 to 600 z
circuit or short Resistance Between R07 (male) (3) and (4) Max. 1 z
circuit) Between R07 (male) (3) and (5) Min. 1 Mz
2. Disconnect cable only from terminal C on starting motor safety relay.
3. Insert T-adapters into connector R17.
4. Turn starting switch to START position and perform troubleshooting.
Between safety
relay terminal B power supply 20 to 30 V
and E
Between safety
Input from
relay terminal R
alternator Max. 1 V
Defective starting (R17-2) and safety
generation
relay terminal E
13 motor safety relay
Voltage Between safety
(internal defect)
relay terminal S Starting input to
(R17-1) and safety starting motor 20 to 30 V
relay terminal E
Between safety
Starting output from
relay terminal C
starting motor 20 to 30 V
(R28) and safety
safety relay
relay terminal E
If power supply, input from alternator generation, and starting input to starting
motor are normal but starting output from starting motor safety relay is abnormal,
starting motor safety relay is defective.
Between starting
Defective starting motor terminal B power supply 20 to 30 V
(SB) and ground
14 motor Voltage
(internal defect) Between starting
Starting input to
motor terminal C 20 to 30 V
starting motor
(SC) and ground
If power supply and starting input to starting motor are normal but starting motor
does not rotate, starting motor is defective.
a Be ready with starting switch at OFF, then turn starting switch to ON position
Defective alternator and perform troubleshooting.
15 (internal open Between alternator
circuit) Alternator Max. 1 V
Voltage terminal L and
generation output
ground
40-540 PC290LC-10
40 Troubleshooting

2. Disconnect connector D01 and connect T-adapters to diode.
Defective diode
D01 a Check by using multimeter in diode range.
16 Between D01 (male) (1) (+) and (5) (-) No continuity
(iternal open circuit
or short circuit) Between D01 (male) (5) (+) and (1) (-) Continuity
Continuity
Open circuit in • Battery relay
17 (wire breakage or
defective contact of Between terminal R02 and H15 (female)
Resistance (2) Max. 1 z
connector)
• Battery relay
Open circuit in 2. Turn starting switch to ON position.
wiring harness a Check to where 24 V power is supplied to locate open section.
18 (wire breakage or
defective contact of Between terminals R04 and R01 20 to 30 V
connector) Between terminals R02 and R01 20 to 30 V
Voltage
Between terminals R03 and R01 20 to 30 V
Between terminal R01 and ground Max. 1 V
• Alternator and starting motor
2. Disconnect battery ground cable.
3. Insert T-adapters into connectors H15, S14, S18, R07, R17, E10 and E12.
a Check to where 24 V power is supplied to locate open section.
Between H15 (4) and ground 20 to 30 V
Between S14 (1) and ground 20 to 30 V
Open circuit in
wiring harness Between S14 (3) and ground 20 to 30 V
19 (wire breakage or Between S18 (1) and ground 20 to 30 V
defective contact of Between S18 (2) and ground 20 to 30 V
connector) Between R07 (4) and ground 20 to 30 V
Voltage Between R17 (1) and ground 20 to 30 V
Between R17 (2) and ground 20 to 30 V
Between E10 (1) and ground 20 to 30 V
Between E12 (1) and ground 20 to 30 V
Between alternator terminal B and
ground 20 to 30 V
Between starting motor terminal B and 20 to 30 V
ground
PC290LC-10 40-541
40 Troubleshooting

a If fuse or fusible link is blown, replace it with new one.
2. Disconnect H15, S14, R06 and R07.
3. Connect T-adapters to each female side of H15, R06 and R07, and to male
side of S14.
4. Remove fuse F01-3.
Between H15 (female) (4) and R06
Between R06 (female) (5) and R07
Between R07 (female) (1) and S14
(male) (1) Max. 1 z
Open circuit in Between R07 (female) (2) and CM01
wiring harness (female) (6) Max. 1 z
20 (wire breakage or Between R07 (female) (4) and starting
motor terminal S
connector) Between alternator B and starting motor
Max. 1 z
Resistance B
Between starting motor B and battery
relay R03 Max. 1 z
Between alternator L and starting motor
Max. 1 z
R
Between alternator L and D01 (female)
(6) Max. 1 z
Between F01-3 and S14 (male) (1) Max. 1 z
Between S14 (male) (3) and R06 (male)
(1) Max. 1 z
Between R06 (female) (2) and ground
(T05) Max. 1 z
Defective battery If only terminal R03 voltage is abnormal during battery relay check for cause 18,
21 relay battery relay is defective.
(does not turn ON)
2. Disconnect H15, S14, R06 and R07.
3. Connect T-adapters to each female side of H15, R06 and R07, and to male
side of S14.
Between ground and H15 (female) (4) or
R06 (female) (3) Min. 1 Mz
Between ground and R06 (female) (5) or
Ground fault in R07 (female) (3) Min. 1 Mz
wiring harness Between ground and R07 (female) (4) or
22 (contact with GND
R17 (female) (1) Min. 1 Mz
circuit)
Between ground and starting motor
Resistance safety relay B or battery relay R03 Min. 1 Mz
Between ground and starting motor
safety relay C or starting motor C (SC) Min. 1 Mz
Between ground and F01-3 or S14
Between ground and S14 (male) (3) or Min. 1 Mz
R06 (female) (1)
40-542 PC290LC-10
40 Troubleshooting

2. Insert T-adapter into connector R17 or E08.
wiring harness
circuit) Between ground and R17 (female) (2) or
Voltage Max. 1 V
E08 (1)
PC290LC-10 40-543
40 Troubleshooting
Circuit diagram related to engine start circuit
40-544 PC290LC-10
40 Troubleshooting
E-2 Manual preheating system does not work

Failure • Manual preheating function does not work.
a This troubleshooting describes procedures to be followed when manual preheating does
not function to heat ribbon heater mounting section.
• "Automatic preheating function" and "manual preheating function" are available for
preheating. Whichever function is turned on, preheating monitor lights up. (When only
Related preheating monitor does not light up, perform troubleshooting for "E-4 Preheating monitor
information does not light up when preheater is operated(PAGE 40-550) ")
• If "machine monitor does not light up" or "battery relay does not make operating sound"
when turning starting switch to ON position, main electric power supply system may be
defective. So, perform troubleshooting for E-5 and E-1.
• Before performing troubleshooting, check that no related failure code is displayed.
(If failure codes [D110KB] is displayed, perform troubleshooting for it first.)
Defective fuse No. If fuse No. 17 in fuse box F01 is broken, circuit probably has ground fault. In this
1 case, perform troubleshooting for cause 8 first.
17 in fuse box F01
Loose terminal or 1. Turn starting switch to OFF position.
2 open circuit at Check terminals of heater relay, battery relay, ribbon heater, etc.
terminal
Defective diode 1. Turn starting switch to OFF position.
D02 2. Disconnect connector D02 and connect T-adapters to diode.
3 (internal open a Check by using multimeter in diode range.
circuit or short Between D02 (male) (1) (+) and (5) (-) No continuity
circuit ) Continuity
Defective ribbon 1. Turn starting switch to OFF position.
heater 2. Disconnect terminal E01.
4
(internal open
Continuity Between E01 terminal and ground Continuity
circuit)
2. Disconnect battery ground cable.
Defective starting 3. Disconnect connector H15 and connect T-adapters to male side.
5 4. Turn starting switch to OFF/HEAT position and perform troubleshooting.
switch
Between H15 OFF Min. 1 Mz
Resistance (male) (1) and (3) HEAT Max. 1 z
short circuit in 2. Disconnect connectors CM01 and H15, and connect T-adaptersto female side
6
wiring harness of H15.
Continuity Between H15 (female) (3) and ground Continuity
Open circuit or
7 short circuit in
wiring harness Between input terminal on contact side
Voltage 20 to 30 V
of heater relay and ground
2. Disconnect heater relay terminal R16.
Open circuit or a To prevent current from flowing in heater when starting switch is turned to
8 short circuit in HEAT position.
wiring harness 3. Turn starting switch to HEAT position (connect R1).
Between heater relay terminal R15 and
Voltage 20 to 30 V
ground
Defective heater If no failure is found by check on causes 6 and 7, and heater relay operation sound
9 relay is not heard, heater relay is defective.
PC290LC-10 40-545
40 Troubleshooting

a If no failure is found by checks on causes 6 and 7, this check is not required.
2. Disconnect connectors H15 and CM01, terminals R15 and E01, and starting
Ground fault in motor terminal B.
wiring harness Between heater relay terminal R15
10 (contact with GND Min. 1 Mz
(wiring harness side) and ground
circuit) Between input terminal on contact side
Resistance of heater relay and ground Min. 1 Mz
Between heater relay terminal E01
(wiring harness side) and ground Min. 1 Mz
40-546 PC290LC-10
40 Troubleshooting
Circuit diagram related to preheating of engine
PC290LC-10 40-547
40 Troubleshooting
E-3 Automatic preheating system does not work

Failure • Automatic preheating function does not work.
• Automatic preheating function works when boost temperature is - 4°C or below.
(Monitoring code: 18500 Boost temperature)
• If automatic preheating does not work, check if manual preheating work.
Related • Engine controller generates failure code [CA2555] or [CA2556] if it detects failure in
information primary (coil) side of preheat relay (connector R18).
• Engine controller generates failure code [CA153] or [CA154] if it detects failure in boost
temperature sensor.
Defective fuse No. If fuse No. 6 in fuse box F01 is blown, circuit probably has ground fault. In this
1 case, perform troubleshooting for cause 5 first.
6 in fuse box F01
Defective preheat 1. Turn starting switch to OFF position.
relay R18 2. Replace preheat relay (connector R18) with other relay like horn relay
(connector).
2 (internal open
circuit or short
If automatic preheating function works when boost temperature is - 4°C or below,
circuit)
original preheat relay is defective.
2. Disconnect connectors CM01 and R18, and connect T-adapters to female side
of R18.
Open circuit or
3 ground fault in a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is
wiring harness below 1 z, wiring harness has short circuit.
a Heater relay coil resistance
Resistance Between R18 (female) (5) and ground Approx. 20 z
Open circuit in 2. Disconnect connectors R18 and CM01, and connect T-adapters to female side
wiring harness of R18.
4 (wire breakage or 3. Remove fuse No. 6 in fuse box F01.
defective contact of Between R18 (female) (3) and F01-6 Max. 1 z
connector) Resistance Between R18 (female) (5) and heater
relay terminal R15 Max. 1 z
If the fuse is not blown, this check is not required.
Ground fault in
wiring harness
5 2. Disconnect connectors CM01, R18, and starting motor terminal B, and connect
(contact with GND
T-adapters to female side of R18.
circuit)
Resistance Between R18 (female) (3) and ground Min. 1 Mz
40-548 PC290LC-10
40 Troubleshooting
PC290LC-10 40-549
40 Troubleshooting
E-4 Preheating monitor does not light up when preheater is operated

Failure • While performing preheating, preheating monitor does not light up.
• "Automatic preheating function" and "manual preheating function" are available for
Related preheating. When either function is activated, preheating monitor lights up.
information • Check that manual preheater operates first.
Open circuit in 2. Disconnect connectors H15, CM01, and R18, and connect T-adapters to each
1 (wire breakage or Between H15 (female) (3) and CM01
defective contact of (female) (12) Max. 1 z
Between R18 (female) (5) and CM01
• Reference
Defective machine 3. Disconnect heater relay terminal R16.
2
monitor
a To prevent current from flowing in heater when starting switch is turned to
HEAT position.
4. Turn starting switch to HEAT position.
Resistance Between CM01 (12) and (3) 20 to 30 V
40-550 PC290LC-10
40 Troubleshooting
PC290LC-10 40-551
40 Troubleshooting
E-5 When starting switch is turned to ON position, machine monitor

displays nothing
Failure • When starting switch is turned to ON position, machine monitor displays nothing
• When starting switch is turned to ON position, machine monitor displays KOMATSU logo
screen, Password input screen (if set), Breaker mode confirmation screen (if set), Check
before starting screen, Working mode and travel speed confirmation screen, and
Related standard screen in order.
information • When engine is started, battery voltage may lower suddenly, depending on ambient
temperature and condition of battery.
In this case, machine monitor goes off for a moment. This phenomenon is not failure,
however.
Battery disconnect Turn starting switch to OFF position and check that battery disconnect switch is in
1 ON position.
switch at OFF
a Be ready with starting switch at OFF, then perform troubleshooting without
turning starting switch to ON position.
Low charge level of Battery voltage (2
2 battery Min. 24 V
pieces)
Electrolyte specific
gravity (one piece) Min. 1.26
Defective fusible If fuse is blown, ground fault probably occurs. (See Cause 9.)
3
link F05
Defective fuse F01- If fuse is blown, ground fault probably occurs. (See Cause 9.)
4
15
Defective fuse F01- If fuse is blown, ground fault probably occurs. (See Cause 9.)
5
17
a If machine monitor is not replaced, this check is not required.
Wrong connection Check machine monitor connectors for wrong connection.
6
of connector a For connectors CM02 and CM03, their male and female connectors can
connect with wrong counterpart between them. Check connector colors. Male
and female connectors of CM03 are green.
Defective wiring 3. Connect battery ground cable, and turn starting switch to ON position (connect
harness, starting ACC).
7
switch, or machine Between CM01 (1) and (3) 20 to 30 V
monitor
Voltage Between CM01 (2) and (4) 20 to 30 V
Between CM01 (10) and (4) 20 to 30 V
Defective starting 2. Disconnect connector H15 and connect T-adapters to male side.
switch 3. Turn starting switch to ON position and perform troubleshooting again.
8 Starting switch at
(internal open Min. 1 Mz
circuit) Between H15 OFF
Resistance (male) (1) and (5) Starting switch at Max. 1 z
ON
40-552 PC290LC-10
40 Troubleshooting

If no failure is found by check on cause 7 , this check is not required.
2. Disconnect fusible link F05, No. 15 and 17 of fuse F01, and connectors H15
and CM01.
3. Connect T-adapters to male side of connector F05 and female side of H15 and
CM01.
Between battery (-) and ground Max. 1 z
Defective starting Between battery (+) and F05 (male) (1) Max. 1 z
switch
9 Between F05 (male) (2) and F01-16F Max. 1 z
(internal open Between F01-17 and each of CM01
circuit) (female) (1) and (2) Max. 1 z
Resistance Between ground and each of CM01
Between F01-17 and H15 (female) (1) Max. 1 z
Between H15 (female (5) and F01-15E Max. 1 z
Between F01-15 and CM01 (female)
(10) Max. 1 z
If no failure is found by check cause 5 , this check is not required.
2. Disconnect fusible link F05, No. 17 of fuse F01, terminal 14D, and connectors
H15, CM01, and CP01.
3. Connect T-adapters to male side of connector F05 and female side of H15 and
CM01.
Ground fault in Between ground and battery (+) or F05
wiring harness
10 (contact with GND
Between ground and F05 (male) (2) or
circuit) Min. 1 Mz
F01-16F
Between F01-17 and ground, or
Resistance between each of CM01 (female) (1) and
(2) and ground, or between H15 (female) Min. 1 Mz
(1) and ground
Between ground and H15 (female) (5) or
CM01 (female) (10) Min. 1 Mz
monitor
PC290LC-10 40-553
40 Troubleshooting
Circuit diagram related to machine monitor power supply
40-554 PC290LC-10
40 Troubleshooting
E-6 When starting switch is turned to ON position (before starting

engine), engine oil level monitor lights up in yellow
• When starting switch is turned to ON position (with engine stopped), engine oil level
Failure monitor lights up in yellow.
Related
information
Defective engine oil Carry out troubleshooting for failure code [B@BAZK].
level switch system
1
(Machine monitor
system)
monitor
PC290LC-10 40-555
40 Troubleshooting
E-7 When starting switch is turned to ON position (before starting

engine), radiator coolant level monitor lights up in yellow
• When starting switch is turned to ON position (with engine stopped), radiator coolant level
Failure monitor lights up in yellow.
Related
information
Low radiator Coolant level may be low. Check coolant level and add coolant if necessary.
coolant level
1
(When system
works properly)
Defective radiator Carry out troubleshooting for failure code [B@BCZK].
2 sub tank coolant
level switch system
40-556 PC290LC-10
40 Troubleshooting
E-8 Coolant temperature monitor lights up in white while engine is

running
Failure • Engine coolant temperature monitor lights up white while engine is running.
Related transmitted to machine monitor through CAN communication system.
information • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
Insufficient warm-If coolant temperature monitor lights up white, engine coolant temperature may be
up of machine low (below approx. 30°C). Perform warm-up operation.
1
(when system • Lighting up in white: Engine coolant temperature is low.
works properly) • Lighting up in blue: Engine coolant temperature is proper.
If no failure is found by above check, engine coolant temperature gauge system
Defective engine may be defective. Perform the following troubleshooting.
coolant • E-19 Coolant temperature gauge indicate either Min or Max and does not move
2 temperature gauge (PAGE 40-568)
system • E-20 Coolant temperature gauge indicates incorrect temperature (indicates
PC290LC-10 40-557
40 Troubleshooting
E-9 Hydraulic oil temperature monitor lights up in white while engine is

running
Failure • Hydraulic oil temperature monitor lights up white while engine is running.
information • Hydraulic oil temperature can be checked with monitoring function.
Insufficient warm- If coolant temperature monitor lights up white, engine coolant temperature may be
up of machine low (below approx. 30°C). Perform warm-up operation.
1
(when system • Lighting up in white: Engine coolant temperature is low.
works properly) • Lighting up in blue: Engine coolant temperature is proper.
If no failure is found by above check, hydraulic oil temperature gauge system may
be defective. Perform the following troubleshooting.
Defective hydraulic
oil temperature • E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not
2
gauge system move(PAGE 40-570)
• E-22 Hydraulic oil temperature gauge indicates incorrect temperature
(indicates neither Min nor Max)(PAGE 40-572)
40-558 PC290LC-10
40 Troubleshooting
E-10 Charge level monitor lights up while engine is running

Failure • Charge level monitor lights up while engine is running.
Related • Power generation signal from alternator can be checked with monitoring function.
information (Code: 04300 Charge voltage)
Defective alternator Perform troubleshooting for failure code [AB00KE].
1 system
PC290LC-10 40-559
40 Troubleshooting
E-11 Fuel level monitor lights up in red while engine is running

Failure • Fuel level monitor lights up red while engine is running.
Related • Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel sensor voltage)
Low fuel level Fuel level may be low. Check it and add fuel if necessary.
1 (When system
works properly)
If no failure is found by above checks, fuel level gauge system may be defective.
Perform troubleshooting.
Defective fuel level • E-17 Fuel gauge indicate either full or empty and does not move(PAGE 40-
2 gauge system 566)
• E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)
(PAGE 40-567)
40-560 PC290LC-10
40 Troubleshooting
E-12 Air cleaner clogging monitor lights up in yellow while engine is

running
Failure • Air cleaner clogging monitor lights up in yellow while engine is running
Related • Air cleaner clogging switch signal can be checked with monitoring function.
information (Code: 04501 Monitor Input 2)
Clogging of air Air cleaner may be clogged. Check it, then clean or replace if necessary.
cleaner
1
(When system
works properly)
Defective air Carry out troubleshooting for failure code [AA10NX].
2 cleaner clogging
switch system
PC290LC-10 40-561
40 Troubleshooting
E-13 Water separator monitor lights up while engine is running

Failure • Water separator monitor lights up while engine is running.
Related • Water level sensed by WIF sensor can be checked with monitoring function.
information (Code: 18800 Condition of WIF sensor)
High water level in Water is detected in water separator. Check and drain water separator.
water separator
1
(When system
works properly)
Defective fuel filter If no failure is found by above checks, fuel filter system may be defective. Perform
sensor system troubleshooting for failure codes [CA428] and [CA429].
2
(engine controller
circuit)
monitor
40-562 PC290LC-10
40 Troubleshooting
E-14 Coolant temperature monitor lights up in red while engine is

running
Failure • Engine coolant temperature monitor lights up red while engine is running.
information • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
If monitor lights up red, engine coolant temperature may be high (about 102°C or
Overheating of above). Decrease engine coolant temperature (Run engine at low idle).
engine coolant • Lighting up in red: Engine coolant temperature is high (overheating).
1 • Lighting up in blue: Engine coolant temperature is proper.
(When system
works properly) Perform troubleshooting for failure code "S-17 Coolant temperature rises too high
(Overheating)(PAGE 40-694)".
If no failure is found by above check, engine coolant temperature gauge system
Defective engine may be defective. Perform the following troubleshooting.
coolant • E-19 Coolant temperature gauge indicate either Min or Max and does not move
2 temperature gauge (PAGE 40-568)
system • E-20 Coolant temperature gauge indicates incorrect temperature (indicates
PC290LC-10 40-563
40 Troubleshooting
E-15 Hydraulic oil temperature monitor lights up in red while engine is

running
Failure • Hydraulic oil temperature monitor lights up red while engine is running.
• Signal of hydraulic oil temperature sensor is input to pump controller and then the data is
information • Hydraulic oil temperature can be checked with monitoring function.
Overheating of If monitor lights up red, hydraulic oil temperature may be high (about 102°C or
hydraulic oil above). Decrease hydraulic oil temperature (Run engine at low idle or stop it).
1
(When system • Lighting up in red: Hydraulic oil temperature is high (overheating).
works properly) • Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by above check, hydraulic oil temperature gauge system may
be defective. Perform the following troubleshooting.
Defective hydraulic
oil temperature • E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not
2
gauge system move(PAGE 40-570)
• E-22 Hydraulic oil temperature gauge indicates incorrect temperature
(indicates neither Min nor Max)(PAGE 40-572)
40-564 PC290LC-10
40 Troubleshooting
E-16 Engine oil pressure monitor lights up in red while engine is running
Failure • Engine oil pressure monitor lights up in red while engine is running
• Signals from the engine oil pressure switch is input to the engine controller. If engine oil
Related pressure switch is turned ON while engine is running, failure code [B@BAZG] is
information transmitted from engine controller to machine monitor through CAN.
Low engine oil Engine oil level may be low. If oil level is low, carry out troubleshooting in "S-14
pressure Engine oil pressure drops(PAGE 40-691)".
1
(When system
works properly)
Defective engine oil If no abnormality is found by above diagnoses, engine oil pressure switch system
2 pressure switch may be defective. Carry out troubleshooting for failure code [CA435].
system
PC290LC-10 40-565
40 Troubleshooting
E-17 Fuel gauge indicate either full or empty and does not move
• While fuel is added, fuel level gauge does not rise from red range (E).
Failure • While fuel level is low, fuel level gauge does not lower from top green range (F).
Defective fuel level 1. Starting switch: OFF
sensor 2. Disconnect connector P21 and connect T-adapters to male side.
1 Between P21 Fuel level: FULL Approximately 12 z
(internal open or
short circuit) Resistance (male) (1) and
ground Fuel level: EMPTY 85 - 110 z
Open circuit or 2. Disconnect connector CM01 and connect T-adapter to female side.
2 short circuit in Between CM01 Fuel level: FULL Approximately 12 z
wiring harness Resistance (female) (15) and
Open circuit in a if no failure is found by check on cause 2, this check is not required
wiring harness 1. Starting switch: OFF
3 (wire breakage or 2. Disconnect connectors CM01 and P21, and connect T-adapters to each female
connector) Between CM01 (female) (15) and P21
Resistance (female) (1) 1 z Max.

Ground fault in 2. Disconnect connectors CM01 and P21, and connect T-adapter to either female
4
(contact with Between CM01 (female) (15) and
ground circuit) Resistance ground, or between P21 (female) (1) and Min. 1 Mz
ground
wiring harness 3. Insert T-adapter into connector CM01 or connect T-adapter to female side of
5 connector P21.
(contact with 24 V 4. Starting switch: ON
circuit)
Between CM01 (15) and ground, or
Voltage Approx. 3.3 V
between P21 (female) (1) and ground
monitor
Circuit diagram related to fuel level sensor
40-566 PC290LC-10
40 Troubleshooting
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor
empty)
• Indication of fuel level gauge is different from actual fuel level.
Failure • Indication of fuel level gauge is different from display of fuel level monitor.
Defective fuel level 1. Starting switch: OFF
sensor 2. Disconnect connector P21 and connect T-adapters to male side.
1 Between P21 Fuel level: FULL Approximately 12 z
(internal open or
short circuit) Resistance (male) (1) and
a Turn starting switch to ON position or start engine and perform troubleshooting.

Reading of fuel
Fuel level
level gauge Blue
304 l
6
Reading of fuel
Fuel level
level gauge Blue
245 l
5
Reading of fuel
Fuel level
Defective machine level gauge Blue
2 Color of monitor 200 l
monitor 4
light (a) Reading of fuel
Fuel level
level gauge Blue
100 l
3
Reading of fuel
Fuel level
level gauge Blue
60 l
2
Reading of fuel
Fuel level
level gauge Red
41 l
1
Fuel level gauge and fuel level monitor
PC290LC-10 40-567
40 Troubleshooting
E-19 Coolant temperature gauge indicate either Min or Max and does not
move
• While engine coolant temperature is rising properly, temperature gauge indicator does not
rise above white range (C).
Failure • Although engine coolant temperature is stabilized at the proper level, temperature gauge
rises to red range (H).
information • Engine coolant temperature can be checked with monitoring function
(Code: 04107 Coolant temperature)
Defective engine The engine coolant temperature sensor system may be defective. Carry out
coolant troubleshooting for failure codes [CA144] and [CA145].
system
monitor
Engine coolant temperature gauge and engine coolant temperature

monitor
40-568 PC290LC-10
40 Troubleshooting
E-20 Coolant temperature gauge indicates incorrect temperature

(indicates neither Min nor Max)
• Indication of engine coolant temperature gauge is different from actual engine coolant
temperature.
Failure • Indication of engine coolant temperature gauge is different from display of engine coolant
temperature monitor.
• Signal voltage of engine coolant temperature sensor is input to engine controller and then
Related data is transmitted to machine monitor through CAN communication system.
information • Engine coolant temperature can be checked with monitoring function
(Code: 04107 Coolant temperature)
Defective engine The engine coolant temperature sensor system may be defective. Carry out
coolant troubleshooting for failure codes [CA144] and [CA145].
system
a Defective machine monitor Turn starting switch to ON position or start engine
and perform troubleshooting.
Engine coolant Water temperature
temperature gauge level Red
105°C 6
temperature gauge level Red
102°C 5
Defective machine temperature gauge level Blue
2
monitor Color of monitor 100°C 4
light (a) Engine coolant Water temperature
temperature gauge level Blue
85°C 3
temperature gauge level Blue
60°C 2
temperature gauge level White
30°C 1

monitor
PC290LC-10 40-569
40 Troubleshooting
E-21 Hydraulic oil temperature gauge indicate either Min or Max and
does not move
• While hydraulic oil temperature is rising normally, indication of temperature gauge does
not rise from white range (C).
Failure • While hydraulic oil temperature is stabilized normally, indication of temperature gauge
rises to red range (H).
information • Hydraulic oil temperature can be checked by using monitoring function
Defective hydraulic 10°C Approx. 90 kz
oil temperature Between P22 30°C Approx. 35 kz
1 sensor (male) (1) and (2) Approx. 6.5 kz
80°C
(internal open or Resistance 100°C Approx. 3.5 kz
short circuit)
Between P22 100°C
(male) (2) and Min. 1 Mz
ground Whole range

Open circuit or Between CP01 (female) (28) and (46)
2 short circuit in
a Resistance accords with value on 3.5 – 90 kz
wiring harness Resistance temperature characteristics table in
cause 1.
wiring harness 2. Disconnect connectors CP01 and P22, and connect T-adapter to either female
3 (Open circuit or side.
defective contact in Between CP01 (female) (28) and P22

wiring harness 2. Disconnect connectors CP01 and P22, and connect T-adapter to either female
4 side.
(contact with
ground circuit) Between CP01 (female) (28) and
Resistance ground, or between P22 (female) (2) and Min. 1 Mz
ground
Hot short circuit in 2. Disconnect connector P22.
wiring harness 3. Insert T-adapter to connector CP01 or connect T-adapter to female side of
5 connector P22.
(contact with 24 V 4. Starting switch: ON
circuit)
Between CP01 (28) or P22 (female) (2)
Voltage Approx. 5 V
and ground
controller
40-570 PC290LC-10
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
PC290LC-10 40-571
40 Troubleshooting
E-22 Hydraulic oil temperature gauge indicates incorrect temperature

(indicates neither Min nor Max)
• Indication of hydraulic oil temperature gauge is different from actual hydraulic oil
temperature.
Failure • Indication of hydraulic oil temperature gauge is different from display of hydraulic oil
temperature monitor.
information • Hydraulic oil temperature can be checked by using monitoring function
Reading of
Hydraulic oil
hydraulic oil
temperature Red
temperature gauge
105°C
6
Reading of
Hydraulic oil
hydraulic oil
temperature Red
temperature gauge
102°C
5
Reading of
Hydraulic oil
hydraulic oil
temperature Blue
Defective machine temperature gauge
1 Color of monitor 100°C
monitor 4
light (a) Reading of
Hydraulic oil
hydraulic oil
temperature Blue
temperature gauge
85°C
3
Reading of
Hydraulic oil
hydraulic oil
temperature Blue
temperature gauge
40°C
2
Reading of
Hydraulic oil
hydraulic oil
temperature White
temperature gauge
20°C
1
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
40-572 PC290LC-10
40 Troubleshooting
E-23 Content of display on machine monitor is different from that of

actual machine
Failure • Displays on machine monitor are different from those for actual machine
Related
information
a Turn starting switch to ON position and perform troubleshooting (with
monitoring function).
Model selection 1 =
OFF
Model selection 2 =
ON
Defective model
1 code signal Correct display Monitoring code 00201 Switch Input Model selection 3 =
2 ON
Model selection 4 =
ON
Model selection 5 =
OFF
If display on monitor is incorrect, perform troubleshooting for failure code
[DA29KQ].
Defective machine If no problem is found by above checks, machine monitor is defective. (Since this
2 is an internal defect, troubleshooting cannot be performed.)
monitor
PC290LC-10 40-573
40 Troubleshooting
E-24 Machine monitor does not display some items

Failure • Some areas of machine monitor are not displayed
• The LCD panel sometimes has black points (points which are not lighted) and bright
Related points (points which do not go off) for the reason of its characteristics. If the number of the
information bright points and black points does not exceed 10, The LCD panel is not faulty or
defective.
Defective machine a Turn starting switch to ON position to perform troubleshooting.

monitor When following switches are operated, if whole LCD panel is lighted up (whole
1
(LCD panel) surface becomes white), LCD panel has no failure.
• Switch operation: [4] + [F2] (Press simultaneously)
monitor
40-574 PC290LC-10
40 Troubleshooting
E-25 Function switch does not work

Failure • Function switch does not operate
Related • Condition of signal of function switch can be checked with the monitoring function.
information (Code: 04503 Monitor function switch)
Defective machine Machine monitor may be defective. (Since this is an internal defect,
1 troubleshooting cannot be performed.)
monitor
PC290LC-10 40-575
40 Troubleshooting
E-26 Automatic preheating system does not work (In cold season)
Failure • Automatic warm-up system does not operate (in cold weather).
• Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant
temperature is below 30°C.
• With starting switch at ON position or after engine is started, if fuel control dial is kept at
70% throttle position or higher for 3 seconds, automatic warm-up operation is canceled.
Related • If machine is equipped with air conditioner, when blower is turned on, ambient
information temperature is below 5°C and engine coolant temperature is below 55°C, automatic
warm-up function increases engine speed to 1,300 rpm. If engine coolant temperature
reaches 60°C, automatic warm-up function is canceled.
• If engine oil Pressure is below 50 kPa {0.51 kg/cm2}, turbocharger protection function
works to keep engine speed below 1,050 rpm for up to 20 seconds after engine is started.
Engine coolant
temperature 6 (a: Red)
105°C
Engine coolant
temperature 5 (a: Red)
102°C
Engine coolant
temperature 4 (a: Blue)
Coolant Monitoring code
100°C
temperature gange 04107 Coolant
Defective engine Engine coolant
level temperature
coolant temperature 3 (a: Blue)
1 temperature signal 85°C
system Engine coolant
temperature 2 (a: Blue)
60°C
Engine coolant
temperature 1 (a: White)
30°C
If engine coolant temperature does not match with coolant temperature gauge
level, perform the following troubleshooting procedures.
• E-19 Coolant temperature gauge indicate either Min or Max and does not move
(PAGE 40-568)
• E-20 Coolant temperature gauge indicates incorrect temperature (indicates
Defective engine If no problem is found by above checks, engine controller is defective. (Since this
controller

monitor
40-576 PC290LC-10
40 Troubleshooting
E-27 Auto-deceleration monitor does not light up or does not go out

when auto-deceleration switch is operated
• When auto-deceleration switch is operated, auto-deceleration monitor does not light up or
Failure does not go off.
• Condition of signal of auto-deceleration switch can be checked by using monitoring
Related function.
information (Code: 04504 Monitor 1st & 2nd row switches)
monitor
PC290LC-10 40-577
40 Troubleshooting
E-28 Auto-deceleration is not actuated or canceled when lever is

operated
Failure • Auto-decelerator is not operated or canceled interlocking with work equipment lever.
Related • Since auto-deceleration set speed is 1,050 rpm, auto-deceleration is not operated or
information canceled if engine speed higher than this speed is set by fuel control dial.
a Start engine and perform troubleshooting (with monitoring function).
When lever
operated: ON
Swing
With lever in
NEUTRAL: OFF
When lever
operated: ON
Travel
With lever in
NEUTRAL: OFF
When lever
operated: ON
Boom LOWER
Monitoring code With lever in
NEUTRAL: OFF
01900 Pressure When lever
switch 1 operated: ON
Boom RAISE
With lever in
NEUTRAL: OFF
When lever
Defective PPC operated: ON
1 Correct display Arm IN
pressure signal With lever in
NEUTRAL: OFF
When lever
operated: ON
Arm OUT
With lever in
NEUTRAL: OFF
When lever
operated: ON
Bucket CURL
With lever in
NEUTRAL: OFF
When lever
Monitoring code
operated: ON
01901 Pressure Bucket DUMP
With lever in
switch 2
NEUTRAL: OFF
When lever
operated: ON
Service
With lever in
NEUTRAL: OFF
If monitoring data show any abnormality, perform troubleshooting for "E-49 to 57
Monitoring function does not display *** normally".
monitor
controller
Defective engine If no problem is found by above checks, engine controller is defective. (Since this
controller
40-578 PC290LC-10
40 Troubleshooting
PC290LC-10 40-579
40 Troubleshooting
E-29 Working mode selector screen selection screen is not diplayed

when working mode switch is operated
Failure • When working mode switch is operated, working mode selection screen is not displayed.
Related • Condition of signal of working mode switch can be checked by using monitoring function.
monitor
40-580 PC290LC-10
40 Troubleshooting
E-30 Engine or hydraulic pump setting does not change when working
mode is changed
Failure • When working mode is changed, setting of engine and hydraulic pump is not changed.
Related
information
monitor
Defective pump Pump controller may be defective. (Since this is an internal defect, troubleshooting
controller
PC290LC-10 40-581
40 Troubleshooting
E-31 Travel speed monitor does not change when travel speed switch is
operated
Failure • When travel speed switch is operated, travel speed monitor does not change.
Related • Condition of signal of travel speed switch can be checked by using monitoring function.
monitor
40-582 PC290LC-10
40 Troubleshooting
E-32 Travel speed does not change when travel speed is shifted
Failure • When selection of travel speed is changed, actual travel speed does not change.
• When failure due to cause 1 occurs, actual travel speed does not decrease when travel
Related speed setting is changed to "Lo".
wiring harness 2. Disconnect connector V04 and connect T-adapter to female side.
(contact with 24 V
circuit) Voltage Between V04 (female) (2) and ground Max. 1 V
monitor
controller
PC290LC-10 40-583
40 Troubleshooting
E-33 Alarm buzzer does not stop sounding

Failure • Alarm buzzer cannot be canceled
• Condition of signal of alarm buzzer cancel switch can be checked by using monitoring
Related function.
monitor
40-584 PC290LC-10
40 Troubleshooting
E-34 When starting switch is turned to OFF position, service meter is not
displayed
Failure • When starting switch is in OFF position, service meter is not displayed.
• While starting switch is in OFF position, if following switches are operated, service meter
Related is displayed at top center of screen.
information Switch operation: [4] + [1] (Press simultaneously)
If machine monitor displays nothing when the starting switch is turned ON, the
Defective backup backup power supply system is supposed to be defective. Carry out the following
1 power supply troubleshooting procedures.
system • E-5 When starting switch is turned to ON position, machine monitor displays
nothing(PAGE 40-552)
monitor
PC290LC-10 40-585
40 Troubleshooting
E-35 Service mode cannot be selected

Failure • Service mode can not be selected
Related • Following switch operation sets machine monitor in service mode.
information Switch operation: [4] + [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)
monitor
40-586 PC290LC-10
40 Troubleshooting
E-36 Any of work equipment, swing and travel does not work
Failure • All work equipment, swing, and travel system do not operate
Related
information
Defective fuse F01- If fuse is broken, circuit probably has grounding fault. (See troubleshooting for
1 cause 7.)
3
Defective lock lever 1. Starting switch: OFF
switch 2. Disconnect connector S14 and connect T-adapter to female side.
2
(internal open Between S14 Lock lever: Lock Min. 1 Mz
circuit) Resistance (female) (1) and (2) Lock lever: Free 1 z Max.
Defective PPC lock 1. Starting switch: OFF
solenoid 2. Disconnect connector V01 and connect T-adapter to male side.
3
(internal open or Between V01 (male) (1) and (2) 20 - 60 z
short circuit) Resistance
Defective diode 2. Remove diode array D01 and connect T-adapter to male side.
array D01
4 a Check using multimeter in diode range.
(internal short
Continuity
wiring harness 2. Set lock lever to FREE position.
5 (wire breakage or 3. Remove fuse F01-3.
defective contact of Between F01-3 and ground (coil
connector) Resistance resistance of PPC lock solenoid) 20 - 60 z
a If no failure is found by above check, this check is not required.

Open circuit in 2. Remove fuse F01-3.
wiring harness 3. Disconnect connectors S14 and V01 and then connect T-adapters to male side
6 (wire breakage or of S14 and female side of V01.
defective contact of Between F01-3 and S14 (male) (1) 1 z Max.
connector) Between S14 (male) (2) and V01
Resistance
Between V01 (female) (2) and ground
(T09) 1 z Max.

Ground fault in 3. Disconnect connectors S14, V01, and D01, and then connect T-adapter to
wiring harness male side of S14 or female side of V01 or D01.
7
(contact with Between F01-3 and ground, or between
S14 (male) (1) and ground Min. 1 Mz
ground circuit)
Resistance
Between S14 (male) (2), V01 (female)
(1) or D01 (female) (4) and ground Min. 1 Mz
PC290LC-10 40-587
40 Troubleshooting
Related circuit diagram
40-588 PC290LC-10
40 Troubleshooting
E-37 Any of work equipment, swing and travel can not be locked
Failure • All of work equipment, swing, and travel mechanism do not lock
Related
information
Defective lock lever 1. Starting switch: OFF
switch 2. Disconnect connector S14 and connect T-adapter to female side.
1
(internal open Between S14 Lock lever: Lock Min. 1 Mz
circuit) Resistance (female) (1) and (2) Lock lever: Free 1 z Max.
wiring harness 2. Connect T-adapter to connector V01.
(contact with 24 V
circuit) Voltage Between V01 (female) (1) and (2) Max. 1
Related circuit diagram
PC290LC-10 40-589
40 Troubleshooting
E-38 Machine can not swing while swing brake cancel switch is canceled
Failure • When swing brake cancel switch is set to CANCEL position, machine cannot swing.
Related • Signal of swing lock switch can be checked with monitoring function.
information (Pump controller system code: 02200 Switch input 1)
Defective fuse F01- If fuse F01-1 is broken, circuit probably has ground fault. In this case, carry out
1 troubleshooting for cause 6 first.
1
Defective swing 2. Disconnect connector S25 and connect T-adapter to female side.
brake cancel switch Swing brake cancel
2 Between S25 Min. 1 Mz
(internal short switch: Normal
circuit) Resistance (male) (13) and
(14) Swing brake cancel
1 z Max.
switch: Cancel
Defective diode 2. Remove diode array and connect T-adapter to male side.
array D01
(internal short
Continuity
Defective diode 2. Remove diode array and connect T-adapter to male side.
array D03
(internal short
Continuity
2. Disconnect connector V03 and connect T-adapter to female side.
Defective wiring
5 Swing brake cancel
harness 20 - 30 V
Between V03 switch: Cancel
Voltage
(female) (1) and (2) Swing brake cancel
Max. 1 V
switch: Normal
wiring harness 2. Disconnect connectors V03 and S25 and connect T-adapter to each male side.
6 (wire breakage or Between V03 (female) (1) and S25
defective contact of (female) (14) 1 z Max.
Between V03 (female) (2) and CP02

Ground fault in required.
wiring harness
7 1. Starting switch: OFF
(contact with 2. Disconnect connectors S25, V03, D01, and D03, and connect T-adapter to
ground circuit) female side of V03.
Resistance Between V03 (female) (1) and ground Min. 1 Mz
40-590 PC290LC-10
40 Troubleshooting
PC290LC-10 40-591
40 Troubleshooting
E-39 Swing brake does not operate while swing brake cancel switch is
locked
• When swing brake cancel switch is set to Normal position, swing holding brake does not
Failure operate.
Related
information
Defective swing 2. Disconnect connector S25 and connect T-adapter to female side.
brake cancel switch Swing brake cancel
1 Between S25 Min. 1 Mz
(internal short switch: Normal
circuit) Resistance (male) (13) and
(14) Swing brake cancel
1 z Max.
switch: Cancel
(contact with 24 V 4. Turn swing lock switch to ON position.
circuit)
40-592 PC290LC-10
40 Troubleshooting
PC290LC-10 40-593
40 Troubleshooting
E-40 One-touch power maximizing function does not work or monitor is

not displayed
• When L.H. knob switch is pressed, work equipment power is not increased.
Failure • When L.H. knob switch is pressed, one-touch power maximizing monitor is not displayed.
• One-touch power maximizing function does not operate when working mode is not power
Related mode (P) or economy mode (E).
information • Condition of L.H. knob switch signal can be checked with monitoring function.
When L.H. knob switch is pressed, if work equipment power is increased but fact
Defective machine is not displayed on monitor, machine monitor may be defective (Since this is an
1
monitor internal defect, troubleshooting cannot be performed.)
Defective fuse No. If fuse is broken, circuit probably has grounding fault. (See troubleshooting for
2 cause 6.)
9
Defective left knob 2. Disconnect connector S11, and connect T-adapter to male side.
switch L.H. knob switch:
3 Min. 1 Mz
(internal open Between S11 Released
circuit in harness) Resistance (female) (1) and (2) L.H. knob switch:
1 z Max.
Pressed
Defective 2-stage 1. Starting switch: OFF
4
(internal open or Between V05 (male) (1) and (2) 20 - 60 z
short circuit) Resistance
Open circuit or
5 ground fault in a Ignore displayed failure code.
wiring harness L.H. knob switch:
Between CP01 Max. 1 V
Voltage (female) (42) and Released
ground L.H. knob switch:
20 - 30 z
Pressed
wiring harness 2. Remove fuse F01-8.
6 (wire breakage or 3. Disconnect connectors CP01 and S11, and connect T-adapters to each female
connector) Between F01-8 and S11 (female) (1) 1 z Max.
Resistance Between S11 (female) (2) and CP01

Ground fault in 2. Remove fuse F01-8.
wiring harness 3. Disconnect connectors CP01 and S11, and connect T-adapter to female side of
7 S11.
(contact with
ground circuit) Between F01-8 or S11 (female) (1) and
ground Min. 1 Mz
Resistance
Between S11 (female) (2) or CP01
(female) (42) and ground Min. 1 Mz
controller
40-594 PC290LC-10
40 Troubleshooting
Circuit diagram related to one-touch power maximizing switch
PC290LC-10 40-595
40 Troubleshooting
E-41 One-touch power maximizing function cannot be released

Failure • When L.H. knob switch is released, work equipment power is not returned to normal.
Related • Condition of L.H. knob switch signal can be checked with monitoring function.
information (Code: 02200 Switch input 1)
(contact with 24 V
circuit) Voltage Between V05 (female) (1) and (2) Max. 1 V
controller
40-596 PC290LC-10
40 Troubleshooting
E-42 Travel alarm does not sound when machine travels

Failure • When the machine is traveling, the travel alarm does not sound.
Related • Output to travel alarm can be checked with monitoring function.
information (Code: 03701 Controller output 2)
Defective travel 1. Starting switch: OFF
1 alarm 2. Disconnect connector M14 and connect T-adapter to male side.
(internal defect) Continuity Between M14 (male) (1) and (2) Continuity
Open circuit in 2. Disconnect connectors M14 and CP02 and connect T-adapters to each female
2 (wire breakage or Between CP02 (female) (107) and M14

wiring harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either female
3 side.
(contact with
Between CP02 (female) (107) or M14
ground circuit) Resistance Min. 1 Mz
PC290LC-10 40-597
40 Troubleshooting
E-43 Travel alarm does not stop sounding when machine stops
Failure • When the machine stops traveling, the travel alarm does not stop sounding.
Related
information
wiring harness 2. Disconnect connector M14, and connect T-adapter to female side.
(contact with 24 V
circuit) Voltage Between M14 (female) (1) and ground Max. 1 V
40-598 PC290LC-10
40 Troubleshooting
E-44 Horn does not sound

Failure • The horn does not sound.
Related
information
Defective fuse F01- If fuse F01(5) is broken, circuit probably has ground fault. In this case, carry out
1 troubleshooting for cause 7 first.
5
Defective horn 1. Starting switch: OFF
relay 2. Replace horn relay (connector: R08) with another relay.
(internal open or
4. Press L.H. knob switch.
short circuit)
If horn sounds, original horn relay is defective.
switch 2. Disconnect connector S10 and connect T-adapters to male side.
3
(internal open or Between S10 Switch: OFF Min. 1 Mz
short circuit) Resistance (male) (1) and (2) Switch: ON 1 Max. z
Defective high-tone 1. Starting switch: OFF
horn (M07) or low- 2. Disconnect connectors M07 and M08, and connect T-adapters to each male
4 tone horn (M08) side.
(internal open or Between M07 (male) (1) and (2) Continuity
Continuity
short circuit) Between M08 (male) (1) and (2) Continuity
2. Disconnect connector R08 and connect T-adapter to female side.
5 4. Press L.H. knob switch.
harness
Between R08 (female) (1) and (2) 20 - 30 V
Voltage
Between R08 (female) (3) and (2) 20 - 30 V
wiring harness 2. Disconnect connector R08 and connect T-adapter to female side.
6 (wire breakage or Between R08 (female) (5) and ground Continuity
defective contact of Continuity
connector) Between R08 (female) (1) and ground Continuity

Open circuit in 2. Remove fuse F01-5.
wiring harness 3. Disconnect connectors R08 and S10, and connect T-adapters to each female
side.
7 (wire breakage or
Between F01-5 and S10 (female) (1) 1 z Max.
connector) Between S10 (female) (2) and R08
Resistance
Between R08 (female) (2) and ground 1 z Max.
Between R08 (female) (3) and F01-5 1 z Max.
a If fuse is not broken, this check is not required.
Ground fault in 2. Remove fuse F01-5.
wiring harness 3. Disconnect connectors R08, M07, and M08, and connect T-adapter to female
8
(contact with side of R08.
ground circuit) Between R08 (female) (1) and ground Min. 1 Mz
Resistance Between R08 (female) (3) and ground Min. 1 Mz
Between R08 (female) (5) and ground Min. 1 Mz
Defective horn If no failure is found by above checks, horn may be defective.
9
(internal defect)
PC290LC-10 40-599
40 Troubleshooting
Circuit diagram related to horn
40-600 PC290LC-10
40 Troubleshooting
E-45 Horn does not stop sounding

Failure • Horn does not stop sounding.
Related
information
relay 2. Remove horn relay (connector R08).
1
(internal open or 3. Starting switch: ON
short circuit) If horn stops sounding, original horn relay is defective.
Hot short circuit in 2. Disconnect connectors M07 and M08, and connect T-adapters to their female
wiring harness sides.
(contact with 24 V
circuit) Between M07 (female) (2) and (1) Max. 1 V
Voltage
Between M08 (female) (2) and (1) Max. 1 V
Circuit diagram related to horn
PC290LC-10 40-601
40 Troubleshooting
E-46 Wiper monitor does not light up or go out when wipper switch is
operated
Failure • When wiper switch is operated, wiper monitor does not light up or go off.
Related • Condition of wiper switch signal can be checked by using monitoring function.
monitor
40-602 PC290LC-10
40 Troubleshooting
E-47 Wiper does not operate when wipper switch is operated

Failure • When wiper switch is operated, windshield wiper does not operate.
• Condition of window rear limit switch signal can be checked by using monitoring function.
Related (Code: 02204 Switch input 5)
information • Wiper motor is troubleshooted for failure codes [DY20KA], [DY20MA], [DY2DKB], and
[DY2EKB].
2. Disconnect connector W03.
Defective rear limit Front window:
switch for window When installed to Min. 1 Mz
1
(internal short Between W03 front
circuit) Resistance (male) (1) and (2) Front window:
When retracted to 1 z Max.
rear
Defective wiper 1. Starting switch: OFF
motor 2. Disconnect connector M05 and connect T-adapter to female side.
2
(internal open
circuit in harness) Continuity Between M05 (female) (1) and (3) Continuity
Open circuit in
a Wiper motor system
wiring harness
See troubleshooting for [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].
3 (wire breakage or
connector)
Open circuit in a Rear limit switch system
wiring harness 1. Starting switch: OFF
4 (wire breakage or 2. Disconnect connectors CP01 and connect T-adapters to each female side.
defective contact of 3. Pull up front window.
connector) Between CP01 (female) (76) and ground
Resistance Max. 1 Mz
wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
5
(contact with 3. Front window installed to front
ground circuit) Resistance Between CP01 (female) (76) and ground Min. 1 Mz
controller
PC290LC-10 40-603
40 Troubleshooting
40-604 PC290LC-10
40 Troubleshooting
E-48 Window washer does not operate when window washer switch is
operated
Failure • When window washer switch is operated, window washer does not operate.
• Condition of window washer switch signal can be checked with monitoring function.
Related (Code: 04504 Monitor 1st, 2nd line switches)
information • As for window washer, perform troubleshooting for failure code [DY2CKB].
monitor
PC290LC-10 40-605
40 Troubleshooting
E-49 BOOM LOWER indication is not displayed properly with monitoring

function
Failure • "Boom LOWER" is not displayed properly by monitoring function.
Related • Monitoring code: 01900 Pressure switch 1
information
Defective boom Carry out troubleshooting for failure code [DHS9MA].
LOWER PPC oil
1 pressure sensor
(internal open or
short circuit)
40-606 PC290LC-10
40 Troubleshooting
E-50 ARM DUMP indication is not displayed properly with monitoring

function
Failure • "Arm OUT (Arm Dump)" is not displayed properly with monitoring function.
information
Defective arm OUT Carry out troubleshooting for failure code [DHSCMA].
PPC oil pressure
1 sensor system
(internal open or
short circuit)
PC290LC-10 40-607
40 Troubleshooting
E-51 ARM IN indication is not displayed properly with monitoring

function
Failure • "Arm IN" is not displayed properly with monitoring function
information
Defective arm IN Carry out troubleshooting for failure code [DHS3MA].
PPC oil pressure
1 sensor system
(internal open or
short circuit)
40-608 PC290LC-10
40 Troubleshooting
E-52 BOOM RAISE indication is not displayed properly with monitoring

function
Failure • "Boom RAISE" is not displayed properly by monitoring function.
information
Defective boom Carry out troubleshooting for failure code [DHS8MA].
RAISE PPC oil
pressure sensor
1 system
(internal open or
short circuit)
PC290LC-10 40-609
40 Troubleshooting
E-53 BUCKET CURL indication is not displayed properly with monitoring

function
Failure • "Bucket CURL" is not displayed properly with monitoring function.
information
Defective bucket Carry out troubleshooting for failure code [DHS4MA].
CURL PPC oil
1 pressure sensor
system
40-610 PC290LC-10
40 Troubleshooting
E-54 BUCKET DUMP indication is not displayed properly with monitoring

function
Failure • "Bucket DUMP" is not displayed properly with monitoring function.
information
Defective bucket Carry out troubleshooting for failure code [DHSDMA].
DUMP PPC oil
1 pressure sensor
system
PC290LC-10 40-611
40 Troubleshooting
E-55 SWING indication is not displayed properly with monitoring

function
Failure • "Swing" is not displayed properly with monitoring function.
information
Defective swing Carry out troubleshooting for failure codes [DHSAMA] and [DHSBMA].
PPC pressure
1 sensor system
(internal open or
short circuit)
40-612 PC290LC-10
40 Troubleshooting
E-56 TRAVEL indication is not displayed properly with monitoring

function
Failure • Travel indicator is not displayed properly with monitoring function.
information
Defective travel Carry out troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA]
PPC oil pressure and [DHSJMA].
1 sensor system
(internal open or
short circuit)
PC290LC-10 40-613
40 Troubleshooting
E-57 Service is not displayed properly with monitoring function

Failure • Attachment is not displayed properly with monitoring function.
• Monitoring code: 01901 Pressure switch 2
Related • For safety, use "short connector" 799-601-7230 for 2-pin X connector in tests for Causes
information 1 to 4.
k Do not check oil pressure switch connector while engine is running.
A. If "Service" operation signal displayed on monitoring screen is not "ON" when
engine is started and attachment control pedal is depressed at front end
Defective pre- 1. Starting switch: OFF
service PPC oil 2. Disconnect connector P14 and connect "short connector" to male side.
1 pressure switch 3. Starting switch: ON
(P14) a After finishing troubleshooting, return connectors as they were.
If "Service" operation signal displayed on monitoring screen changes to "ON", front
service PPC pressure switch (P14) is defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
Defective pre-
service PPC oil 1. Starting switch: OFF
2 pressure switch 2. Disconnect connector P14.
(P14) 3. Starting switch: ON
If "Service" operation signal displayed on monitoring screen changes to "OFF",
front service PPC pressure switch (P14) is defective (Note 2).
A. If "Service" operation signal displayed on monitoring screen is not "ON" when
engine is started and attachment control pedal is depressed at rear end
Defective post- 1. Starting switch: OFF
service PPC oil 2. Disconnect connector P15 and connect "short connector" to male side.
3 pressure switch 3. Starting switch: ON
(P15) a After finishing troubleshooting, return connectors as they were.
If "Service" operation signal displayed on monitoring screen changes to "ON", rear
service PPC pressure switch (P15) is defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
Defective post-
service PPC oil 1. Starting switch: OFF
4 pressure switch 2. Disconnect connector P15.
(P15) 3. Starting switch: ON
If "Service" operation signal displayed on monitoring screen changes to "OFF",
rear service PPC pressure switch (P15) is defective (Note 2).
2. Insert T-adapters into P13.
3. Start engine.
Defective wiring 4. Operate attachment control pedal, and perform troubleshooting.
5 harness or pump Attachment control
controller Approx. 7 V
pedal: NEUTRAL
Between P13 (1)
Voltage Attachment control
and (2) Max. 1 V
pedal: front end or
rear end depressed
40-614 PC290LC-10
40 Troubleshooting

2. Disconnect connectors CP01, P14, and P15, and connect T-adapters to each
female side.
Open circuit in Between CP01 (female) (35) and P14
wiring harness (female) (1) 1 z Max.
6 (wire breakage or Between CP01 (female) (35) and P15
Between P14 (female) (2) and ground
(T06) 1 z Max.
Between P15 (female) (2) and ground
(T06) 1 z Max.

Ground fault in 2. Disconnect connectors CP01, P14, and P15, and connect T-adapter to either
7
(contact with Between CP01 (female) (35), P14
ground circuit) Resistance (female) (1), or P15 (female ) (1) and Min. 1 Mz
ground
2. Disconnect connectors P14 and P15, and connect T-adapter to either female
Short circuit in side.
8 wiring harness 3. Starting switch: ON
Between P14 (female) (1) or P15
Voltage Approx. 7 V
controller
Note 1: If voltage between CP01 (35) and ground is below 1 V but “Service“ operation signal displayed on
monitoring screen remains “OFF“, pump controller is defective.
Note 2: If voltage between CP01 (35) and ground is approximately 7 V but “Service“ operation signal
displayed on monitoring screen remains “ON“, pump controller is defective.
PC290LC-10 40-615
40 Troubleshooting
Circuit diagram related to attachment control pedal PPC oil pressure

switch (service pressure switch)
40-616 PC290LC-10
40 Troubleshooting
E-58 Attachment hydraulic circuit cannot be changed

• Attachment circuit can not be changed
Failure 1. Working mode: When P or E is selected, crusher circuit (two-way circuit) is not selected.
2. Working mode: When B is selected, breaker circuit (one-way circuit) is not selected.
Related • Failures (open circuit/short circuit) of attachment oil return selector solenoid are
information troubleshot for failure codes [DWA2KA] and [DWA2KB].
Defective 1. Starting switch: OFF
attachment oil 2. Disconnect connector V07, and connect T-adapter to male side.
return selector
1 Between V07 (male) (1) and (2) 20 - 60 z
solenoid
(internal short Resistance
circuit)
(contact with 24 V
circuit) Voltage Between V07 (female) (1) and ground Max. 1 V
Circuit diagram related to attachment oil return selector solenoid
PC290LC-10 40-617
40 Troubleshooting
E-59 KOMTRAX system does not work properly

Failure • KOMTRAX system does not work properly
• If KOMTRAX system administrator asks for checking whether system installed on
Related machine has trouble, perform following troubleshooting.
information • Even if KOMTRAX system has trouble, problem does not appear on machine.
• Perform all troubleshooting on service menu screen of machine monitor.
Defective 2. Display the "Terminal Status" screen.
1
communication 1
Check item Communication start check Completion
2. Open the "GPS & Communication Status" screen.
Defective N ###,##,##
2 measurement with (Latitude)
GPS Check item Positioning W ###,##,##
(Longitude)
In positioning
Defective If latitude and longitude are not displayed in 5 minutes on open patch, notify
3 measurement with KOMTRAX service hot line.
GPS
2. Open the "GPS & Communication Status" screen.
Defective "Communication
4
communication established" or
Check item Communication
"Communication
not established"
If the message "Communication with satellite established" is not displayed within
Defective 15 seconds when the machine is started in an area open to the sky, the TC330
5
communication connector or the antenna on the cab top is not correctly installed.
Defective 2. Open the "GPS & Communication Status" screen.
6
communication 2
Check item Number of items not transmitted 0 to 9 (Normally 0)
a Select "Terminal Status" from "11 Display of

KOMTRAX setting" in the service menu of the
machine monitor.
a Select "GPS & Communication Status" from "11

Display of KOMTRAX setting" in the service
menu of the machine monitor.
40-618 PC290LC-10
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Information mentioned in troubleshooting table (H mode)
(Rev. 2011/01)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on machine
information
1
2 Probable causes for <Contents of description>
trouble (Each number is
3 serial number, not priority • Criteria to judge probable causes
4 sequence.) • Remarks required for judgment
5
PC290LC-10 40-619
40 Troubleshooting
mode)
System chart for hydraulic system
a This is a system chart that is drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
40-620 PC290LC-10
40 Troubleshooting
mode)
PC290LC-10 40-621
40 Troubleshooting
mode)
Failure mode and cause table

Failed parts
Tank Hydraulic pump
Diagnosis codes
Engine system
PC-EPC valve
LS-EPC valve
Damper
Piston pump
Servo piston
Hydraulic oil
PC valve
LS valve
stainer
Cap
Failure mode
Speed or power of all work equipment, swing and travel is low. q q q q q q q q q q H-1
Engine speed lowers extremely or engine stalls. q q q q q q q q H-2

Any of work equipment,
All work equipment, travel, and swing systems do not work. q q q H-3
swing and travel
Abnormal sound comes out from around hydraulic pump q q q q H-4
Fine control performance or response is low q q q H-5
Speed or power of boom is low. H-6
Speed or power of arm is low. H-7
Speed or power of bucket is low H-8
Work equipment single operation does not function. H-9

Work equipment
Boom H-10
Hydraulic drift of work equipment is large. Arm H-11
Bucket H-12
Time lag in work equipment operation is large. Q H-13

When performing hydraulic relief of a work equipment, other work
H-14
equipment move.
Power maximizing function does not work. H-15
Work equipment on large load side moves slower during combined
H-16
operation
Swing and
When performing combined operation of swing and boom RAISE , boom

boom
H-17
RAISE speed is slow.
Swing and
When performing combined operation of swing and travel , travel speed

travel
H-18
lowers significantly.
Machine deviates during travel q H-19
Travel speed is low q H-20

Travel
Machine is not steered well or steered-travel power is low. H-21
Travel speed does not switch or travel speed is too low or high. q H-22
One of tracks does not run H-23
40-622 PC290LC-10
40 Troubleshooting
mode)
Failed parts
Tank Hydraulic pump
Diagnosis codes
Engine system
PC-EPC valve
LS-EPC valve
Damper
Piston pump
Servo piston
Hydraulic oil
PC valve
LS valve
stainer
Cap
Failure mode
Upper structure swings
H-24
neither to the right nor left
Machine does not swing
Upper structure does not
H-25
swing in only one direction
Poor or low for both of the
Swing acceleration is poor or swing speed is right and left H-26
low Poor or low for only in one

H-27
direction
Largely for both of the right
Swing
Upper structure overruns considerably when H-28

and left
it stops swinging Largely for only in one
H-29
direction
Large shock is made when upper structure stops swinging H-30
Large unusual noise is heard when upper structure stops swinging. H-31
When swing brake works H-32

Swing drift on a slope is excessive
Attachment circuit is not switched to desired one. H-34

Attachment
Flow rate of attachment circuit cannot be adjusted H-35
PC290LC-10 40-623
40 Troubleshooting
mode)
Failed parts
Control valve
Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Pump merge-divider main valve
Pump merge-divider LS valve

Boom throttle EPC solenoid
Service valve (safety valve)

Boom regeneration valve
Arm regeneration valve

Diagnosis codes
Swing LS select valve
Back pressure valve
Boom lock valve
Main relief valve
LS shuttle valve
Arm lock valve

LS line throttle
Suction valve
Unload valve
Safety valve
Spool
Failure mode
Speed or power of all work equipment, swing and travel is low. q q q H-1
Engine speed lowers extremely or engine stalls. H-2

All work equipment, travel, and swing systems do not work. q H-3
swing and travel
Abnormal sound comes out from around hydraulic pump H-4
Fine control performance or response is low q H-5
Speed or power of boom is low. q q q q q q q q q q q q H-6
Speed or power of arm is low. q q q q q q q q q q q q H-7
Speed or power of bucket is low q q q q q H-8
Work equipment single operation does not function. q q H-9

Work equipment
Boom q q q q H-10
Hydraulic drift of work equipment is large. Arm q q q H-11
Bucket q q q q H-12
Time lag in work equipment operation is large. q q H-13

q H-14
equipment move.
Power maximizing function does not work. q H-15
q H-16
operation
Swing and
When performing combined operation of swing and boom RAISE ,

boom
q H-17
boom RAISE speed is slow.
Swing and
When performing combined operation of swing and travel , travel

travel
q q H-18
speed lowers significantly.
40-624 PC290LC-10
40 Troubleshooting
mode)
Failed parts
Control valve
Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Pump merge-divider main valve
Pump merge-divider LS valve

Boom throttle EPC solenoid
Service valve (safety valve)

Boom regeneration valve
Arm regeneration valve

Diagnosis codes
Swing LS select valve
Back pressure valve
Boom lock valve
Main relief valve
LS shuttle valve
Arm lock valve

LS line throttle
Suction valve
Unload valve
Safety valve
Failure mode Spool
Machine deviates during travel q q q q q H-19
Travel speed is low q q q q q H-20

Travel
Machine is not steered well or steered-travel power is low. q q q q q q q q q H-21
Travel speed does not switch or travel speed is too low or high. H-22
One of tracks does not run q H-23

neither to the right nor q H-24
Machine does not swing left

Upper structure does
not swing in only one q H-25
direction
Poor or low for both of
Swing acceleration is poor or swing speed is the right and left q q H-26
low Poor or low for only in

q q H-27
one direction
Swing
Largely for both of the

Upper structure overruns considerably when right and left H-28

q H-29
direction
Large unusual noise is heard when upper structure stops swinging. q H-31
When swing brake
H-32
Swing drift on a slope is excessive works
When swing brake
q q H-33
works
Attachment circuit is not switched to desired one. q H-34
Attachment
PC290LC-10 40-625
40 Troubleshooting
mode)
Failed parts
Solenoid valve Swing motor
Oil flow adjuster EPC valve for attachment

Swing PPC slow return valve
Travel interconnection solenoid
Travel speed selector solenoid

Work equipment lock solenoid
PPC valve (travel lever)
Swing holding brake solenoid

PPC valve (right lever)
ATT return selector solenoid

PPC valve (left lever)
PPC valve (service)
Diagnosis codes
2-stage relief solenoid
Shockless valve
Parking brake
Suction valve
Check valve
Piston motor
Safety valve
Failure mode
Speed or power of all work equipment, swing and travel is low. H-1
Engine speed lowers extremely or engine stalls. q H-2

All work equipment, travel, and swing systems do not work. H-3
swing and travel
Fine control performance or response is low H-5
Speed or power of boom is low. q H-6
Speed or power of arm is low. q H-7
Speed or power of bucket is low q H-8
Work equipment single operation does not function. q q H-9

Work equipment
Boom H-10
Hydraulic drift of work equipment is large. Arm H-11
Bucket H-12
Time lag in work equipment operation is large. H-13

H-14
equipment move.
Power maximizing function does not work. q H-15
H-16
operation
Swing and

boom
H-17
Swing and

travel
H-18
40-626 PC290LC-10
40 Troubleshooting
mode)
Failed parts
Solenoid valve Swing motor
Oil flow adjuster EPC valve for attachment

Swing PPC slow return valve
Travel interconnection solenoid
Travel speed selector solenoid

Work equipment lock solenoid
PPC valve (travel lever)
Swing holding brake solenoid

PPC valve (right lever)
ATT return selector solenoid

PPC valve (left lever)
PPC valve (service)
Diagnosis codes
2-stage relief solenoid
Shockless valve
Parking brake
Suction valve
Check valve
Piston motor
Safety valve
Failure mode
Machine deviates during travel q q H-19
Travel speed is low q H-20

Travel
Machine is not steered well or steered-travel power is low. q q H-21
One of tracks does not run H-23

q q Q q H-24
q q q H-25
Swing acceleration is poor or swing speed is right and left q q q H-26

q q q H-27
direction
Swing
Upper structure overruns considerably when q q H-28

and left
q q q q H-29
direction
Large shock is made when upper structure stops swinging q q q H-30
Large unusual noise is heard when upper structure stops swinging. q q H-31
When swing brake works q q H-32

When swing brake works q q q q H-33
Attachment circuit is not switched to desired one. q H-34

Attachment
Flow rate of attachment circuit cannot be adjusted q q H-35
PC290LC-10 40-627
40 Troubleshooting
mode)
Failed parts
Travel motor
Center swivel joint
Hydraulic cylinder
Swing machinery
Diagnosis codes
Parking brake
Check valve
Piston motor
Safety valve
Final drive
Failure mode
Speed or power of all work equipment, swing and travel is low. H-1
Engine speed lowers extremely or engine stalls. H-2

All work equipment, travel, and swing systems do not work. H-3
swing and travel
Fine control performance or response is low H-5
Speed or power of boom is low. q H-6
Speed or power of arm is low. q H-7
Speed or power of bucket is low q H-8
Work equipment single operation does not function. H-9

Work equipment
Boom q H-10
Hydraulic drift of work equipment is large. Arm q H-11
Bucket q H-12
Time lag in work equipment operation is large. H-13

H-14
equipment move.
Power maximizing function does not work. H-15
H-16
operation
Swing and

boom
H-17
Swing and

travel
H-18
40-628 PC290LC-10
40 Troubleshooting
mode)
Failed parts
Travel motor
Center swivel joint
Hydraulic cylinder
Swing machinery
Diagnosis codes
Parking brake
Check valve
Piston motor
Safety valve
Final drive
Failure mode
Machine deviates during travel q q q q q H-19
Travel speed is low q q H-20

Travel
Machine is not steered well or steered-travel power is low. q q q q H-21
One of tracks does not run q q q q q H-23

q H-24
H-25
Swing acceleration is poor or swing speed is right and left q H-26

H-27
direction
Swing
Upper structure overruns considerably when H-28

and left
H-29
direction
Large unusual noise is heard when upper structure stops swinging. q H-31

Attachment circuit is not switched to desired one. H-34

Attachment
PC290LC-10 40-629
40 Troubleshooting
mode)
H-1 All of work equipment, swing and travel operation lacks speed or
power
Failure • All of work equipment, and swing and travel systems operate slowly or lack power.
• Perform all troubleshooting with working mode in power mode (P).
• For systems other than swing system, check whether its speed becomes normal when
Related swing lock switch is turned to ON position.
information If speed becomes normal, check swash plate sensor of No. 1 and No. 2 pumps for
malfunction.
If speed does not become normal, perform troubleshooting for causes No. 3 and after.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.
Measurement Sensor output voltage
Malfunction of condition
1 swash plate sensor All levers in
NEUTRAL position 1.57 ± 0.63 V
(front) of pump
Run one track idle
off ground
3.75 ± 0.63 V
Swing lock switch:
ON
high idle.
(rear) of pump
Run one track idle
off ground
3.75 ± 0.63 V
Swing lock switch:
ON
high idle.
Malfunction of
3 unload valve (front) Control lever Unload pressure
All levers in 3.5 ± 1.0 MPa
high idle.
Malfunction of
4 unload valve (rear) Control lever Unload pressure
All levers in 3.5 ± 1.0 MPa
high idle.
Poor adjustment of L.H. work
5 main relief valve equipment control Main relief pressure
(front) lever
Arm IN to hydraulic 33.1 to 37.2 MPa
relief {338 to 380 kg/cm2}
high idle.
(rear) lever
relief {338 to380 kg/cm2}
40-630 PC290LC-10
40 Troubleshooting
mode)

Malfunction of main If pressure is not adjusted to normal value, main relief valve may malfunction or
7 relief valve (front) has internal defects. Check it.
8 relief valve (rear) has internal defects. Check it.
Malfunction of self- high idle.
9 pressure reducing 2.84 to 3.4 MPa
valve Control circuit
source pressure Control levers: all levers in NEUTRAL {29 to 35 kg/cm2}
PC290LC-10 40-631
40 Troubleshooting
mode)

a Be ready with engine stopped, then perform troubleshooting with engine at low
idle and high idle.
PC-EPC valve
Engine Control lever
Malfunction of PC- output pressure
10 EPC valve (front)
2.9 MPa
At low idle All levers in NEUTRAL position
{30 kg/cm2}
0.52 to 0.91 MPa
At high idle All levers in NEUTRAL position
{5.3 to 9.3 kg/cm2}
idle and high idle.
PC-EPC valve
11 EPC valve (rear)
2.9 MPa
{30 kg/cm2}
0.52 to 0.91 MPa
{5.3 to 9.3 kg/cm2}
high idle.
Measured oil
Measurement condition Oil pressure ratio
Poor adjustment of pressure
12
PC valve Pump delivery Swing lock switch: ON
pressure 1
Arm IN to hydraulic relief
PC valve output Swing lock switch: ON Approx. 0.6
pressure Arm IN to hydraulic relief (Approx. 3/5)
Malfunction of PC If pressure is not adjusted to normal value, PC valve may malfunction or has
13
valve internal defects. Check PC valve.
high idle.
Approx. 2.9 MPa
Malfunction of LS- Travel lever:
14 Travel speed: Lo {Approx. 30 kg/
EPC valve LS-EPC valve NEUTRAL
cm2}
output pressure
Travel lever: 0 MPa
Travel speed: Hi
Operation {0 kg/cm2}
high idle.
Operation of levers and oil pressure ratio
Run track idle off
Measured oil
Poor adjustment of ground.
15 pressure All levers in NEUTRAL position
LS valve (Lever operated
halfway)
Pump delivery
Almost same pressure 1
pressure
LS valve out put Approx. 0.6
Almost same pressure
pressure (Approx. 3/5)
Malfunction of LS If pressure is not adjusted to normal value, LS valve may malfunction or has
16
valve internal defects. Check LS valve.
Malfunction of Servo piston may malfunction. Check change in voltage from swash plate sensor
17 servo piston by using monitoring function.
Defective piston Piston pump may have performance deterioration, malfunction or internal defect.
18 pump
40-632 PC290LC-10
40 Troubleshooting
mode)
H-2 Engine speed lowers significantly or engine stalls

Failure • Engine speed drops largely or engine stalls
• Perform all troubleshooting with working mode in power mode (P).
• Check whether speed becomes normal when swing lock switch is turned to ON position.
Related If speed becomes normal, check swash plate sensor of No. 1 and No. 2 pumps for
information malfunction.
If speed does not become normal, perform for causes No. 3 and after.
high idle.
(front) of pump
Run one track idle
off ground
3.75 ± 0.63 V
Swing lock switch:
ON
high idle.
(rear) of pump
Run one track idle
off ground
3.75 ± 0.63 V
Swing lock switch:
ON
high idle.
(front) lever
relief {338 to 380 kg/cm2}
high idle.
(rear) lever
relief {338 to380 kg/cm2}
5 relief valve (front) has internal defects. Check it.
6 relief valve (rear) has internal defects. Check it.
idle and high idle.
PC-EPC valve
7 EPC valve (front) 2.9 MPa
{30 kg/cm2}
0.52 to 0.91 MPa
{5.3 to 9.3 kg/cm2}
PC290LC-10 40-633
40 Troubleshooting
mode)

idle and high idle.
PC-EPC valve
8 EPC valve (rear) 2.9 MPa
{30 kg/cm2}
0.52 to 0.91 MPa
{5.3 to 9.3 kg/cm2}
high idle.
Measured oil
Measurement condition Oil pressure ratio
Poor adjustment of pressure
9
PC valve Pump delivery Swing lock switch: ON
pressure 1
Arm IN to hydraulic relief
PC valve output Swing lock switch: ON Approx. 0.6
pressure Arm IN to hydraulic relief (Approx. 3/5)
Malfunction of PC- If pressure is not adjusted to normal value, PC valve may malfunction or has
10 EPC valve (front) internal defects. Check PC valve.
high idle.
Run track idle off
Measured oil
halfway)
Pump delivery
pressure
12
Clogged orifice or Orifice or filter in pump servo mechanism may be clogged. Check them.
13
filter in serve device
40-634 PC290LC-10
40 Troubleshooting
mode)
H-3 Any of work equipment, swing and travel does not work
Failure • All work equipment, and swing and travel systems do not operate.
Related • Perform all troubleshooting with working mode in power mode (P).
information
Malfunction of work high idle.
1 equipment lock Lock lever position Solenoid output pressure
solenoid valve LOCK 0 MPa {0 kg/cm2}
FREE 2.9 MPa {30 kg/cm2}
2 pressure reducing
valve Control circuit Control lever: All levers in NEUTRAL 2.84 to 3.43 MPa
source pressure position {29 to 35 kg/cm2}
Piston pump may malfunction or have internal defect. Check it by following
Defective piston method.
3 pump • Remove main oil pressure pickup plug and crank engine.
If oil flows out, it is normal.
4 Defective damper Pump shaft may not rotate due to some internal defect of damper. Check damper.
PC290LC-10 40-635
40 Troubleshooting
mode)
H-4 Unusual sound is heard from around hydraulic pump

Failure • Unusual noise is heard from around hydraulic pump
Related
information
Lowered hydraulic Check it.
1
oil level
Improper hydraulic Air may be mixed in hydraulic oil. Check oil.
2
oil
Clogged hydraulic Negative pressure may be generated in hydraulic tank because of clogged
3 tank cap hydraulic tank cap. Check it.
Clogged hydraulic Strainer in hydraulic tank may be clogged, causing negative pressure in suction
4
tank strainer circuit. Check strainer.
Defective piston Piston pump may have performance deterioration, malfunction or internal defect.
5 pump
40-636 PC290LC-10
40 Troubleshooting
mode)
H-5 Fine control performance or response is poor

Failure • Fine control performance or response is poor.
information
high idle.
Approx. 2.9 MPa
cm2}
output pressure
Travel lever: 0 MPa
Travel speed: Hi
Clogged LS circuit Orifice in LS circuit may be clogged. Check orifice.
2
orifice
high idle.
Run track idle off
Measured oil
halfway)
Pump delivery
pressure
4
PC290LC-10 40-637
40 Troubleshooting
mode)
H-6 Boom operation lacks speed or power

Failure • Boom lacks speed or power.
information
Malfunction of R.H. high idle.
1 PPC valve (boom NEUTRAL 0 MPa {0 kg/cm2}
PPC valve output R.H. work
circuit)
pressure equipment control Boom RAISE and 2.84 to 3.43 MPa
lever Boom LOWER {29 to 35 kg/cm2}
Malfunction of Merge-divider main EPC valve may malfunction. Check it.
2 merge-divider main
EPC valve
Malfunction of Merge-divider LS-EPC valve may malfunction. Check it.
3 merge-divider LS-
EPC valve
Malfunction of Merge-divider main valve may malfunction. Check it.
valve
Malfunction of Merge-divider LS valve may malfunction. Check it.
5 merge-divider LS
valve
Malfunction of Boom throttle EPC solenoid may malfunction. Check it.
boom throttle EPC
6 solenoid valve
(raise side only)
Malfunction of Spool of boom control valve may malfunction. Check it.
7 boom control valve
(spool)
Malfunction of Pressure compensation valve of boom control valve may malfunction. Check it.
boom control valve
8 (pressure
compensation
valve) (RAISE)
Malfunction of Pressure compensation valve of boom control valve may malfunction. Check it
boom control valve directly.
9 (pressure
compensation
valve) (LOWER)
Malfunction of Regeneration valve of boom control valve may malfunction or sealing may be
boom control valve defective. Check it.
10 (regeneration
valve)
Malfunction of Lock valve of boom control valve may malfunction. Check it.
(lock valve)
Malfunction or Safety valve for lock valve may malfunction or sealing may be defective. Check it.
defective sealing of
12
safety valve for lock
valve
Malfunction or Suction valve (bottom side) of boom control valve may malfunction or sealing may
defective sealing of be defective. Check it.
(suction valve)
Malfunction or Suction-safety valve (head side) of boom control valve may malfunction or sealing
defective sealing of may be defective. Check it.
(suction-safety
valve)
40-638 PC290LC-10
40 Troubleshooting
mode)

Malfunction of LS LS shuttle valve of L.H. travel control valve may malfunction. Check it.
15 shuttle valve (L.H.
travel)
Malfunction of LS LS shuttle valve of bucket control valve may malfunction. Check it.
16 shuttle valve
(bucket)
Malfunction of LS LS shuttle valve of service control valve may malfunction. Check it.
17 shuttle valve
(service valve)
Defective boom high idle.
18 cylinder R.H. work
Leakage from Boom RAISE to
boom cylinder equipment control hydraulic relief 20 cc/min
lever
PC290LC-10 40-639
40 Troubleshooting
mode)
H-7 Arm operation lacks speed or power

Failure • Arm lacks speed or power.
information
high idle.
Malfunction of L.H.
0 MPa
1 PPC valve (arm NEUTRAL
PPC valve output L.H. work {0 kg/cm2}
circuit)
pressure equipment control
Arm IN and arm 2.84 to 3.43 MPa
lever
OUT {29 to 35 kg/cm2}
EPC valve
3 merge-divider LS-
EPC valve
valve
5 merge-divider LS
valve
Malfunction of arm Spool of arm control valve may malfunction. Check it.
6 control valve
(spool)
Malfunction of arm Pressure compensation valve of arm control valve may malfunction. Check it
control valve directly.
7 (pressure
compensation
valve) (RAISE)
8 (pressure
compensation
valve) (LOWER)
Malfunction of arm Regeneration valve of arm control valve may malfunction. Check it directly.
control valve
9 (regeneration
valve)
Malfunction of arm Quick return valve of arm control valve may malfunction. Check it.
10 control valve (quick
return valve)
Malfunction or Safety valve of lock valve may malfunction or sealing may be defective. Check it.
11
safety valve for lock
valve
Malfunction or Suction valve of arm control valve may malfunction. Check it.
12 arm control valve
(suction valve)
Malfunction or Suction-safety valve of arm control valve may malfunction or sealing may be
defective sealing of defective. Check it.
13 arm control valve
(suction-safety
valve)
Malfunction of R.H. LS shuttle valve of R.H. travel control valve may malfunction. Check it.
14 travel control valve
(LS shuttle valve)
40-640 PC290LC-10
40 Troubleshooting
mode)

Malfunction of LS shuttle valve of boom control valve may malfunction. Check it.
(LS shuttle valve)
Malfunction of L.H. LS shuttle valve of L.H. travel control valve may malfunction. Check it.
(LS shuttle valve)
Malfunction of LS shuttle valve of bucket control valve may malfunction. Check it.
bucket control
17 valve (LS shuttle
valve)
Malfunction of LS shuttle valve of service control valve may malfunction. Check it.
service control
18 valve (LS shuttle
valve)
Defective arm high idle.
19 cylinder L.H. work
Leakage from arm Arm IN to hydraulic
cylinder equipment control 20 cc/min
relief
lever
PC290LC-10 40-641
40 Troubleshooting
mode)
H-8 Bucket operation lacks speed or power

Failure • Bucket lacks speed or power.
information
Malfunction of R.H. high idle.
1 PPC valve (bucket NEUTRAL 0 MPa {0 kg/cm2}
PPC valve output R.H. work
circuit)
pressure equipment control Bucket CURL and 2.84 to 3.43 MPa
lever bucket DUMP {29 to 35 kg/cm2}
Malfunction of Spool of bucket control valve may malfunction. Check it.
2 bucket control
valve (spool)
Malfunction of Pressure compensation valve of bucket control valve may malfunction. Check it.
bucket control
3 valve (pressure
compensation
valve) (CURL)
bucket control
4 valve (pressure
compensation
valve) (DUMP)
Malfunction or Suction-safety valve of bucket control valve may malfunction or sealing may be
bucket control
5 valve (suction-
safety valve)
(CURL)
Malfunction or Suction-safety valve of bucket control valve may malfunction or sealing may be
bucket control
6 valve (suction-
safety valve)
(DUMP)
Malfunction of LS LS shuttle valve of service control valve may malfunction. Check it.(If service valve
7 shuttle valve is installed)
(service valve)
Defective bucket high idle.
Leakage from Bucket CURL to
bucket cylinder equipment control hydraulic relief 20 cc/min
lever
40-642 PC290LC-10
40 Troubleshooting
mode)
H-9 Work equipment does not move in single operation

• Boom does not move when it is operated independently.
Failure • Arm does not move when it is operated independently.
• Bucket does not move when it is operated independently.
information
high idle.
Malfunction of PPC
1 NEUTRAL 0 MPa {0 kg/cm2}
valve PPC valve output Work equipment 2.84 to 3.43 MPa
pressure control levers Operation
{29 to 35 kg/cm2}
Malfunction of Spool of boom control valve may malfunction. Check it.
(spool)
3 control valve
(spool)
4 bucket control
valve (spool)
PC290LC-10 40-643
40 Troubleshooting
mode)
H-10 Hydraulic drift of boom is large

Failure • Hydraulic drift of boom is large.
information
Defective boom high idle.
Leakage from Boom RAISE to
boom cylinder equipment control hydraulic relief 20 cc/min
lever
Malfunction of Lock valve of boom control valve may malfunction. Check it.
(lock valve)
Defective sealing Sealing for safety valve for lock valve may malfunction. Check it.
3 for safety valve of
lock valve
40-644 PC290LC-10
40 Troubleshooting
mode)
H-11 Hydraulic drift of arm is large

Failure • Hydraulic drift of arm is large.
information
Defective arm high idle.
1 cylinder L.H. work
Leakage from arm Arm IN to hydraulic
cylinder equipment control 20 cc/min
relief
lever
Sealing for safety valve (bottom side) of arm control valve may be defective.
Defective sealing Check it.
2 for arm control
valve (safety valve) a You may replace this safety valve with another one and check change in
symptom for determining whether it is normal or not.
Defective sealing Sealing for suction valve (bottom side) of arm control valve may be defective.
for arm control Check it.
3 valve (suction a You may replace this suction valve with another one and check change in
valve) symptom for determining whether it is normal or not.
4 control valve
(spool)
5 (pressure
compensation
valve) (LOWER)
PC290LC-10 40-645
40 Troubleshooting
mode)
H-12 Hydraulic drift of bucket is large

Failure • Hydraulic drift of the bucket is large
information
Defective bucket high idle.
Leakage from Bucket CURL to
bucket cylinder equipment control hydraulic relief 20 cc/min
lever
Defective sealing Sealing for suction-safety (bottom side) of bucket control valve may be defective.
for bucket control Check it.
2 valve (suction- a You may replace this suction-safety valve with another one and check change
safety valve) in symptom for determining whether it is normal or not.
3 bucket control
valve (spool)
bucket control
4 valve (pressure
compensation
valve) (DUMP)
40-646 PC290LC-10
40 Troubleshooting
mode)
H-13 Time lag of work equipment is large

Failure • Time lag of work equipment is large.
information
high idle.
Approx. 2.9 MPa
cm2}
output pressure
Travel lever: 0 MPa
Travel speed: Hi
Malfunction of Regeneration valve of boom control valve may malfunction. Check it.
boom control valve
2 (regeneration
valve)
Malfunction of arm Regeneration valve of arm control valve may malfunction. Check it directly.
control valve
3 (regeneration
valve)
Malfunction of Suction-safety valve (head side) in boom control valve may malfunction. Check it.
boom control valve
4 a You may replace this suction-safety valve with another one and check change
(suction-safety
in symptom for determining whether it is normal or not.
valve)
Malfunction of arm Suction-safety valve (bottom side) in arm control valve may malfunction. Check it.
control valve
5 a You may replace this suction-safety valve with another one and check change
(suction-safety
in symptom for determining whether it is normal or not.
valve)
Defective sealing Sealing for suction-safety (bottom side) of bucket control valve may be defective.
6 valve (suction- a You may replace this suction-safety valve with another one and check change
safety valve) in symptom for determining whether it is normal or not.
boom control valve
7 (pressure
compensation
valve) (RAISE)
Malfunction of Pressure compensation valve of boom control valve may malfunction. Check it
boom control valve directly.
8 (pressure
compensation
valve) (LOWER)
9 (pressure
compensation
valve) (RAISE)
10 (pressure
compensation
valve) (LOWER)
PC290LC-10 40-647
40 Troubleshooting
mode)

bucket control
11 valve (pressure
compensation
valve) (CURL)
bucket control
12 valve (pressure
compensation
valve) (DUMP)
40-648 PC290LC-10
40 Troubleshooting
mode)
H-14 When part of work equipment is relieved singly, other parts of work
equipment move
Failure • While one of work equipment is in hydraulic stall, other work equipment move.
Related
information
boom control valve
1 (pressure
compensation
valve) (RAISE)
2 (pressure
compensation
valve) (RAISE)
Defective sealing Sealing for pressure compensation valve of bucket control valve may be defective.
3 valve (pressure
compensation
valve) (DUMP)
Defective sealing Sealing for pressure compensation valve of bucket control valve may be defective.
4 valve (pressure
compensation
valve) (CURL)
PC290LC-10 40-649
40 Troubleshooting
mode)
E-15 One-touch power maximizing function does not work

Failure • One-touch power maximizing function does not work.
information
Malfunction of 2- high idle.
1 stage relief OFF 0 MPa {0 kg/cm2}
solenoid valve Solenoid output
Swing lock switch 2.9 MPa
pressure ON
{30 kg/cm2}
Malfunction of main Main relief valve of control valve may malfunction. Check it.
2 relief valve (front)
Malfunction of main Main relief valve of control valve may malfunction. Check it.
3 relief valve (rear)
40-650 PC290LC-10
40 Troubleshooting
mode)
H-16 In combined operation of work equipment, equipment having

heavier load moves slower
Failure • In combined operation of work equipment, equipment having larger load moves slower
Related
information
Pressure compensation valve of control valve on smaller load side may
Malfunction of malfunction. Check it.
control valve Combination of
(pressure Larger load side Smaller load side
1 combined operation
compensation Boom RAISE
valve) (arm IN) on
smaller load side + Boom RAISE Arm IN
Arm IN
Malfunction of Pressure compensation valve of control valve on smaller load side may
control valve malfunction. Check it.
(pressure Combination of
Larger load side Smaller load side
2 compensation combined operation
valve) (boom Boom RAISE
RAISE) on smaller + Arm OUT Boom RAISE
load side Arm OUT
valve) (bucket Boom RAISE
CURL) on smaller + Boom RAISE Bucket CURL
load side Bucket CURL
valve) (bucket Arm OUT
CURL) on smaller + Arm OUT Bucket CURL
load side Bucket CURL
control valve Combination of
(pressure Larger load side Smaller load side
combined operation
5 compensation Boom LOWER
valve) (boom
LOWER) on + Arm OUT Boom LOWER
smaller load side Arm OUT
PC290LC-10 40-651
40 Troubleshooting
mode)
H-17 In combined operations of swing and boom RAISE, boom rising

speed is low
Failure • In combined operations of swing and boom RAISE, boom speed is low.
• If boom RAISE speed is slow even in single operation of boom RAISE, perform following
Related troubleshooting.
information
• H-6 Boom operation lacks speed or power(PAGE 40-638)
Malfunction of or LS select valve of swing control valve may malfunction or sealing may be
defective sealing defective. Check it.
1 for swing control
valve (LS select
valve)
40-652 PC290LC-10
40 Troubleshooting
mode)
H-18 In combined operations of swing and travel, travel speed drops

largely
Failure • Travel speed drops significantly in combined operation of swing and travel
• If travel speed is slow even in single operation of travel, perform following
Related troubleshooting.
information
• H-20 Travel speed is too low(PAGE 40-655)
(LS shuttle valve)
Malfunction of LS shuttle valve of swing control valve may malfunction. Check it.
2 swing control valve
(LS shuttle valve)
PC290LC-10 40-653
40 Troubleshooting
mode)
H-19 Machine does not travel straight

Failure • Machine deviates during travel.
information
Malfunction of high idle.
1
travel PPC valve PPC valve output FORWARD and 2.84 to 3.43 MPa
pressure Travel lever
REVERSE {29 to 35 kg/cm2}
2 pressure reducing
high idle.
Run track idle off
Measured oil
halfway)
Pump delivery
pressure
4
5 travel junction NEUTRAL 0 MPa {0 kg/cm2}
solenoid valve Solenoid valve
Travel lever When either lever is 2.9 MPa
output pressure
operated {30 kg/cm2}
Malfunction of Travel junction valve may malfunction. Check it.
6 travel junction valve
Malfunction of Spool of travel control valve may malfunction. Check it.
(spool)
Defective center Connect right and left hoses connecting swivel joint and travel motors to opposite
8 swivel joint ports with each other, and check if deviation direction changes.
Defective travel high idle.
9 FORWAD or
motor Leakage from
Travel lever REVERSE to motor 27.2 l/min
travel motor
stall
Final drive may have internal defect. Check it.
10 Defective final drive a You may judge by unusual noise, abnormal heating, metallic powders in drain
oil, etc.
40-654 PC290LC-10
40 Troubleshooting
mode)
H-20 Travel speed is too low

Failure • Travel speed is low.
information
high idle.
Malfunction of
travel PPC valve PPC valve output
Travel lever FORWARD and 2.84 to 3.43 MPa
pressure
2 pressure reducing
high idle.
Approx. 2.9 MPa
cm2}
output pressure
Travel lever: 0 MPa
Travel speed: Hi
(spool)
Malfunction of Pressure compensation valve of travel control valve may malfunction. Check it.
travel control valve
(pressure
5 compensation
valve) (R.H.
forward)
(pressure
6 compensation
valve) (R.H.
reverse)
(pressure
7 compensation
valve) (L.H.
forward)
(pressure
8 compensation
valve) (L.H.
reverse)
Malfunction of Suction valve of travel control valve may malfunction. Check it.
(suction valve)
PC290LC-10 40-655
40 Troubleshooting
mode)

10 shuttle valve
(bucket)
11 FORWAD or
motor Leakage from
Travel lever REVERSE to 27.2 l/min
travel motor hydraulic relief
oil, etc.
40-656 PC290LC-10
40 Troubleshooting
mode)
H-21 Machine is hard to steer or travel power is low

Failure • Machine does not turn easily or lacks steering power.
information
high idle.
Malfunction of
travel PPC valve PPC valve output
Travel lever FORWARD and 2.84 to 3.43 MPa
pressure
2 travel junction NEUTRAL 0 MPa {0 kg/cm2}
solenoid valve Solenoid valve
Travel lever When either lever is 2.9 MPa
output pressure
operated {30 kg/cm2}
Malfunction of Travel junction valve may malfunction. Check it.
3 travel junction valve
EPC valve
5 merge-divider LS-
EPC valve
valve
7 merge-divider LS
valve
(spool)
(pressure
9 compensation
valve) (R.H.
forward)
(pressure
10 compensation
valve) (R.H.
reverse)
(pressure
11 compensation
valve) (L.H.
forward)
(pressure
12 compensation
valve) (L.H.
reverse)
PC290LC-10 40-657
40 Troubleshooting
mode)

(suction valve)
14 shuttle valve
(bucket)
Defective sealing Sealing for check valve at LS oil pressure pickup port may be defective. Check it.
for check valve
15 (front) at LS oil
pressure pickup
port
Defective sealing Sealing for check valve at LS oil pressure pickup port may be defective. Check it.
for check valve
16 (rear) at LS oil
pressure pickup
port
Defective center Connect right and left hoses connecting swivel joint and travel motors to opposite
17 swivel joint ports with each other, and check if deviation direction changes.
Sealing for safety valve of travel motor may be defective. Check it.
Malfunction of R.H.
18 travel motor (safety a You may interchange safety valves from forward and reverse circuits of motor
valve) or those from right and left motors and check changes in symptom for
determining whether safety valve is normal or not.
Malfunction of L.H.
Sealing for check valve of travel motor may be defective. Check it.
Malfunction of R.H.
20 travel motor (check a You may interchange check valves from forward and reverse circuits of motor
determining whether check valve is normal or not.
Malfunction of L.H.
40-658 PC290LC-10
40 Troubleshooting
mode)
H-22 Travel speed does not change, or travel speed is too low or high
Failure • Travel speed does not change or travel speed is too low or high.
information
high idle.
*: Travel speed at Lo setting can be adjusted with adjustment function of machine
Malfunction of LS- monitor. Therefore, if it has been changed from initial set value, indicated value
1 changes more or less.
EPC valve
Travel speed: Lo 617 mA (See *)
Monitoring code: Travel lever:
Travel speed: Mi 679 mA
01500 Operation
Travel speed: Hi 0 mA
high idle.
Malfunction of LS- Approx. 2.9 MPa
2 Travel lever: Travel speed: Lo
EPC valve NEUTRAL {Approx. 30 kg/
LS-EPC valve
cm2}
output pressure
Travel lever:
Travel speed: Hi 0 MPa {0 kg/cm2}
Operation
high idle.
Malfunction of
travel speed Travel lever: Travel speed: Lo 0 MPa {0 kg/cm2}
3 NEUTRAL
selector solenoid Solenoid valve
valve Approx. 2.9 MPa
output pressure Travel lever:
Travel speed: Hi {Approx. 30 kg/
Operation
cm2}
Malfunction of Speed-select unit of travel motor may malfunction. Check it.
4 travel motor
(speed-select unit)
PC290LC-10 40-659
40 Troubleshooting
mode)
H-23 One of tracks dose not run

Failure • One of tracks does not run.
information
(suction valve)
Malfunction of R.H.
Malfunction of L.H.
Malfunction of R.H.
Malfunction of L.H.
Malfunction of Parking brake of travel motor may malfunction. Check it.
6 travel motor
(parking brake)
7 FORWAD or
motor Leakage from
Travel lever REVERSE to 27.2 l/min
travel motor hydraulic relief
oil, etc.
40-660 PC290LC-10
40 Troubleshooting
mode)
H-24 Upper structure does not swing to the right or left

Failure • Upper structure swings neither to right nor left.
information
swing holding Output pressure of 0 MPa {0 kg/cm2}
1 L.H. work NEUTRAL
brake solenoid swing holding
valve equipment control Swing LEFT or 2.9 MPa
brake solenoid
lever RIGHT {30 kg/cm2}
valve
Malfunction of Spool of swing control valve may malfunction. Check it.
(spool)
Malfunction of Swing holding brake of swing motor may malfunction. Check it.
3 swing motor (swing
holding brake)
a Be ready with engine stopped, then perform troubleshooting engine at high
Poor adjustment of idle.
4 swing motor (safety L.H. work
valve) Swing relief Swing lock switch: equipment control 28.9 to 32.9 MPa
pressure ON lever: Swing to {295 to 335 kg/cm2}
hydraulic relief
Malfunction of If pressure is not adjusted to normal value, safety valve of swing motor may
5 swing motor (safety malfunction or has internal defects. Check it.
valve)
high idle.
Defective swing L.H. work
6
motor Leakage from Swing lock switch: equipment control
swing motor lever: Swing to 10 l/min Max.
ON
hydraulic relief
Swing machinery may have internal defect. Check it.
Defective swing
7 machinery a You may judge by unusual sound, abnormal heating, metal chips in drain oil,
etc.
PC290LC-10 40-661
40 Troubleshooting
mode)
H-25 Upper structure swing only to the right or left

Failure • Upper structure does not swing only in one direction
information
high idle.
Malfunction of
1 swing PPC valve L.H. work NEUTRAL 0 MPa {0 kg/cm2}
PPC valve output
equipment control Swing LEFT or 2.84 to 3.43 MPa
pressure
lever RIGHT {29 to 35 kg/cm2}
(spool)
Suction valve of swing motor may malfunction. Check it.
Malfunction of
3 swing motor a You may interchange right and left swing suction valves of swing motor and
(suction valve) check changes in symptom for determining whether suction valve is normal or
not.
Check valve of swing motor may malfunction. Check it.
Malfunction of
4 swing motor (check a You may interchange right and left swing check valves of swing motor and
valve) check changes in symptom for determining whether check valve is normal or
not.
40-662 PC290LC-10
40 Troubleshooting
mode)
H-26 Swing acceleration is poor or swing speed is low (both right and
left)
Failure • Swing acceleration or swing speed is low in both right and left directions.
information
(spool)
Malfunction of R.H. LS shuttle valve of R.H. travel control valve may malfunction. Check it.
(LS shuttle valve)
(LS shuttle valve)
Malfunction of LS shuttle valve of boom control valve may malfunction. Check it.
(LS shuttle valve)
Malfunction of arm LS shuttle valve of arm control valve may malfunction. Check it.
5 control valve (LS
shuttle valve)
Malfunction of LS shuttle valve of bucket control valve may malfunction. Check it.
bucket control
6 valve (LS shuttle
valve)
Malfunction of LS shuttle valve in service control valve may malfunction. Check it.
service control
7 valve (LS shuttle
valve)
holding brake)
hydraulic relief
Malfunction of If pressure is not adjusted to normal value, safety valve of swing motor may
valve)
high idle.
11
ON
hydraulic relief
Defective swing
etc.
PC290LC-10 40-663
40 Troubleshooting
mode)
H-27 Swing acceleration is poor or swing speed is low (either right or

left)
Failure • Swing acceleration or speed is low in either direction.
information
high idle.
Malfunction of
PPC valve output
pressure
(spool)
Malfunction of R.H. Pressure compensation valve of R.H. swing control valve may malfunction. Check
swing control valve it.
3 (pressure
compensation
valve)
Malfunction of L.H. Pressure compensation valve of L.H. swing control valve may malfunction. Check
4 (pressure
compensation
valve)
Malfunction of
not.
Malfunction of
not.
40-664 PC290LC-10
40 Troubleshooting
mode)
H-28 Upper structure overruns excessively when it stops swinging (both

right and left)
• Upper structure overruns excessively when it stops swinging in both directions (right and
Failure left).
information
hydraulic relief
Poor adjustment of If pressure is not adjusted to normal value, safety valve of swing motor may
valve)
high idle.
3
ON
hydraulic relief
PC290LC-10 40-665
40 Troubleshooting
mode)
H-29 Upper structure overruns excessively when it stops swinging

(either right or left)
Failure • Upper structure overruns excessively when it stops swinging in either direction.
information
high idle.
Malfunction of
PPC valve output
pressure
R.H. swing PPC slow return valve may malfunction. Check it.
Clogged R.H.
2 swing PPC slow a You may interchange right and left swing PPC slow return valves of swing
return valve motor and check changes in symptom for determining whether swing PPC
slow return valve is normal or not.
L.H. swing PPC slow return valve may malfunction. Check it.
Clogged L.H. swing
3 PPC slow return a You may interchange right and left swing PPC slow return valves of swing
valve motor and check changes in symptom for determining whether swing PPC
(spool)
Malfunction of
not.
Malfunction of
not.
40-666 PC290LC-10
40 Troubleshooting
mode)
H-30 Shock is large when upper structure stops swinging

Failure • Shock is large when upper structure stops swinging.
information
high idle.
Malfunction of
PPC valve output
pressure
R.H. swing PPC slow return valve may malfunction. Check it.
Clogged R.H.
2 swing PPC slow a You may interchange right and left swing PPC slow return valves of swing
return valve motor and check changes in symptom for determining whether swing PPC
L.H. swing PPC slow return valve may malfunction. Check it.
Clogged L.H. swing
3 PPC slow return a You may interchange right and left swing PPC slow return valves of swing
valve motor and check changes in symptom for determining whether swing PPC
Malfunction of Shockless valve of swing motor may malfunction. Check it.
4 swing motor
(shockless valve)
PC290LC-10 40-667
40 Troubleshooting
mode)
H-31 Large unusual noise is heard when upper structure stops swinging
Failure • Large unsual noise is heard when upper structure stops swinging
information
Malfunction of back Back pressure valve of control valve may malfunction. Check it.
1 pressure valve
Malfunction of Safety valve of swing motor may malfunction. Check it.
2 swing motor (safety
valve)
Malfunction of
not.
Defective swing
etc.
40-668 PC290LC-10
40 Troubleshooting
mode)
H-32 Swing drift on a slope is large while swing holding brake is applied
• Swing drift on a slope is large.
Failure (While swing holding brake is applied)
• When swing lock switch is in ON position, or swing brake cancel switch is in normal
Related position, swing holding brake is applied and disc brake holds upper structure.
information • Perform all troubleshooting with working mode in power mode (P).
swing holding Output pressure of 0 MPa {0 kg/cm2}
1 L.H. work NEUTRAL
brake solenoid swing holding
valve equipment control Swing LEFT or 2.9 MPa
brake solenoid
lever RIGHT {30 kg/cm2}
valve
holding brake)
PC290LC-10 40-669
40 Troubleshooting
mode)
H-33 Swing drift on a slope is large while swing holding brake is released
• Swing drift on a slope is large.
Failure (While swing holding brake is released)
• When swing brake cancel switch is in emergency position, swing holding brake is
Related released and upper structure is held with only hydraulic pressure.
information • Perform all troubleshooting with working mode in power mode (P).
(spool)
Malfunction of R.H. Pressure compensation valve of R.H. swing control valve may malfunction. Check
2 (pressure
compensation
valve)
Malfunction of L.H. Pressure compensation valve of L.H. swing control valve may malfunction. Check
3 (pressure
compensation
valve)
Defective swing Sealing for safety valve of swing motor may be defective. Check it.
4 motor (safety valve)
Defective swing Sealing for suction valve of swing motor may be defective. Check it.
5 motor (suction
valve)
Defective swing Sealing for check valve of swing motor may be defective. Check it.
6 motor (check valve)
Malfunction of Shockless valve of swing motor may malfunction. Check it.
7 swing motor
(shockless valve)
40-670 PC290LC-10
40 Troubleshooting
mode)
H-34 Attachment circuit cannot be changed while attachment is installed

Failure • When attachment is installed, attachment circuit is not switched to desired one.
• For machines with provision for attachment, service circuit changes as shown below
according to selected working mode.
1. In ATT mode: 2-way circuit is selected and low-pressure setting is selected for safety
Related valve.
information 2. In B mode: 1-way circuit is selected and high-pressure setting is selected for safety
valve.
• Setting of safety valve is changed on only port B side. Setting on port A side is kept to
low-pressure setting.
attachment return Attachment return ATT mode 0 MPa {0 kg/cm2}
1
selector solenoid selector solenoid
valve Working mode 2.9 MPa
valve output B mode
pressure {30 kg/cm2}
Malfunction of Attachment return selector valve may malfunction. Check it.
2 attachment return
selector valve
Malfunction of Safety valve (port B side) of service control valve may malfunction. Check it.
3 service control
valve (safety valve)
PC290LC-10 40-671
40 Troubleshooting
mode)
H-35 Oil flow in attachment circuit cannot be controlled

Failure • Flow rate of attachment circuit cannot be adjusted.
• For machines with provision for attachment, flow rate of service circuit can be changed
Related from user mode of machine monitor.
information • Procedure for adjusting flow rate in ATT mode is different from that in B mode. For details,
see Operation and Maintenance Manual.
Malfunction of Attachment flow rate adjustment EPC valve may malfunction. Check it.
attachment flow
1
rate adjustment
EPC valve
Malfunction of Service PPC valve may be malfunction. Check it.
2
service PPC valve
40-672 PC290LC-10
40 Troubleshooting
Troubleshooting of engine (S-mode)
Information mentioned in troubleshooting table (S mode)
(Rev. 2011/01)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment
PC290LC-10 40-673
40 Troubleshooting
S-1 When starting switch is turned to START position, engine does not
crank
Failure When starting switch is turned to "START" position, engine does not crank.
Related • For troubleshooting of electrical system, see E-1 in E mode troubleshooting.
information • If a failure code is displayed, perform troubleshooting for it first.
No. Cause Check item and remarks Remedy
Defective starting • When starting switch is turned to START, starter Perform troubleshooting
1 circuit wiring pinion does not plunge. for E-1 and repair failure.
• Rasping sound is heard around starting motor Perform troubleshooting
pinion. for E-1 and repair failure.
(When starting switch is turned to START, starting
motor pinion plunges.)
• Starting motor pinion returns halfway.
Defective starting
2 motor (safety relay
section)
• Brattle is heard and starting motor does not rotate.
(Reference: Brattle is made by starting motor pinion
when it repeats plunging and returning.)
• If rasping sound is heard from starting motor pinion Replace if broken.
Broken flywheel
3 and starting motor does not rotate, visually check
ring gear
flywheel ring gear.
Cracked EGR • Remove gas piping from EGR inlet and outlet, and Replace EGR cooler, and
cooler check if water containing coolant flows out of them. then remove water in
4 (Reference: engine cylinders.
a Moisture in exhaust gas may condense into water.
Coolant in exhaust So, check whether water contains coolant.
pipe)
40-674 PC290LC-10
40 Troubleshooting
S-2 When engine cranks, smoke does not come out

Failure Engine is cranked but exhaust gas does not come out.
Related • If a failure code is displayed, perform troubleshooting for it first.
information
Insufficient fuel in • When fuel tank is inspected, it is found to be empty. Add fuel.
1
tank
Clogged breather • Breather hole in fuel tank cap is clogged. Flush air breather hole in
2 hole in fuel tank fuel tank cap and clean
cap surrounding area.
Clogged fuel filter • Check used hours of fuel filter. If used beyond Replace fuel filter
3 specified hours, fuel filter element may be clogged. element.
element
Foreign material in • Rust and water are found when fuel tank is drained. Replace fuel.
4
fuel
• When air bleeding operation for fuel system is Perform air bleeding
performed, air comes out. operation.
5 Air in fuel piping (Reference: See Testing and adjusting, "Bleeding Correct or replace fuel
air from fuel system".) piping.
• Fuel is leaking from fuel piping. Correct or replace fuel
Leakage from fuel
6 (Reference: See Testing and adjusting, "Testing piping related parts.
piping system
fuel circuit for leakage".)
Defective supply • See Testing and adjusting, "Testing fuel delivery, Replace supply pump and
7 pump return and leakage".) pressure limiter.
Defective priming • When priming pump is operated, no resistance is Replace priming pump.
8 pump felt or it is heavy.
• After common rail pressure (Code: 36400 Loosen mounting nuts of
Defective air
[Common rail pressure) is checked on machine injection pipe and high-
bleeding from
9 monitor and engine is stopped, common rail pressure pipe on common
common rail and
pressure does not decrease. rail side to bleed air.
injection pipe
(If air remains, pressure does not decrease)
PC290LC-10 40-675
40 Troubleshooting
S-3 Engine does not start while fuel is injected (Incomplete combustion)
Fuel is injected but engine does not start (Low-order burst, almost starts but actually does
Failure not).
information
• Specific gravity of electrolyte and voltage of battery Refill with electrolyte or
1 Defective battery
are low. charge battery.
2
tank
element
5
fuel
Leakage from fuel
piping system
Clogged air cleaner • Air cleaner dust indicator indicates caution level. Check and clean air
9
element cleaner element.
• Even if starting switch is turned to HEAT, intake air Replace air intake heater.
heater mount does not become warm.
Defective air intake • When preheating is performed or when
10
heater temperature is low, preheating monitor does not
operate normally.
• Check valve clearance. Replace valve and rocker
(Reference: See "Testing and adjusting valve arm.
Worn valve or clearance" in Testing and adjusting.)
11
rocker arm • When engine is cranked, unusual noise is heard
around cylinder head.
• Check compression pressure. Replace piston ring or
Defective piston
12 ring (Reference: See "Testing compression pressure" in piston.
Testing and adjusting.)
40-676 PC290LC-10
40 Troubleshooting
S-4 Startability is poor

Failure Engine startability is poor.
• If a failure code is displayed, perform troubleshooting for it first.
• Common rail fuel injection system (CRI) controls fuel injection timing electrically.
Related Accordingly, even if engine is cranked properly, engine may not start until crankshaft
information rotates two turns under most disadvantageous condition. This phenomenon does not
mean a problem, however.
• Specific gravity of electrolyte and voltage of battery Refill with electrolyte or
1 Defective battery
are low. charge battery.
2
tank
• Fuel other than specified one is used. Use fuel specified in
• Fuel used is not suitable for ambient temperature. Operation and
Use of unspecified (Reference: If engine starts at normal temperature Maintenance Manual.
3
fuel but dos not start easily at low temperature)
• Wax is deposited (milky) on clear ball of fuel pre-
filter.
element
6
fuel
Leakage from fuel
piping system
Clogged air cleaner • Air cleaner dust indicator indicates caution level. Check and clean air
10
element cleaner element.
• Even if starting switch is turned to HEAT, intake air Replace air intake heater.
heater mount does not become warm.
Defective air intake • When preheating is performed or when
11
heater temperature is low, preheating monitor does not
operate normally.
Cracked EGR • Remove the gas piping from EGR inlet and outlet, Replace EGR cooler, and
cooler and check if water containing coolant flows out of then remove water in
12 (Reference: them. engine cylinders.
Coolant in exhaust a Moisture in exhaust gas may condense into water.
pipe) So, check whether water contains coolant.
• When exhaust manifold is touched immediately Replace injector.
after starting engine, temperature of some cylinder
is low.
13 Defective injector • When a certain cylinder is cut out, engine speed
does not change.
(Reference: See Testing and adjusting, "Handling
cylinder cutout mode operation".)
PC290LC-10 40-677
40 Troubleshooting

• Measure compression pressure (see standard Correct or replace valve
values table). or valve seat.
Defective contact of (Reference: See Testing and adjusting, "Testing
14 valve with valve compression pressure".)
seat • Test the valve clearances.
(Reference: See Testing and adjusting, "Testing
and adjusting valve clearance".)
• Open the exhaust gas color measuring hole before Replace piston ring or
the KDPF and check the color of the exhaust gas. piston.
exhaust gas color".)
Defective piston
15 ring • Measure the compression pressure (see standard
values table).
compression pressure".)
• Check piston rings and piston ring grooves.
40-678 PC290LC-10
40 Troubleshooting
S-5 Engine does not pick up smoothly

Failure Engine does not pick up smoothly.
information
1
tank
element
4
fuel
Leakage from fuel
piping system
• If 'crankcase pressure high error' (failure code: Performs checks on
CA555) is indicated after KCCV filter element is causes 10 and after.
Abnormally high
8 replaced, blowby pressure is probably high. (See
crankcase pressure
Testing and adjusting, "Testing blowby pressure")
KVGT may be seized or broken.
after starting engine, temperature of some cylinders
is low.
9 Defective injector • Even if a cylinder is cut out, engine speed does not
change.
(Reference: see "Handling cylinder cutout mode
operation" in Testing and adjusting.)
• Unusual sound is heard from KVGT. Replace KVGT.
KVGT seized or • Check if KVGT shaft rotates.
10 (Move KVGT vanes with hand in axial and radial
broken
directions to judge.)
• When engine is cranked, unusual noise is Adjusting valve clearance.
generated around cylinder head.
Incorrect valve • Check valve clearance.
11
clearance (Reference: See Testing and adjusting, "Testing
Defective piston
values table).
PC290LC-10 40-679
40 Troubleshooting
S-6 Engine stops during operation

Failure Engine stops during running.
information
1
tank
element
4
fuel
Leakage from fuel
piping system
Defective air intake • Visually check the air intake hose for damage. Replace air intake hose
hose
9
(from air cleaner to
KVGT inlet)
Defective air intake • Check the intake manifold for internal damage. Replace air intake
10
manifold manifold.
Defective boost • Air comes out of boost piping. Repair or replace boost
piping and joint piping.
11 (Between KVGT
and air intake
manifold)
Defective exaust • Check exhaust pipes for damage and exhaust gas Replace exhaust gas
pipes leakage. piping.
12 (from exhaust (Check heat insulation cover and soot on heat
manifold to KDPF shield plate.)
inlet)
• Check valve and rocker arm. Replace valve and rocker
Damage of valve (Engine is stopped suddenly after unusual sound is arm.
13
and rocker arm heard.)
• Metal particles are found in oil drained from oil pan. Replace piston and
Broken or seized • Remove oil pan and check piston and connecting connecting rod.
14 piston connecting rod.
rod (Reference: Engine is stopped after abnormal usual
sound is heard or overheated.)
Broken or seized • Metal particles are found in oil drained from oil pan. Replace crankshaft main
15 crankshaft main • Remove oil pan and check crankshaft main bearing.
bearing bearing.
Defective engine • Check engine controller power supply wiring. Repair engine controller
16 controller power (Reference: See Troubleshooting by failure code power supply wiring.
supply wiring [CA343].)
40-680 PC290LC-10
40 Troubleshooting

Defective starting • Check starting switch wiring. Perform troubleshooting
17 switch wiring for E-1 and repair.
Malfunction of • See H mode, "H-2 Engine speed lowers Perform troubleshooting
18 hydraulic system significantly or engine stalls". forH-2 and repair.
PC290LC-10 40-681
40 Troubleshooting
S-7 Engine runs rough or is unstable

Failure Engine runs rough or is unstable.
Related • If a failure code is displayed, troubleshoot it first.
information
1
tank
element
4
fuel
Perform air bleeding
• When air bleeding operation for fuel system is
5 Air in fuel piping (Reference: See Testing and adjusting, "Bleeding
Correct or replace fuel
Leakage from fuel
piping system
• Check whether leakage is present in boost system Repair the section around
Leakage in boost
7 (between KVGT outlet and after cooler, and boost piping or replace it.
system
between after cooler and intake manifold).
Defective mass air • Replace sensor and see if engine becomes normal. Replace mass air flow
8 flow and (Failure code may not appear due to dusts on and temperature sensor.
temperature sensor sensor.)
40-682 PC290LC-10
40 Troubleshooting
S-8 Engine lacks power

Failure Engine lacks power
Related • If any failure code is displayed, carry out troubleshooting for it first.
information
1
tank
element
4
fuel
Leakage from fuel
piping system
Defective air • Check air cleaner and airflow screen for Correct or replace air
8
cleaner deformation. cleaner.
Defective air intake • Visually check the air intake hose for damage. Replace air intake hose
hose
9
(from air cleaner to
KVGT inlet)
Defective air intake • Check the intake manifold for internal damage. Replace air intake
10
manifold manifold.
Defective boost • Air flows out from boost piping Correct or replace boost
piping and piping
connections
11
(From KVGT outlet
to air intake
manifold)
Improperly installed • Air leaks from boost pressure sensor mounting. Correct mounting of boost
12 boost pressure pressure sensor.
sensor
inlet)
Gas leakage from • Gas leaks from EGR piping Replace EGR piping
14 EGR piping
Check intake and • Measure boost pressure Correct or replace
exhaust system (Reference: See Testing and adjusting, "Measuring defective parts
(from KVGT outlet boost pressure(PAGE 30-10)".)
15 through intake
manifold and
exhaust manifold to
KDPF inlet)
broken
PC290LC-10 40-683
40 Troubleshooting

• Open the exhaust gas color measuring hole before Clean or change the
Large amount of the KDPF and check the color of the exhaust gas KDPF.
17 soot is (see standard value table).
accumulated. (Reference: See Testing and adjusting, "Measuring
exhaust gas color(PAGE 30-11)".)
• KDPF clogging - check exhaust pressure before Clean or change KDPF.
18 Defective KDPF
KDPF
19
is low.
does not change.
Defective piston
values table).
40-684 PC290LC-10
40 Troubleshooting
S-9 Exhaust smoke is black (KDPF clogs up early)

Failure Exhaust gas color is black (KDPF is prematurely plugged).
information
Use of unspecified
1 Operation and
fuel
Maintenance Manual.
2
fuel
Defective air • Check air cleaner and airflow screen for Correct or replace air
3
cleaner deformation. cleaner.
inlet)
Improperly installed • Air leaks from boost pressure sensor mounting. Correct mounting of boost
5 boost pressure pressure sensor.
sensor
Defective boost • Air flows out from boost piping Correct or replace boost
piping and piping
connections
6
(From KVGT outlet
to air intake
manifold)
• KDPF clogging - check exhaust pressure before Clean or change KDPF.
7 Defective KDPF
KDPF
Gas leakage from • Gas leaks from EGR piping Replace EGR piping
8 EGR piping
broken
is low.
does not change.
• Measured fuel return rate is large. Repair or replace fuel
Defective fuel (Reference: See "Testing fuel delivery, return and return pipe.
11 return piping leakage" in Testing and adjusting.)
• Check fuel return piping for clogging.
Defective mass air • Replace sensor and see if engine becomes normal. Replace mass air flow
12 flow and (Failure code may not appear due to dusts on and temperature sensor.
temperature sensor sensor.)
13
PC290LC-10 40-685
40 Troubleshooting

Defective piston
values table).
40-686 PC290LC-10
40 Troubleshooting
S-10 Engine oil consumption is too much

Failure Engine oil consumption is excessive.
information
Dust sucked in • Dust is in intake air piping between air cleaner and Clean or replace intake air
1 intake system engine. piping.
• Measured blowby gas pressure is higher than Repair or replace piston
standard value. ring.
• Blowby pressure remains high after KCCV filter
Broken or worn element is replaced.
2 piston ring • Measure compression pressure (see standard
value table).
(Reference: see "Testing compression pressure" in
Oil leakage from • Check for oil leakage from KCCV oil return piping. Repair or replace oil
3 KCCV oil return piping.
piping
External oil leakage • Check for oil leakage. Repair oil leaking part.
4 from engine
Oil leakage from oil • Check for oil leakage from oil filter. Reinstall or replace oil
5
filter filter.
Oil leakage from oil • Check for oil leakage from oil piping. Repair or replace oil
6 piping piping.
Oil leakage from oil • Check for oil leakage from oil drain plug. Retighten oil drain plug.
7 drain plug
Oil leakage from oil • Check for oil leakage from oil pan Repair or replace oil pan
8 pan
Oil leakage from • Check for oil leakage from cylinder head. Repair or replace oil pan.
9 cylinder head
Worn or damaged • Oil level in clutch chamber or damper chamber on Repair or replace rear oil
10 machine is high. seal.
rear oil seal
• Inlet and outlet of KVGT blower and outlet of Replace KVGT.
turbine are blemished with oil.
Oil leakage from • Check whether KVGT shaft rotates.
11
KVGT (Check above by moving blades of KVGT in axial
direction and direction vertical to shaft.)
• Oil is in coolant. Replace oil cooler
• Remove and check oil cooler for oil leakage to
Oil leakage from oil
12 outside.
cooler
• Check oil cooler for leakage by using compressed
air.
Oil leakage from • When EGR valve is removed, outlet port is found to Replace EGR valve.
13 be dirty with oil.
EGR valve stem
• Check valve guide and stem seal. Replace valve guide and
Worn or damaged • Remove cylinder head and check inside of guide stem seal.
14 valve guide or stem and stem seal for damage.
seal (Reference: see Maintenance standard)
PC290LC-10 40-687
40 Troubleshooting
S-11 Oil becomes contaminated early

Failure Oil becomes contaminated early.
information
Use of unspecified
1 Operation and
fuel
Maintenance Manual.
• Oil other than specified one is used. Use oil specified in
Use of unspecified
2 Operation and
oil
Maintenance Manual.
• Check exhaust gas color before KDPF (see Perform troubleshooting
Black exhaust gas standard value table). for "S-9 Exhaust gas color
3 color entering (Reference: See "Testing exhaust gas color" in is black".
KDPF Testing and adjusting.)
(Exhaust gas color entering KDPF is black.)
• Measured blowby pressure exceeds standard Perform following
Excessive blowby value. troubleshooting.
4 gas • The blowby pressure remains high after KCCV filter
element is replaced.
Defective seal on • Rotate KVGT shaft to check for play. Replace KVGT.
5 turbine side of (Check above by moving blades of KVGT in the
KVGT axial direction and in direction vertical to shaft).
• Remove EGR valve and check stem seal, guide Replace EGR valve.
Worn EGR valve
6 and stem.
guide
• Outlet port of removed EGR valve is dirty with oil.
• Check if oil is excessive. Adjust oil level properly.
7 Excessive oil (If oil level is too high, oil is heated high and
deteriorated earlier)
• Visually check oil cooler element for dirt. Repair or replace oil
Dirty oil cooler (Oil temperature is raised due to dirty oil cooler cooler element.
8
element element).
• Measured blowby gas pressure is higher than Repair or replace piston
standard value. ring.
• Blowby pressure remains high after KCCV filter
Broken or worn element is replaced.
9 piston ring • Measure compression pressure (see standard
value table).
• Check valve guide and stem seal. Replace valve guide and
Worn or damaged • Remove cylinder head and check inside of guide stem seal.
10 valve guide or stem and stem seal for damage.
seal (Reference: see Maintenance standard)
40-688 PC290LC-10
40 Troubleshooting
S-12 Fuel consumption is excessive

Failure Fuel consumption is excessive.
information
• Check spill rate from injector. Replace injector.
Excessive spillage (Reference: see "Testing fuel delivery, return and Since much dust may be
1 from injector leakage" in Testing and adjusting.) contained in fuel, check
fuel control condition.
• Check fuel return pipe for clogging. Repair or replace fuel
Clogged fuel return
2 (Clogging of fuel return pipe increases injection return pipe.
pipe
volume).
after starting engine, temperature of some cylinders
is low.
change.
Fuel leakage inside • Check if oil level increases. Repair defective parts.
4 cylinder head • Check for smell of diesel fuel.
Fuel leakage • Engine oil level rises and oil smells of diesel fuel. Replace feed pump oil
5 through feed pump • Check feed pump oil seal seal.
oil seal
External fuel • Check engine for external leakage of fuel. Repair defective parts.
6 leakage
PC290LC-10 40-689
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
Failure Oil is in coolant (or coolant spurts back or coolant level goes down).
information
• Engine oil level rises and oil is milky. Perform troubleshooting
1 Milky oil for "S-16 Coolant in oil
(milkiness)".
Broken oil cooler • Check oil cooler element. Replace oil cooler
2
element element.
• Coolant spurts due to an unusual volume of air Replace cylinder head.
bubbles in radiator.
Damaged cylinder
3 • Disassemble engine, and conduct pressure
head
tightness test on cylinder head to check for any
trouble.
• Coolant spurts due to large number of air bubbles Replace cylinder head
Broken cylinder contained in radiator. gasket.
4 head gasket • Disassemble engine, and check cylinder head
gasket for any trouble.
Cracking or pitting • Engine oil level rises and oil is milky. Replace cylinder block.
5 of inside of cylinder • Disassemble engine and check inside of cylinder
block block for cracking or pitting.
40-690 PC290LC-10
40 Troubleshooting
S-14 Engine oil pressure drops

Failure Engine oil pressure decreases.
Related
• Check whether machine is operated on a slope steeper than that specified in Operation
information
and Maintenance Manual.
• Oil level in oil pan is low. Supply oil.
1 Lack of oil in oil pan • If machine is operated on a slope, oil pressure
monitor may lights up.
Defective oil • Check oil pressure sensor, wiring harness, and Replace oil pressure
2 pressure sensor or connector. sensor, wiring harness,
wiring harness and connector.
• Perform oil analysis to determine whether fuel is If oil is mixed with fuel,
mixed in oil. perform troubleshooting
3 Fuel in oil
• If mixed, oil has smell of diesel fuel. for "S-15 Fuel in engine
oil".
• Perform oil analysis to determine whether fuel is If oil is mixed with water,
mixed in oil. perform troubleshooting
4 Water in oil • If mixed, oil is milky. for "S-16 Water in engine
oil (milkiness)".
• Check oil filter. Replace oil filter.
(Reference: when oil filter has been used for more
5 Clogged oil filter than specified period, oil may be deteriorated
extremely).
• Oil filter may be blocked when water is in oil
6 Clogged oil strainer • Check oil strainer. Clean oil strainer.
Crushed or clogged • Hydraulic piping may be crushed or clogged. Replace hydraulic piping.
7 hydraulic piping
• Check oil pump. Replace oil pump.
8 Defective oil pump (Worn or broken gear)
• Oil pump rotation is heavy or play is in oil pump.
Defective regulator • Check valve spring for fatigue and damage Replace regulator valve
9
valve
Defective oil pump • Valve spring of oil pump relief valve is fatigued or Replace oil pump relief
10 damaged. valve.
relief valve
Cracked oil pump • Check oil pump suction piping (cracking of piping). Replace oil pump suction
11 suction piping piping.
Defective seal • Check seal. Replace seal.
between oil pump
12 and oil pump
suction piping
Defective boost oil • Check boost oil pump. Replace boost oil pump.
13 pump
Leakage from EGR • Check EGR hydraulic piping. Replace EGR hydraulic
14 hydraulic piping piping.
• Check main journal bearing. Replace main journal
Worn main journal
15 • Metal particles may be found in oil drained from oil bearing
bearing
pan
Worn pin journal • Check pin journal bearing Replace pin journal
16 bearing • Metal particles are found in oil drained from oil pan. bearing.
Worn idler bushing • Check idler bushing and idler gear. Replace idler bushing and
17 or broken idler gear idler gear.
Broken or removed • Check piston cooling nozzle. Replace piston cooling
18 piston cooling nozzle.
nozzle
PC290LC-10 40-691
40 Troubleshooting
S-15 Fuel is contaminated in engine oil

Failure Fuel mixes with engine oil (engine oil smells of diluted diesel fuel).
information
• If exhaust manifold is touched immediately after Replace injector.
starting engine, temperature of some cylinders is
low.
change.
(Reference: See "Handling cylinder cutout mode
Fuel leakage from • Check injector and O-ring. Replace oil injector and
2 injector and O-ring O-ring.
(spill circuit)
Defective sealing • Check sealing between injector and injection pipe, Repair or replace.
between injector and injection pipe.
3 and injection pipe,
and cracked
injection pipe
Defective supply • Replace supply pump and see if fuels stops Replace supply pump.
4 pump entering.
40-692 PC290LC-10
40 Troubleshooting
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)

Failure Engine oil is mixed with water (milkiness)
• If oil is mixed with coolant, perform troubleshooting for "S-13 Coolant in oil".
If you repeat stopping and restarting of engine under low ambient temperatures, moisture
Related in blowby gas may condense into water in installed KCCV, making oil cloudy or causing
information emulsion on inner surface of engine. These symptoms do not matter unless coolant
leakage is not recognized.
If coolant level decreases in short period, perform following troubleshooting.
• When EGR cooler outlet gas piping is removed, Replace EGR cooler.
water containing coolant flows out.
(Check whether it is coolant containing antifreeze
Cracked EGR or condensed water.)
1
cooler (Reference: lowered coolant level may cause
cracks on EGR cooler. Before replacing EGR
cooler, check cooling system piping for leakage.)
• Check of oil cooler element and O-ring. Replace oil cooler
Damaged oil cooler
2 • Pressure tightness test of oil cooler allows for element and O-ring.
element and O-ring
detection of oil leakage.
Leakage through • Check water pump mechanical seal for leakage. Replace water pump
3 water pump mechanical seal.
mechanical seal
Clogged water • Check water pump drain hole. Clean water pump drain
4
drain hole hole.
Daaged cylinder • Disassemble engine and check cylinder head and Replace cylinder head or
5 head gasket. cylinder head gasket.
head
Cracking or pitting • Engine oil level rises and oil is milky. Replace cylinder block.
6 of inside of cylinder • Disassemble engine and check inside of cylinder
block block for cracking or pitting.
PC290LC-10 40-693
40 Troubleshooting
S-17 Coolant temperature rises too high (Overheating)

Failure Coolant temperature rises too high (overheating).
information
Clogged radiator • Check radiator core for clogging. Clean radiator core.
1
core
Malfunction of • Thermostat does not open at specified opening Replace thermostat.
2 temperature.
thermostat
• Coolant temperature error is displayed but actual Replace coolant
Defective coolant
3 radiator coolant temperature is normal. temperature sensor,
temperature gauge
monitor, or wiring harness.
• Fuel injection rate is high. Perform troubleshooting
Increased fuel for "S-12 Fuel
4 injection rate consumption is
excessive".
5 Low coolant level • Check if coolant level is low. Add coolant.
6 Coolant leakage • Check coolant piping for coolant leakage Replace coolant pipe
• Visually check water pump. Replace water pump.
7 Broken water pump (Water leakage through shaft seal, broken impeller,
broken shaft)
Overheat due to • Check mass air flow and temperature for any Replace mass air flow
increased EGR rate trouble. and temperature sensor.
(ratio of EGR
volume to volume
8 of external air taken
in) caused by
defective mass air
flow and
temperature sensor
Overheat due to • Check air cleaner and airflow screen for Repair or replace air
increased EGR rate deformation. cleaner.
(ratio of EGR
volume to volume
9
of external air taken
in) caused by
deformation of air
cleaner
Defective cylinder • Check whether coolant spurts due to large number Perform troubleshooting
10 head or cylinder of air bubbles in radiator is recognized. for "S-13 Coolant in oil".
head gasket
Defective piston
values table).
40-694 PC290LC-10
40 Troubleshooting
S-18 Unusual noise is heard

Failure Unusual noise is heard
• Determine source of unusual noise, namely internal or external noise, before starting
troubleshooting.
• Engine runs in low-temperature mode if it is not warmed up sufficiently. As a result,
Related engine sound may become a little larger but it does not mean any problem.
information • When engine is accelerated, it runs in acceleration mode and its sound becomes a little
larger for 3 to 5 seconds. However, it does not indicate any problem.
• Gas may leak from piping between exhaust Repair or replace related
Gas leakage from manifold and KVGT and that between KVGT outlet parts.
1 each piping and KDPF.
• Gas may leak from EGR piping
Vibration of • Visually check for vibration. Check and retighten pipe
2 exhaust pipe and fixing bracket.
exhaust bellows
• Check whether KVGT shaft rotates. Replace KVGT.
Seizure or damage (Check above by moving blades of KVGT in axial
3
of KVGT direction and in direction vertical to shaft.)
Damaged inside of • Check inside of KDPF. Clean or replace KDPF.
4
KDPF
is low.
does not change.
• Testing valve clearance Adjusting valve clearance.
Incorrect valve (Reference: See "Measuring and adjusting valve
6
clearance clearance(PAGE 30-13)" in Testing and adjusting.)
Seized pin bushing, • Check inside of oil pan for metal powder. Repair or replace
7 front bearing, or damaged part.
main bearing
• If metallic powders are recognized in oil pan or oil Replace piston ring.
filter, disassemble engine and check piston ring.
• Measure compression pressure (see standard
8 Worn piston rings value table).
Damage of valve • Disassemble engine and check parts of valve and Replace valve and rocker
9
and rocker arm rocker arm. arm.
Broken periphery • Disassemble engine and check parts of idler gear. Replacement idler gear.
10 parts of idler gear
PC290LC-10 40-695
40 Troubleshooting
S-19 Vibration is excessive

Failure Vibration is excessive.
• If unusual noise is made and vibrations are excessive, perform troubleshooting for "S-18
Related Unusual noise is heard", too.
Loosened engine • Visually check engine mounting bolts for looseness Retighten bolts and
1 mounting bolts and and cushions for cracking and hardening. replace cushions.
defective cushions
Worn spigot joint of • Check spigot joint of front support trunnion for wear. Replace front support.
2 front support
trunnion
Broken engine • Visually check viscous damper for discoloration Replace engine damper.
3 damper
Broken output shaft • Check output shaft and inside of damper for Replace related parts.
4 or inside of damper breakage.
Excessive radial • Measure radial and facial runouts of coupling Replace related parts.
and facial runouts portions of engine and hydraulic pump.
5 of coupling portions
of engine and
hydraulic pump
• If exhaust manifold is touched immediately after Replace injector.
starting engine, temperature of some cylinders is
low.
change.
Worn main bearing • If metallic powders are recognized in oil pan or oil Repair or replace
7 and connecting rod filter, disassemble and check engine. damaged part.
bearing
• If metallic powders are recognized in oil pan or oil Repair or replace
Seizure of valve
8 filter, open cylinder head cover, and check valve damaged part.
and rocker arm
and rocker arm.
• If metallic powders are recognized in oil pan or oil Replace camshaft
Worn camshaft
9 filter, disassemble engine and check camshaft bushing.
bushing
bushing.
40-696 PC290LC-10
40 Troubleshooting
S-20 Automatic regeneration is operated frequently

Failure Automatic regeneration starts frequently.
information
• Check whether machine performs heavy-duty Perform manual
Inappropriate
1 operation with engine running in middle speed stationary regeneration to
usage
range. remove soot completely.
• Expose exhaust gas color inspection hole before Perform troubleshooting
KDPF and check exhaust gas color (see standard for "S-9 Exhaust gas color
Defective exhaust
2 value table). is black".
gas color
(Reference: see "Testing exhaust gas color" in
Plugged KDOC due • If automatic regeneration frequency does not Clean KDOC.
3 to defective become normal after taking measures against
exhaust gas cause 2, KDOC is plugged.
• Oil other than specified one is used. Use oil specified in
Use of unspecified
4 Operation and
oil
Maintenance Manual.
Plugged KCSF due • If automatic regeneration frequency does not Clean or replace KSCF.
5 to use of become normal after taking measures against
unspecified oil cause 4, KCSF is plugged.
• Check coolant for low level. Perform troubleshooting
Leakage of coolant
6 for "S-16 Coolant in oil
to exhaust system
(milkiness)."
Plugged KCSF due • Check KCSF inlet for clogging. Clean or replace KSCF.
to leakage of
7 coolant to exhaust
system
Use of unspecified
8 Operation and
fuel
Maintenance Manual.
• KDOC is degraded by high sulfur content. Replace KDOC.
Deteriorated KDOC
(If automatic regeneration frequency does not
9 due to use of
become normal after taking measures against
unspecified fuel
causes 1 to 8, KDOC is degraded.)
• If automatic regeneration frequency does not Clean KDOC.
10 Plugged KDOC become normal after taking measures against
causes 1 to 9, KDOC is plugged.
11 Damaged KDOC • Check KDOC for breakage. Replace KDOC.
PC290LC-10 40-697
40 Troubleshooting
S-21 Active regeneration is operated for long

Failure A longer time is taken for active regeneration.
information
• Check KDOC inlet temperature during regeneration Replace KVGT.
for service (min.250°C).
Malfunction of (Reference: If KDOC inlet temperature does not
1 reach 250°C or above but KVGT solenoid current is
KVGT
constantly maintained at about 1000 mA during
regeneration for service, KVGT may malfunction.)
• Expose exhaust gas color inspection hole before Perform troubleshooting
KDPF and check exhaust gas color (see standard for "S-9 Exhaust gas color
Defective exhaust
2 value table). is black".
gas color
(Reference: see "Testing exhaust gas color" in
Plugged KDOC due • If automatic regeneration frequency does not Clean KDOC.
3 to defective become normal after taking measures against
exhaust gas cause 2, KDOC is plugged.
Leakage of coolant
to exhaust system
(milkiness)."
Plugging of KCSF • Check KCSF for plugging. Clean KCSF.
due to leakage of
system
Use of unspecified
6 Operation and
fuel
Maintenance Manual.
• KDOC is deteriorated by high sulfur content. Replace KDOC.
Deteriorated KDOC
(If active regeneration duration is not shortened
7 due to use of
after taking measures against causes 1 to 6, KDOC
unspecified fuel
is degraded.)
• If measurements taken on cause 1 to 7 do not Clean KDOC.
8 Plugged KDOC
improve regeneration time, KDOC is plugged.
40-698 PC290LC-10
40 Troubleshooting
S-22 White smoke comes out in the process of active regeneration

Failure White smokes are emitted during active regeneration.
• White smokes may be visible for a short while immediately after operating machine in
Related cold weather or during regeneration. It, however, does not indicateany problem.
Leakage of coolant
to exhaust system
(milkiness)."
Plugged KDOC due • If white smoke emission is not reduced after taking Clean or replace KDOC.
to leakage of measures against cause 1, KDOC is plugged.
system
Use of unspecified
3 Operation and
fuel
Maintenance Manual.
• KDOC is degraded by due to high sulfur content. Replace KDOC.
Deteriorated KDOC
(If white smoke emission is not reduced after taking
4 due to use of
measures against causes 1 to 3, KDOC is
unspecified fuel
degraded.)
• If white smoke emission is not reduced after taking Clean KDOC.
5 Plugged KDOC
measures against causes 1 to 4, KDOC is plugged.
7 Broken KCSF • Check KCSF for breakage. Replace KCSF.
PC290LC-10 40-699
40 Troubleshooting
40-700 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
50 Disassembly and assembly

7 50 Disassembly and assembly
PC290LC-10 50-1
Table of contents
Table of contents
50 Disassembly and assembly ........................................................................................................... 50-1
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-14
Engine and cooling system ........................................................................................................ 50-17
Removal and installation of supply pump assembly............................................................... 50-17
Removal and installation of injector assembly....................................................................... 50-22
Removal and installation of cylinder head assembly.............................................................. 50-31
Removal and installation of radiator assembly ...................................................................... 50-51
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-53
Removal and installation of aftercooler assembly .................................................................. 50-56
Removal and installation of engine and main pump assembly ................................................ 50-58
Removal and installation of engine front oil seal .................................................................... 50-70
Removal and installation of engine rear oil seal..................................................................... 50-74
Removal and installation of fuel cooler assembly .................................................................. 50-77
Removal and installation of fuel tank assembly ..................................................................... 50-78
Removal and installation of engine hood assembly ............................................................... 50-81
Removal and installation of KDPF assembly......................................................................... 50-84
Disassembly and assembly of KDPF ................................................................................... 50-92
Removal and installation of KCCV assembly ...................................................................... 50-100
Removal and installation of air cleaner assembly ................................................................ 50-102
Power train system ................................................................................................................. 50-105
Removal and installation of travel motor and final drive assembly ......................................... 50-105
Disassembly and assembly of final drive ............................................................................ 50-106
Removal and installation of swing motor and swing machinery assembly .............................. 50-114
Disassembly and assembly of swing machinery.................................................................. 50-117
Removal and installation of swing circle assembly .............................................................. 50-125
Undercarriage and frame......................................................................................................... 50-126
Separation and connection of track shoe assembly ............................................................. 50-126
Removal and installation of sprocket.................................................................................. 50-128
Removal and installation of idler and idler cushion assembly ............................................... 50-129
Disassembly and assembly of idler .................................................................................... 50-130
Disassembly and assembly of idler cushion........................................................................ 50-133
Disassembly and assembly of track roller ........................................................................... 50-135
Disassembly and assembly of carrier roller......................................................................... 50-137
Removal and installation of revolving frame assembly ......................................................... 50-140
Removal and installation of counterweight assembly ........................................................... 50-142
Hydraulic system .................................................................................................................... 50-145
Removal and installation of center swivel joint assembly ..................................................... 50-145
Disassembly and assembly of center swivel joint ................................................................ 50-147
Removal and installation of hydraulic tank assembly ........................................................... 50-148
Removal and installation of main pump assembly ............................................................... 50-152
Removal and installation of control valve assembly ............................................................. 50-156
Disassembly and assembly of control valve........................................................................ 50-163
Disassembly and assembly of work equipment PPC valve................................................... 50-167
Disassembly and assembly of travel PPC valve.................................................................. 50-169
Work equipment ..................................................................................................................... 50-172
Removal and installation of work equipment assembly ........................................................ 50-172
Disassembly and assembly of work equipment cylinder....................................................... 50-175
Removal and installation of operator's cab assembly........................................................... 50-181
Removal and installation of operator cab glass (adhered glass) ........................................... 50-186
Removal and installation of front window assembly ............................................................. 50-194
Removal and installation of floor frame assembly................................................................ 50-200
50-2 PC290LC-10
Table of contents
Removal and installation of air conditioner unit assembly..................................................... 50-206

Removal and installation of operator's seat......................................................................... 50-210
Removal and installation of seat belt .................................................................................. 50-212
Removal and installation of front wiper assembly ................................................................ 50-214
Electric system ....................................................................................................................... 50-220
Removal and installation of air conditioner compressor assembly......................................... 50-220
Removal and installation of air conditioner condenser assembly .......................................... 50-223
Removal and installation of engine controller assembly ....................................................... 50-225
Removal and installation of pump controller assembly......................................................... 50-227
Removal and installation of machine monitor assembly ....................................................... 50-230
Removal and installation of pump swash plate sensor ......................................................... 50-232
Removal and installation of Mass air flow and temperature sensor ....................................... 50-233
Removal and installation of KOMTRAX terminal assembly .................................................. 50-234
PC290LC-10 50-3
General information on disassembly and assembly

How to read this manual
(Rev.2010.10) • Common tools that are necessary for installation
are described as [1], [2] ... etc. and their part
T T T T Removal and installation of assemblies numbers, part names and quantities are not
Special tools described.
• Marks shown in the installation section are
• Special tools which are necessary for removal or
explained below.
installation of assemblies are described as
A1•••X1 etc. and their part numbers, part names, k: This mark indicates safety-related
necessities, and quantities are described in the precautions which must be followed when
special tool list. performing the work.
• Marks used in the column of necessity are
explained below. a : This marks gives guidance or precautions
t: Tools are not substituted, must always be when performing the work.
equipped (used).
q: Tools extremely useful if available or tools 4 : This mark shows the weight of a part or
that can be substituted with commercially the assembled parts for a device.
available tool.
2 : This mark indicates a specific coating
• For details and the sketches of the special tools,
agent to be used.
see "special tool list" and "sketches of special
tools". 3 : This mark indicates the specified
Removal tightening torque.
• In the removal section, the work procedures,
precautions and know-how to do the work and 5 : This mark indicates the amount of oil or
the amount of oil and coolant to be drained are coolant to be added.
discribed. Disassembly and assembly of T T T T assembly
• Common tools that are necessary for the Special tools
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities • Special tools which are necessary for
are not described. disassembly and assembly of assemblies are
• Marks used in the removal section are explained described as A1•••X1 etc. and their part
below. numbers, part names, necessities, and
quantities are described in the special tool list.
k: This mark indicates safety-related • Marks used in the column of necessity are
precautions which must be followed when explained below.
performing the work. t: Tools are not substituted, must always be
equipped (used).
a : This mark gives guidance or precautions when q: Tools extremely useful if available or tools
performing the work. that can be substituted with commercially
[*1]: [*1]: This mark indicates that instructions or available tool.
precautions for the assembly installation work are • For details and the sketches of the special tools,
given in the installation section. see "special tool list" and "sketches of special
tools".
6 : This mark shows the amount of oil or Disassembly
coolant to be drained. • In the disassembly section, the work
procedures, precautions and know-how to do
4 : This mark shows the weight of a part or the work, and the amount of oil and coolant to be
the assembled parts for a device. drained are described.
Installation • Common tools that are necessary for the
• Unless otherwise instructed the installation of disassembly work are indicated as [1], [2] ... etc.
assemblies is to be made in the reverse order to and their part numbers, part names, and
removal. quantities are not described.
• Instructions and precautions for assembly • Marks used in the disassembly section are
installation are shown with [*1] mark in the explained below.
removal section, identifying which step the
instructions are intended for.
50-4 PC290LC-10
k: This mark indicates safety-related

precautions which must be followed when
performing the work.
a : This marks gives guidance or precautions

when performing the work.
6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of a part or

the assembled parts for a device.
Assembly
• In the assembly section, the work procedures,
precautions and the know-how to do the work,
and the amount of oil or coolant to be added are
described.
• Common tools that are necessary for the
disassembly work are indicated as [1],[2] ... etc.
and their part numbers, part names, and
quantities are not described.
• Marks used in the assembly section are
explained below.
k ：This mark indicates safety-related
precautions which must be followed when
a : This mark gives guidance or precautions when

4 : This mark shows the weight of a part or

the assembled parts for a device.
2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified
tightening torque.
5 : This mark indicates the amount of oil or

coolant to be added.
PC290LC-10 50-5
Coating materials list

(Rev.2009.08)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming out.
• Use for plastic (except polyethylene,
20g Polyethy- polypropylene, tetrafluoroethylene, and
LT-1B 790-129-9050 (2 pcs. lene vinyl chloride), rubber, metal, and non-
contained) container metal parts which require immediate and
strong adhesion.
• Features: Resistance to heat and
Polyethy- chemicals
LT-2 09940-00030 50 g lene • Use to prevent bolts and plugs from
container coming loose and as sealant.
790-129-9060 Adhesive:
(Set of 1 kg • Use to bond and seal metal, glass and
LT-3 Can plastics.
adhesive and Hardener:
hardener) 500 g
Polyethy-
LT-4 790-129-9040 250 g lene • Use to seal plugs for blank holes.
container
Holtz
790-129-9120 75 g Tube • Heat-resistant seal used to repair engines
MH705
• Instantaneous adhesive
Polyethy- • Curing time: From 5 sec. to 3 min.
Three- 50 g
790-129-9140 lene • Use mainly to bond metals, rubbers,
Bond1735
container plastics, and woods.
• Instantaneous adhesive
Polyethy- • Quick-curing type (max. strength is
Aron Alpha 2g
790-129-9130 lene obtained after 30 minutes)
201
container • Use mainly to bond rubbers, plastics, and
metals.
• Features: Resistance to heat and
Polyethy- chemicals
Loctite 648-50 79A-129-9110 50 cc lene • Use for fitted portions used at high
container temperatures.
50-6 PC290LC-10
Liquid gasket
• Use to seal various thread portions, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene • Use to seal taper plugs, elbows, and
container nipples for hydraulic piping.
• Features: Silicon-based heat and cold-
resistant sealant
LG-6 790-129-9160 200 g Tube • Use to seal thread portions and flange
surface.
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, old, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based, heat and cold-
resistant, vibration-resistant, impact-
ThreeBond 419-15-18131 100 g Tube resistant sealant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the circle
LG-9 gear top seal which is not clamped by
ThreeBond 790-129-9310 200 g Tube bolts, gaps in the weld which must be
1206D caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are put on.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with solid
gaskets.
ThreeBond 790-129-9330 200 g Tube • Use for covers of the transmission case
1121 and steering case etc.
ThreeBond
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211
Molybdenum disulfide lubricant
• Use to prevent galling and seizure of
press-fitted portions, shrinkage-fitted
LM-P 09940-00040 200 g Tube portions, and thread portions.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are made
on metal surfaces to prevent the metals
— 09995-00250 190 g Can from galling.
• Use for the drive shaft splines, needle
bearings, pins and bolts of various links,
etc.
PC290LC-10 50-7
Seizure prevention compound
• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust manifold
and the turbocharger, etc.
Grease
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI
• Lithium grease with extreme pressure
G0-LI (*) SYGA- Various Various lubrication performance, general purpose
*: For cold 160CNLI type
regions SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.
Caution:
Molybdenum 400 g x 10 Bellows- • Do not use this grease for rolling
SYG2-400M
disulfide type bearings like swing circle bearings, etc.
grease SYG2-400M-A 400 g x 20 container and splines.
LM-G (G2-M) SYGA-16CNM 16 kg Can • Use this grease for work equipment
pins only when installing them, but do
not use it afterward.
Hyper White SYG2-400T-A
Grease SYG2-16CNT Bellows- • Higher seizure resistant, heat resistant and
G2-T 400 g type water resistant than molybdenum disulfide
SYG0-400T-A grease.
G0-T (*) (*) 16 kg container
• Not conspicuous on machine since color is
*: For cold SYG0-16CNT Can white.
regions (*)
Bio grease
G2-B SYG2-400B
G2-BT (*) SYGA-16CNB Bellows-
400 g type • Since this grease is biodegradable in short
*: For use at SYG2-400BT period, it has less impact on
(*) 16 kg container
high microorganisms, animals, and plants.
temperature SYGA- Can
and under high 16CNBT(*)
load
• Silicone grease with wide usable
G2-S temperature range, high resistance to
thermal-oxidative degradation and
ThreeBond — 200 g Tube performance to prevent deterioration of
1855 rubber and plastic parts
• Use for oil seals of the transmission, etc.
• Urea (organic system) grease with heat
resistance and long life. Enclosed type.
G2-U-SENS
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
grease
damper.
Caution: Do not mix it with lithium grease.
50-8 PC290LC-10
Primer (For adhering cab glass)
• Use as primer for painted cab sheet metal
Sunstar Paint
Glass surface.
Primer 580 20 ml
container (Effective period: 4 months after
Super
417-926-3910 manufacture)
Sunstar Glass • Use as primer for cab glass surface.
Primer 580 Glass (Effective period: 4 months after
20 ml
Super container manufacture)
• Use as primer for painted cab sheet metal
Sunstar Paint Glass surface.
22M-54-27230 20 ml (Effective period: 4 months after
Primer 435-95 container
manufacture)
• Use as primer for black ceramic-coated
glass surface and for hard polycarbonate-
Sunstar Glass coated surface.
22M-54-27240 150 ml Steel can
Primer 435-41 (Effective period: 4 months after
manufacture)
• Use as primer for sash (Almite)
Sunstar Sash Glass (Effective period: 4 months after
22M-54-27250 20 ml
Primer GP-402 container manufacture)
Adhesive (For adhering cab glass)
• Use "S" in high temperature season and

Sunstar "W" in low temperature season as
Polyethy-
Penguin Seal adhesive for glass.
417-926-3910 320 ml lene
580 Super "S" (Effective period: 4 months after
container
or "W" manufacture)
Sika Japan, Polyethy- • Use as adhesive for glass.

Sikaflex 20Y-54-39850 310 ml lene (Effective period: 6 months after
256HV container manufacture)
Sunstar Ecocart • Use as adhesive for glass.
Penguin Super 22M-54-27210 320 ml (Special (Effective period: 6 months after
560 container) manufacture)
Caulking material (For adhering cab glas)
Sunstar Polyethy- • Use to seal joints of glass parts.
Penguin Seal 417-926-3920 320 ml lene (Effective period: 4 months after
No.2505 container manufacture)
Sekisui Polyethy- • Use to seal front window.
Silicone 20Y-54-55130 333 ml lene (Effective period: 6 months after
Sealant container manufacture)
• Use to seal glass-to-glass joint.
GE Toshiba Translucent white seal.
Silicones 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL 381 manufacture)
PC290LC-10 50-9
Special tools list

a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tool.
a New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification
a Tools marked with Q in the sketch column have the sketches. (See Sketches of special tools)
New/Redesign
Necessity
Symbol
Sketch
Detail of work,
Q'ty
Work Part number Part name
remarks
Removal and
Holding of supply
installation of supply 1 795-799-6130 Support t 1
pump gear
pump assembly
Removal of injector
2 795-799-6700 Puller t 1
Removal and assembly
installation of injector Adjustment of valve
assembly and cylinder 3 795-799-1131 Gear t 1
clearance
head assembly Removal of inlet
4 795-799-8150 Remover q 1
connector
Removal and
installation of cylinder Angle tightening of
5 790-331-1120 Wrench (angle) q 1
head assembly and bolt
engine front seal
Removal and
Check of cylinder
installation of cylinder 6 795-790-4510 Gauge q 1 head bolt length
head assembly
Removal and
Seal puller Installation of engine
installation of engine A 7 795-799-6400 t 1
front seal
front seal
Removal and
Seal puller t 1 Installation of engine
installation of engine 8 795-799-6500
rear seal
rear seal
Removal, installation
9 796T-401-1110 Plate q 1 Q of engine mounting
Removal and
bolts
installation of engine
Removal and
and main pump
installation of engine
assembly 10 795-799-9300 Lifting tool q 1 and main pump
assembly
Installation, removal, Removal and
disassembly and Commercially Long socket (1/2 in) installation of V-
11 q 1
assembly of KDPF available clamp
Removal, installation, Removal and
disassembly and Commercially Long socket (7/16 in) installation of V-
12 q 1
assembly of cylinder available clamp and band
head and KDPF
50-10 PC290LC-10
New/Redesign
Necessity
Symbol
Sketch
Detail of work,
Q'ty
remarks
Removal and
1 796-627-1610 Wrench assembly t 1 installation of ring nut
t 1 Installation of floating
2 791-580-1510 Installer
seal
796T-627-1630 Push tool t 1 Q
790-101-2510 Block t 1
Disassembly and 791-830-1320 Rod t 2
assembly of final drive F
3 01580-11613 Nut t 2
Installation of hub
790-101-2570 Plate t 2 assembly
01643-31645 Washer t 2
790-105-2100 Jack assembly t 1
790-101-1102 Pump t 1
4 790-331-1110 Wrench t 1
Press fit of main
1 790-201-2860 Push tool t 1
bearing
Disassembly and Press fit of sub
2 796-426-1120 Push tool t 1
assembly of swing G bearing
machinery 796T-426-1130 Plate t 1 Q
3 790-101-5421 Grip t 1 Press fit of oil seal
01010-81240 Bolt t 1
Disassembly and Installation of floating
J 796-570-1020 Installer t 1
assembly of idler seal
Disassembly and Installation of floating
assembly of track roller K 796-670-1010 Installer t 1
seal
Disassembly and
Installation of floating
assembly of carrier L 791-430-3230 Installer t 1
seal
roller
791-685-8006Compressor t 1
791-635-3160Extension t 1 Disassembly and
1 Cylinder (686 kN {70 assembly of idler
790-101-1600 ton}) t 1 cushion
Disassembly and
assembly of idler M 790-101-1102 Pump t 1
cushion 790-201-1500 Push tool kit t 1
790-201-1620 • Plate 1
2 Press fit of dust seal
790-101-5021 • Grip 1
01010-50816 • Bolt 2
1 791-630-3000 Remover and installer t 1
Separation and Removal and
Cylinder (980 kN {100
connection of track N 2 790-101-1300 ton}) t 1 installation of master
shoe assembly pin
3 790-101-1102 Hydraulic pump t 1
Disassembly and 1 796T-416-1010 Push tool t 1 Q Press fit of bushing
assembly of travel PPC Q 2 796T-416-1030 Push tool t 1 Q Press fit of bushing
valve 3 796T-416-1020 Push tool t 1 Q Press fit of pin
Removal and 1 796-460-1210 Oil stopper q 1
installation of hydraulic
oil cooler assembly, To stop flow of oil
engine and main pump R 2 796-770-1320 Adapter q 1 from hydraulic tank
assembly, and main
pump assembly
PC290LC-10 50-11
New/Redesign
Necessity
Symbol
Sketch
Detail of work,
Q'ty
remarks
790-101-2501 Push-puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly and 791-112-1180 • Nut 1
Removal of rotor and
assembly of center S 790-101-2540 • Washer 1 ring
swivel joint 790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2650 • Adapter 2
796-946-1310 Guide f 21.8 mm
t 1
(For 723-46-40100)
796-946-1610 Guide f 21.4 mm
t 1
(For 723-46-41100)
796-946-1810 Guide f 21.2 mm
1 t 1
(For 723-46-43100 and 723-46-43400)
796-946-1910 Guide f 21.0 mm
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2210 Guide f 20.6 mm
t 1
(For 723-46-45100 and 723-46-45700)
796-946-1320 Guide f 21.8 mm
t 1
(For 723-46-40100)
796-946-1620 Guide f 21.4 mm
t 1
(For 723-46-41100)
796-946-1820 Guide f 21.2 mm
t 1
(For 723-46-43100 and 723-46-43400) Replacement of
Disassembly and 2
796-946-1920 Guide f 21.0 mm pressure
assembly of control T t 1
(For 723-46-46101 and 723-46-46300) compensation valve
valve
seal
796-946-2220 Guide f 20.6 mm
t 1
(For 723-46-45100)
796-946-1420 Guide f 21.6 mm
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
t 1
(For 723-46-43100 and 723-46-43400)
3
796-946-1930 Sleeve
t 1
(For 723-46-46101 and 723-46-46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
50-12 PC290LC-10
New/Redesign
Necessity
Symbol
Sketch
Detail of work,
Q'ty
remarks
790-502-1003 Cylinder repair stand q 1 Disassembly and

1 assembly of work
790-101-1102 Pump q 1 equipment cylinder
790–102–4300 Wrench assembly t 1 Installation of piston
2 ring
790–102–4310 Pin t 1
3 790–720–1000 Expander q 1
Rubber band (for
796–720–1670 boom and bucket) q 1
4 07281-01279 Clamp q 1
796–720–1680 Rubber band (for arm) q 1
Disassembly and 07281–01589 Clamp q 1
Press fit of bushing
assembly of work U 790–201–1702 Push tool kit t 1
equipment cylinder • Push tool (for
790-201–1841 boom and bucket) 1
5
790–201–1851 • Push tool (for arm) 1
790–101–5021 Grip 1
01010–50816 Bolt 2
790–201–1500 Push tool kit t 1
• Plate (for boom
790–201–1650 and bucket) 1
6
Press fit of dust seal
790–201–1660 • Plate (For arm) 1
790–101–5021 • Grip 1
01010–50816 • Bolt 2
796-900-1200 Remover t 1
796-900-1210 • Sleeve 1
792-900-1520 • Plate 1
799-900-1230 • Screw 1
Removal and 796-900-1240 • Adapter 1 Removal of boom
installation of work V 01643-33080 • Washer 1 foot pin
equipment assembly 01803-13034 • Nut 1
Puller (490 kN {50 ton}
790-101-4000 long) t 1
Pump (294 kN {30
790-101-1102 ton}) t 1
Removal and 1 793-498-1210 Lifter (Suction cup) t 2 Holding of glass
installation of operator's
cab glass (adhered X
2 20Y-54-13180 Stopper rubber t 2 Fixing of glass
window glass)
Commercially Eyebolt
1 q 2 M48 x 3
Removal and available
installation of Commercially
Z 2 Impact wrench q 1
counterweight available
assembly Commercially Width across flats: 46
3 Socket wrench q 1
available mm
PC290LC-10 50-13
Sketches of special tools

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A9: Plate
F3: Push tool
G3: Plate
50-14 PC290LC-10
Q1: Push tool
Q2: Push tool
PC290LC-10 50-15
Q3: Push tool
50-16 PC290LC-10

Removal and installation of supply pump assembly
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
A 1 795-799-6130 Support t 1

Removal
5. Disconnect fuel filter hoses (7) and (8) from
supply pump assembly (20). [*1]
1. Close the cock of fuel stop valve (1).
a While pressing locks (L) on both sides, pull
the hose in the direction of (a).
2. Remove under cover (2).

6. Disconnect fuel return hose (9). [*2]
7. Disconnect wiring harness connector (10).
8. Disconnect fuel supply hose (11). [*3]
9. Disconnect high-pressure pipe (13) according to
the following procedure. [*4]
1) Remove fuel spray prevention caps (12) and
(17).
2) Disconnect two tube clamps (14).
3) Disconnect high-pressure pipe (13).
10.Disconnect spill tube (16) according to the
following procedure. [*5]
1) Disconnect tube clamp (15).
3. Open engine hood (3). 2) Remove spill tube (16).
4. Remove the following parts, referring to "
Removal and installation of KCCV assembly".
• Step (4)
• KCCV ventilator assembly (5)
• Bracket (6)
PC290LC-10 50-17
a Supply pump assembly (20) comes off with

the gear. The gear is not worked on its teeth
(no missing tooth) to show the mark for 1, 6
TDC adjustment.
12.When removing the gear from the supply pump

assembly, follow the procedure described below.
[*7]
1) While locking the gear by using tool A1 and
1/2-inch spin handle [1], loosen nut (21).
a Do not remove nut (21) from the shaft.
2) Install puller [2] between the flange and gear

11.Remove three nuts (at locations A), then remove (22).
supply pump assembly (20). [*6]
a Pull supply pump assembly (20) sideways in
a straight line when removing it. Otherwise
the pump assembly may interfere with the
end of boost pump (26).
3) Install puller [3] on puller [2] and the shaft.

4) Turn center bolt [4] until the gear comes off
the shaft.
5) Remove pullers [2] and [3].
50-18 PC290LC-10
6) Remove nut (21), lock washer (23) and gear [*2]

(22) from shaft (24).
3 Fuel return hose (9) mounting bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*3]
3 Fuel supply hose (11) mounting bolt:
25.4 to 34.3 Nm {2.6 to 3.5 kgm}
[*4]
Install high-pressure pipe (13) according to the
1. Tighten the sleeve nut of high-pressure pipe (13)
by hand. (both sides)
2. Tighten the sleeve nuts on the supply pump side
and then on the common rail side.
Installation
3 Sleeve nut:
Perform installation in the reverse order to removal.
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
[*1] 3. Install tube clamps (14) (2 places).
When installing a connector of quick coupler type,
3 Clamp bolt:
observe the following points.
24 ± 4 Nm {2.45 ± 0.41 kgm}
a The internal parts of the fitting may be damaged 4. Install fuel spray prevention caps (12) and (17).
when the hose or tube is removed. Accordingly,
do not reuse the hose or tube. a Install the fuel spray prevention cap with the
slit out and down.
When installing, replace it with a new one.
a The caps are installed so that fuel will not
a Ensure that mud or dirt is not sticking to the hose
spout over the hot parts of the engine and
joint portions in advance.
catch fire if it leaks for some reason.
a Push the connector straight (in the direction of
(b)). Do not pry it in or shake it.
If it is difficult to insert the connector, do not push
it in forcibly but pull it out. Then, check the male
and female couplings for damage and sticking
mud.
PC290LC-10 50-19
a Use a new socket when installing supply pump

assembly mounting nuts (19) because the
cylinder block side nuts are hard to install.
a If an old socket is used, the nut may fall or be
damaged due to excessive clearance between
the socket and mounting nut (19).
3 Supply pump assembly mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*7]
Install gear (22) according to the following
procedure.
[*5]
a Clean and dry the mating surfaces on shaft (24)
3 Spill tube (16) mounting bolt:
and gear (22) so that the surfaces are free of dirt
24 ± 4 Nm {2.45 ± 0.41 kgm} and foreign material.
3 Tube clamp (15) mounting bolt: 1. Install gear (22) to shaft (24).
24 ± 4 Nm {2.45 ± 0.41 kgm} 2. Install lock washer (23) and nut (21) and finger-
tighten the nut.
[*6]
Install supply pump assembly (20).
a If too much grease is applied to O-ring (18), it will
ooze out. Accordingly, do not apply grease so
much. (Apply grease to the O-ring groove area
of part B.)
a When installing new supply pump mounting stud
bolts (25) to replace the existing ones, apply
LOCTITE to them.
3 Stud bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}
3. While locking the gear by using tool A1 and 1/2-
inch spin handle [1], tighten nut (21) to the
specified torque.
3 Supply pump gear mounting nut:
105 ± 5 Nm {10.7 ± 0.51 kgm}
50-20 PC290LC-10
• Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
PC290LC-10 50-21
Removal and installation of injector assembly

a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
2 795-799-6700 Puller t 1
A 3 795-799-1131 Gear t 1
4 795-799-8150 Remover q 1

5. Disconnect EGR gas temperature sensor

Removal connector (EXHAUST GAS TEMPERATURE)
(7).
1. Remove under cover (1). 6. Loosen hose clamp (8), then disconnect hose
(9). [*1]
7. Remove four mounting bolts (10), then remove
EGR piping flange (11). [*2]
2. Drain the coolant through drain valve (2). Drain

hose: inside diameter f7 mm)
6 Coolant: 8. Disconnect connectors (12), (13), and (14).

36 l • Connector (12): KVGT stroke sensor (SVGT)
(VGT_REV)
CONNECT)
3. Open engine hood (3).

4. Remove the following parts, referring to
"Removal and installation of KCCV assembly".
• Step (4)
• KCCV ventilator assembly (5) 9. Disconnect hoses (15) and (16). [*3]
• Bracket (6)
50-22 PC290LC-10
k When disconnecting the hoses, always

disconnect at the intake manifold side to
avoid splashing oil to high temperature
area which causes fire.
• Hose (15): KVGT control pressure circuit
circuit
17.Remove air hose (26).

a Put marks on the hose end and tube to
indicate their fitting positions.
10.Remove fan guards (17) and (18).
18.Disconnect four wiring harness clamps (27).

19.Disconnect intake air heater E01 (28) and the
wiring harness clamp.
20.Remove intake assembly (29).
11.Disconnect hose clamp (19).[*4]

12.Disconnect radiator hose (20).[*5]
21.Disconnect wiring harness connectors (30), (31),

and (32).
a After the disconnection, move wiring harness
13.Disconnect dipatick pipe (21). (33) toward the counterweight.
14.Disconnect tubes (22) and (23).
15.Remove lower bracket (24) of the EGR valve.
16.Remove EGR valve (25).
PC290LC-10 50-23
29.Remove 12 bolts (46), then remove rocker arm

assembly (47), crosshead (48), and the rocker
arm support.
a Loosen lock nuts (49) and then loosen
adjustment screws (50) a few turns each to
prevent excessive forces from working on
the push rods when the rocker arms are
installed.
a Record the installed position and direction
(shapes of holes (a) and (b)) of each
crosshead. (This is necessary to reinstall
them in the original directions.)
22.Remove 14 fuel spray prevention caps (41) of
high-pressure pipes (34) to (40).
23.Remove high-pressure pipes (34) to (39).
24.Remove the clamp, then remove high-pressure
pipe (40).
25.Loosen the mounting bolts of common rail (125).
26.Remove blowby duct (42).

27.Remove six nuts (43), then remove head cover
(44).
30.Remove retaining nuts (51), then remove six

inlet connectors (52).
a Clean the surrounding area to remove mud
and other contamination in advance to
prevent them from entering the connector
hole.
a Use tool A4 to remove inlet connector (52).
31.Remove mounting bolts (53) of injector
28.Remove nuts (45) for the wiring harnesses from
assembly (55), then remove holder (54).
the injector assembly.
32.By using tool A2, remove fuel injector assembly
Wiring harness Cylinder No. (55).
color
White 1, 3, 5
Black 2, 4, 6
a Do not remove injector wiring harness

connector (60) from the rocker housing
unless needed.
50-24 PC290LC-10
2 O-ring (58) of injector (57) and

cylinder head side surface:
Engine oil (EO15W-40)
3) Engage the male and female parts at (A) to
install holder (54) to injector (57).
a Take care that dirt and foreign material do not

enter the injector assembly mounting area.
4) Install injector assembly (55) into the cylinder

head with the fuel inlet hole facing toward the
air intake manifold.
5) Screw in holder mounting bolts (53) three to
four threads.
6) Check the inlet connector visually. If it has
any of the following faults, replace it.
1] Burrs or wear is recognizable in the inlet
connector top-end (a) and rear-end (b)
portions.
Installation 2] There is foreign matter in the edge filter at
1. Injector assembly rear end (c) of the inlet connector.
3] Cracks or deterioration is recognizable in
a When replacing the injector assembly with a O-ring of the inlet connector upper portion
new one, be sure to replace the inlet (d).
connector with a new one, as well.
a Check that injector sleeve (56) is free from
flaws or dirt.
4] There is a worn part or an uneven seat

contact mark on seating face (e) at the
top end of the inlet connector.
1) Install O-ring (58) and gasket (59) to injector a If high-pressure fuel leaks through the
(57). inlet connector, the seal face has fine
a Replace the O-ring and gasket with new streaks or cracks.
ones.
2) Apply engine oil to O-ring (58) of injector (57)
and the cylinder head side surface.
PC290LC-10 50-25
3 Retaining nut (51) (tightening to

the specified torque):
50 ± 5 Nm {5.1 ± 0.5 kgm}
7) Apply engine oil to O-ring (part C) of inlet

connector (52) and the cylinder head (part
B).
2 Inlet connector O-ring and cylinder
head:
8) Insert inlet connector (52) in the mounting
hole for injector assembly (55) and lightly
tighten retaining nut (51).
a The positioning balls (part D) on the inlet
connector must be at the guide groove in 2. Rocker arm and crosshead assembly
the cylinder head when installed. 1) Install rocker arm assembly (47), crosshead
(48), and the rocker arm support.
3 Retaining nut (51) (tightening
lightly): a When reusing the crosshead, install the
15 ± 5 Nm {1.53 ± 0.51 kgm} same intake and exhaust valves in the
same direction because the shapes of its
holes (a) and (b) are different,
9) Tighten mounting bolts (53) of holder (54)

alternately.
3 Holder mounting bolt: a Check that the spherical portion of
8 ± 0.8 Nm {0.82 ± 0.08 kgm} adjustment screw (50) is set in the push
10)Tighten retaining nut (51) of inlet connector rod socket securely and then tighten
(52). mounting bolts (46).
36 ± 5 Nm {3.7 ± 0.5 kgm}
2) Adjust the valve clearance.
50-26 PC290LC-10
a See Testing and adjusting, "Testing and 3 Connector flange mounting bolt
adjusting valve clearance". (63):
a Adjust the valve clearance at each 10 ± 2 Nm {1 ± 0.2 kgm}
cylinder by using tool A3 to turn the
crankshaft.
3) After valve clearance adjustment, ensure
that lock nut (49) is tightened to the specified
torque.
3 Lock nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install wiring harness mounting nuts (45) to
injector assembly (55).
a Check that the wiring harness does not
a Installed positions of wiring harnesses
Wiring harness color Cylinder No.
White 1, 3, 5
Black 2, 4, 6
3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a If injector wiring harness connector (60) is
removed, apply liquid gasket LG-7 to O-
ring (61) and flange (62) of the connector.
Apply a bead of liquid gasket, f3 mm in
diameter to the O-ring so that the ring
3. Head cover
groove is completely covered.
1) Install the gasket and then install head cover
If the O-ring is damaged, replace it and
(44) with mounting nuts (43).
the wiring harness assembly as a unit.
3 Mounting nut:
2 O-ring and flange face of
connector: 24 ± 4 Nm {2.45 ± 0.41 kgm}
2) Install blowby duct (42).
Liquid gasket (LG-7)
3 Mounting bolt:
7 ± 2 Nm {0.7 ± 0.2 kgm}
4. High-pressure pipe
k Do not use high-pressure pipes with

bending modification.
PC290LC-10 50-27
k Be sure to use the genuine high-pressure 5) Tighten common rail (125) with 4 bolts.
pipe fixing clamp and observe the
a Apply liquid gasket to the thread portion
tightening torque.
of two bolts (P) inside engine.
k Install each high-pressure pipe and wiring 2 Thread portion of bolt (P):
harness at least 10 mm apart from each Liquid gasket (LG-7)
other.
3 Mounting bolt:
a A high-pressure pipe may cause fuel leakage 24 ± 4 Nm {2.45 ± 0.41 kgm}
if visible lengthwise streaks (b) or spots (c) 6) Tighten the tube clamp to the specified
are found at the joint's taper seal at part (a) torque.
(within 2 mm from the end), or the stepped
wear at part (d) (2 mm from the end of taper 3 Mounting bolt:
seal) is as severe as it can be felt with a 24 ± 4 Nm {2.45 ± 0.41 kgm}
fingernail. If there is any of those defects, 7) Install fuel spray prevention cap (41).
replace the high-pressure pipe.
k When installing the fuel spray prevention
caps, direct their slits outward or
downward.
1) Tighten common rail (125) and high pressure

pipes (34) to (39) lightly.
3 Mounting bolt and sleeve nut
(tightening lightly):
0.2 to 0.8 Nm {0.02 to 0.08 kgm}
2) Tighten high-pressure pipes (34) to (39) to
the specified torque according to the
1] High-pressure pipe (34) connector end,
Pipe (35) connector end, Pipe (36)
connector end, Pipe (34) common rail
end, Pipe (35) common rail end, then
Pipe (36) common rail end
5. EGR valve
end, Pipe (38) common rail end, then 1) Install gasket (64).
Pipe (39) common rail end a Note the orientation of the part number
3 Sleeve nut: tag when installing the gasket.
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
3) Lightly tighten the sleeve nuts of high-
pressure pipes (40) and tube clamp.
4) Tighten high-pressure pipe (40) in the order
of its supply pump end and its common rail
end.
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
50-28 PC290LC-10
2 Clamp bolt thread portion (BC):

Lubricant (THREEBOND
PANDO 18B)
a Impact wrench is not allowed to use.
• If hoses are to be reused
Install the clamp to the clamp mark put on
the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
• When using a new hose
Tighten the clamp so that BDG dimension
2) Install intake assembly (29). is as follows.
BDG: 7 to 10 mm
3 Mounting bolt of intake assembly:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3) Install intake air heater connector E01 (28)
and the wiring harness clamp.
3 Mounting nut for intake air heater
connector:
3.4 to 4.6 Nm {0.34 to 0.47 kgm}
4) Install wiring harness connector and harness
clamp (27).
3 Mounting bolt (at intake assembly
side face):
24 ± 4 Nm {2.45 ± 0.41 kgm}
6) Fit gasket and install EGR valve (25).
top): 3 Mounting bolt for EGR valve:
43 ± 6 Nm {4.4 ± 0.6 kgm} 43 ± 6 Nm {4.4 ± 0.6 kgm}
5) Install air hose (26). 7) Install tubes (22) and (23).
3 Sleeve nut:
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
8) Install bracket (24) to EGR valve (25) using
four mounting bolts.
• Upper (EGR valve side)
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
• Middle and lower (engine side)
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
9) Install dipstick pipe (21).
• MIKALOR clamps 3 Mounting bolt:
a Use a new clamp. 24 ± 4 Nm {2.45 ± 0.41 kgm}
1] Set the hose to the original (marked)
position.
a Reference
Air hose fitting length: 80 mm (both
upper and lower sides)
2] Set the bridge (BR) under the clamp bolt
and lap it over band (BD) by at least 5
mm (b).
Dimension b: Min. 5 mm
PC290LC-10 50-29
3 Sleeve nut:
15 ± 1 Nm {1.5 ± 0.1 kgm}
Perform the following installation in the reverse

order to removal.
[*1]
[*4]
3 Hose clamp:
3 Mounting bolt:
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
34 ± 5 Nm {3.5 ± 0.5 kgm}
[*2]
[*5]
a Use an open-head type torque wrench when
Radiator hose fitting length: 50 mm
installing EGR piping flange (11). It is difficult to
tighten by using a common type torque wrench. 3 Hose clamp:
3 Mounting bolt (10): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
24 ± 4 Nm {2.45 ± 0.41 kgm} • Refilling of coolant
Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Coolant:
36 l
[*3]
• Hose (15): KVGT control pressure
circuit
3 Sleeve nut:
25 ± 1.5 Nm {2.6 ± 0.15 kgm}
• Hose (16): KVGT actuator drive
pressure circuit
50-30 PC290LC-10
Removal and installation of cylinder head assembly
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
2
795-799-6700 Puller t 1
3
795-799-1131 Gear t 1
4
795-799-8150 Remover q 1
A 5
790-331-1120 Wrench (Angle) q 1
6
795-790-4510 Gauge q 1
Commercially Long socket (7/16 4. Remove mounting bolts (118) and (119) from
12 in) q 1 frame (6) and cover (117).
available

Removal

6 Coolant:
36 l
5. Remove frames (6).
4 Frame:
15 kg
3. Open the engine hood, then remove step (3) and

covers (4) and (5).
PC290LC-10 50-31

(VGT_REV)
CONNECT)
6. Remove cover (117) while raising it.[*1]

a Take care not to let the cover damage any
wiring harness and hose.
a Cover (117) can be removed as it is, without
12.Disconnect hoses (15) and (16).[*4]
separating it into the upper and lower halves.
k When disconnecting the hoses, always
disconnect at the intake manifold side to
avoid splashing oil to high temperature
area which causes fire.
circuit
7. Remove the KCCV ventilator assembly and

bracket, referring to " Removal and installation of
KCCV assembly".
8. Disconnect EGR gas temperature sensor
connector (EXHAUST GAS TEMPERATURE)
(7).
9. Loosen hose clamp (8), then disconnect hose
(9).[*2]
10.Remove four mounting bolts (10), then remove 13.Remove fan guards (17) and (18).
EGR piping flange (11).[*3]
14.Disconnect hose clamp (19).[*5]

11.Disconnect connectors (12), (13), and (14). 15.Disconnect radiator hose (20).[*6]
50-32 PC290LC-10
16.Disconnect dipstick pipe (21). 24.Disconnect wiring harness connectors (30), (31),
17.Disconnect tubes (22) and (23). and (32).
18.Remove lower bracket (24) of the EGR valve.
a After the disconnection, move wiring harness
19.Remove EGR valve (25).
(33) toward the counterweight.
20.Remove air hose (26).

25.Remove 14 fuel spray prevention caps (41) of
a Put marks on the hose end and tube to high-pressure pipes (34) to (40).
indicate their fitting positions. 26.Remove high-pressure pipes (34) to (39).
27.Remove the clamp, then remove high-pressure
pipe (40).
28.Loosen the mounting bolts of common rail (125).
[*7]
21.Disconnect four wiring harness clamps (27).

22.Disconnect intake air heater E01 (28) and the
wiring harness clamp.
23.Remove intake assembly (29).
29.Remove KDPF assembly (116) referring to
"Removal and installation of KDPF assembly ".
PC290LC-10 50-33
30.Removal of base brackets 38.Disconnect tube (55) from the KVGT.

1) Remove tube support bracket (43). a The KVGT side is jointly fastened.
2) Disconnect hose clamp (44), harness clamp 39.Disconnect tube (56).
(45), and tube clamp (46) from base bracket
(42). a The KVGT side is jointly fastened.
3) Remove eight mounting bolts (47), then sling 40.Disconnect tube (57).
and remove base bracket (42). a The KVGT side is jointly fastened. Be careful
that there is only a narrow work space
4 Base bracket: available.
25 kg
41.Loosen the hose clamp, then remove KVGT

31.Remove tube (48). return tube (58).
42.Remove the four mounting bolts, then sling and
remove KVGT (59).
4 KVGT:
25 kg
32.Disconnect hose (49).

34.Remove clamp (51).
35.Disconnect tube (52).
37.Disconnect hose (54). 43.Remove bracket (60).
44.Remove heat insulation plate (61).
45.Remove tube (62) of the EGR cooler.
50-34 PC290LC-10
46.Remove air conditioner compressor belt (111)

1) Loosen four bolts (112).
2) Loosen lock nut (113).
3) Turn jack bolt (114) and move air conditioner
compressor (115) in the direction of
loosening belt tension.
4) Loosen the tension on air conditioner
compressor belt (111) and remove the belt.
48.Disconnect terminal B (67)and connector E12

(68) from alternator (66).
49.Disconnect harness clamp (69).
50.Remove alternator (66).
51.Disconnect connector (EXHAUST PRESSURE)
(70) of the exhaust manifold pressure sensor.
47.Remove fan belt (64).

a Insert a wrench to the portion (A) (width
across flats T 12.7 mm) of the tensioner
assembly (65), and rotate it to the opposite to
the winding-up direction (R) to decrease the
fan belt (64) tension, then remove the fan
belt.

assembly (65) at portion A before
applying turning force to the wrench. (The
spring of tensioner assembly (65) is
strong. If the wrench is loosely inserted,
the wrench can accidentally come off and
this is extremely dangerous.)

k Be careful not to get your fingers caught

between the pulley and fan belt (64)
during work.
52.Disconnect tube clamp (71).
PC290LC-10 50-35
53.Loosen hose clamp (72).

54.Disconnect and remove tube (55) from the EGR
cooler.
61.Remove spill tube (82).

62.Remove blowby duct (83).
63.Remove six mounting nuts (84), then remove
55.Remove tube (73). head cover (85).
56.Remove mounting bolt (74), then separate EGR
cooler (75) from exhaust manifold (76).
a Pay attention to the gasket which may fall
away when separating these components.
64.Remove nuts (86) for the wiring harnesses from

the injector assembly.
Wiring harness Cylinder No.
color
White 1,3,5
57.Remove tube (77).
Black 2,4,6
58.Remove mounting bolt (78), then remove
exhaust manifold(76). a Do not remove injector wiring harness
a Pay attention to the gasket which may fall connector (97) from the rocker housing
away when separating these components. unless needed.
65.Remove 12 bolts (87), then remove rocker arm
assembly (88), crosshead (89), and the rocker
arm support.
a Loosen lock nuts (90) and then loosen
adjustment screws (91) a few turns each to
prevent excessive forces from working on
the push rods when the rocker arms are
installed.
a Record the installed position and direction
(shapes of holes (a) and (b)) of each
crosshead. (This is necessary to reinstall
them in the original directions.)
59.Remove lower tube (79) of the EGR cooler.
60.Remove EGR cooler (75) and bracket (81).
50-36 PC290LC-10
69.Remove push rods (98).

70.Remove mounting bolt (99), then remove rocker
housing (100).
66.Remove retainers (92) and then remove 6 inlet

connectors (93).
and other contamination in advance to 71.Remove 26 mounting bolts (101), then remove
prevent them from entering the connector cylinder head assembly (102).
hole.
4 Cylinder head assembly:
a Use tool A4 to remove inlet connector (93). 75 kg
67.Remove mounting bolts (94) of injector 72.Remove cylinder head gasket (103).
assembly (96), then remove holder (95).
68.By using tool A2, remove fuel injector assembly Installation

(96). 1. Cylinder head assembly
a Take care so that dirt and foreign material do 1) Measure nominal length a of all the cylinder
not enter the injector assembly mounting head mounting bolts to check that each falls
area. within the using limit.
• Using limit length of bolt: less than 132.1
mm
PC290LC-10 50-37
a If a bolt is longer than the using limit, do

not reuse it but replace it.
a Measure the length by using tool A6.
2) Install cylinder head gasket (103) in position

on the cylinder block.
a Check that the cylinder head mounting
face and inside of the cylinders are free
from dirt and foreign matter.
a Check that the holes in cylinder head
gasket (103) are aligned with the holes in
the cylinder head.
3) Install cylinder head assembly (102) in • When not using angle tightening tool
position on the cylinder block, and finger- Put a mark across the cylinder head and
tighten mounting bolts (101) more than two bolt with a marker pen, then retighten the
to three turns. bolt by 90 ± 5 deg.
4 Cylinder head assembly:

75 kg
4) Tighten mounting bolts (101) in the order
shown in the figure as follows.
a Coat mounting bolt threads and bolt head
seat surface with engine oil.
2 Threads of mounting bolt and
seating surface of bolt head:
3 Mounting bolt:
1] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2. Install rocker housing assembly (100) with
2] 90 ± 3 Nm {9.2 ± 0.3 kgm} mounting bolt (99).
3] 90 ± 5 deg. (Use tool A5 to
angle tighten)) 3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3. Install push rod (98).
a Check that the push rod is in the tappet.
a Fill the push rod socket with engine oil.
2 Push rod socket:
50-38 PC290LC-10
4) Install injector assembly (96) into the cylinder

head with the fuel inlet hole facing toward the
air intake manifold.
5) Screw in holder mounting bolts (94) three to
four threads.
6) Check the inlet connector visually. If it has
any of the following faults, replace it.
1] Burrs or wear is recognizable in the inlet
connector top-end (a) and rear-end (b)
portions.
2] There is foreign matter in the edge filter at
rear end (c) of the inlet connector.
4. Injector assembly 3] Cracks or deterioration is recognizable in
O-ring of the inlet connector upper portion
a When replacing the injector assembly with a (d).
new one, be sure to replace the inlet
connector with a new one, as well.
a Check that injector sleeve (104) is free from
flaws or dirt.
4] There is a worn part or an uneven seat

contact mark on seating face (e) at the
top end of the inlet connector.
a If high-pressure fuel leaks through the
1) Install O-ring (106) and gasket (107) to inlet connector, the seal face has fine
injector (105). streaks or cracks.
a Replace the O-ring and gasket with new
ones.
2) Apply engine oil to O-ring (106) of injector
(105) and the cylinder head side surface.
2 O-ring (106) of injector (105) and
the head side:
3) Engage the male and female parts at (A) to
install holder (95) to injector (105).
7) Apply engine oil to O-ring (part C) of inlet

connector (93) and the cylinder head (part
B).
2 Inlet connector O-ring and cylinder
head:
8) Insert inlet connector (93) in the mounting
hole for injector (96) and lightly tighten
retainer (92).
PC290LC-10 50-39

a The positioning balls (part D) on the inlet
connector must be at the guide groove in
the cylinder head when installed.
3 Retaining nut (92) (tightening
lightly):
15 ± 5 Nm {1.53 ± 0.51 kgm}
5. Rocker arm and crosshead assembly
1) Install rocker arm assembly (88), crosshead
(89), and the rocker arm support.
a When reusing the crosshead, install the
same intake and exhaust valves in the
same direction because the shapes of its
holes (a) and (b) are different.
9) Tighten mounting bolts (94) of holder (95)

alternately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.82 ± 0.08 kgm}
10)Tighten retaining nut (92) of inlet connector
(93).
3 Retaining nut (92) (tightening to
the specified torque): a Check that the spherical portion of
50 ± 5 Nm {5.1 ± 0.5 kgm} adjustment screw (91) is set in the push
rod socket securely and then tighten
mounting bolts (87).
36 ± 5 Nm {3.7 ± 0.5 kgm}
2) Adjust the valve clearance.
a See Testing and adjusting, " Measuring
and adjusting valve clearance".
a Adjust the valve clearance at each
cylinder by using tool A3 to turn the
crankshaft.
3) After valve clearance adjustment, ensure
that lock nut (90) is tightened to the specified
torque.
3 Lock nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install wiring harness mounting nuts (86) to
injector assembly (96).
a Check that the wiring harness does not
50-40 PC290LC-10
a Installed positions of wiring harnesses 2) Install blowby duct (83).

Wiring harness Cylinder No. 3 Mounting bolt:
color
7 ± 2 Nm {0.7 ± 0.2 kgm}
White 1, 3, 5
3) Install spill tube (82).
Black 2, 4, 6
3 Joint bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a If injector wiring harness connector (97) is
removed, apply liquid gasket to O-ring
(108) and flange (109) of the connector.
Apply a bead of liquid gasket, f3 mm in
diameter to the O-ring so that the ring
groove is completely covered.
If the O-ring is damaged, replace it and
the wiring harness assembly as a unit.
2 O-ring and flange face of
connector:
7. High-pressure pipe
3 Connector flange mounting bolt k Do not use high-pressure pipes with
(110): bending modification.
10 ± 2 Nm {1 ± 0.2 kgm}
k Be sure to use the genuine high-pressure
pipe fixing clamp and observe the
tightening torque.
k Install each high-pressure pipe and wiring

harness at least 10 mm apart from each
other.
a A high-pressure pipe may cause fuel leakage
if visible lengthwise slits (b) or spots (c) are
found at the joint's taper seal at part (a)
(within 2 mm from the end), or the stepped
wear at part (d) (2 mm from the end of taper
seal) is as severe as it can be felt with a
fingernail. If there is any of those defects,
replace the high-pressure pipe.
6. Head cover
1) Install the gasket and then install head cover
(85) with mounting nuts (84).
1) Tighten common rail (125) and high pressure
3 Mounting nut: pipes (34) to (39) lightly.
24 ± 4 Nm {2.45 ± 0.41 kgm}
PC290LC-10 50-41
3 Mounting bolt and sleeve nut

(tightening lightly):
0.2 to 0.8 Nm {0.02 to 0.08 kgm}
2) Tighten high-pressure pipes (34) to (39) to
the specified torque according to the
Pipe (36) common rail end
Pipe (38) connector end, Pipe (39) 8. EGR cooler and exhaust manifold
connector end, Pipe (37) common rail 1) Install bracket (81).
Pipe (39) common rail end 3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Sleeve nut:
2) Lightly tighten EGR cooler (75) to bracket
35 ± 3.5 Nm {3.57 ± 0.36 kgm} (81).
3) Lightly tighten the sleeve nuts of high-
pressure pipes (40) and tube clamp. a After lightly tightening the exhaust
4) Tighten high-pressure pipe (40) in the order manifold, tighten the EGR cooler to the
of its supply pump end and its common rail specified torque.
end. 3) Install tube (79) at the lower side of the EGR
cooler.
3 Sleeve nut:
3 Mounting bolt:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
5) Tighten common rail (125) with 4 bolts. 9.5 ± 2 Nm {0.97 ± 0.2 kgm}
a Apply liquid gasket to the thread portion 3 Hose clamp:

of two bolts (P) inside engine. 5 ± 1 Nm {0.5 ± 0.1 kgm}
2 Thread portion of bolt (P):
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
6) Tighten the tube clamp to the specified
torque.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
7) Install fuel spray prevention cap (41).
k When installing the fuel spray prevention

caps, direct their slits outward or 4) Install a new gasket and lightly tighten
downward. exhaust manifold (76) to the cylinder head
and EGR cooler (75) using mounting bolts
(74) and (78).
a By loosening and tightening the mounting
bolts, adjust so that there is no phase
shift or play in the cylinder head, exhaust
manifold, and EGR cooler.
5) Tighten the exhaust manifold mounting bolts
(78) in order specified in the figure.
3 Mounting bolt:
50-42 PC290LC-10
1] Tighten the bolts to 53 ± 5 Nm {5.4 ± 0.5 3 Tube mounting bolt:

kgm} in the order of [1] to [12] shown in 9.5 ± 2 Nm {0.96 ± 0.2 kgm}
the figure. 11)Install tube clamp (71).
2] Retighten bolts [1] to [4] only shown in the
figure to 53 ± 5 Nm {5.4 ± 0.5 kgm}. 3 Mounting nut:
6) Tighten bolt (74) to the specified torque. 9.5 ± 2 Nm {0.96 ± 0.2 kgm}
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
7) Tighten EGR cooler (75) to the bracket to the
specified torque.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
8) Install tube (77).
3 Joint bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}
3 Sleeve nut:
15 ± 1 Nm {1.5 ± 0.1 kgm} 9. Alternator
9) Install tube (73). 1) Install exhaust manifold pressure sensor
3 Sleeve nut (sensor bracket side): connector (EXHAUST PRESSURE) (70).
2) Install alternator (66).
24.5 ± 9.8 Nm {2.5 ± 1.0 kgm}
3 Mounting bolt (to bracket):
3 Sleeve nut (exhaust manifold
side): 43 ± 6 Nm {4.4 ± 0.6 kgm}
18 ± 3 Nm {1.8 ± 0.3 kgm} 3 Mounting bolt (to plate):
24 ± 4 Nm {2.45 ± 0.41 kgm}
3) Install terminal B (67) and connector E12
(68) to alternator (66).
3 Terminal B (67):
5.9 to 9.8 Nm {0.6 to 1.0 kgm}
4) Install wiring harness clamp (69).
10)Install tube (55).

3 Hose clamp (72):
5 ± 1 Nm {0.5 ± 0.1 kgm}
PC290LC-10 50-43
5) Install fan belt (64). 6) Install air conditioner compressor belt (111).
a Insert a wrench to the portion A (width a See Testing and adjusting, " Checking
across flats T 12.7 mm) of the tensioner and adjusting air conditioner compressor
assembly (65), and rotate it to the belt tension".
counter-direction (R) to the winding-up
direction to decrease fan belt (64) tension,
then install.

applying turning force to the wrench.
(The spring of tensioner assembly (65)
is strong. If the wrench is loosely
inserted, the wrench can accidentally
come off and this is extremely
dangerous.)
k After installation of fan belt (64), 10.KVGT

restore tensioner assembly (65) slowly 1) Fit gasket and install tube (62) on the EGR
with care. cooler side.
3 Mounting bolt:
k Be careful not to get your fingers
caught between the pulley and fan belt 24 ± 4 Nm {2.45 ± 0.41 kgm}
(64) during work. 2) Install the tube clamp of tube (62) to the
bracket.
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
3) Install heat insulation plate (61).
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install bracket (60).
50-44 PC290LC-10
5) Fit a new gasket and install KVGT (59).
4 KVGT:
25 kg
3 Mounting nut:
43 ± 6 Nm {4.4 ± 0.6 kgm}
6) Fit a new gasket and install KVGT return
tube (58).
3 Hose clamp:
5 ± 1 Nm {0.5 ± 0.1 kgm}
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
10)Install tube (52).

3 V-clamp:
7) Install tube (57).
7 ± 1.1 Nm {0.7 ± 0.11 kgm}
a The KVGT side is jointly fastened. Be • MIKALOR clamps
careful that there is only a narrow work
space available. a Use a new clamp.
3 Sleeve nut:
position.
24 ± 4 Nm {2.45 ± 0.41 kgm}
8) Install tube (56). a Reference
Air hose fitting length: 50 mm
a The KVGT side is jointly fastened.
(aftercooler end)
3 Sleeve nut: Air hose fitting length: 40 mm
24 ± 4 Nm {2.45 ± 0.41 kgm} (KVGT end)
9) Install tube (55) to the KVGT. 2] Set the bridge (BR) under the clamp
bolt and lap it over band (BD) by at
a The KVGT side is jointly fastened.
least 5 mm (b).
a Install banjo connector (80) that is jointly Dimension b: Min. 5 mm
fastened with tube (55) at an angle of 15
2 Clamp bolt thread portion
± 5 deg.
(BC): Lubricant
3 Sleeve nut: (THREEBOND PANDO 18B)
24 ± 4 Nm {2.45 ± 0.41 kgm} a Impact wrench is not allowed to
use.
the hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
PC290LC-10 50-45
Tighten the clamp so that BDG dimension a V-clamp can be reused, however, replace
is as follows. it with a new one in the following
BDG: 7 to 10 mm conditions.
• Deformation of V-clamp
• Damage on T-bolt thread portion
• Crack at V groove
• Peeling at V groove
11)Install hose (53).

3 Hose clamp:
10.0 to 11.0 Nm {1.02 to 1.12 kgm}
• Width across flats of V-clamp fastening
3 Hose clamp:
nut: 7/16 in (11.1 mm)
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
13)Install hose (50). 3 V-clamp fastening nut:
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
3 Hose clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm} a V-clamp mounting angle: 15°
15)Install tube (48) with V-clamp by using tool

A12 (long socket).
11.Mounting of base brackets:

1) Sling and install base bracket (42).
4 Base bracket:
25 kg
50-46 PC290LC-10
2) Install hose clamp (44), wiring harness clamp 3 Mounting nut for intake air heater
(45), and tube clamp (46) to base bracket connector:
(42). 3.4 to 4.6 Nm {0.34 to 0.47 kgm}
3) Lightly tighten tube support bracket (43). 4) Install wiring harness connector and harness
clamp (27).
side face):
24 ± 4 Nm {2.45 ± 0.41 kgm}
top):
43 ± 6 Nm {4.4 ± 0.6 kgm}
5) Install air hose (26).
12.Install KDPF assembly (116), referring to "

Removal and installation of KDPF assembly".
• MIKALOR clamps
a Use a new clamp.
position.
13.EGR valve a Reference
1) Install gasket (64). Air hose fitting length: 80 mm (both
a Note the orientation of the part number upper and lower sides)
tag when installing the gasket. 2] Set the bridge (BR) under the clamp
bolt and lap it over band (BD) by at
least 5 mm (b).
Dimension b: Min. 5 mm
4 Clamp bolt thread portion

(BC): Lubricant
(THREEBOND PANDO 18B)
a Impact wrench is not allowed to
use.
the hose.
2) Install intake assembly (29). 3 Clamp bolt:

Min. 6 Nm {0.6 kgm}
3 Mounting bolt of intake assembly: • When using a new hose
24 ± 4 Nm {2.45 ± 0.41 kgm} Tighten the clamp so that BDG dimension
3) Install intake air heater connector E01 (28) is as follows.
and the wiring harness clamp. BDG: 7 to 10 mm
PC290LC-10 50-47
6) Fit gasket and install EGR valve (25). • As seen from the engine.
3 Mounting bolt for EGR valve:
43 ± 6 Nm {4.4 ± 0.6 kgm}
7) Install tubes (22) and (23).
3 Sleeve nut:
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
8) Install bracket (24) to EGR valve (25) using
four mounting bolts.
• Upper (EGR valve side)
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
• Middle and lower (engine side)
[*2]
3 Mounting bolt:
3 Hose clamp:
24 ± 4 Nm {2.45 ± 0.41 kgm}
9) Install dipstick pipe (21). 10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
[*3]
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm} a Use an open-head type torque wrench when
installing EGR piping flange (11). It is difficult to
tighten by using a common type torque wrench.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}

order to removal.
[*1]
When installing cover (117), insert the cover in clips
(120) (five places) shown in the figure and tighten [*4]
the mounting bolts.
• As seen from the control valves.
3 Sleeve nut:
25 ± 1.5 Nm {2.6 ± 0.15 kgm}
• Hose (16): KVGT actuator drive pressure circuit
50-48 PC290LC-10
3 Sleeve nut: a For the testing procedure, see Testing

15 ± 1 Nm {1.5 ± 0.1 kgm} and adjusting," Checking fuel circuit for
leakage".
2. If necessary, replace pressure limiter (113)
1) Before removing the pressure limiter, remove
mud, etc. from around it thoroughly and
clean it.
2) Remove the pressure limiter.
a If the leakage through the pressure limiter
exceeds the specified value, do not reuse
that pressure limiter.
3) Check that there is no damage on high-
pressure sealing surfaces (A) on the
pressure limiter and common rail.
[*5] 4) Install a new pressure limiter.
3 Mounting bolt: 2 Pressure limiter:
34 ± 5 Nm {3.5 ± 0.5 kgm} Gear oil (#90)
[*6]
3 Pressure limiter:
Radiator hose fitting length: 50 mm
100 ± 4 Nm {10.2 ± 0.4 kgm}
3 Hose clamp:
a Excessive tightening can cause leakage.
10.8 to 11.8 Nm {1.1 to 1.2 kgm} Take care not to tighten too strongly.
[*7] 5) Start the engine and check that fuel does not
leak.
a Handling of common rail pressure sensor and
pressure limiter a For the testing procedure, see Testing
1. If necessary, replace common rail pressure and adjusting," Checking fuel circuit for
sensor (112) according to the following leakage".
procedure.
a Do not remove common rail pressure sensor
(112) from common rail (111) for a purpose
other than replacement.
a Be sure to replace the sensor removed from
the common rail with a new sensor.
1) Before removing the sensor, clean the area
around it to remove dirt, etc. thoroughly.
2) Remove the common rail pressure sensor.
3) Check the common rail pressure sensor
connector for crack, breakage, damage of
the seal, foreign matter on the pin and
corrosion, bend and breakage of the pin.
4) Install a new common rail pressure sensor.
2 Thread portion of common rail
pressure sensor:
Gear oil (#90)
3 Thread portion of common rail
pressure sensor:
70 ± 5 Nm {7.1 ± 0.5 kgm}
5) Connect the engine harness. At this time,
take care not to connect the connector in
reverse.
6) Start the engine and check that fuel does not • Refilling of coolant
leak.
PC290LC-10 50-49

5 Coolant:
36 l
50-50 PC290LC-10
Removal and installation of radiator assembly

Removal
10.Open hose clamps (14) and pull reservoir tank

hose (7) out of cover (15).
11.Remove cover (15).

6 Coolant:
36 l
3. Disconnect radiator hose (3). [*1]
a In order to indicate the original position of the
hose, put a mark of the hose-end on the 12.Remove five mounting bolts (16), then remove
radiator. bracket (17).
4. Remove two cover mounting bolts (4), then 13.Remove two wing nuts (18) and remove net
remove cover (5). (19).
5. Open engine hood (6) and disconnect reservoir 14.Lift and remove radiator assembly (20). [*3]
tank hose (7). a Carefully lift the radiator assembly so that its
6. Disconnect hose clamps (8) and (9). lower part is not caught.
7. Disconnect radiator hose (10) and aeration hose
(11). [*2] 4 Radiator assembly:
8. Remove cover (12). 30 kg
9. Remove cover (13).
PC290LC-10 50-51
5 Coolant:
36 l
Installation

[*1][*2]
a Reference
Radiator hose fitting length: 45 mm (both upper
and lower sides)
3 Radiator hose clamp:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
[*3]
a Make sure that the insulation seal (sponge) at
the radiator periphery is not damaged.
a If the heat insulation seal (sponge) is damaged,
replace it.
a When installing the radiator assembly, carefully
lower it to avoid the insulation seal (sponge) at
the periphery from being damaged.
a Check that the convexed parts (A) at the bottom
of the radiator properly fits with the concaved
parts (B) of the machine from the undercover
side.
• Refilling of coolant
50-52 PC290LC-10
Removal and installation of hydraulic oil cooler assembly

a Special tools a If tools R1 and R2 are used, remove the
hydraulic tank strainer and stop oil with tools
Necessity
Symbol
R1 and R2.
Q'ty
Part No. Part Name
1 796-460-1210 Oil stopper q 1

R
2 796-770-1320 Adapter q 1
k Park the machine on a level ground, lower

the work equipment to the ground stably, and
stop the engine.
k Set the lock lever in the LOCK position.
k Release the remaining pressure in the

hydraulic circuit. For details, see Testing and
3. Open the left side cover and remove battery
adjusting, "Releasing residual pressure from
cover (3).
hydraulic circuit".

Removal
1. Remove undercovers (1) and (23).
4. Remove batteries (4). [*1]

a Disconnect the cable from the negative (-)
terminal of the battery.
2. Remove drain plug (2) to drain oil from the

hydraulic tank.
6 Hydraulic tank:
132 l
5. Disconnect wiring harness clamp (5).

6. Remove plug (7) from outlet tube (6) of the
hydraulic oil cooler to drain the remaining oil.
a After draining the oil, close plug (7).
7. Remove U-bolt (8).
8. Disconnect hydraulic oil cooler outlet tube (6).
PC290LC-10 50-53
9. Open engine hood (9) and disconnect reservoir 17.Disconnect inlet tube (21) of the hydraulic oil
tank hose (10). cooler and move it aside so that it does not
10.Remove covers (11) and (12). interfere with the hydraulic oil cooler.
11.Remove brackets (13) and (14).
18.Sling and remove hydraulic oil cooler assembly

12.Open hose clamps (15) and pull reservoir tank (22) by using eyebolts (M10) [1]. [*2]
hose (10) out of cover (16).
a Carefully lift the hydraulic oil cooler assembly
so that its lower part is not caught.
14.Remove two hydraulic oil cooler mounting bolts
(17).
4 Hydraulic oil cooler assembly:
15.Remove two wing nuts (18) and remove net
(19). 30 kg
16.Remove U-bolt (20). Installation

[*1]
a When installing the battery, tighten the double
nuts to the following torque.
50-54 PC290LC-10
3 First battery mounting nut:

1.47 to 1.96 Nm {0.15 to 0.2 kgm}
3 Battery mounting nut lock nut:
11.8 to 19.6 Nm {1.2 to 2.0 kgm}
[*2]
a Check that the heat insulation seal (sponge) on
the hydraulic oil cooler periphery is not
damaged.
a If the heat insulation seal (sponge) is damaged,
replace it.
a When installing the hydraulic oil cooler assembly,
carefully lower it to avoid the heat insulation seal
(sponge) on the periphery from being damaged.
a Check that the convexed parts (A) at the bottom
of the hydraulic oil cooler properly fits with the
concaved parts (B) of the machine from the
bottom side.
• Refilling of oil
a Before supplying oil, check that the oil cooler
drain plug is securely tightened.
a Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
5 Hydraulic tank:
132 l
PC290LC-10 50-55
Removal and installation of aftercooler assembly

Removal 4 Aftercooler assembly:
10 kg
1. Open engine hood (1) and remove cover (2).
Installation
2. Sling aftercooler assembly (3) and remove
mounting bolts (4). Perform installation in the reverse order to removal.
3. Disconnect hoses (5) and (6) from aftercooler [*1]
assembly (3). [*1] 1. Reconnect the disconnected air tubes according
a MIKALOR clamps to the following procedure.
a Put a mark of the hose end on the tube so a Use new MIKALOR clamps.
that the original position of the hose can be 1) Set the hose to the original (marked)
indicated. position.
a Air hose fitting length: a Reference
45 mm (both R.H. and L.H. sides) Air hose fitting length:
45 mm (both R.H. and L.H. sides)
2) With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) laps over
with the band by dimension (b) indicated
below.
Dimension (b): Min. 5 mm
Lubricant (THREEBOND PANDO
18B)
Install the clamp to the clamp mark put on the
hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
Tighten the clamp so that BDG dimension is as
follows.
BDG: 7 to 10 mm
4. Sling and remove aftercooler assembly (3).
50-56 PC290LC-10
PC290LC-10 50-57
Removal and installation of engine and main pump assembly

a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
9 796T-401-1110 Plate q 1
10 795-799-9300 Lifting tool q 1
A
Commercially Long socket (7/16
12 in) q 1
available
1 796-460-1210 Oil stopper q 1
R
2 796-770-1320 Adapter q 1
k Park the machine on a level ground, lower 3. Drain coolant through the drain valve. Drain
the work equipment to the ground stably, and hose: inside diameter f7 mm)
stop the engine.
6 Coolant:
k Set the lock lever in the LOCK position. 36 l
4. Open the right side cover and remove rubber-
k Release the remaining pressure in the lined cover (4).
adjusting, referring to "Releasing residual
pressure from hydraulic circuit".

a Attach tags to the hoses to indicate their

installed positions to prevent any mistake when
installing.
Removal
1. Remove undercovers (1), (2), and (3) .
5. Remove engine hood referring to " Removal and
installation of engine hood assembly(PAGE 50-
81)".
6. Remove step (5) and covers (6), (7) and (8) .
2. Remove the strainer of the hydraulic tank and

stop oil from flowing by using tools R1 and R2.
a If you do not use tools R1 and R2, remove
the drain plug to drain oil from the hydraulic
tank and piping.
6 Hydraulic tank:
132 l
50-58 PC290LC-10
9. Remove covers (9) and (11) by raising them. [*1]

a Each of covers (9) and (11) can be removed
as it is, without separateing it into the upper
and lower halves.
7. Remove bolts (10) that fasten cover (9) and

bolts (12) that fasten cover (11) .
10.Remove the KCCV ventilator assembly and

bracket, referring to " Removal and installation of
KCCV assembly".
11.Remove the KDPF assembly, referring to
"Removal and installation of KDPF assembly".
12.Removal of base brackets
1) Remove tube support bracket (14) .
2) Remove tube (15) . [*2]
3) Disconnect hose clamp (17), harness clamp
(18), and tube clamp (19) from base bracket
(16) .
4) Remove eight mounting bolts (20), then sling
and remove base bracket (15) .
4 Base bracket:
25 kg
8. Remove frames (13) .
4 Frame:
15 kg
13.Disconnect harness clamp (21) .

14.Disconnect connectors V19 (22) and V11 (23) .
15.Disconnect connectors V12 (24) and P22 (25) .
PC290LC-10 50-59
24.Sling hose bracket (45) and remove two

mounting bolts (46) .
25.Sling and remove hose bracket (45) together
with hoses (42) and (43) .
4 Hose bracket (including hoses):

9 kg
16.Disconnect hose clamp (26) .

17.Disconnect the six hoses.
• (27): Case drain port hose
• (28), (29): EPC source pressure input port
• (30): Pump pressure input port
• (31): Rear load pressure input port
• (32): Front load pressure input port
18.Disconnect harness clamps (33), (34), (35), and
26.Remove four mounting bolts (47) and
(36) .
disconnect pump suction port tube (48) .
19.Disconnect swash plate sensor P28 (37) of the
rear pump and swash plate sensor P27 (38) of
the front pump.
20.Remove KDPF water drain tube (39) .
27.Remove brackets (49) and (50) .
21.Disconnect discharge port hose (40) of the rear

pump and discharge port hose (41) of the front
pump.

29.Disconnect radiator hose (52) .
22.Disconnect hoses (42) and (43) .

50-60 PC290LC-10
30.Disconnect the following hoses and tubes of 34.Disconnect connector E01 (62) of the intake air
KVGT. [*3] heater and harness clamp (63) . [*7]
1) Disconnect hose (53) .
3) Disconnect clamp (55) .
4) Disconnect tube (56) .
35.Remove air conditioner compressor (67) and

compressor belt (68), referring to " Removal and
installation of air conditioner compressor
assembly(PAGE 50-220)".
31.Disconnect fuel filter hoses (59) from the supply

pump. [*4]
a While pressing locks (L) on both sides, pull
the hose in the direction of (a) .
32.Disconnect fuel return hose (60) . [*5]
33.Disconnect fuel supply hose (61) . [*6]
36.Remove bracket (69) .
PC290LC-10 50-61
37.Remove bracket (70) for the air conditioner

compressor.
39.Disconnect fan (71) . [*9]
38.Remove fan belt (64) . [*8]

belt.

spring of tensioner assembly (65) is 40.Disconnect terminal B (72) and connector E12
strong. If the wrench is loosely inserted, (73) from alternator (66) . [*10]
the wrench can accidentally come off and 41.Disconnect harness clamp (74) .
this is extremely dangerous.) 42.Remove alternator (66) . [*11]

carefully restore tensioner assembly (65) .

during work.
43.Disconnect hose (75) . [*12]

44.Disconnect hose (76) .
50-62 PC290LC-10
a Note that the hose mounting clips are hard to

remove and install.
45.Disconnect engine ground strap (77) and engine

controller ground strap (78) .
47.Disconnect connector CE03 (83) from the

engine controller.
a The connectors are locked with hexagonal
socket head bolts (84) (4 mm) .
46.Disconnect connector E24 (79) from the engine
controller as follows.
1) Roll up rubber cover (80) and slide red lever
(81) downward to unlock.
48.Disconnect terminal B (85), terminal C (85), and

harness connector (103) from the starting motor.
[*13]
2) Grab the connector (79) and pull it down

while pressing locking tab (82) to disconnect
the connector.
a Locking tab (82) is provided on the farther
side of connector (5) .
PC290LC-10 50-63
49.Disconnect connector E10 (87) . 54.Sling and remove engine and main pump
50.Disconnect connectors E08 (88) and P44 (89) . assembly (94) .
51.Disconnect clamp (90) .
a Attach the sling to two points on the engine
and to one point on the main pump when
removing the assembly.
a Before removing the assembly, make sure
that all the necessary wiring and piping are
disconnected.
4 Engine and main pump assembly:

840 kg

53.Remove four engine mounting bolts (92) . [*14]
a Nuts except for those at the alternator
mounting side are not welded. When
removing engine mounting bolts (92), hold
tool A9 against rotation with bolt (B) to
prevent nuts (93) from rotating.
55.Remove main pump assembly (95) from the

removed engine and main pump assembly
according to the following procedure. [*15]
1) Remove drain plug (104) and drain the
damper oil.
6 Damper case:
0.65 l
50-64 PC290LC-10
2) Remove fuel filter bracket (96) and [*2]

disconnect fuel filter (97) .
Install tube (15) with V-clamp by using tool A12
3) Sling main pump assembly (95), remove
(long socket).
housing mounting bolts (98), and then
remove main pump assembly (95) . a V-clamp can be reused, however, replace it with
a new one in the following conditions.
4 Main pump: • Deformation of V-clamp
190 kg • Damage on T-bolt thread portion
Installation
• Width across flats of V-clamp fastening nut: 7/16
[*1] in (11.1 mm)
When installing covers (9) and (11), insert the
3 V-clamp fastening nut:
covers in clips (102) (five places) shown in the
figure and tighten the mounting bolts. 13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
• As seen from the control valves. a V-clamp mounting angle: 15°
• As seen from the engine.

[*3]
PC290LC-10 50-65
Install the hoses and tubes to the KVGT according 3 Hose clamp:
to the following procedures. 3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
1. Install tube (56). 5. Install hose (53).
3 V-clamp:
7 ± 1.1 Nm {0.7 ± 0.11 kgm}
• MIKALOR clamps
a Use a new clamp.
1) Set the hose to the original position
(marked position).
a Reference
Air hose fitting length: 50 mm
(aftercooler end)
Air hose fitting length: 40 mm (KVGT
end) [*4]
2) Set the bridge (BR) under the clamp bolt
When installing a connector of quick coupler type,
and lap it over band (BD) by at least 5
observe the following points.
mm (b).
Dimension b: Min. 5 mm a The internal parts of the fitting may be damaged
when the hose or tube is removed. Accordingly,
do not reuse the hose or tube.
Lubricant (THREEBOND
PANDO 18B) When installing, replace it with a new one.
a Impact wrench is not allowed to use. a Ensure that mud or dirt is not sticking to the hose
• If hoses are to be reused joint portions in advance.
Install the clamp to the clamp mark put on a Push the connector straight (in the direction of
the hose. (b)). Do not pry it in or shake it.
3 Clamp bolt: If it is difficult to insert the connector, do not push
Min. 6 Nm {0.6 kgm} it in forcibly but pull it out. Then, check the male
• When using a new hose and female couplings for damage and sticking
Tighten the clamp so that BDG dimension is mud.
as follows.
BDG: 7 to 10 mm
[*5]
3 Fuel return hose mounting bolt:
2. Install hose (57).
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3 Hose clamp:
[*6]
10.0 to 11.0 Nm {1.02 to 1.12 kgm}
3. Install hose (58). 3 Fuel supply hose mounting bolt:
25.4 to 34.3 Nm {2.6 to 3.5 kgm}
3 Hose clamp:
[*7]
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
50-66 PC290LC-10
3 Mounting nut for intake air heater • Blade tip clearance (at top/bottom/left/right of
connector: shroud)
3.4 to 0.47 Nm {0.34 to 0.47 kgm} d: Min. 13 mm
[*8]
Install fan belt (64).
a Insert a wrench to the portion A (width across
flats T 12.7 mm) of the tensioner assembly (65),
and rotate it to the counter-direction (R) to the
winding-up direction to decrease fan belt (64)
tension, then install.
k Firmly set the wrench on tensioner assembly
(65) at portion A before applying turning
force to the wrench. (The spring of tensioner
assembly (65) is strong. If the wrench is
loosely inserted, the wrench can accidentally [*10][*11]
come off and this is extremely dangerous.)
Install alternator (66) according to the following
k After installation of fan belt (64), restore procedure.
tensioner assembly (65) slowly with care. 1. Install alternator (66).
3 Mounting bolt (to bracket):
between the pulley and fan belt (64) during 43 ± 6 Nm {4.4 ± 0.6 kgm}
work. 3 Mounting bolt (to plate):
24 ± 4 Nm {2.4 ± 0.4 kgm}
2. Install terminal B (72) and connector E12 (73) to
alternator (66).
3 Terminal B (72):
5.9 to 9.8 Nm {0.6 to 1.0 kgm}
3. Install wiring harness clamp (74).
[*9]
After fan (71) is installed, check the clearance (d)
between the fan blade tips and shroud (100). If the
clearance is out of the standard value range, loosen
six mounting bolts (101) and adjust the position of
the shroud.
PC290LC-10 50-67
[*12]
a Note that the hose mounting clips are hard to
remove and install.
3 Hose clamp:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
3 Engine mounting bolt (4 places):

245 to 308.9 Nm {25 to 31.5 kgm}
a Nuts except for those at the alternator mounting
side are not welded. Therefore, fix nut (93) by
using tool A9 and bolt (B) to restrict nut (93) from
turning, then install engine mounting bolt (92).
[*13]
Install terminal B (85) and terminal C (85) to the
starter.
3 Terminal B (85):
17.7 to 24.5 Nm {1.8 to 2.5 kgm}
3 Terminal C (86):
2.6 to 4.6 Nm {0.27 to 0.47 kgm}
[*15]
2 Main pump involute splines:
Molybdenum disulfide grease (LM-G)
2 Mating face on main pump case:
a Take care not to torque the bolts excessively
since the flywheel housing is made of aluminum.
[*14] a Reference
a The bolt length to be used on the engine front 3 Engine mounting bracket bolts (four
side is shorter than that on the rear side. places) (99):
a The size of the engine mounting rubber to be 122.5 to 147 Nm {12.5 to 15 kgm}
used on the engine front side is smaller than that
on rear side.
50-68 PC290LC-10
• Bleeding air
See Testing and adjusting, " Bleeding air from
hydraulic circuit".
a Reference
Overview of the fitting depths of the air hoses
and radiator hoses.
• Filling of oil (damper case)

Supply oil through the oil filler port to the
specified level.
5 Damper case:
0.65 l
3 Damper case drain plug:
45 ± 5 Nm {4.6 ± 0.5 kgm}
• Refilling of oil (hydraulic tank)
Supply hydraulic oil through the oil filler port to
level again.
5 Hydraulic tank:
132 l
3 Hydraulic tank drain plug:
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
• Refilling of coolant
Supply coolant through the coolant filler port to
the coolant through the system. Then, check the
5 Coolant:
36 l
PC290LC-10 50-69
Removal and installation of engine front oil seal

7. Remove mounting bracket (6) of the aftercooler
assembly.
a Special tools
8. Remove mounting bolt (7), then remove stay (2).
Necessity
Symbol
Q'ty
Part No. Part Name
5 790-331-1120 Wrench (Angle) q 1

A
7 795-799-6400 Seal puller t 1
Removal
1. Remove the radiator assembly, referring to "
Removal and installation of radiator assembly
(PAGE 50-51)".
2. Remove the hydraulic oil cooler assembly,
referring to " Removal and installation of
hydraulic oil cooler assembly(PAGE 50-53)". 9. Remove mounting bolt (8), then remove stay (4).
3. Remove the aftercooler assembly, referring to " a Remove mounting bolt (8) from the upper
Removal and installation of aftercooler assembly side.
(PAGE 50-56)".
4. Remove mounting bolts, open air conditioner
condenser (1), and move it aside.
a Hold air conditioner condenser (1) using
something like a piece of string to prevent it
from closing.
10.Remove fan guards (9), (10), and (11).
5. Remove mounting bolt (3) of stay (2).

6. Remove mounting bolt (5) of stay (4).
a Remove mounting bolt (5) from the
undercover side.
11.Remove fan (12). [*1]
50-70 PC290LC-10
14.Remove six mounting bolts and remove

vibration damper (20).
12.Remove air conditioner compressor belt (17)

compressor (16) in the direction of loosening
belt tension.
4) Loosen the tension on air conditioner
compressor belt (17) and remove the belt.
15.Remove engine front oil seal (21) as follows.

1) Install tool A5 to the crankshaft.
2) Screw in tapping screw [1] of tool A7 to the
seal carrier section of engine front oil seal
(21).
3) Turn the handle clockwise and remove
engine front oil seal (21).
13.Remove fan belt (18). [*3]
belt.

spring of tensioner assembly (19) is
strong. If the wrench is loosely inserted,
the wrench can accidentally come off and
a Take care in the removal so that the
this is extremely dangerous.)
crankshaft is not damaged.


during work.
PC290LC-10 50-71
2) Tightening procedure for vibration damper

mounting bolts
3 Vibration damper mounting bolt:
1] Tighten to 55 ± 5 Nm {5.6 ± 0.5
kgm} in a diagonal order.
2] Loosen bolts 180 deg.
3] Tighten to 55 ± 5 Nm {5.6 ± 0.5
kgm} in a diagonal order.
4] Retighten 90 ± 5 deg. in a
diagonal order.
a Use tool A5 to angle-tighten.
Installation
1. By using tool A7, install engine front oil seal (21).
a Before installing the seal, check that the end
corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and rust.
a When installing the seal, do not apply oil or
grease to the shaft and seal lip. Also,
thoroughly wipe off oil or grease from the
shaft.
• When not using angle tightening tool

Put marks on the vibration damper and
bolts with a felt-tip pen, and then tighten
the bolts an additional 90 deg. ± 5 deg.
a Engine front oil seal (21) on cover (c):

• Protrusion x: Max. 0.38 mm
• Facial runout y : Max 0.25 mm

order to removal.
[*1]
a After fan (12) is installed, check the clearance
between the fan blade tips and shroud (22). If
the clearance is out of the standard value range,
loosen six mounting bolts (23) and adjust the
position of the shroud.
• Blade tip clearance (at top/bottom/left/right of
shroud)
2. Vibration damper d: Min. 13 mm
1) Install vibration damper (20), aligning its
dowel hole with dowel pin B on the
crankshaft.
50-72 PC290LC-10
[*2]
a See Testing and adjusting, " Checking and
adjusting air conditioner compressor belt
tension".
[*3]
Install fan belt (18).
a Insert a wrench to the portion A (width across
flats T 12.7 mm) of the tensioner assembly (19),
and rotate it to the counter-direction (R) to the
winding-up direction to decrease fan belt (18)
tension, then install.
k Firmly set the wrench on tensioner assembly
(19) at portion A before applying turning
force to the wrench. (The spring of tensioner
assembly (19) is strong. If the wrench is
loosely inserted, the wrench can accidentally
come off and this is extremely dangerous.)
k After installation of fan belt (18), restore

tensioner assembly (19) slowly with care.

between the pulley and fan belt (18) during
work.
PC290LC-10 50-73
Removal and installation of engine rear oil seal

a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
A 8 795-799-6500 Seal puller t 1
Removal
1. Remove the main pump assembly. For details,

see "Removal and installation of main pump
7. Remove engine rear oil seal (5) as follows.
2. Remove mounting bolt (1) and install guide bolt 1) Install tool A8 on the crankshaft.
[1]. 2) Screw tapping screw [3] of tool A8 into the
3. Remove damper assembly (2). seal carrier of engine rear oil seal (5).
3) Turn the handle clockwise to remove rear oil
seal (5).
4. Remove mounting bolts (3) and insert guide

bolts [2]. [*1]
a Width across flats: 18 mm a Take care in the removal so that the
5. Sling flywheel assembly (4) and pull it out. crankshaft is not damaged.
a Be careful not to let the guide bolts drop out.
Installation
6. Sling and remove flywheel assembly (4). [*2]
1. Install the engine rear oil seal (5) according to
4 Flywheel assembly: the following procedure.
35 kg
a Do not remove pilot [4] which is attached to
engine rear oil seal (5) until engine rear oil
seal (5) is installed to the crankshaft.
50-74 PC290LC-10
a Before installing the engine rear oil seal,

degrease, clean and dry the crankshaft
sealing face and the seal lip face to prevent
oil leakage.

order to removal.
[*1]
a Tighten the eight flywheel assembly mounting
2. Install pilot [4] to crankshaft (6) and push engine bolts in the order shown in the figure.
rear oil seal (5) into flywheel housing (7).
3. Push in engine rear oil seal (5) further and then 3 Flywheel assembly mounting bolt:
pull out pilot [4]. 137 ± 7 Nm {13.97 ± 0.71 kgm}
4. Use tool A8 to install engine rear oil seal (5) to

a Use plate [5] to prevent the flywheel assembly
the proper depth in flywheel housing (7). from rotating when tightening the bolts.
a Push in engine rear oil seal (5) with care not
to bend it.
a Extrusion of engine rear oil seal (5) from
flywheel housing (7)
X: Max. 0.38 mm
[*2]
• Measuring radial runout
a Radial runout: Max. 0.13 mm
1. Install dial gauge [6] on the stand, and set
the stand on flywheel housing (7).
PC290LC-10 50-75
2. Make the probe of dial gauge contact with

spigot joint portion (a) or outer circumference
of the flywheel at a right angle.
3. Rotate the flywheel 360 deg. and measure
the maximum swing width of the dial gauge
indicator.
a Check that the dial gauge indicator is
back in the original position after the
flywheel is rotated 360 deg.
• Measuring facial runout
a Facial runout: Max. 0.20 mm
1. Similarly to the measurement of radial runout,
make the probe of dial gauge contact at a
right angle with the end face (b) near the
outer circumference of the flywheel.
a Perform the measurement with the
crankshaft pulled to either the front or
rear side of the engine to prevent errors
caused by backlash.
2. Rotate the flywheel 360 deg. and measure
the maximum swing width of the dial gauge
indicator.
50-76 PC290LC-10
Removal and installation of fuel cooler assembly

a Make sure to hold elbow (L) on the fuel cooler by
using another spanner while connecting the
hoses to avoid stressing the cooler.
a If a spanner is not used, stress will be applied to
a If the fuel is too much, drain the fuel in order to the cooler and the welded portions (M) may
stop the fuel flow from the fuel tank return hose. come apart.
Removal
1. Open the left side cover and remove plate (1).
2. Disconnect hose clamps (2).

3. Disconnect two hoses (3). [*1]
a Make sure to hold elbow (L) on the fuel
cooler by using another spanner while
disconnecting the hoses to avoid stressing
the cooler.
a If a spanner is not used, stress will be
applied to the cooler and the welded portions
(M) may come apart.
4. Remove fuel cooler mounting bolts (4).
5. Remove fuel cooler (5).
Installation

[*1]
PC290LC-10 50-77
Removal and installation of fuel tank assembly
k Park the machine on a level ground, swing

the upper structure by 90 deg., lower the
work equipment to the ground stably, and
stop the engine.
k Set the lock lever in the Lock position.

Removal
a The lower mounting end of handrail (6) is
1. Remove undercovers (1) and (2). fixed to the inside of tool case (7).
2. Open the right side cover and open fuel tank 5. Open cover (8) of tool case (7) and remove
drain valve (3) to drain the fuel. rubber cap (9).
6 Fuel tank (when full):

400 l
6. Remove right headlamp cover (10).

7. Disconnect washer hose (11).
8. Disconnect washer motor connector M06 (12).
3. Remove handrail (4) and plate (5). 9. Remove washer tank (13) and bracket together.
4. Remove handrail (6).
50-78 PC290LC-10
10.Remove grease gun (14) and grease gun 15.Remove four mounting bolts (19), then remove
mounting bracket (15). cover (27).
11.Disconnect connector L02 (16) for the right 16.Disconnect wiring harness clamp (20) and
headlamp wiring. connector P21 (21) of the fuel level sensor.
12.Remove right headlamp (17). [*1]
13.Remove four tool case mounting bolts (18).
17.Disconnect fuel tank lower hoses (22), (23), and

(24).
14.Sling and remove tool case (7). 18.Remove three mounting bolts (25). [*2]
a Placing block [1] under tool case (7)
facilitates the lifting work.
4 Tool case:
35 kg
PC290LC-10 50-79
19.Sling and remove fuel tank assembly (26).
4 Fuel tank assembly:

180 kg
Installation

[*1]
3 R.H. headlamp mounting nut:
17.6 to 19.6 Nm {1.78 to 2.00 kgm}
[*2]
3 Fuel tank mounting bolt:
235 to 285 Nm {23.5 to 29.5 kgm}
• Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
50-80 PC290LC-10
Removal and installation of engine hood assembly
Removal
1. Open engine hood (1) and support it by using a
sling.
4. Close engine hood (1) and remove hinge covers

(6) from the rear of the engine hood.
a The engine hood must be kept slung when
closing it.
2. Remove gas springs (2), (3), and (4).

3. Remove stay (5).
5. Remove four mounting bolts (7) and open two

hinges (8) to disconnect them from engine hood
(1). [*1][*2]
6. Sling and remove engine hood (1).
4 Engine hood:
55 kg
PC290LC-10 50-81
3. Adjust fore-and-aft location of engine hood (1),

so that box (14) for spring of catcher (9)
becomes nearly perpendicular.
Installation
4. Look through holes (A) and (B) in the closed
engine hood to check the clearance inside the
[*1] engine hood.
Adjustment procedure for installing engine hood • As seen through hole (A), clearance (a)
1. Fasten hinges (8) of engine hood (1) with four between bracket (12) and the engine hood
mounting bolts (7). must be 1 mm or more.
• As seen through hole (B), clearance (b)
a Lightly tighten the bolts to the degree that the
between bracket (13) and the engine hood
engine hood does not move to the right and
must be large enough to avoid interference.
left, and back and forth when it is opened
and closed.
a Keep the engine hood slung after installation
to perform adjustments.
2. Lower engine hood (1) slowly to bring catch (9)

near to pin (10) on the chassis and check the
engagement.
5. If either of the brackets interfere with the engine

hood, check if brackets (12) and (13) are
installed at their correct positions on frame (11).
X: 747 ± 1 mm
Y: 353 ± 1 mm
50-82 PC290LC-10
6. If adjustment is necessary, loosen the four 3. While pulling up catcher (9) to the end with
engine hood mounting bolts and move the keeping lever level, put a mark of lower face of
engine hood to adjust. catcher pedestal.
4. Tighten mounting bolt (15) to match with the
a Repeat steps 2 to 5 until the engine hood is
mark.
opened and closed smoothly.
7. When adjustment is completed, tighten
mounting bolts (7) for hinges (8) to the specified
torque.
5. Check if locking of catcher (9) is smooth.

a Repeat steps 1 to 4 until locking of catcher
(9) becomes smooth.
[*2]
Adjustment procedure of catcher
a When installing the engine hood, adjust lock
portion of catcher (9) according to the following
procedure.
1. Loosen mounting bolts (15) of catcher (9).
2. While pulling the lever of catcher (9) to the level,

hook catcher-hook (16) to the tooth of pin (10) at
frame side.
PC290LC-10 50-83
Removal and installation of KDPF assembly

a Special tools
Necessity
Symbol
Q'ty
1- Commercially Long socket (1/2 in) q 1

1 available
A
2 available

2. Disconnect harness clamps (3), (4), (18) and
(19).
Removal
1. Open the engine hood and disconnect

connectors E25 (1) and E26 (2).
3. Remove V-clamp (5) by using tool A12 (long

socket) and disconnect tube (6).
a Since this is a datum location for installation,
don't loosen tube (6).
a Connector disconnecting procedure • Width across flats of V-clamp fastening nut:
7/16 in (11.1 mm)
1) Slide the lever (red) of the connector to
unlock.
4. Remove three mounting bolts (20) and one

2) While pressing the knob on the upper portion mounting bolt (21).
of the connector, pull out the connector. 5. Sling and remove KDPF bracket assembly (8).
a When slinging, hook it to sling plate (29).
a Pay attention to the gasket at the tube
connection that may fall away during the
removal.
50-84 PC290LC-10
4 KDPF bracket assembly:

75 kg
9. Sling and remove KDPF assembly (14).

a When slinging, hook it to hanger (30).
6. Disconnect sensor harness clamps (9) and (10) a Be careful not to deform eye-joint (15) when
on the thermal guard side. lowering the removed KDPF assembly.
4 KDPF assembly:
45 kg
7. Remove four mounting bolts (11) and remove

thermal guard (12).
8. Remove the double nuts and washers, then

remove U-bolts (13). 10.Removal of accessories to KDPF assembly
a Loosen nuts alternately to prevent U-bolt a When replacing the KDPF filter, exhaust pipe
thread galling. (17), I-joint (15) and wiring harness clamp
bracket (22) must be replaced.
1) Remove V-clamp (16) for the exhaust pipe by
using tool A12 (long socket), then remove
exhaust pipe (17) and gasket.
nut: 7/16 in (11.1 mm)
2) Remove eye-joint (15).
PC290LC-10 50-85
a V-clamp can be reused, however, replace

it with a new one in the following
conditions.
3) Remove wiring harness clamp bracket (22).

nut: 7/16 in (11.1 mm)
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
4) Install wiring harness clamp bracket (22).
Installation
1. Installation of accessories to KDPF assembly

a When replacing the KDPF filter, exhaust pipe
(17), I-joint (15) and wiring harness clamp
bracket (22) must be replaced.
a After the KDPF assembly is installed to the
machine, insert I-joint (15) into the KDPF
water drain tube and install.
1) Clean exhaust pipe (17) and the outlet side
flange of KDPF assembly (14) by using parts
cleaner fluid.
2) Install a new gasket between exhaust pipe
(17) and the KDPF flange.
3) Install V-clamp (16), adjust the angle
between exhaust pipe (17) and the T-bolt of
V-clamp to 45 deg. and then fasten the V-
clamp by using tool A12 (long socket).
2. Preparatory work for installation of KDPF

bracket assembly:
1) Sling KDPF assembly (14) to place it on
bracket (25), and lightly tighten U-bolts (13),
washers, and the first nut (27) of double-nuts
50-86 PC290LC-10
at 4 places so that the position can be 1) Install a new gasket on flange connecting
adjusted. part of tube (6).
2) Sling KDPF bracket assembly (8) to install to
a Use hanger (30) to sling KDPF assembly
base bracket (24) by mating KDPF inlet
(14).
flange part and flange surface of tube (6).
a When nut (27) is chamfered only one side,
a Use sling plate (29) to sling KDPF bracket
install it with its chamfered side
assembly (8).
downward.
a When installing KDPF bracket assembly
4 KDPF assembly: (8), take care not to drop the gasket.
45 kg
75 kg
3) Install KDPF bracket assembly (8) and
tighten three mounting bolts (20) and one
mounting bolt (21).
• Length of bolt (20): 30 mm
2) Move KDPF assembly (14) back or forth or

rotate it to obtain correct clearance (a) to
bracket (25) and set the exhaust pipe (17)
upright.
• Clearance (a): 10 mm
4) Loosen V-clamp (31) of KVGT side of tube

(6) and tube support bracket (23), then adjust
the clearance between the inlet flange part of
KDPF assembly (14) and flange connecting
part of tube (6) where the gasket seats.
a If it is hard to work, you may remove step
(32).
a The clearance between flange and the
gasket which is in between KDPF
assembly (14) and tube (6) must be
3. Position adjustment of the KDPF inlet flange within 5 mm all around the circumference.
connecting part 5) While the clearance at flange is being
adjusted, lightly tighten tube support bracket
a Since the adjustment procedure depends on
(23). Install V-clamp (5) with pressing tube
whether the flange surface of tube (6) can be
(6) and lightly tighten by using tool A12 (long
the reference point for positioning, refer to
socket).
either procedure to perform installation.
• When the flange surface of tube (6) can be
the reference point for positioning.
(When tube (6) is not removed.)
a Adjust the position based on tube (6)
flange surface so that the bellows of tube
(6) does not get any strain and KDPF
assembly can be installed with same
flange position before removal.
PC290LC-10 50-87

75 kg
4) Install KDPF bracket assembly (8) and
tighten three mounting bolts (20) and one
mounting bolt (21).
5) Loosen tube support bracket (23), then

adjust the clearance between the inlet flange
part of KDPF assembly (14) and flange
connecting part of tube (6) and gasket where
the gasket seats.
• When the flange surface of tube (6) can not
be the reference point for positioning. a The clearance between flange and the
(When tube (6) is removed.) gasket which is in between KDPF
assembly (14) and tube (6) must be
within 5 mm all around the circumference.
(32).
6) While the clearance at flange is being
adjusted, lightly tighten tube support bracket
(23). Install V-clamp (5) with pressing tube
(6) and lightly tighten by using tool A12 (long
socket).
nut: 7/16 in (11.1 mm)
1) Loosen V-clamp (20) of KVGT side of tube

(6).
a Adjust the position based on bracket so
that the bellows of tube (6) does not get
any strain.
2) Install a new gasket on flange connecting
part of tube (6).
3) Sling KDPF bracket assembly (8) to install it
to base bracket (24).
a Use sling plate (29) to sling KDPF bracket
assembly (8).
a When installing KDPF bracket assembly
(8), take care not to drop the gasket.
50-88 PC290LC-10
4. Tightening of each part 2) Close engine hood (7) to check that the
1) Tighten tube (6) to the specified torque in the exhaust pipe (17) stands upright. If the
order of V-clamp (31) of KVGT side and V- exhaust pipe does not stand upright, loosen
clamp (5) of KDPF side by using tool A12 V-clamp (26) on KDPF assembly (14) by
(long socket). using tool A11 (long socket) and move the
KDPF outlet part by rotating it for fine
a Do not fully tighten 2 places of KDPF U- adjustment of exhaust pipe (17).
bolts (13) and tube support bracket (23) • Width across flats of V-clamp fastening
before fastening V-clamp (31) and (5) so nut: 1/2 in (12.7 mm)
as not to make any strain on the tube.
3 V-clamp (26) fastening nut:
(32). 18 to 22 Nm {1.8 to 2.2 kgm}
nut: 7/16 in (11.1 mm)
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
a KVGT side V-clamp (31) mounting angle:
15 deg.
a KDPF side V-clamp (5) mounting angle:

30 deg.
3) Tighten first nut (27) of the double-nuts on U-

bolts (13) evenly (4 places).
3 U-bolt tightening nut (first):
7.6 to 13.3 Nm {0.78 to 1.36 kgm}
4) Tighten second nut (28) of the double-nuts
on U-bolts (13) evenly (4 places).
PC290LC-10 50-89
a When nut (28) is chamfered only one side,

install it with its chamfered side
downward.
3 U-bolt tightening nut (second):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
5) First partially loosen support bracket (23) of

tube (6) so as not to make any strain on the
tube, then tighten it to the specified torque
with no clearance.
5. Reinstallation of KDPF surrounding components

1) Install thermal guard (12).
• Details of portion B 2) Clamp sensor wiring harnesses (9) and (10).
a The position of each wiring harness must
be adjusted to maintain clearance of 20
mm or more to the surrounding
components.
a When tightening nuts (27) and (28) at

(A) part and (B) part, install spanner-
shaped head to torque wrench (head
exchangeable) and perform the work.
3) Insert I-joint (15) into KDPF water drain tube
(18) and install it to the KDPF assembly.
a Tighten bolt by holding the I-joint so as
not to make any deformation on the tube.
• Tube insertion length: 32 mm
50-90 PC290LC-10
3 I-joint mounting bolt:

24.5 to 34.3 Nm {2.5 to 3.5 kgm}
4) Install wiring harness clamps (3), (4), (18)

and (19).
5) Insert connecters E25 (1) and E26 (2) into

their mating sensor connecters, and push in
the red lever to lock them.
6) Close engine hood (7) to check for

interference between exhaust pipe (17) and
engine hood hole. If necessary, loosen V-
clamp (16) for the exhaust pipe by using tool
A12 (long socket) to adjust the angle with T-
bolt to 45 deg. and retighten.
nut: 7/16 in (11.1 mm)
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
PC290LC-10 50-91
Disassembly and assembly of KDPF

a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name

1 available
A
2 available
k Since the temperature of KDPF or KDOC

becomes 500 °C or higher, take care not to
get burn injury.
a Prepare block [1] referring to the figure below,
and use it with wooden plate to float the inlet
side flange from the ground.
k Stop the engine and wait until the
temperature of piping around engine drops,
then remove KDPF.
k When cleaning, replacing or disposing KDPF

and CSF, use dust mask during the work to
prevent inhaling deposited soot, ash, mat
material or metallic powder inside KDPF.
k Install KCSF with care to the mounting

direction.
2. Put a match mark on the assembly for correct
k KDPF is fragile against shock such as falling, alignment of inlet and outlet angles at
handle with care, and never use damaged reassembly.
part.
a Put a marking on the V-clamp, inlet body and
outlet body in alignment with the KDPF filter
and mounting portion of the differential
k Keep the record for each KDPF unit to pressure sensor pipe.
monitor the life, and never use the KDPF
exceeded its life. a The angle can be adjusted at the installation
of the KDPF assembly, slight misalignment of
a V-clamp and band used in KDPF is made of marking is allowed.
stainless steel, accordingly never use air tool for • Inlet side
removal and installation of nut to avoid damage
on the thread part.
a Prepare new gaskets or bands when removing
them.
Disassembly
1. Secure the KDPF assembly at 4 places to

support its inlet body and filter assembly by
using block [1].
• Outlet side
50-92 PC290LC-10
3. Disconnect connectors of KDOC inlet 4. Remove KDOC outlet temperature sensor (2),
temperature sensor (1), KDOC outlet and KDPF outlet temperature sensor (3).
temperature sensor (2), and KDPF outlet • Width across flats of the nut for temperature
temperature sensor (3) from sensor table (13). sensor: 14 mm
a Close the sensor mounting portions with
plugs [2].
Plug [2] screw size: M12 x 1.25
a Connector disconnecting procedure

1) Slide the lever (white) of the connector to
unlock.
5. Remove differential pressure sensor pipes (5)
and (6).
1) Loosen the nuts on the filter.
• Width across flats of the nut for pipe (5):
11/16 in (17.5 mm)
• Width across flats of the nut for pipe (6):
5/8 in (15.9 mm)
2) When disconnecting connectors of
differential pressure sensor pipes (5) and (6),
pull them out while pushing lock (L) at the
fitting.
a Lock (L) at the fitting of differential
2) While pressing the knob on the upper portion
pressure sensor pipe (6) is located
of the connector, pull out the connector.
behind.
PC290LC-10 50-93
3) Remove differential pressure sensor pipes 8. When replacing KDPF filter (16), remove sensor
(5) and (6). table (13) and hanger (15) according to the
a Since the tube is inserted inside of CSF,
pull out pipe (5) upright. 1) Remove band (12) by using tool A12 (long
socket) to remove sensor table (13).
a Close the sensor mounting portions with 2) Remove band (14) by using tool A12 (long
plugs [3] and [4]. socket) to remove hanger (15).
Plug [3] threads: M16 x 1.5 • Width across flats of band (12), (14)
Plug [4] threads: M14 x 1.5 tightening nut: 7/16 in (11.1 mm)
3) Remove the plug from KDPF filter assembly
(11), if so attached.
6. Remove V-clamps (7) and (8) by using tool A11

(long socket) and remove inlet body (9) and
outlet body (10).
• Width across flats of V-clamp (7), (8)
tightening nut: 1/2 in (12.7 mm)
9. When replacing differential pressure sensor (19),

remove it according to the following procedure.
1) Loosen mounting bolt (20), and remove
7. Remove gaskets (17) and (18) to get KDPF filter differential pressure sensor (19) from sensor
assembly (11). table (13).
2) Disconnect the fitting of differential pressure
sensor pipes (5) and (6) to remove
differential pressure sensor (19)
50-94 PC290LC-10
a When disconnecting connectors of

differential pressure sensor pipes (5) and
Assembly
(6), pull them out while pushing lock (L) at
the fitting. 1. Install KDPF assembly inlet body (9), KDPF filter
a Lock (L) at the fitting of differential assembly (11) and outlet body (10) in sequence.
pressure sensor pipe (6) is located a The blocks used at disassembly are used at
behind. assembly.
a Since lock nut is applied to the V-clamp,
tighten lightly until V-clamp does not move by
using tool A11 (long socket).
a V-clamp can be reused, however, replace it
with a new one in the following conditions.
1) Place new gasket (17) on end of KDPF filter

assembly (11).
10.When replacing KDOC inlet temperature sensor
(1), remove it according to the following
procedure.
1) Disconnect wiring harness clamp (4) for
KDOC inlet temperature sensor (1) from
sensor table (13).
• With across flats of clamp bolt: 10 mm
2) Remove KDOC inlet temperature sensor (1).
• Width across flats of the nut for
temperature sensor: 14 mm
2) Assemble inlet body (9) to KDPF filter

assembly (11) matching with the location of
fitting for differential pressure sensor pipe
according to the marking put before removal.
a Place V-clamp (7) to inlet body (9) before
installing them to KDPF filter assembly
(11).
a When assembling inlet body (9) and
KDPF filter assembly (11), take care that
gasket (17) does not come out.
PC290LC-10 50-95
3) Tighten V-clamp (7) lightly according to the a When assembling outlet body (10) and
marking put before removal and the angle KDPF filter assembly (11), take care that
shown below. gasket (18) does not come out.
• Width across flats of V-clamp fastening 6) Tighten V-clamp (8) lightly according to the
nut: 1/2 in (12.7 mm) marking put before removal and the angle
• Mounting angle of V-clamp T-bolt: 35 ± 5° shown below.
• Mounting angle of V-clamps (7) and (8) • Width across flats of V-clamp fastening
nut: 1/2 in (12.7 mm)
• Mounting angle of V-clamp T-bolt: 35 ± 5°
• Mounting angle of V-clamps (7) and (8)
4) Install new gasket (18) on end of KDPF filter

assembly (11).
2. Tighten V-clamps (7) and (8) according to the

1) Tighten the nuts of V-clamps (7) and (8) by
using tool A11 (long socket).
nut: 1/2 in (12.7 mm)
18 to 22 Nm {1.8 to 2.2 kgm}
2) Tap the entire periphery of the V-clamp with a
rubber hammer in the following order: aob,
cod.
5) Assemble outlet body (10) to KDPF filter 3) Tighten the nuts of V-clamps (7) and (8)
assembly (11) matching with the location of again.
fitting for differential pressure sensor pipe
according to the marking put before removal.
nut: 1/2 in (12.7 mm)
a Place V-clamp (8) to outlet body (9)
before installing them to KDPF filter
assembly (11). 18 to 22 Nm {1.8 to 2.2 kgm}
50-96 PC290LC-10
a Adjust the direction of band and its installing

place according to the marking location put
before removal and the angle shown below.
• Mounting angle of band T-bolt: 135 ± 5°
a Since lock nut is applied to the band, tighten
lightly until band does not move.
a When new KDPF filter assembly (11) is
installed, put hanger (15) at the same angle
with hanger (21) at inlet body, and adjust it
upwards when installing on the machine, and
then fasten band (14).
3. When a new KDPF filter is installed, install • Width across flats of band (14) fastening nut:
sensor table (13) and hanger (15) according to 7/16 in (11.1 mm)
the following procedure.
3 Band (14) fastening nut (tightening to
a Once a band is tightened, it gets the folding the specified torque):
mark with the edge of the part to be fixed.
6.3 to 8.3 Nm {0.6 to 0.8 kgm}
Accordingly, do not reuse the band but
replace it with a new one.
1) Fasten hanger (15) lightly with new band (14)
by using tool A12 (long socket).
a Install hanger (15) upward and adjust it
when the V-clamp is installed.
• Width across flats of band (14) fastening
nut: 7/16 in (11.1 mm)
2) Fasten sensor table (13) lightly with new
band (12) by using tool A12 (long socket).
a Install sensor table (13) at a position that
permits easy installation of piping and
adjust it during installation of the piping. 4. Install differential pressure sensor pipes (5) and
• Width across flats of band (12) fastening (6) according to the following procedure.
nut: 7/16 in (11.1 mm) a Remove any plugs put on the mounting holes
at the removal.
1) Install differential pressure sensor pipes (5)
and (6) so that they extend horizontally, and
then lightly tighten the nuts.
a When a new KDPF filter is installed,
adjust the position of sensor table (13), at
which differential pressure sensor pipes
(5) and (6) can be installed easily, and
then fasten band (12) by using tool A12
(long socket).
PC290LC-10 50-97
• Width across flats of band (12) fastening 3 Thread portion of temperature sensor:
nut: 7/16 in (11.1 mm) Seizure prevention compound (LC-G)
3 Band (12) fastening nut: • Width across flats of the nut for temperature
6.3 to 8.3 Nm {0.6 to 0.8 kgm} sensor: 14 mm
2) Install connectors of differential pressure 3 Temperature sensor mounting nut:
sensor pipes (5) and (6) to differential
24 to 36 Nm {2.5 to 3.7 kgm}
pressure sensor (19).
a Push in fitting of connectors until locking
sound is heard.
3) Install differential pressure sensor pipes (5)
and (6).
• Width across flats of the nut for Hi side
pipe (5): 11/16 in (17.46 mm)
3 Hi side pipe (5) mounting nut:
24.5 to 36.5 Nm {2.5 to 3.7 kgm}
• Width across flats of the nut for Lo side
pipe (6): 5/8 in (15.88 mm)
3 Lo side pipe (6) mounting nut: 6. Install connectors of KDOC inlet temperature
13.6 to 19 Nm {1.39 to 1.9 kgm} sensor (1), KDOC outlet temperature sensor (2),
and KDPF outlet temperature sensor (3) to
sensor table (13).
a Do not install connectors at wrong positions.
7. When replacing differential pressure sensor (19),

install it according to the following procedure.
1) Tighten mounting bolt (20) of differential
pressure sensor (19) lightly.
2) Install connectors of differential pressure
sensor pipes (5) and (6) to differential
pressure sensor (19).
a Push in fitting of connectors until locking
sound is heard.
5. Install KDOC outlet temperature sensor (2), and
3) Tighten mounting bolt (20) of differential
KDPF outlet temperature sensor (3).
sensor (19) to the specified torque.
a Remove any plugs put on the mounting holes • Width across flats of differential pressure
at the removal. sensor mounting bolt: 10 mm
a When installing the temperature sensor, 3 Differential pressure sensor
apply seizure prevention compound to thread mounting bolt:
portion.
10.9 to 16.3 Nm {1.1 to 1.7 kgm}
50-98 PC290LC-10
8. When replacing KDOC inlet sensor (1), install it

1) Install KDOC inlet sensor (1) and tighten the
nut lightly.
a When installing KDOC inlet sensor (1),
apply seizure prevention compound to
thread portion.
2 Thread portion of temperature
sensor:
Seizure prevention compound
(LC-G)
• Width across flats of the nut for
temperature sensor: 14 mm
3 Temperature sensor mounting nut:
24 to 36 Nm {2.4 to 3.6 kgm}
2) Install wiring harness clamp (4) for KDOC
inlet temperature sensor (1).
a Adjust wiring harness clamp (4) to install
as the angle and length (a) shown in the
figure.
• Adjusted wiring harness length (a): 115
mm
• Wiring harness clamp mounting angle:
90°
3) Install connector of KDOC inlet temperature
sensor (1) to sensor table (13).
PC290LC-10 50-99
Removal and installation of KCCV assembly

Removal
1. Open engine hood (1).
2. Remove step (2).
3. Disconnect two wiring harness clamps (3).

4. Disconnect wiring harness connector P57 (4).
5. Disconnect KCCV inlet drain hose (5) and KCCV
drain hose (6).[*1]
a While disconnecting hoses, pay attention to 11.When KCCV inlet hose (5) is replaced, remove
the drooping oil. the hose according to the following procedure.
a Plug the hose to prevent entry of dirt, dust, a As replacement of the KCCV inlet hose is
etc. after disconnection. difficult with the KDPF in position, it is
recommended that the hose be replaced at
the time of cleaning or replacement of the
KDPF.
1) Remove bracket (13).
6. Disconnect hose clamp (7).

7. Disconnect KCCV outlet hose (8).[*2]
8. Disconnect gas spring (9) and stay (10).
a The engine hood is not locked any more
once the stay is disconnected. So hold the 2) Remove KDPF bracket assembly (14),
engine hood open using something like rope referring to " Removal and installation of
to prevent it from closing. KDPF assembly".
9. Remove two mounting bolts (11), then remove
KCCV ventilator assembly (12) with bracket
(18).
10.Disconnect bracket (18) from KCCV ventilator
assembly (12).
50-100 PC290LC-10
a Bind KCCV drain hose (6) by placing it on the

counterweight side and fix it to KCCV inlet hose
(5) at its red taped part (a) by using band (15).
3) Disconnect band (15) of the hose. [*3]
[*4]
a Clamp hose (5) with hose clamp (16) at the
white taped part (b) of hose (5).
4) Disconnect hose clamp (16).[*4]

5) Remove KCCV inlet hose (5).[*5]
a Reference
When removing, installing or replacing check
valve (17) from KCCV drain hose (6), install
check valve (17) with its gray part to the KCCV
side as shown on the left side of the figure.
3 Hose clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
Installation
[*1][*5]
3 KCCV inlet hose clamp:
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
3 KCCV drain hose:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
[*2]
3 KCCV outlet hose clamp:
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*3]
PC290LC-10 50-101
Removal and installation of air cleaner assembly

Removal
1. Open the engine hood and remove cover (1)
and (2).
5. Disconnect connector P55 of intake air flow/

temperature sensor (8) and connector P23 of air
cleaner clogging sensor (9).
2. Remove mounting bolts (4) for cover (3).

3. Put cover (3) aside toward engine to remove
cover (5).
6. Remove bands (10) and (11), and pull out air

cleaner assembly (12) from tube (13) to remove
it. [*2]
a Be careful about sponge (7) from being torn.
a Entering lubricant into air cleaner clogging
sensor (9) causes failure, never use lubricant
when pulling out air cleaner assembly (12)
from tube (13).
4. Remove 6 bolts (6) and cover (5). [*1]

7. Immediately after removing air cleaner assembly
(12), plug the opening of tube (13) and air
cleaner with clean vinyl.
a Entering dust into air intake piping may
cause engine failure.
50-102 PC290LC-10
Installation
When replacing air cleaner

Remove intake air flow/temperature sensor (8), air
cleaner clogging sensor (9) and cover (14), then
install them to the installing air cleaner.
a Since intake air flow/temperature sensor (8) is a
precision part, neither air-blow inside nor spray
detergent liquid on it.
3 Screw for air intake flow/temperature
sensor (8):
0.98 to 1.27 Nm {0.1 to 0.13 kgm}
a Apply liquid gasket to the thread portion of air
cleaner clogging sensor (9).
2 Air cleaner clogging sensor (9):
3 Air cleaner clogging sensor (9):
1.96 to 3.92 Nm {0.2 to 0.4 kgm}
a Insert cover (14) until it touches the air cleaner.
3 Clamp fastening nut for cover (14):
3.4 to 4.4 Nm {0.35 to 0.45 kgm} [*2]
a Plug the opening of the air cleaner with vinyl till a Installation of air cleaner assembly
just before installing air cleaner to prevent the If rubber ring (16) is detached, install it to tube
dust from entering. (13) beforehand.
Perform the rest of installation in the reverse order 3 Band fastening nut (10):
to removal. 10.0 to 11.0 Nm {1.02 to 1.12 kgm}
[*1]
3 Band fastening nut (11):
a Installation of cover 8.8 to 10.8 Nm {0.9 to 1.1 kgm}
Insert cover (15) and (5) to fit mating surface of
sponge (7) and install.
PC290LC-10 50-103
50-104 PC290LC-10
Power train system
Power train system

Removal and installation of travel motor and final drive assembly
4 Travel motor and final drive assembly:
k Park the machine on a level place, lower the 590 kg
stop the engine.
k Set the lock lever in the Lock position.

hydraulic circuit".
Removal
1. Remove the sprocket referring to the section
"Removal and installation of sprocket".
2. Remove cover (1). Installation
[*1]
3 Mounting bolt of travel motor and final
drive assembly:
490 to 608 Nm {50 to 62 kgm}
• Refilling of oil
Supply oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
• Bleeding air
Bleed air from the travel motor circuit. For details,
3. Disconnect drain hose (2), travel speed selector see Testing and adjusting, "Bleeding air from
hose (3), and motor hoses (4) and (5). hydraulic system".
4. Sling travel motor and final drive assembly (6).

5. Remove 21 mounting bolts and sling and
remove the travel motor and final drive assembly
(6). [*1]
a Take care that the hose mounting block is not
damaged.
PC290LC-10 50-105
Power train system
Disassembly and assembly of final drive

a Special tools
Necessity
Symbol
Q'ty
1 796-627-1610 Wrench assembly t 1

2 791-580-1510 Installer t 1
796T-627-
Push tool t 1
1630
791-830-1320 Rod t 2
F 3 01580-11613 Nut t 2
790-101-2570 Washer t 2
2) Disassemble No. 1 planetary carrier
01643-31645 Washer t 2
790-101-2102 Jack assembly t 1
1] Drive pin (4) into shaft (5) to remove shaft
790-101-1102 Pump t 1
(5) from No. 1 planetary carrier (6).
4 790-331-1110 Wrench t 1
a After removing shaft (5), remove pin
Disassembly (4) from shaft (5).
1. Oil draining 2] Remove thrust washer (7), No. 1
Remove the drain plug to drain the oil from the planetary gear (8), needle bearing (9),
final drive case. and thrust washer (10).
6 Final drive case:

9l
2. Remove 20 mounting bolts. Using eyebolts [1],
sling and remove cover (1).
4 Cover:
30 kg
a If ring gear (12) is slung together with the
cover, gently tap the ring gear off the cover
by using a plastic hammer.
5. No. 1 sun gear shaft

Remove No. 1 sun gear shaft (11).
6. No. 2 sun gear
Remove No. 2 sun gear (14).
7. Remove thrust washer (13).
3. Washer
Remove washer (2).
4. No. 1 planetary carrier assembly
1) Remove No. 1 planetary carrier assembly
(3).
8. Thrust washer
Remove thrust washer (15).
50-106 PC290LC-10
Power train system
9. Ring gear 11.Ring nut

Remove ring gear (12). 1) Remove lock plate (24).
4 Ring gear:
45 kg
2) Use tool F1 to remove ring nut (25).
10.No. 2 planetary carrier assembly

1) Remove No. 2 planetary carrier assembly
(16).
12.Hub assembly
1) Using eyebolts [2], sling and remove hub
assembly (26) from the travel motor.
2) Disassemble the No. 2 planetary carrier

1] Drive pin (17) into shaft (18) to remove
shaft (18) from No. 2 planetary carrier
(19).
(17) from shaft (18).
2] Remove thrust washer (20), No. 2
planetary gear (21), needle bearing (22),
and thrust washer (23).
PC290LC-10 50-107
Power train system
4 Hub assembly:
110kg
Assembly
a Clean the parts completely and inspect them for
2) Remove floating seal (27). any foreign material or damage. Apply power
train oil (TO30) to the sliding surface before
assembly.
1. Hub assembly
1) Using the push tool, press fit bearings (29)
and (30) into hub (28).
3) Remove bearings (29) and (30) from hub

(28).
2) Using tool F2, install floating seal (27).

a Install the floating seal after degreasing
and drying the O-ring and O-ring
contacting surface completely.
a After installing the floating seal, check the
inclination of the seal. It must be 1 mm or
less.
a After installing the floating seal, apply a
thin coat of power train oil on the sliding
13.Remove floating seal (32) from travel motor (31).
surfaces.
50-108 PC290LC-10
Power train system
2 Sliding surface:
4 Hub assembly:
Power train oil (TO30)
110 kg
2. Using tool F2, install floating seal (32) to travel

4. Ring nut
motor (31).
1) Install the ring nut according to the following
a Install the floating seal after degreasing and procedure.
drying the O-ring and O-ring contacting
1] Rotate the hub two to three times.
surface completely.
2] Use tool F3 and push tool [5] to press the
a After installing the floating seal, check the inner race of bearing (27).
inclination of the seal. It must be 1 mm or
a Pressing force:
less.
12.7 to 16.7 kN {1.3 to 1.7 ton}
a After installing the floating seal, apply a thin 3] Before pressing the bearing inner race,
coat of power train oil on the sliding surfaces. rotate the hub two to three times.
2 Sliding surface:
Power train oil (TO30)
4] Measure dimension (a) under the

condition described in Step 3].
3. Using eyebolts [2], place hub assembly (26) on a After measuring dimension (a),
the travel motor. remove tool F3.
PC290LC-10 50-109
Power train system
5] Measure the thickness of ring nut (25) a Do not apply the adhesive (LT-2) to the
and name it (b) dimension. threads of the nut.
6] Subtract (b) from (a) and name it (c).
7] Using tool F1, tighten ring nut (25) until
dimension (d) is as follows.
(Dimension (d): c (+0.1/0) mm
5. No. 2 planetary carrier assembly

1) Assemble the No. 2 planetary carrier
a Replace thrust washers (20) and (23) as
2) Measure the tangential force of the hub
against the motor case in the rotation well as pin (17) with new ones.
direction using the push scale [6]. a There is trace of punching on the end
face of carrier side hole (e) which was
a Tangential force:
caused when the pin was inserted and
Max. 490 N {50 kg} locked. Before installing the pin, remove
a The tangential force denotes the the protrusion in the pin hole as a result of
maximum force at start of the rotation. punching.
1] Install needle bearing (22) to No. 2
planetary gear (21). Fit upper and lower
thrust washers (20) and (23) and set the
gear assembly on No. 2 planetary carrier
(19).
2] Align pin holes on shaft (18) and the
carrier, and install shaft (18) by tapping it
lightly by using a plastic hammer.
a Install the shaft, while rotating No. 2
planetary gear (21) with care not to
damage the thrust washers.
3) Install lock plate (24).

a Install the lock plate so that the splines
(part A) of the motor and the lock plate
are in full contact.
2 Mounting bolt thread:
Adhesive (LT-2)
3] Insert pin (17).
50-110 PC290LC-10
Power train system
a When inserting the pin, take care that

the three claws (parts f) on the
periphery of the pin will not be placed
on thin-wall parts (g) of the No. 2
planetary carrier. The thin-wall part
may be on the opposite side
depending on carriers. Check each
carrier and avoid setting any claw of
the pin to the thin-wall part. If there is
a groove, avoid the groove.
a After assembling No. 2 planetary
carrier, check that No. 2 planetary
gear (21) rotates smoothly. 6. Ring gear
a After inserting the pin, punch the 1) Install the O-ring to the hub.
portion (B) of the pin on the carrier. 2) Install ring gear (12) to the hub.
4 Ring gear:
60 kg
a Degrease the mating faces of the ring
gear and hub. Do not apply liquid gasket
on the mating faces.
a Align the bolt holes of the ring gear with
those of the hub.
7. Thrust washer
Install thrust washer (15).
2) Install No. 2 planetary carrier assembly (16).

a Align the four gear shaft ends of No. 2
planetary carrier assembly (16) with the
four dimples on the motor case end
surface to install.
8. No. 2 sun gear

Install No. 2 sun gear (14).
9. No. 1 sun gear shaft
Install No. 1 sun gear shaft (11).
10.Thrust washer
PC290LC-10 50-111
Power train system
Install thrust washer (13). a When inserting the pin, take care that
the three claws (parts f) on the
on thin-wall parts (g) of the No. 1
planetary carrier. The thin-wall part
may be on the opposite side
depending on carriers. Check each
carrier and avoid setting any claw of
the pin to the thin-wall part. If there is
a groove, avoid the groove.
a After assembling the carrier, check
that No. 1 planetary gear (8) rotates
smoothly.
11.No. 1 planetary carrier assembly a After inserting the pin, punch the
1) Assemble the No. 1 planetary carrier portion (C) of the pin on the carrier at
according to the following procedure. two locations.
a Replace thrust washers (7) and (10) as

well as pin (4) with new ones. (Pin (4):
See Step 3])
a There is trace of punching on the end
face of carrier side hole (h) which was
caused when the pin was inserted and
locked. Before installing the pin, remove
the protrusion in the pin hole as a result of
punching.
1] Install needle bearing (9) to No. 1
planetary gear (8). Fit upper and lower
thrust washers (7) and (10) and set the
gear assembly on No. 1 planetary carrier
(6).
2) Install No. 1 planetary carrier assembly (3).

12.Washer
Install washer (2).
2] Align pin holes on shaft (5) and the No. 1
planetary carrier, install shaft (5) by a After installing washer (2), measure
tapping it lightly by using a plastic dimension (i) from the upper end face of No.
hammer. 1 planetary gear (8) to that of ring gear (12)
to check for the correct assembly condition.
a Install the shaft, while rotating No. 1
planetary gear (8) with care not to
damage the thrust washers.
3] Insert pin (4).
50-112 PC290LC-10
Power train system
a If the upper end of planetary gear (8) is 3 Mounting bolt

projected from ring gear (12), check again, 1st time: 98 Nm {10 kgm}
since the parts cannot be assembled
2nd time: 100 to 110 deg. (rotating
correctly.
angle)
14.Refilling of oil
Tighten the drain plug and supply power train oil
(TO30) from the oil filler port.
5 Final drive case:

9l
a Do a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.
13.Cover
1) Using eyebolts [1], install cover (1).
4 Cover:
30 kg
2 Mating faces of cover and ring
gear:
a Do not apply liquid gasket (LG-6) to the
tap.
2) Using tool F4, install the 20 mounting bolts.
PC290LC-10 50-113
Power train system
Removal and installation of swing motor and swing machinery assembly

the work equipment to the ground, and stop
the engine.

adjusting, “Releasing residual pressure from
hydraulic circuit”.
a Note connector numbers and installed positions

before disconnecting wiring and hoses.
a Fit a plug or flange to the disconnected hydraulic
hose to prevent oil from flowing out. 4. Remove the return filter and the accumulator
Removal mounting bracket assembly according to the
following procedure. (for machines equipped
a Since PC240LC-10 is used in the figure, the with attachment)
layout of the piping is somewhat different from
1) Disconnect hoses (4) and (6) (four bolts) and
the layout of this model.
hose (5) (2 bolts) at its connection to the
1. Remove cover (1) (four bolts). relay block, hoses (7) and (8) (four bolts) at
their connections to the control valve, and
hose (9) (two bolts) at its connection to the
tube.
• Hose (4): To attachment work equipment
• Hose (5): To return oil filter
• Hose (6): To attachment work equipment
• Hose (7): To control valve (Port (A-1))
• Hose (8): To control valve (Port (B-1))
• Hose (9): To control valve (Port (ATT))
2) Disconnect hoses (10) and (11) at their
connections to the relay block.
• Hose (10): To solenoid valve
2. Remove drain hose (2) (two bolts). • Hose (11): To hydraulic tank
3. Open the engine hood, then remove cover (3) 3) Sling return filter mounting bracket assembly
(five bolts). (12).
4) Remove bolts (13) (four pcs.) and bolts (14)
(two pcs.) then sling and remove return oil
filter and bracket assembly (12).
50-114 PC290LC-10
Power train system
a Return oil filter bracket assembly (12) is

rather difficult to lift in its horizontal
position, as the center of gravity can not
easily be located. Keep the assembly
horizontal by attaching the sling to three
points on it.
7. Remove swing machinery mounting bolts (25)

(14 pcs.) [*2]
5) Sling accumulator mounting bracket

assembly (15).
6) Remove four bolts and then sling and
remove accumulator mounting bracket
assembly (15).
8. Sling and remove swing motor and swing

machinery assembly (26).
a Keep hose (H) away from the assembly by
pulling it with rope [1] to prevent hose (H)
from interference.
a Sling the assembly carefully and slowly to
prevent the drain hose at the bottom from
being caught on their parts.
5. Disconnect hoses (16) to (22) at their a Sling the assembly carefully and slowly until
connections to the swing motor. [*1] it gets clear of hose (H) of the center swivel
• Hose (16): Port (MA) joint.
• Hose (17): Port (MB)
• Hose (18): Port (S) 4 Swing motor and swing machinery
• Hose (19): Port (T) assembly (26):
• Hose (20): Port (T) 280 kg
• Hose (21): Port (B)
• Hose (22): Port (SI)
6. Disconnect cramp (23) and nipple (24).
PC290LC-10 50-115
Power train system
Installation
[*1]
Hoses are connected as follows.
• Hose (16): Control valve port (B4)
• Hose (17): Control valve port (A4)
• Hose (18): Control valve port (TSW)
• Hose (19): Center swivel joint port (DR2)
• Hose (20): To hydraulic tank
• Hose (21): Swing holding brake solenoid valve
• Hose (22): 2-stage relief solenoid valve
[*2]
3 Swing machinery mounting bolt (25):
490 to 608 Nm {50 to 62 kgm}
5 Hydraulic tank (refilling only):

(For details, see "Table of fuel, coolant
and lubricants".)
50-116 PC290LC-10
Power train system
Disassembly and assembly of swing machinery

a Special tools
Necessity
Symbol
Q'ty
1 790-201-2860 Push tool t 1

2 796-426-1120 Push tool t 1
G 796T-426-1130 Plate t 1
3 790-101-5421 Grip t 1
01010-81240 Bolt t 1
a The figure shows the equipment on PC200-8.

PC290LC-10 is basically the same as PC200-8 2) Disassemble No. 1 planetary carrier
but the different figures are noted in the texts. according to the following procedure.
1] Remove snap ring (8), thrust washer (9),
Disassembly No. 1 planetary gear (10), bearing (11),
1. Set the swing motor and swing machinery and thrust washer (12) in that order.
assembly on block [1]. 2] Remove plate (13).
2. Loosen oil drain plug (1) of the swing machinery 3] Reverse carrier (14) and remove snap
to drain the oil from the swing machinery case. ring (15).
a PC290LC-10
6 Swing machinery case:
8.2 l
3. Remove oil level gauge/ oil filler cap (2).
4. Remove drain hose (3).
5. Remove the six swing motor mounting bolts to
sling and remove swing motor (4).
4 Swing motor:
55 kg
a Put match marks on swing motor (4) and
swing machinery assembly (5) for correct
matching during reassembly.
a Since PC240LC-10 is used in the figure, the 3) Using push tool [2], remove shaft (16) from
layout of the piping is somewhat different carrier (14).
from the layout of this model. • Press-fitting force of shaft (reference):
13.5 to 30.8 kN {1,374 to 3,140 kg}
6. Remove No. 1 sun gear (6).

7. Disassembly of No. 1 planetary carrier 8. Remove No. 2 sun gear (17).
1) Remove No. 1 planetary carrier assembly 9. Remove 22 bolts (18) and sling and remove ring
(7). gear (19).
PC290LC-10 50-117
Power train system
10.Remove bolt (20). 3) Reverse shaft and case assembly (29) again
11.Disassembly of No. 2 planetary carrier and set it to the press.
1) Remove No. 2 planetary carrier assembly 4) Using push tool [3], remove shaft assembly
(21). (32) from shaft and case assembly (29).
2) Disassemble the No. 2 planetary carrier

1] Push in pin (22) and drive out shaft (23)
from No. 2 planetary carrier (24).
(22).
2] Remove thrust washer (25), No. 2
planetary gear (26), and needle bearing
(27).
3] Remove plate (28).
a PC290LC-10
13.Disassembly of shaft assembly
1) Using push tools [4] and [5], remove shaft
(33).
2) Remove bearing (35) and oil seal (36) from
cover (34).
12.Disassembly of shaft and case

1) Reverse shaft and case assembly (29).
2) Remove 12 cover mounting bolts (30).
50-118 PC290LC-10
Power train system
a If the outer race is slanted, bearing (39) binds.

Keep the bearing level while removing it.
Assembly
a Clean all the parts thoroughly, check them for
dirt and flaw, and apply power train oil to the
sliding parts before assembling.
5 Power train oil:

TO30
a Do not reuse the removed bearings and oil seals
but replace them with new ones.
14.Remove spacer (37) and O-ring (38) from shaft
1. Assembly of oil seal
(33).
Using tool G3, install oil seal (1) to cover (2).
a Take care of the direction (top and bottom) of
the oil seal.
2 Outer periphery of oil seal:
a Take care that the liquid gasket (LG-6) does
not stick to the oil seal lip at the time of
press-fitting.
15.Remove bearing (39) from case (40).

a Apply an adequate tool to the outer periphery
(bold line: part Q) of the outer race and tap
the outer periphery of the tool.
a Tap the periphery alternately and evenly.
a If tool G3 is not to be used, use a push tool

that can press outer periphery (A) of oil seal
(1) evenly.
PC290LC-10 50-119
Power train system
a Take care not to slant oil seal (1). a Take care that O-ring (8) is not to be
caught.
a Press-fitting force of spacer:
4.71 to 25.4 kN {480 to 2,590 kg}
2. Using push tool [9], press fit bearing (3) to case

(4).
3) Set case assembly (10) on shaft (9).

2 Oil seal lip:
Grease (G2-LI)
a Set case assembly (10) on with care not
to touch the oil seal.
4) Using tool G1, push tool [10], and hammer
[11], press fit the inner race of bearing (12)
into position by tapping.
k Press fit to such an extent that shaft

3. Install cover assembly (6) to case assembly (5). (9) does not drop when it is lifted.
2 Cover mounting face: a Slack sling [12].
3 Cover assembly (6) mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
a Take care that liquid gasket (LG-6) does not
stick to drain port (DP).
a Match the drain portion of the cover with
drain port (DP).
5) Set the assembly to the press.

6) Using tool G1 and push tools [13] and [14],
press fit bearing (12).
a Press-fitting force of bearing (inner race):
41.7 to 117.8 kN {4,250 to 12,000 kg}
a Arrange push tool [14] for the event that
case assembly (13) slants.
4. Assembly of shaft and case a If case assembly (13) slants, correct it by
1) Install O-ring (8) to spacer (7). hitting the flange lightly.
2) Using pushing tool [16], press fit spacer (7) to
shaft (9).
50-120 PC290LC-10
Power train system
a Just before oil seal (14) enters shaft (B), 1) Assemble No. 2 planetary carrier according
hold case assembly (13) horizontally so to the following procedure.
that it is aligned with the center of shaft
a There is trace of punching on the end
(9), thereby the oil seal lip is prevented
face of No. 2 planetary carrier (16) side
from being damaged.
hole (h) which was caused when the pin
was inserted and locked. Before installing
the pin, remove the protrusion in the pin
hole as a result of punching. (See Step
5])
1] Install plate (17) to No. 2 planetary carrier
(16).
2] Install needle bearing (19) and two thrust
washers (20) at the top and bottom to No.
2 planetary gear (18).
3] Set the No. 2 planetary gear assembly to
No. 2 planetary carrier (16).
a PC290LC-10
5. Assembly of bearing 4] Align the pin holes of shaft (21) and

Using tool G2 and push tool [15], press fit carrier (16) by lightly tapping by using a
bearing (15). plastic hammer, and then install shaft
a Press fit bearing (15) by pushing the inner (21).
race and outer race of the bearing a Install shaft (21), while rotating No. 2
simultaneously. Do not push only the inner planetary gear with care not to
race. damage the thrust washers.
a Press-fitting force of bearing: 5] Insert pin (22).
21.5 to 60.6 kN {2,190 to 6,180 kg} a When inserting pin (22), take care that
the three claws (part a) on the
a After press-fitting bearing (15), check that the
case rotates smoothly.
on thin-wall part (part b) of the carrier.
The thin-wall part may be on the
opposite side depending on carriers.
Check each carrier and avoid setting
any claw of the pin to the thin-wall
part.
6. Assembly of No. 2 planetary carrier
PC290LC-10 50-121
Power train system
a After inserting the pin, punch two a PC290LC-10

places (c) around the pin hole of the
carrier.
9. Install O-ring (30).
2) Install No. 2 planetary carrier assembly (23)

and secure it in position with bolts (24).
2 No. 2 planetary carrier assembly
(23) mounting bolt threaded
portion:
Adhesive (LT-2)
2 No. 2 planetary carrier assembly
(23) mounting bolt:
157 to 196 Nm {16 to 20 kgm}
3) Install O-ring (25) to case (26).
10.Assembly of No. 1 planetary carrier
1) Assemble No. 1 planetary carrier according
1] Press fit shaft (31) to carrier (33) until the
groove of snap ring (32) is seen from the
direction of arrow (1st direction).
2] After installing snap ring (32), push it
back from the opposite side (2nd
direction) until snap ring (33) contacts
tightly with face P of the carrier. Take care
not to push the snap ring excessively.
a Press-fitting force of shaft:
7. Install No. 2 sun gear (27).
8. Assembly of ring gear 13.5 to 30.8 kN {1,374 to 3,140 kg}
Using the eyebolts (M10 x 1.5), install ring gear
(28).
a Degrease the mating faces of ring gear (28)
and case (26).
a Do not deposit liquid gasket on the mating
faces of ring gear (28) and case (26).
a When installing ring gear (28), match its
match mark (c) with convex part (d) of the
case flange as shown in the following figure.
3 Ring gear (28) mounting bolt (29):
157 to 196 Nm {16 to 20 kgm}
3] Install plate (34) to carrier (35).
4] Install thrust washer (36), needle bearing
(37), No. 1 planetary gear (38), thrust
50-122 PC290LC-10
Power train system
washer (39), and snap ring (40) in that a Install No. 1 sun gear (42) with longer
order. shouldered portion (g) facing up.
a PC290LC-10
2) Install No.1 carrier assembly (41).
12.Assembly of swing motor

Install swing motor assembly (43) to ring gear
(28).
11.Install No. 1 sun gear (42).
4 Swing motor:
55 kg
a Degrease the mating faces of swing motor
assembly (43) and ring gear (28).
a Do not deposit liquid gasket on the mating
faces of swing motor assembly (43) and ring
gear (28).
a When installing them, match the match
marks put during disassembly.
3 Swing motor mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
PC290LC-10 50-123
Power train system
a Since PC240LC-10 is used in the figure, the 3 Drain hose:

layout of the piping is somewhat different 128 to 186 Nm {13.0 to 19.0 kgm}
from the layout of this model. 15.Tighten the drain plug and supply power train oil
(T030) through the oil filler port to the specified
level.
3 Drain plug:
19.6 to 24.5 Nm {2.0 to 2.5 kgm}
5 Swing machinery case:

8.2 l
a When installing a new swing motor assembly,

position drain elbow (44) and dipstick pipe/
filler port cap (45) as shown in the following
figure.
a PC290LC-10
13.Check the mounting angle and tightening torque

of drain elbow (44).
3 Elbow:
128 to 186 Nm {13.0 to 19.0 kgm}
a Elbow mounting angle: 15 deg.
14.Install the drain hose.

a Install the drain hose so that the drain plug
faces down.
50-124 PC290LC-10
Power train system
Removal and installation of swing circle assembly

3 Swing circle mounting bolt:
Removal 824 to 1,030 Nm {84 to 105 kgm}
1. Remove the revolving frame assembly referring
to the section "Removal and installation of
revolving frame assembly".
2. Remove swing circle assembly (1) mounting
bolts (2) and sling swing circle assembly (1).
[*1]
a Leaving one mounting bolt each in the front
and rear, sling swing circle assembly (1) by
3-point lifting method.
3. Remove the remaining mounting bolts to remove
swing circle assembly (1).
4 Swing circle assembly (1):

450 kg
Installation
[*1]
a Install the swing circle assembly to the track
frame with the soft zone S mark inside the inner
race facing the right side as shown in the figure.
2 Amount of grease filled in grease bath:
Grease (G2-LI) 33 l
2 Swing circle mounting bolt threaded
portion:
Adhesive (LT-2)
PC290LC-10 50-125

Separation and connection of track shoe assembly
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
Remover and
1 791-630-3000 t 1
installer
N 2 790-101-1300 Cylinder (980 kN
t 1
{100 ton})
3 790-101-1102 Hydraulic pump t 1
Separating track
1. Turn the upper structure by 90 deg. 4. By using tool N, remove master pin (2). [*2]
2. Loosen lubricator (1), and then slacken the a With guide pin (GP), push out master pin (2).
tension of the track. [*1]
k Since the internal pressure of the

adjustment cylinder is very high, do not
loosen the lubricator more than one turn.
If the grease does not come out
sufficiently, start the engine and move the
machine backwards and forwards.
5. Change the location of guide pin (GP).

1) Lift the tracks with the work equipment
extended against ground.
2) Move away blocks [1] that were set under the
track below the idler and sprocket.
3) Move guide pin (GP) to the front of the idler.
4) Relieve the extended work equipment, and
3. Position master pin (2). lower the machine.
5) Place block [1] under track (3) in front of the
1) Lift the tracks with the work equipment idler.
extended against ground.
2) Position master pin (2) in around the center
of lower track and between two track rollers.
3) Put blocks [1] under the track below the idler
and sprocket.
6. Pull out guide pin (GP), and move the machine

back slowly to separate track (3). [*3]
50-126 PC290LC-10
a Put some blocks between the track and the a Using tool N, press fit master pin (2), so that the
track frame to prevent damages. protrusion amount (a) of the master pin is the
dimension designated below.
Connecting track Protrusion of master pin
Perform connection in the reverse order to a: 4.2 ± 2 mm
separation.
[*1]
a See Testing and adjusting, “Testing and
adjusting track shoe tension”.
[*2]
a Apply grease to master pin (2). (in the area
where bushing (4) and master pin (2) come
contact: shown hatched)
2 Between bushing and master pin
(hatched area):
Grease
[*3]
NIGTIGHT LYK-2 from Nippon grease Co.,
Ltd.: part no. 44392708 or equivalent 1. Using bar [2], roll up track (3) while the machine
moves forward slowly.
a When replacing dust seals, apply grease to the 2. As for latter half of the operation, use a forklift
end surfaces of bushing and the contact surface truck or the work equipment, to pull wire [3] to fix
(B) of dust seals. the track.
2 Contact surface (B portion) between
bushing and dust seal:
Grease
NIGTIGHT LYK-2 from Nippon grease Co.,
Ltd.: part no. 44392708 or equivalent
a Press fit master pin (2) and push guide pin (GP)
out.
PC290LC-10 50-127
Removal and installation of sprocket

Removal
1. Separate track shoe assembly. For details, see
"Separation and connection of track shoe
assembly".
2. Swing the work equipment 90 deg., then push
up chassis with work equipment and place block
[1] between the track frame and the track.
3. Remove the mounting bolt, then sling and

remove sprocket (1).
4 Sprocket:
70 kg
Installation
[*1]
2 Threads of sprocket mounting bolt:
Adhesive (LT-2)
3 Sprocket mounting bolt:
640 to 785 Nm {65 to 80 kgm}
50-128 PC290LC-10
Removal and installation of idler and idler cushion assembly

4 Idler cushion assembly:
Removal 800 kg
1. Separate the track shoe assembly. For details,
see "Separation and connection of track shoe
assembly".
2. By using bar [1], move idler and idler cushion
assembly (1) forward to a position where it can
be lifted.
Installation
3. Lift idler and idler cushion assembly (1), pull it

forward to remove it from track frame (2).
4 Idler and idler cushion assembly:

970 kg
4. Disconnect idler cushion assembly (4) from idler

assembly (3).
4 Idler assembly:
170 kg
PC290LC-10 50-129
Disassembly and assembly of idler

a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
J 796-570-1020 Installer t 1
5. Remove dowel pin (8), and then remove support

(7) from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
Assembly
1. Press fit bushings (9) and (10) to idler (4).
Disassembly
1. Remove dowel pin (1) to remove support (2).
2. Remove floating seals (3) from support (2) and
idler (4).
3. Remove idler (4) from the assembly of shaft (5)
and support (7).
a Since 230 ± 10 cc of oil is filled in, drain it at
this timing, or underlay some cloth against
any careless smearing.
4. Remove floating seals (6) on the other side from
idler (4) and the assembly of shaft (5) and 2. Install shaft (5) with O-ring (12) to support (2),
support (7). and insert dowel pin (1).
50-130 PC290LC-10
a Be sure to assemble shaft (5) with the UP

marking facing upward.
4. Install the assembly of shaft (5) and support (2)

to idler (4).
5. Turn it over, and supply oil between shaft (5) and

3. Using toolJ, install floating seal (3) to idler (4) idler (4).
and the assembly of shaft (5) and support (2).
5 Amount of oil to be sealed (EO-30DH):
a Completely clean, degrease, and dry the 230 ± 10 cc
contact surfaces (hatched area shown in the
figure) of the floating seal and the O-ring.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
a After inserting the floating seal, check that
the inclination is less than 1 mm and
protrusion (a) is within the range of 5 to 7
mm.
PC290LC-10 50-131
6. Using tool J, install floating seal (6) to idler (4)

and support (7).
a Completely clean, degrease, and dry the
on it.
a After inserting the floating seals, check that
the inclination is less than 1 mm and
protrusion (a) is within the range of 5 to 7
mm.
a When mounting the idler assembly on the

machine, make sure that plug (13) faces right
side of the machine.
7. Install shaft (5) with O-ring (11) to support (7),

and insert dowel pin (8).
a See figure of structure.
8. Supply oil and tighten plug (13) with O-ring (14).
3 Plug (13): 130 to 180 Nm {13 to 18
kgm}
50-132 PC290LC-10
Disassembly and assembly of idler cushion

a Special tools
Necessity
Symbol
Q'ty
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
1 Cylinder
790-101-1600 t 1
(686 kN {70 ton})
M 790-101-1102 Pump t 1
790-201-1500 Push tool q 1
790-101-1620 • Plate 1 2) Apply hydraulic pressure gradually to
2
790-101-5021 • Grip 1 compress the spring and remove lock plate
01010-50816 • Bolt 1 (3) and nut (4).
k Since the load at installed length of the a Compress the spring until the nut
spring is large and dangerous, set the recoil becomes loose.
spring assembly securely to the tool. a Release the hydraulic pressure slowly to
release the tension of the spring.
a Figure of structure
a Free length of spring: 811.5 mm
3) Remove yoke (6), cylinder (7), collar (8), and
dust seal (9) from spring (5).
3. Further disassembly of the piston assembly
1) Remove lock plate (11) from piston assembly
(10), then remove valve (12).
2) Remove snap ring (13), then remove U-
packing (14) and ring (15).
Disassembly
1. Remove piston assembly (2) from idler cushion
assembly (1).
2. Disassembling idler cushion
1) Set idler cushion assembly (1) on tool M1.
a Load at installed length of spring: 208,741
N {21,287 kg}
PC290LC-10 50-133
Assembly
3) Apply hydraulic pressure slowly to compress

the spring, and then tighten nut (4) so that
the installed length of the spring is dimension
(a) and secure it with lock plate (3).
a Installed length (a) of spring: 635 mm
1. Assembly of piston (2) 4) Remove idler cushion assembly (1) from tool
1) Install ring (15) and U-packing (14) to piston M1.
assembly (10) and secure them with snap 3. Install piston assembly (2) to the idler cushion
ring (13). assembly (1).
2) Tighten valve (12) lightly and secure it with
2 Sliding surface of cylinder: Grease
lock plate (11).
(G2-LI)
2. Assembly of idler cushion
1) Using tool M2, install dust seal (9) to cylinder 2 Wear ring: Grease (G2-LI)
(7). a Install the piston assembly with the valve
installed position facing outward.
a Pump 180 cc of grease (G2-L1) into the
cylinder and bleed air. Check that grease
comes out of the grease hole.
2) Install cylinder (7), collar (8), and yoke (6) to

spring (5), and install the assembly to tool M1.
2 Sliding surface of cylinder: Grease
(G2-LI)
50-134 PC290LC-10
Disassembly and assembly of track roller

a Special tools
Necessity
Symbol
Q'ty
K 796-670-1010 Installer t 1
Assembly
1. Using push tool [1], press fit bushings (9) and
(10) to roller (4).
2. Install O-ring (11), install collar (8) to shaft (5)
and install pin (7).
3. Using tool K, install floating seal (6a) to collar

(8).
a Completely clean, degrease, and dry the
Disassembly
1. Remove pin (1), then remove collar (2).\ a Take care that dirt dose not stick to the
2. Remove floating seals (3) from collar (2) and contact face of the floating seal.
roller (4). a After inserting the floating seal, check that
3. Pull out roller (4) from shaft (5) and collar (8) the inclination is less than 1 mm and
assembly. protrusion (a) is within the range of 7 to 11
a Since approx. 250 cc of oil is filled in, drain it mm.
at this timing, or underlay some cloth against 4. Using tool K, install floating seals (6b) and (3b)
any careless smearing. to roller (4).
4. Remove floating seals (6) on the other side from a As to precautions for installation of floating
roller (4), and the assembly of shaft (5) and seals (6b) and (3b), refer toamarked
collar (8). comments in step 3.
5. Remove pin (7) and then collar (8) from shaft (5).
6. Remove bushings (9) and (10) from roller (4).
PC290LC-10 50-135
9. Supply oil and tighten plug (13).
5 Amount of oil to be sealed (EO30-DH):

250 to 280 cc
3 Plug (13): 10 to20 Nm {1 to 2 kgm}
a When mounting the track roller assembly on
the machine, make sure that plug (13) faces
outward.
5. Install shaft (5) to roller (4).

6. Reverse the assembly of roller (4) and shaft (5).
7. Using tool K, install floating seal (3a) to collar

(2).
a As to precautions for installation of floating
seals (3a), refer toamarked comments in
step 3.
on it.
8. Install O-ring (12), then install collar (2) to shaft
(5) with pin (1).
50-136 PC290LC-10
Disassembly and assembly of carrier roller

a Special tools
Necessity
Symbol
Q'ty
L 791-430-3230 Installer t 1
• Sectional view
a A number in the drawing is the number shown in
the text.
3. Remove plate (8) from roller (1).

4. Pull shaft (7) out of roller (1).
Disassembly
1. Remove plug (11) and drain the oil from the
carrier roller assembly.
5. Remove floating seal (5) from shaft (7).
6 Carrier roller: 145 to 155 cc
a Take care not to damage the sealing surface.
6. Remove ring (4) from shaft (7).
7. Remove floating seal (6) from roller (1).
2. Remove cover (9) from roller (1).

a O-ring (10) is provided on cover (9).
8. Using push tool, remove bushings (2) and (3)
from roller (1).
• Press-fitting force (reference):
Bushing (2): 32 to 67 kN {3,300 to 6,800 kg}
Bushing (3): 26 to 54 kN {2,700 to 5,500 kg}
PC290LC-10 50-137
Assembly
1. Bushing
1) Using push tool, press fit bushing (2) to roller
(1).
2) Reverse roller (1) and press fit bushing (3)
using push tool.
• Press-fitting force (reference):
Bushing (2): 32 to 67 kN {3,300 to 6,800
kg}
Bushing (3): 26 to 54 kN {2,700 to 5,500
kg}
2. Floating seal
3. Insert shaft (7) to roller (1), then install plate (8).
1) By using toolL, install floating seal (5) to ring
(4). a Apply oil to the sliding surface of the floating
2) Using toolL, install floating seal (6) to roller seal, and take care not to have any dirt stuck
(1). on it.
• End play in axial direction of roller (1): 0.5 to
a When installing the floating seal,
0.7 mm
completely clean, degrease and dry the
contact surfaces (hatched part) of the O-
ring and floating seal. Take care that dirt
dose not stick to the contact face of the
floating seal.
a When installing floating seals, use tool L
and make sure to press the O-ring.
a After installing the floating seals, check
that the inclination is less than 1 mm and
the protrusion (a) is within the range of 5
to 7 mm.
50-138 PC290LC-10
4. Press fit ring (4) to the shaft by using push tool

5 Carrier roller: 145 to 155 cc (EO30-DH)
[1] until the height difference between roller (1)
and ring (4) becomes 3 ± 0.2 mm.
a Use push tool [2] to support shaft (7).
• Press-fitting force: 22 to 25 kN {2.2 to 2.5
ton}
a Be careful not to give any impact until
installing cover (10) so that press-fitted ring
(4) may not move out.
5. Install ring (10) to cover (9).

6. Install cover (9) to roller (1).
7. Apply standard pressure to roller oil filler port,

and check leakage of air from seal.
a Standard pressure: 0.1 MPa {1 kg/cm2}
8. Fill carrier roller assembly with oil and tighten

plug (11).
PC290LC-10 50-139
Removal and installation of revolving frame assembly

the engine.

hydraulic circuit".

before disconnecting wirings and hoses.
a Fit a plug or flange to the disconnected hydraulic
hose to prevent oil from flowing out.
Removal
a Since PC240LC-10 is used in the figure, the
1. Remove the work equipment assembly, referring
to "Removal and installation of work equipment
assembly".
2. Remove the counterweight assembly, referring
to "Removal and installation of counterweight
assembly".
3. Remove the engine hood assembly, referring to
"Removal and installation of engine hood 7. Disconnect hoses (6) to (11) from center swivel
assembly". joint (5). [*1]
4. Disconnect hose (1) of the boom cylinder. • Hose (6): Port (DR2)
• Hose (7): Port (E2)
• Hose (8): Port (B2)
• Hose (9): Port (D2)
• Hose (10): Port (A2)
• Hose (11): Port (C2)
8. Pulling out pin (12) from center swivel joint (5)
side and disconnect stopper plate (13) from
center swivel joint (5).
a Remove the cotter pin at the lower end of pin
(12) beforehand.
5. Sling the boom cylinder assembly (2).

6. Remove plate (3) and pin (4), then sling and
remove boom cylinder assembly (2).
3 Boom cylinder assembly (2): 240 kg
9. Sling revolving frame assembly (14).
50-140 PC290LC-10
a Use two of the holes for counterweight oil through the system. Then, check the oil level
mounting bolts and two of the holes for the again.
boom cylinder foot pins to lift revolving frame • Bleeding air
assembly (14) at 4 places. Bleed air from the hydraulic pump circuit. For
10.Remove 32 mounting bolts, then sling and details, see Testing and adjusting, "Bleeding air
remove revolving frame assembly (14). [*2] from hydraulic system".
a First adjust the longitudinal and lateral
balance of revolving frame assembly (14)
using a lever block, etc. with two or three
mounting bolts left unremoved each at the
front and rear locations of the assembly.
Remove these remaining bolts after the
assembly is horizontally balanced.
a Lift revolving frame assembly (14) slowly
take care not to let it hit against center swivel
joint (5).
4 Revolving frame assembly (14):

12,900 kg
Installation
[*1]
Hoses are connected to the following places.
• Hose (6): Swing motor port (T)
• Hose (7): Travel speed increase solenoid valve
[*2]
2 Swivel circle mating surface: Liquid
gasket (LG-6)
2 Threads of revolving frame mounting
bolt: Adhesive (LT-2)
3 Revolving frame assembly mounting
bolt: 981 to 1,177 Nm {100 to 120 kgm}
• Refilling of oil (Hydraulic tank)
PC290LC-10 50-141
Removal and installation of counterweight assembly
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
Commercially Eyebolt (M48 x 3)

1 q 2
available
Commercially Impact wrench
Z 2 q 1
available
Commercially Socket wrench (width
3
available across flats: 46 mm) q 1
4. Using socket wrench Z3, remove four mounting
k Park the machine on a level ground, lower bolts (4).
the work equipment to the ground, and stop a For bolts using shims, check the locations
the engine. and the quantities of shims. [*1]
Removal
1. Open right side cover (1) of the machine.
5. Lift and disconnect counterweight assembly (3).

[*2]
a Remove carefully so that it does not hit the
machine.
4 Counterweight assembly (3): 5,510 kg

2. Disconnect connector (2).
• Connector (2): Intermediate connector (A40)
of the rear view camera
Reference: Removal of rear view camera

assembly
3. Sling counterweight assembly (3) by using 1. Remove cover (1).
eyebolts Z1 installed in the eyebolt holes in the
assembly.
50-142 PC290LC-10
4. Disconnect connector (4) and remove rear view

camera assembly (5).
• Connector (4): Rear view camera (A45)
2. Remove bolt (2) to remove cover (6). [*3]

a For bolts using shims (7), check their
locations and the quantities of shims.
(Shims (7) are put on cover (6), be careful Installation
not to drop them.)

[*1]
2 Counterweight assembly (3) mounting
bolt (4) threads:
Adhesive (LT-2)
3 Counterweight assembly (3) mounting
bolt (4):
1.72 to 1.91 Nm {175 to 195 kgm}
[*2]
Installing and adjusting counterweight
a Adjust the level difference (vertical clearance)
among the exterior parts with shims.
• Shim part No.: 206-46-31450
a Install counterweight (6) so that the clearances
between side cover (5) and counterweight (6),
and revolving frame (7) and counterweight (6) in
the direction of front and rear are even and
within the limit of 10 ± 5 mm . However, the
difference between the clearance at point S and
the clearance at point T must be less than 3 mm.
a The horizontal clearance in right to left direction
3. Remove two bolts (3). between side cover (5) and counterweight (6)
must be 9 ± 4 mm.
a The horizontal clearance in right to left direction
between revolving frame (7) and counterweight
(6) must be less than 5 mm.
a The vertical clearance between upper cover (8)
and counterweight (6) must be less than 5 mm.
a Reference (enlarged view of R.H. side seen from
rear of machine)
PC290LC-10 50-143
[*3]
Installation and adjustment of rear view camera
cover
a Using shims (7), adjust the vertical clearance
between the counterweight and cover (6) to 2
mm or less.
a Hook shim (7) to cover (6) or insert it from
outside after inserting the bolt temporarily.
50-144 PC290LC-10
Hydraulic system
Hydraulic system
Removal and installation of center swivel joint assembly
the engine.

hydraulic circuit".

a Fit a plug or flange in the place of the hydraulic
hose is disconnected from to prevent oil from 3. Disconnect lower hoses (3) to (8). [*2]
flowing out.
• Hose (3): Port (DR1)
Removal • Hose (5): Port (B1)
a Since PC240LC-10 is used in the figure, the • Hose (6): Port (D1)
layout of the piping is somewhat different from • Hose (7): Port (A1)
the layout of this model. • Hose (8): Port (C1)
1. Stop the upper structure after swinging it 45 deg.
clockwise, and remove two undercovers (1).
a The upper structure must be swung to the
position for draining oil from the hydraulic
tank.
a For the work method in which an oil stopper
is used and the oil does not need to be
drained from the hydraulic tank, see
"Removal and installation of main pump
assembly".
4. Disconnect lower hoses (9) and (10). [*2]

5. Remove cotter pin (13) from pin (12) of stopper
plate (11).
a Work from the underside of the machine.
a Slightly push up pin (12) for easy removal of
the pin from above.

hydraulic tank. [*1]
6 Hydraulic tank: 132l

l
PC290LC-10 50-145
Hydraulic system
6. Disconnect upper hoses (14) to (19). [*2] Installation

• Hose (16): Port (B2) [*1]
• Hose (17): Port (D2) Refilling of oil (Hydraulic tank)
• Hose (18): Port (A2) Supply oil through the oil filler port to the specified
• Hose (19): Port (C2) level. Run the engine to circulate the oil through the
7. Pull out pin (12), then disconnect stopper plate system. Then, check the oil level again.
(11) from center swivel joint (20).
l
3 Drain plug (2): 68.6 ± 9.8 Nm {7.0 ± 1.0
kgm}
[*2]
Hoses are connected to the following places.
• Hose (3): L.H. travel motor port (T)
• Hose (4): R.H. travel motor port (T)
• Hose (5): L.H. travel motor port (PA)
• Hose (6): R.H. travel motor port (PB)
• Hose (7): L.H. travel motor port (PB)
• Hose (8): R.H. travel motor port (PA)
8. Remove four mounting bolts (21) of center • Hose (9): L.H. travel motor port (P)
swivel joint (20). • Hose (10): R.H. travel motor port (P)
• Hose (14): Swing motor port (T)
• Hose (15): Travel speed increase solenoid valve
Bleeding air
Bleed air from the hydraulic pump circuit. For details,
see Testing and adjusting, "Bleeding air from
hydraulic system".
9. Sling and removal center swivel joint (20).
4 Center swivel joint (20): 40 kg
50-146 PC290LC-10
Hydraulic system
Disassembly and assembly of center swivel joint

a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
790-101-2501 Push-puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
S 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4 5. Remove slipper seals (10) and O-rings (11) from
790-101-2560 • Nut 2 rotor (8).
790-101-2680 • Adapter 2 6. Remove dust seal (12) from cover (13).
a Figure of structure Assembly
1. Install plug (14) to shaft (9).
3 Plug (14):
33.3 ± 3.9 Nm {3.4 ± 0.4 kgm}
a Before installing plug (14), clean, degrease,
and dry its thread portion.
a After installing plug (14), check that its head
is lower than the end face of shaft (9).
2. Install slipper seals (10) and O-rings (11) to rotor
(8).
3. Install dust seal (12) to cover (13).
4. Install cover (13) to shaft (9).
5. Place shaft (9) on the block. Using the push tool,
install rotor (8) to the shaft while tapping the
rotor lightly with a plastic hammer.
2 Contact surfaces on rotor and shaft:
Grease (G2-LI)
a When installing rotor (8), take care not to
damage dust seal (12) and O-rings (11).
6. Install ring (7) and secure it with snap ring (6).
7. Install cover (4) with O-ring (5).
3 Cover (4) mounting bolt:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
8. Install elbows (1), (2) and tee (3).
Disassembly 3 Elbow (1):
1. Remove elbows (1) and (2) and remove tee (3). 128 to 186 Nm {13 to 19 kgm}
3. Remove snap ring (6) and ring (7). 3 Elbow (2) and tee (3):
4. Using tool S, push shaft (9) out of rotor (8). 35 to 63 Nm {3.5 to 6.5 kgm}
PC290LC-10 50-147
Hydraulic system
Removal and installation of hydraulic tank assembly

the engine.

hydraulic circuit".

a Fit a plug or flange to disconnected hydraulic
hose to prevent oil from flowing out. 4. Remove step (4) (four bolts), handrail (5) (six
Removal bolts), and covers (6), (7) (four bolts each), and
(8) (five bolts) .
1. Stop the upper structure after swinging it 45 deg.
clockwise, and remove two undercovers (1) . a Remove handrail (5) first and then remove
cover (6) .
a Leave the upper structure in the swung
position in order to remove the hydraulic tank
mounting bolts and the suction tube.

hydraulic tank. [*1]
6 Hydraulic tank:
132 l
5. Remove three mounting bolts (10) of cover (9)

and four mounting bolts (12) of cover (11) .
as it is without separating it into the upper
and lower halves.
a Remove covers (9) and (11) after removing
frame (14) .
lined cover (3) (five bolts) .
50-148 PC290LC-10
Hydraulic system

9. Remove clamps (15) (one bolt each) and move

them away from hydraulic tank (16) .
6. Remove cover (13) (four bolts) .
10.Remove plate (17) (four bolts) across the frames

and remove lower plate (18) (four bolts) .
11.Remove frame (19) and side cover assembly
(20).
4 Side cover assembly (20):

25 kg
7. Remove frame (14) (seven bolts) .
4 Frame (14):
15 kg
8. Remove covers (9) and (11) by raising them. [*2]
PC290LC-10 50-149
Hydraulic system
12.Disconnect hoses (21) to (25) . 15.Sling and remove hydraulic tank (16) .
• Hose (21): To control valve
• Hose (22): To solenoid valve 4 Hydraulic tank (16):
• Hose (23): To center swivel joint 140 kg
• Hose (24): To PPC valve
a Using eyebolts, lift and remove hydraulic
• Hose (25): To main pump
tank (16), keeping it horizontal.
• Eyebolt: M12 x 1.75
13.Remove hoses (26) to (28) and brackets (29)

and (30) .
• Hose (26): To control valve Installation
• Hose (27): To control valve Perform installation in the reverse order to removal.
• Hose (28): To oil cooler
[*1]
Refilling of oil (hydraulic tank)
Supply oil through the oil filler port to the specified
level. Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank:
132 l
3 Drain plug (2):
68.6 ± 9.8Nm {7.0 ± 1.0 kgm}
[*2]
14.Remove four mounting bolts (31) of the suction When installing covers (9) and (11), engage each
tube and six mounting bolts (32) of the hydraulic cover with clips (1) (five places) shown in the figure,
tank. [*3] and then tighten the mounting bolts.
• As seen from the control valve.
a Be sure to place a container to collect the
hydraulic oil that remains undrained and
flows out when the suction tube is
disconnected.
50-150 PC290LC-10
Hydraulic system
[*3]
3 Suction tube mounting bolt (31):
29.4 to 49.0 Nm {3 to 5 kgm}
3 Hydraulic tank mounting bolt (32):
235 to 285 Nm {23.5 to 29.5 kgm}
Bleeding air
Bleed air from the hydraulic pump circuit. For details,
see Testing and adjusting, "Bleeding air from
hydraulic circuit".
PC290LC-10 50-151
Hydraulic system
Removal and installation of main pump assembly
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
1 796-460-1210 Oil stopper q 1

R
2 796-770-1320 Adapter q 1
k Park the machine on a level place, swing the

upper structure by 45 deg. clockwise, lower
stop the engine. a When tools R1 and R2 are available, remove
the hydraulic tank strainer and use the tools
k Set the lock lever in the LOCK position. to stop the oil.

hydraulic circuit".

a Tag the hoses to show their installed positions

for the prevention of wrong installation.
Removal
3. Remove drain plug (3) and drain the damper oil.
1. Remove under cover (1). 6 Damper case:

0.65 l
re
2. Remove drain plug (2) to drain the hydraulic oil.
6 Hydraulic tank: 4. Remove the KCCV ventilator assembly and

132 l bracket, referring to "Removal and installation of
KCCV assembly(PAGE 50-100)".
5. Remove the KDPF assembly, referring to
"Disassembly and assembly of KDPF(PAGE 50-
92)".
6. Removal of base brackets
1) Remove tube support bracket (4).
50-152 PC290LC-10
Hydraulic system
2) Disconnect hose clamp (6), harness clamp 8. Disconnect harness clamp (15).
(7), and tube clamp (8) from base bracket 9. Disconnect connectors V19 (16) and V11 (17).
(5). 10.Disconnect connectors V12 (18) and P22 (19).
3) Remove eight mounting bolts (9), then sling
and remove base bracket (5).
4 Base bracket:
25 kg
11.Disconnect hose clamp (20).

12.Disconnect six hoses.
• (21): Case drain port hose
• (22), (23): EPC source pressure input port
• (24): Pump pressure input port
7. Removal of covers • (25): Rear load pressure input port
1) Remove five mounting bolts (10), then • (26): Front load pressure input port
remove rubber-lined cover (11). 13.Disconnect harness clamps (27), (28), (29), and
2) Remove the four mounting bolts, then (30).
remove cover (12). 14.Disconnect swash plate sensor P28 (31) of the
rear pump and swash plate sensor P27 (32) of
the front pump.
15.Remove KDPF water drain tube (33).
3) Remove two mounting bolts (13), then

remove cover (14). [*1]
a Cover (14) can be removed as it is, 16.Disconnect discharge port hose (34) of the rear
without separating it into the upper and pump and discharge port hose (35) of the front
lower halves. pump.
PC290LC-10 50-153
Hydraulic system
17.Disconnect hoses (36) and (37). 25.Sling and remove main pump assembly (47).
18.Disconnect hose clamp (38). [*2]
19.Sling hose bracket (39) and remove two
mounting bolts (40). 4 Main pump assembly:
20.Sling and remove hose bracket (39) together 190 kg
with hoses (36) and (37).
4 Hose bracket (including hoses):

9 kg
Installation

21.Remove four mounting bolts (41) and [*1]
disconnect pump suction port tube (42).
a When installing cover (14), engage the cover
with clip (49) shown in the figure, and then
tighten the mounting bolts.
22.Remove brackets (43) and (44).

23.Remove engine oil filter bracket (45) and
reposition it downward..
[*2]
a Harness clamp (46) is tightened together.
2 Main pump involute splines:
Molybdenum disulfide grease (LM-G)
2 Mating face on main pump case:
a Take care not to torque the bolts excessively
since the flywheel housing is made of aluminum.
• Filling of oil (damper case)
specified level.
24.Sling main pump assembly (47) and remove 5 Damper case:

mounting bolts (48).
0.65 l
50-154 PC290LC-10
Hydraulic system
3 Damper case drain plug:

45 ± 5 Nm {4.6 ± 0.5 kgm}
oil through the system. Then, check the oil level
again.
5 Hydraulic tank:
132 l
3 Hydraulic tank drain plug:
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
• Bleeding air
See Testing and adjusting, "Bleeding air from
hydraulic circuit".
PC290LC-10 50-155
Hydraulic system
Removal and installation of control valve assembly

the engine.

adjusting, "Releasing remaining pressure
from hydraulic circuit".
a Turn the battery disconnect switch to the OFF

position and remove the key.
before disconnecting wiring and hoses. 3. Disconnect clamp (3).
a Fit a plug or flange to the disconnected hydraulic 4. Pull connector (4) of each solenoid valve out of
hose ends to prevent oil from flowing out. the clip.
Removal a Connectors (4) are arranged in the following

order from the bottom.
a Since PC240LC-10 is used in the figure, the
• Connector (V01): PPC oil pressure lock
solenoid valve
• Connector (V02): 2-stage relief solenoid
1. Remove undercover (1) and drain oil from the valve
hydraulic tank. [*1] • Connector (V03): Swing holding brake
a The upper structure must be positioned at a solenoid valve
swing angle of approximately zero deg.0 for • Connector (V04): Travel speed increase
the work in Steps 3 to 6 and removal of the solenoid valve
mounting bolts of the control valve. • Connector (V05): Travel junction solenoid
valve
l • Connector (V06): Swing 2-stage relief
solenoid valve
a For the work method in which an oil stopper • Connector (V07): Attachment circuit
is used and the oil does not need to be selector solenoid valve (for machines
drained from the hydraulic tank, see equipped with attachment)
"Removal of main pump assembly".
5. Disconnect solenoid valve hoses (5) to (12).

2. Remove undercover (2).
50-156 PC290LC-10
Hydraulic system
a The hose bands are colored as follows:

• Hose (5): Red (to PPC valve)
• Hose (6): Without band (to control valve)
• Hose (7): Without band (to control valve)
• Hose (8): Blue (to swing motor)
• Hose (9): Red and yellow (to travel motor)
• Hose (10): Brown (to control valve)
• Hose (11): White (to swing motor)
• Hose (12): Green (to attachment circuit
selector solenoid valve) (for machines
equipped with attachment)
9. Open the engine hood, then remove step (17)

(four bolts) and covers (18) (five bolts) and (19)
(four bolts).
a If the machine is equipped with the return oil
filter and accumulator, remove them referring
to Step 4 of "Removal and installation of
swing motor and swing machinery assembly".
(for machines equipped with attachment)
6. Disconnect connector (13) and detach the

harness from two clamps (14).
• Connector (13): Variable back pressure EPC
valve (V25)
7. Remove two solenoid valve mounting bolts (15).
a Move the solenoid valve aside to allow
removing the mounting bolts of the control
valve.

lined cover (16) (five bolts). 10.Remove three mounting bolts (21) of cover (20)
and four mounting bolts (23) of cover (22).
as it is without separating it into the upper
and lower halves.
a Remove covers (20) and (22) after removing
frame (25).
PC290LC-10 50-157
Hydraulic system
13.Disconnect hoses (26) and (27) and connectors

(28) to (30).
a The bands are colored as follows:
• Hose (26): Without band (port (PLS1))
• Hose (27): Red (port (PLS2))
• Connector (28): Red (merge-divider EPC
valve (V23))
• Connector (29): White (merge-divider
EPC valve (V24))
• Connector (30): Rear pump pressure
sensor (P26)
11.Remove frame (25) (seven bolts).
4 Frame (25): 15 kg
14.Remove mounting bolts (31) to (33) of the

brackets.
a Hose (34) is disconnected here to make it
12.Remove covers (20) and (22) by raising them. movable and thus facilitate the work.
[*2]
• Hose (34): Port (T1)
50-158 PC290LC-10
Hydraulic system
16.Disconnect hoses (35) to (41) on the right of the a The hose bands are colored as follows:
control valve. [*3] • Hose (43): Without band (port (PX1))
a The bands are colored as follows: • Hose (44): Without band (port (P-1))
• Hose (45): Without band (port (BP5)) (for
• Hose (35): Without band (port (P-2)) (for
machines equipped with attachment)
• Hose (46): Without band (port (BP5)) (for
• Hose (36): White (port (P2))
• Hose (37): Red (port (P4))
• Hose (47): Black (port (P1))
• Hose (38): Brown (port (P6))
• Hose (48): Without band (port (P3))
• Hose (39): Without band (port (P8))
• Hose (49): Green (port (P5))
• Hose (40): Green (port (P10))
• Hose (50): Red (port (P7))
• Hose (41): Blue (port (P12))
• Hose (51): Blue (port (P9))
• Hose (52): Yellow (port (P11))
• Hose (53): Without band (port (BP1))
• Hose (54): Without band (port (PX2))
a Disconnect hose (53) from the front of the
control valve.
19.Disconnect hose (55). [*3]
• Hose (55): Port (TSW)
a Disconnect hose (55) from the swing
motor, because the hose is difficult to
disconnect from the control valve.
17.Disconnect hose (42). [*3]

• Hose (42): Brown (port (PST))
20.Disconnect hoses (56) and (57) on the rear of

the control valve. [*3]
a The bands are colored as follows:
• Hose (56): Yellow (port (PR))
• Hose (57): Blue (port (PPS2))
18.Disconnect hoses (43) to (54) on the left of the
21.Disconnect tubes (58) and (59). [*3]
control valve. [*3]
• Tube (58): Port (PP1)
• Tube (59): Port (PP2)
22.Disconnect connector (60).
• Connector (60): Pressure sensor (P25)
PC290LC-10 50-159
Hydraulic system
25.Remove bracket (65) (one bolt).
26.Disconnect boom hoses (66).
23.Remove tubes (61) to (63). [*3]

• Tube (61): Port (T)
• Tube (62): Port (ATT) (for machines
27.Remove boom tube mounting clamps (67) to
(70).
• Tube (63): Port (C)
28.Remove horn (71) from the bracket.
a The horn is removed here to facilitate the
removal of tubes (84) and (85) in Step 29.
24.Remove bracket (64) (one bolt).
50-160 PC290LC-10
Hydraulic system
29.Disconnect hoses (72) to (83) and tubes (84) 31.Sling and remove control valve assembly (87).
and (85) on the front of the control valve. [*3]
• Hose (72): Port (A-1) (for machines equipped 4 Control valve assembly (87): 265 kg
with attachment) a Using eyebolts, lift and remove control valve
• Hose (73): Port (A1) assembly (87), keeping it horizontal.
• Eyebolt: M12 x 1.75
• Hose (78): Port (B-1) (for machines equipped
with attachment)
• Tube (84): Port (A3)
• Tube (85): Port (B3)
Installation
[*1]
oil through the system. Then, check the oil level
again.
5 Hydraulic tank: 132 l

3 Drain plug:
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
[*2]
When installing covers (20) and (22), engage each
cover with clips (1) (5 places) shown in the figure,
and then tighten the mounting bolts.
• As seen from the control valves.
30.Remove four mounting bolts (86).
PC290LC-10 50-161
Hydraulic system
• Hose (53): Control valve port (P5) (boom RAISE

PPC valve)
• Hose (55): Swing motor port (S)
• Hose (56): Solenoid valve, PPC valve, EPC
valve
• Hose (57): Front pump LS valve
• Tube (58): Front pump discharge port (PAF)
• Tube (59): Rear pump discharge port (PAR)
• Tube (61): Hydraulic tank
• Tube (62): Attachment (for machines equipped
with attachment)
• Tube (63): Oil cooler
• Hose (72): Attachment (for machines equipped
with attachment)
• Hose (73): Bucket cylinder head end
• Hose (74): Center swivel joint port (A2)
• Hose (75): Swing motor port (MB)
• Hose (76): Center swivel joint port (C2)
• Hose (77): Arm cylinder head end
• Hose (78): Attachment (for machines equipped
with attachment)
• Hose (79): Bucket cylinder bottom end
• Hose (80): Center swivel joint port (B2)
• Hose (81): Swing motor port (MA)
• Hose (82): Center swivel joint port (D2)
• Hose (83): Arm cylinder bottom end
[*3] • Tube (84): Boom cylinder bottom end
Hoses and tubes are connected to the following • Tube (85): Boom cylinder head end
places. Bleeding air
• Hose (35): Attachment PPC valve (for machines Bleed air from the hydraulic pump circuit. For details,
equipped with attachment) see Testing and adjusting, "Bleeding air from
• Hose (36): Relay block (bucket CURL PPC hydraulic system" .
valve)
• Hose (37): L.H. travel forward PPC valve
• Hose (38): Relay block (bucket LOWER PPC
valve)
• Hose (39): Relay block (swing LEFT PPC valve)
• Hose (40): R.H. travel forward PPC valve
• Hose (41): Relay block (arm IN PPC valve)
• Hose (42): Travel junction solenoid valve
• Hose (44): Attachment PPC valve (for machines
• Hose (45): Attachment circuit selector solenoid
valve (for machines equipped with attachment)
• Hose (46): Attachment circuit selector solenoid
valve (for machines equipped with attachment)
• Hose (47): Relay block (bucket DUMP PPC
valve)
• Hose (48): L.H. travel reverse PPC valve
• Hose (49): Relay block (boom RAISE PPC
valve)
• Hose (50): Relay block (swing RIGHT PPC
valve)
• Hose (51): R.H. travel reverse PPC valve
• Hose (52): Relay block (arm OUT PPC valve)
50-162 PC290LC-10
Hydraulic system
Disassembly and assembly of control valve

a This section explains only the precautions for
assembling the contol valve assembly.
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
796-946-1310 Guidef21.8 mm
t 1
(For 723-46-40100)
796-946-1610 Guidef21.4 mm
t 1
(For 723-46-41100)
796-946-1810 Guidef21.2 mm
(For 723-46-43100 and 723-46- t 1
1 43400)
796-946-1910 Guidef21.0 mm
(For 723-46-46101 and 723-46- t 1
46300)
796-946-2210 Guidef20.6 mm
(For 723-46-45100 and 723-46- t 1
45700)
796-946-1320 Guidef21.8 mm
t 1
(For 723-46-40100)
796-946-1620 Guidef21.4 mm
t 1
(For 723-46-41100)
796-946-1820 Guidef21.2 mm
(For 723-46-43100 and 723-46- t 1
43400)
T 2
796-946-1920 Guidef21.0 mm
(For 723-46-46101 and 723-46- t 1
46300)
796-946-2220 Guidef20.6 mm
t 1
(For 723-46-45100)
796-946-1420 Guidef21.6 mm
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
(For 723-46-43100 and 723-46- t 1
43400)
3
796-946-1930 Sleeve
(For 723-46-46101 and 723-46- t 1
46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
PC290LC-10 50-163
Hydraulic system
Procedure for replacing pressure

compensation valve seal
a Since many types of pressure compensation
valves are installed, put a mark on each and
record the installed position when removing
them.
1. Remove piston (2), plug (3) and spring (4) from
pressure compensation valve (1).
2. Remove seals (5) and (6) from piston (2).
5. Install settling tool T3 on piston (2) and keep it

installed for approximately one minute so that
seals (5) and (6) fit in.
a Check that there is no extrusion or cut on the
seal.
a There are many types of pistons.

3. Place tool T1 on piston (2), put seal (5) on the
tool, and then push the seal down slowly in such
a way that it expands evenly to install it in
position.
a Put the seal on the tool and push it down to
the flat part of the tool. Then you may install
the tool to the piston to push in the seal
further. 6. Fit plug (3) and spring (4) to piston (2), then
install pressure compensation valve (1).
a After the installation, push piston (2) by hand
and check that the piston returns with the
spring force alone.
4. Repeat the same process to install another seal

(6). Place tool T2 on the same end of piston (2).
Slowly push seal (6) down in such a way that it
expands evenly to install it in position.
a Put the seal on the tool and push it down to
the flat part of the tool. Then you may install
the tool to the piston to push in the seal
further.
50-164 PC290LC-10
Hydraulic system
Assembly of control valve
a Apply engine oil to the sliding surfaces before

assembling.
a When installing spool (7) to the valve chamber,
set drilled hole (H1) to the direction shown in the
following figure.
a Do the same with section L-L.
• When installing spool (8) to the valve chamber,

set drilled hole (H2) to the direction shown in the
following figure.
a Do the same with H-H, K-K and M-M shown in
the sectional view.
• Upper and lower control valve covers

2 Mating face of upper and lower
a Assemble filter (9) installed to the bottom ports control valve cover blocks (11):
(PLS1) and (PLS2) in the direction shown in the Loctite 222 or equivalent
figure below. (Pay attention to the position of
caulked portion (10).)
PC290LC-10 50-165
Hydraulic system
a Tighten the mounting bolts of the control a Tighten the mounting bolts of the arm
valve upper and bottom cover blocks in the hydraulic drift prevention valve in the same
following order. (A o D o C o B) order as that for the control valve cover
block.
3 Mounting bolts for control valve upper
and lower cover blocks: 3 Mounting bolt of arm hydraulic drift
156.9 – 176.5 Nm {16 – 18 kgm} prevention valve:
58.8 – 73.6 Nm {6 – 7.5 kgm}
a After assembling, put stoppers to prevent
cleaning solvent from entering through f12
holes (13).
• Pressure compensation valve
a Install each pressure compensation valve
paying attention to the matchmark that was
put when removing it.
3 Pressure compensation valve:
372.7 – 411.9 Nm {38 – 42 kgm}
• Main relief valve assembly
• Merge-divider valve a After installing to the control valve, check and
2 Merge-divider valve mating face (12): adjust them. For details, see Testing and
Loctite 222 or equivalent adjusting, "Measuring and adjusting of oil
pressure in work equipment, swing, and
a Tighten the mounting bolts of merge-divider travel circuits".
valve in the same order as that for the control
valve cover block. 3 Main relief valve assembly:
49 to 58.8 Nm {5 to 6 kgm}
3 Merge-divider valve mounting bolt:
156.9 – 176.5 Nm {16 – 18 kgm}
• Variable back pressure valve
a Tighten the mounting bolts of the variable
back pressure valve in the same order as
that for the control valve cover block.
3 Variable back pressure valve
mounting bolt:
58.8 – 73.6 Nm {6 – 7.5 kgm}
• Boom drift prevention valve
a Tighten the mounting bolts of the boom
hydraulic drift prevention valve in the same
order as that for the control valve cover
block.
3 Mounting bolt of boom hydraulic drift
prevention valve:
58.8 – 73.6 Nm {6 – 7.5 kgm}
• Arm quick return valve
a Tighten the mounting bolts of the arm quick
return valve in the same order as that for the
control valve cover block.
3 Mounting bolt of arm quick return
valve:
58.8 – 73.6 Nm {6 – 7.5 kgm}
• Arm drift prevention valve
50-166 PC290LC-10
Hydraulic system
Disassembly and assembly of work equipment PPC valve

Disassembly
a This section contains only the precautions for
disassembling the work equipment PPC valve
assembly.
a Each of springs (6) and (7), consists of two
springs having different load at installed length.
Note their installed positions (hydraulic ports)
and identify them with tags to ensure correct
installation.
PC290LC-10 50-167
Hydraulic system
3 Joint (12):
Assembly
39 to 49 Nm {4 to 5 kgm}
a Only precautions for assembling the work
equipment PPC valve assembly are described
below.
a Before assembly, thoroughly clean the parts and
check them for any dirt, rust or damage to
prevent failures.
a The head of plug (2) must not be projected from
the surface of valve body (1).
3 Plug (2):
6 to 11 Nm {0.6 to 1.1 kgm}
a When installing plug (3) to valve body (1), check
the insertion depth so that the tip of the plug
does not protrude into the f20 hole in the valve a Apply grease (G2-LI) to the rocking parts of joint
body. (12) and to the contact surfaces on disc (13) and
piston (8).
3 Plug (3):
2 Grease (G2-LI)
4 to 9 Nm {0.4 to 0.9 kgm}
• Rocking parts of joint: 2 to 4 cc/entire periphery
a Install spring (5) with its small diameter end • Contact surfaces on disc and piston: 0.3 to 0.8
facing shim (4). cc/part
• Diameter of spring end tum (inside diameter) a Install disc (13), refering to Testing and adjusting,
Small diameter end: f 4.9 mm "Adjusting play of work equipment and swing
Large diameter end: f 5.55 mm PPC valves".
a When installing springs (6) and (7), note that a Lever play:
their installed positions are determined by the
hydraulic ports. 0.5 to 3 mm (at 200 mm from lever pivot point)
• Installed height is 31.9 mm for all springs. 3 Nut (14):
• Load at installed length 69 to 88 Nm {7 to 9 kgm}
Spring (6) (P1, P2): 35.3 N {3.6 kg}
Spring (7) (P1, P2): 21.6 N {2.2 kg}
a Before installing piston (8), apply grease (G2-LI)
to the periphery of the piston and the bore in the
valve body.
3 Bolt (11):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a When installing joint (12) to valve body (1), apply
Loctite according to the following procedure.
1. When installing the joint, apply a drop (approx.
0.02 g) of Loctite (No. 262) to each female
thread portion (A) (2 places) of the valve body.
Before installing the joint, degrease its male
threads and the female threads of the valve
body with Drysol and dry them.
2. Drop Loctite to the following positions.
2 Female thread (A) of valve body:
Loctite No. 262
50-168 PC290LC-10
Hydraulic system
Disassembly and assembly of travel PPC valve

a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
796T-416-
1 Push tool t 1
1010
796T-416-
Q 2 Push tool t 1
1030
796T-416- t 1
3 Push tool
1020
Figure of structure
Disassembly
1. Remove screws (22) and remove damper
assemblies (21).
2. Remove mounting bolt (19) and remove case
(18), shafts (16) and levers (13) as a unit.
3. Remove pins (17).
4. Remove levers (13), bushings (14) and (14a),
and shafts (16) from case (18).
5. Remove mounting bolts (11) to remove plate
(10).
a Note the thickness and installed position of
washer (12).
a Remove pin (24) from valve body (1).
6. Remove seals (9) and collars (8).
7. Remove pistons (7), and then to remove
retainers (6), springs (5) and (4), and shims (3).
a Note the installed position, quantity and
thickness of shims (3) and keep them.
8. Remove valves (2) from valve body (1).
PC290LC-10 50-169
Hydraulic system
a Do not drive the pin directly with a hammer,

Assembly etc.
a Only precautions for assembly are described.

a Before assembly, thoroughly clean the parts and
check them for dirt, rust, or damage to prevent
failure. Assemble the parts with utmost care.
a When installing piston (7), apply grease (G2-LI)
to its periphery and the inside of the valve body
hole.
a Install spring (4) with its small diameter end
facing shim (3).
• Diameter of spring (inside diameter)
Small diameter end: f 4.9 mm 3. Install lever (13).
Large diameter end: f 5.55 mm 4. Install shaft (16).
5. Using tool Q3, install pin (17).
a Install shaft (16) according to the following
procedure. a Installed dimension (C) of pin (17) should be
as follows.
1. Using tool Q1, install bushing (14) to the case.
• Dimension (C): 0 to 0.5 mm
a Install the bushing with its 10 deg. chamfered
side ahead. a Do not drive the pin directly with a hammer,
etc.
a Install the bushing so that dimension (A) is
as follows.
• Dimension (A): 20.4 ± 0.3 mm
a Do not drive the pin directly with a hammer,
etc.
a Apply grease (G2-LI) to the rocking parts of

shaft (16), contact surfaces on lever (13) and
piston (7), and contact surfaces on damper
(21) and pin (20).
2 Grease (G2-LI)
2. Using tool Q2, install bushing (14a) to the case.
Rocking parts of shaft (16): 4 to 8 cc/
a Insert bushing (14a) with its 10-deg. entire periphery
chamfered side ahead.
Contact surfaces on lever (13) and
a Install bushing (14a) so that dimension (B) is piston (7): 0.3 to 0.8 cc/part
as follows (bushing end face is flush with the Contact surfaces on damper (21) and
case end face). pin (20): 0.3 to 0.8 cc/part
• Dimension(B): 0 mm
a For washer (12), install the one 16 mm in
thickness (t) first. If the difference in the lever
angle between right and left when the lever is
at full stroke position exceeds 0.7 degree,
change the thickness of the washer to make
the difference 0.7 degree or smaller.
50-170 PC290LC-10
Hydraulic system
a If the thickness of the washer is reduced by

0.3 mm, the full stroke angle of the lever
increases by 0.39 deg.
• Settings of thickness (t) of washer (12):
1.0, 1.3, 1.6, 1.9, 2.2 mm
a Tighten each part to the following torque.
3 Plug (26):
6 to 11 Nm {0.6 to 1.1 kgm}
3 Plug (25):
4 to 9 Nm {0.4 to 0.9 kgm}
3 Screw (22):
0.441 to 0.588 Nm {0.045 to 0.06 kgm}
3 Bolt (19):
25 to 30 Nm {2.5 to 3.2 kgm}
3 Bolt (11):
27 to 34 Nm {2.8 to 3.5 kgm}
PC290LC-10 50-171
Work equipment
Work equipment
Removal and installation of work equipment assembly
a Cover the cylinder head on a stand with the
piston rod tied by using wire to prevent it
a Special tools
from coming out, or support the cylinder
head with a block to prevent it from lowering.
Necessity
Symbol
When supporting it with a block etc., remove
Q'ty
Part No. Part Name
the grease nipple at the cylinder bottom.
a Remove the boom on the other side in the
796-900-1200 Remover t 1 same manner.
796-900-1210 • Sleeve 1
792-900-1520 • Plate 1 a If bumping of the lifting hook against the
working lamp is anticipated in lifting the work
799-900-1230 • Screw 1
equipment, the lamp must be removed.
796-900-1240 • Adapter 1
6. Stop the engine, and release the pressure
V 01643-33080 • Washer 1 remaining in the circuit. For details, see Testing
01803-13034 • Nut 1 and adjusting, "Releasing remaining pressure
Puller (490 kN {50 from hydraulic circuit."
790-101-4000 ton} long) t 1
7. Disconnect two bucket cylinder hoses (6) and
Pump (294 kN {30 two arm cylinder hoses (7).
790-101-1102 ton}) t 1
a Plug the hose and then fix it to the valve side
k Fully extend the arm and bucket and with rope.
completely lower the work equipment to the 8. Disconnect working lamp intermediate
ground. connector A13 (8).
k Set the lock lever in the LOCK position.

Removal
1. Disconnect grease hose (1).
2. Sling the boom cylinder assembly (2).
3. Remove lock bolt (3).
4. Remove plate (4) and remove boom cylinder
head pin. [*1]
a Shims are installed, so note their quantity 9. Open tool case (9), remove rubber cap (10) and
and thickness. remove the mounting bolts.
4 Boom cylinder head pin: 30 kg
10.Remove mounting bolt (11) and remove cover

(12).
5. Start the engine and then retract the piston rod.
50-172 PC290LC-10
Work equipment
11.Sling the work equipment assembly, then Installation

remove plate (13) and boom foot pin (14). [*2]
[*1]
2 Inner surface of bushing when installing
pin:
Molybdenum disulphide lubricant (LM-P)
2 Pin after installed in position:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust clearance (b) between cylinder rod (16)

• Removal by using tool V and plate (4) to 1.5 mm or less by using shims.
Remove plate (13) and remove boom foot a Install one shim or more on each end face.
pin (14) by using tool V.
a R.H. shim thickness (resin shim)
a Shims are installed, so note their quantity
• Shim (17): 1.0 mm
and thickness.
• Shim (18): 1.0 mm
4 Boom foot pin: 55 kg a L.H. shim thickness (resin shim)
• Shim (19): 1.0 mm
• Shim (20): adjust by combining 1.0 mm and
2.0 mm shims
12.Remove work equipment assembly (15).
4 Work equipment assembly: 4,700 kg

[*2]
2 Inner surface of bushing when installing
pin:
Molybdenum disulphide lubricant (LM-P)
PC290LC-10 50-173
Work equipment
2 Pin after installed in position:

Grease (LM-G)
a Adjust clearance (c) between the foot end face
of boom (21) and bracket (22) to 1 mm or less by
using shims.
a Install one shim or more on each end face.
a R.H. shim thickness (resin shim)
• Shim (23): 2.0 mm
a L.H. shim thickness (resin shim)
• Shim (24): adjust by combining 2.0 mm, 2.5
mm, 3.0 mm, or 3.5 mm shims

Supply hydraulic oil through the oil filler port to
level again.
• Bleeding air
Bleed the air. See Testing and adjusting
"Bleeding air from hydraulic circuit".
50-174 PC290LC-10
Work equipment
Disassembly and assembly of work equipment cylinder

a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
790-502-1003 Cylinder repair stand q 1

1
790-101-1102 Pump q 1
790–102–4300 Wrench assembly t 1
2
790–102–4310 Pin t 2
3 790–720–1000 Expander q 1
Rubber band (for
796–720–1670 boom and bucket) q 1
2. Using a hexagonal wrench (6 mm), remove lock
07281–01279 Clamp q 1
4 screw (3) at the end of piston assembly (4).
Rubber band (for
796–720–1680 arm) q 1 a Above operation is common to the boom,
07281–01589 Clamp q 1 arm and bucket cylinder.
790–201–1702 Push tool kit t 1 • Screw size: M12 x 1.75 mm (16 mm in
U
• Push tool (for length)
790-201–1841 boom and bucket) 1
5 • Push tool (for
790–201–1851 arm) 1
790–101–5021 • Grip 1
01010–50816 • Bolt 2
790–201–1500 Push tool kit t 1
• Plate (for boom
790–201–1650 and bucket) 1
6 • Plate(For arm)
790–201–1660 1
790–101–5021 • Grip 1
01010–50816 • Bolt 2
Disassembly
Disconnecting cylinder assembly and piston rod a If screw (3) is caulked too firmly to be
assembly loosened, squeeze the screw further once
1. Remove the piping from the cylinder assembly. and then apply tap (T) to the threaded portion
2. Remove 12 mounting bolts and disconnect to ease the caulking.
cylinder head assembly (1).
3. Pull out piston rod assembly (2).
a Place a container under the cylinder to
collect oil from the cylinder.
3. Using tool U2, remove piston assembly (4).

a When not using tool U2, use the drilled holes
(H) (f10 mm, two places) to loosen the
piston assembly.
Disassembly of piston rod
1. Set piston rod assembly (2) on tool U1.
PC290LC-10 50-175
Work equipment
4. Remove plunger (5) and collar (6). Disassembling cylinder head

1. Remove the O-ring and backup ring (15).
a Only for the arm and boom cylinders 2. Remove snap ring (16), then remove dust seal
5. Remove cylinder head assembly (7). (17).
3. Remove rod packing (18) and buffer ring (19).
4. Remove snap ring (30).
5. Remove bushing (20).
6. Remove cap (8) to remove 12 balls (9), and

remove plunger (10).
a Arm cylinder only
Disassembling cylinder (arm cylinder only)
1. Remove plug (21).
2. Remove spring (22) and valve (23).
Disassembling piston
1. Remove two rings (11).
2. Remove two wear rings (12).
3. Remove piston ring (13). Assembly
4. Remove the O-ring and two backup rings (14). a Be careful not to damage the packings, dust
seals, O-rings, etc.
a Clean each part. After assembling the cylinder,
cover the piping ports and pin holes to prevent
entering of dirt.
50-176 PC290LC-10
Work equipment
a Before installing the backup ring, warm it in hot

water of approximately 50 to 60 °C. Do not
attempt to force it into position.
Assembly of cylinder (only for arm cylinder)

1. Install valve (23) and spring (22).
2. Install plug (21) with O-ring (24).
a Clean, degrease, and dry the thread portion
of the plug, and then apply liquid gasket to
the entire periphery of the thread portion.
3 Plug (21):
83.4 – 102.9 Nm {8.5 – 10.5 kgm}
2 Plug (21): Assembly of piston
1. Set piston ring (13) on tool U3. Expand piston
Liquid gasket (LG–5) ring (13) by turning the handle 8 to 10 turns.
2. Remove piston ring (13) from tool U3. Install the
ring to the piston.
3. Using tool U4, compress piston ring (13).
Assembly of cylinder head

1. Using tool U5, press fit bushing (20).
2. Install snap ring (30).
3. Install buffer ring (19) and rod packing (18). 4. Install two backup rings (14) and the O-ring.
4. Install dust seal (17) using tool U6, and install a Install the backup rings and O-ring as shown
snap ring (16). in the figure below.
5. Install backup ring (15) and the O-ring. 5. Install wear rings (12) (2 pieces).
6. Install wear rings (11) (2 pieces).
a Be careful not to open the end gap of the ring
too wide.
Assembly of piston rod

1. Set piston rod assembly (2) to tool U1.
PC290LC-10 50-177
Work equipment
both of them are to be replaced with new ones,

see Step 7.)
1) Using tool U2, install piston assembly (4) to
piston rod assembly (2).
a Any burrs or sharp edges on threaded
portions must be removed using files
before installation.
2. Install cylinder head assembly (7).

3. Install the O-ring and the backup rings to collar
(6) and install the collar to the piston rod.
a Install the two backup rings, one each in the
front and rear of the O-ring.
a Only the boom and arm cylinders
4. Install plunger (5).
a Only the boom and arm cylinders a Fully tighten piston assembly (4) until it
contacts with end face (b) of the rod.
Then, at around this position, align screw
holes (H) in the piston and piston rod end
face
a For a cylinder with a head cushion,
ensure that there is a small play in
plunger (5) with piston assembly (4)
installed.
• Only the boom and arm cylinders
5. Place plunger (10) on piston rod assembly (2).

Install 12 balls (9) and cap (8).
a After installing the plunger, check that there
is a little play at its end.
a Arm cylinder only
2) Install screw (3) to lock piston assembly (4)

and piston rod assembly (2).
2 Screw (3) thread portion:
Adhesive (Loctite #262)
3 Screw (3):
58.9 – 73.6 Nm {6 – 7.5 kgm}
a After installing screw (3), caulk the screw
6. If both of piston rod assembly (2) and piston at four peripheral places (a).
assembly (4) are to be reused, assemble them
according to the following procedure. (If either or
50-178 PC290LC-10
Work equipment
Tap drill diameter 10.3

Tap drill hole depth 27
Screw hole size 12 x 1.75
Screw hole depth 20
a After tapping the screw hole, remove

chips and other dirt and thoroughly clean
the area.
7. When replacing either or both of piston rod

assembly (2) and piston assembly (4) with new
ones, assemble the new ones according to the
1) Using tool U2, screw in piston assembly (4)
until it comes into contact with end face (b) of
the rod.
a If the cylinder has the bottom cushion, put
a mark on the rod end face to indicate the 3) Install screw (3) to lock piston assembly (4)
tightening position of the ball cap. and piston rod assembly (2).
3 Piston assembly (4): a After installing screw (3), caulk the screw
at four peripheral places (a).
294 ± 29.4 Nm {30 ± 3.0 kgm}
2 Screw (3) thread portion:
a For a cylinder with a head cushion,
ensure that there is a little play in plunger Adhesive (Loctite #262)
(5) with piston assembly (4) installed. 3 Screw (3):
• Only the boom and arm cylinders 58.9 – 73.6 Nm {6 – 7.5 kgm}
2) Drill a screw hole across the threads of

piston rod assembly (2) and piston assembly Connecting cylinder assembly and the piston
rod assembly
(4).
1. Install piston rod assembly (2) to tool U1.
a With a drill aligned with the V groove
where the threads of piston assembly (4)
and piston rod assembly (2) are mated,
drill a hole straight.
a The cylinder with the bottom cushion
must not be machined in the cushion cap
machining hole position.
• Dimensions of screw hole (mm):
PC290LC-10 50-179
Work equipment
3 Piping fixing band mounting bolt:

27 ± 7 Nm {2.8 ± 0.7 kgm}
2. Install the cylinder assembly to piston rod

assembly (2).
a Align axial center of the cylinder tube, then
insert.
a Check that the ring is not broken and has not
come out, then push in fully.
3. Tighten the mounting bolts for cylinder head

assembly (1).
3 Cylinder head assembly (1) mounting
bolt:
Boom cylinder: 270 ± 39 Nm {27.5 ±
4.0 kgm}
Arm cylinder: 373 ± 54 Nm {38.0 ± 5.5
kgm}
Bucket cylinder: 373 ± 54 Nm {38.0 ±
5.5 kgm}
4. Install piping.
50-180 PC290LC-10

Removal and installation of operator's cab assembly
k Park the machine on a level ground, swing

the upper structure by 90 deg., lower the
stop the engine.


a Positions of the controllers are shown below.
5. Remove box (9) (five bolts).
• A: Pump controller assembly
• B: Air conditioner controller assembly a Disconnect the hose located under box (9).
• C: KOMTRAX terminal 6. Remove box (10) (three bolts).
a Be careful about connectors (11) and (12)
located behind box (10) (for machines
equipped with 12 V power socket).
• Connector (11): 12 V power socket
intermediate harness (M13A)
intermediate harness (M13B)
7. Remove cover (13) (three bolts).
Removal
1. Remove the machine monitor assembly. For
details, see "Removal and installation of
machine monitor assembly".
2. Remove the floor mat.
3. Remove cover (1) first, and then remove cover
(2).
4. Remove cover and duct assembly (3).
a Remove harness (4) by passing it through
the space between cover (5) and duct (6).
8. Remove cover (14) (seven bolts).

a Disconnect connector (15) located behind
cover (14).
PC290LC-10 50-181
• Connector (15): Cigarette lighter (M04)
13.Remove ducts (23) and (24).

14.Disconnect connector (25).
9. Remove duct (16).
10.Remove cover (17). • Connector (25): Room lamp (L03)
a Disconnect connectors (18) and (19) located a Cut the cable ties holding the ducts and
behind cover (17). connectors.
• Connector (18): R.H. console
intermediate harness (H14)
• Connector (19): R.H. console
intermediate harness (H15)
15.Disconnect connectors (26) to (29) from

KOMTRAX terminal (C).
• Connector (26): Communication antenna
(GPS)
• Connector (27): Machine main harness
(CK01).
(CK02).
a Neatly arrange and place the disconnected
connectors on the floor apart from the
operator's cab.
11.Remove plate (20).

12.Pull up lock pin (21) to unlock and remove duct
(22).
50-182 PC290LC-10
16.Remove connector (30) from the clip at the

operator's cab.
• Connector (30): L.H. console intermediate
harness (H16)
a Neatly arrange and place the disconnected
connector on the floor apart from the
operator's cab.
17.Release connectors (31) to (35) from the clips at
the operator's cab and disconnect the
connectors.
intermediate harness (M10) (for machines
20.Disconnect connectors (38) to (40) from air
equipped 12 V power socket)
conditioner controller assembly (B).
• Connector (32): Handsfree microphone
intermediate harness (M46) (for machines • Connector (38): Air conditioner compressor
equipped handsfree microphone) electromagnetic clutch relay (R21)
• Connector (33): AUX intermediate connector • Connector (39): Machine main harness
(M01B) (AC02)
• Connector (34): Operator's cab roof • Connector (40): Machine main harness
intermediate connector (H09) (AC01)
• Connector (35): Loudspeaker intermediate a Air conditioner controller assembly (B) can
connector (H08) be easily removed after the above
a Neatly arrange and place the disconnected connectors are disconnected.
connectors on the floor apart from the a Neatly arrange and place the disconnected
operator's cab. connectors on the floor apart from the
18.Disconnect radio antenna (36). operator's cab.
a Cut the cable ties holding the antenna. 21.Remove two bolts (41) and remove air
conditioner controller assembly (B). Neatly
a Neatly arrange and place the removed arrange and place the assembly on the floor
antenna on the floor apart from the operator's apart from the operator's cab.
cab.
22.Remove ducts (42) and (43).

19.Remove four bolts (37) and remove pump
controller assembly (A). Neatly arrange and a Cut the cable ties holding the ducts.
place the assembly on the floor apart from the 23.Disconnect connector (44).
operator's cab. • Connector (44): Front window wiper motor
(M05)
PC290LC-10 50-183
28.Remove bolt (53) from under the operator's cab

and remove lock plate (54). [*1]
29.Remove cab tipping stopper (55). [*2]
24.Remove ducts (45) to (47).
30.Remove operator's cab mounting bolts (56) and

nuts (57). [*3]
a Bolt (56): 6 places
a Nut (57): 4 places
25.Remove clamp (49).
31.Sling and remove operator's cab assembly (58).

a Lift up the operator's cab little by little while
checking that every hose, connector, and
clamp is disconnected.
4 Operator's cab assembly (58): 530 kg

26.Disconnect window washer hose (50).
27.Cut cable ties (52) holding window washer hose
(50) and harness (51). Arrange them neatly and
place window washer hose (50) and harness
(51) on the floor.
Installation
[*1]
50-184 PC290LC-10
3 Lock plate mounting bolt (53):

98 to 123 Nm {10.0 to 12.5 kgm}:
[*2]
3 Cab tipping stopper (55):
245 to 309 Nm {25.0 to 31.5 kgm}:
[*3]
3 Operator's cab mounting bolt (56):
98.1 to 122.6 Nm {10 to 12.5 kgm}
PC290LC-10 50-185
Removal and installation of operator cab glass (adhered glass)

a Special tools (17): Center trim seal
(18): Rear window glass
Necessity
Symbol
Removal
Q'ty
Part No. Part Name
a Remove the window glass to be replaced
2 793-498-1210 Lifter (suction cup) t 2
X 1. Using seal cutter [1], cut the adhesive between
3 20Y-54-13180 Stopper rubber t 2
broken window glass (7) and operator's cab
a Although some of the figures depict another (metal sheet) (8).
model, the replacement procedure is basically
the same.
a Among the glass panels on the four sides of the
operator's cab, five panes (1) to (4) and (18) are
adhered.
a In this section, the procedures for replacing the
adhered glass are explained.
a When replacing front window glass (4), remove
front window assembly (5). (It is impossible to
replace only the front window glass while the
front window assembly is installed to the
operator's cab.)
a If the window glass is broken into small
a For the procedure for replacing the front window pieces, they may be removed with knife [4]
assembly, see "Removal and installation of front and a flat-head screwdriver.
window assembly".
a Widening the cut with a flat-head screwdriver,
a Figure of structure cut the adhesive and dam rubber with knife
[4].
2. Remove the window glass.

Installation
1. Using a knife and scraper [5], remove the
remaining adhesive and dam rubber from the
sheet metal (adhesion surfaces) of the
(1): Right side window glass operator's cab.
(2): Left side rear window glass
a Remove the adhesive and dam rubber to a
(3): Door lower window glass degree that they will not affect adhesion of
(4): Front window glass the new adhesive. Take care not to scratch
(5): Front window assembly (front window glass and the painted surfaces. (If the painted surfaces
front frame) are damaged, adhesion will be lowered.)
(6): Dam rubber (The figure shows the operator's cab of a wheel
loader.)
50-186 PC290LC-10
a If the primer is stored in a refrigerator,

leave it at the room temperature for at
least half a day before stirring it. (If the
primer is opened just after taken out of
the refrigerator, water will be condensed.
Accordingly, leave the primer at the room
temperature for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and contaminants.
a Prepare respective brushes for the
2. Remove oil, dust, dirt, etc. from the adhesion
painted surface primer and glass primer.
surfaces on cab (8) and window glass (9) with
white gasoline.
a If the adhesion surfaces are not cleaned well,
the window glass may not be bonded
perfectly.
a Clean all the black part on the back of the
window glass.
a After cleaning the adhesion surfaces, leave
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a wheel
loader.)
3) Evenly apply the painted surface primer to

the surfaces on operator's cab (8); the
surface where dam rubber (6) is bonded on
and its outside surfaces where the adhesive
is applied to.
2 Primer for painted surface:
Sunstar Primer 580 Super for
painted surfaces
a Do not apply the primer more than two
times. (Applying primer more than twice
will degrade the performance.)
3. Apply primer (10).
a The primer is good for four months after the
date of manufacture. Do not use the primer
after the expiration date.
a Use the primer within two hours after opening
container.
a Even if the container of the primer is capped
again just after it is opened, use it out within
24 hours after it is opened for the first time.
(Discard the primer which is left unused 24
hours after it is opened.)
1) Stir the primers for painted surface and glass
sufficiently before using them. a Places to apply: Apply over the entire
circumference with dimension (a).
• Primer applying dimension (a): 30 mm
PC290LC-10 50-187
2 Primer for glass:

Sunstar Primer 453-41 for glass
a Do not apply the primer more than two
times. (Applying primer more than twice
will degrade the performance.)
a In addition to the above places, apply

primer to right side window glass (1) and
lower door glass (3).
• Area to apply additional primer for right
side window glass (1): (b)
• Area to apply additional primer for lower
door window glass (3): (c) a Places to apply: Apply the primer to
adhesion surface (d) on window glass (9)
a After applying the primer, leave it in air for
along its circumference, which is
at least five minutes (maximum eight
determined by the installed position of
hours) to dry.
dam rubber (6) and operator's cab (8).
• Primer applying dimension (d): 30 mm
a Do not apply the primer to the boarder
area of about 5 mm wide between the
black portion and transparent portion of
the glass.
a After applying the primer, leave it in air for
at least 5 minutes (maximum 8 hours) to
dry.
a Never apply wrong primer. If painted
surface primer is applied by mistake,
wipe it off with white gasoline.
a Never apply wrong primer. If the paint 4. Stick dam rubber (double-sided tape) (6) to the
primer is applied by mistake, wipe it off operator's cab as follows.
with white gasoline. If glass primer, etc. is
a Do not remove the release tape of dam
applied by mistake, wipe it off with white
rubber on the glass sticking side before
gasoline.
sticking the window glass.
4) Evenly apply the glass primer to the
adhesion surfaces of glass (9). a When sticking the dam rubber, do not touch
the cleaned surface.
50-188 PC290LC-10
a Care should be taken not to slacken the dam

rubber of each sticking corner.
3) Stick dam rubber (6) for door lower window

glass (3) to the position as shown in the
figure.
a When sticking dam rubber (6) all around, do
not overlap the ends. Or, provide a clearance
of approximately 5 mm between ends (e).
1) Stick dam rubber (6) for right side window
figure.
a Stick additional dam rubber (6b) for door

lower window glass (3).
• Positions to stick additional dam rubber
for door lower window glass:
(j): 110 mm
(k): 90 mm
a Stick additional dam rubber (6a) for right (m): 200 mm
side window glass (1).
• Positions to stick additional dam rubber
for right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
4) Stick dam rubber (6) for front window glass

(4) to the position shown in the figure.
2) Stick dam rubber (6) for left side rear window

figure.
PC290LC-10 50-189
a Stick lower dam rubber (6c) for the front

window glass along the outside edge of
the lower frame, differently from other
dam rubbers (6). (If it is stuck along the
inside, it will be seen through the
transparent portion of the glass.)
a When positioning front glass (4),

• set right and left installing positions to
the frame width.
• set its vertical position to make the
height difference (p) between the
frame top and the front window glass
5. Position the new window glass. (4) 3 mm.
1) Check the clearances between the window
glass and the operator's cab on the right, left,
upper, and lower sides, and then position the
window glass so that it is centered.
2) Stick tapes [6] between window glass (9) and
operator's cab (8). Draw a positioning line (n)
on each tape.
a For accurate positioning, stick tape [6]
across the left, right, and bottom edges of
the right side window glass, left side rear
window glass, and door lower window
glass.
3) Cut the tape between window glass (9) and
6. Apply adhesive.
operator's cab (8) with a knife, etc. and then
remove the window glass. a Use either of the two types of adhesives
according to the season.
a Do not remove the tapes left on the
window glass and operator's cab (8) 2 Adhesive (summer):
before installing the window glass. Sunstar penguine seal 580 super "S"
or equivalent
2 Adhesive (winter):
Sunstar penguine seal 580 super "W"
or equivalent
50-190 PC290LC-10
a The using limit of the adhesive is four months

after the date of manufacture. Do not use the
adhesive after the period.
a Keep the adhesive in a dark place where the
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove all the
hardened part from the nozzle tip.
1) Remove aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
4) Remove the release tape from dam rubber
(6) on the glass sticking side.
5) Apply adhesive (15) to the outside of dam
rubber (6) on the operator's cab.
2) Cut the tip of the adhesive nozzle (14) so that

dimensions (q) and (r) are as follows.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
a Adjacent to dam rubber (6) on operator's cab
(8), apply adhesive (15) in dimensions (s)
and (t) as shown in the figure.
• Dimension (s): 10 mm
• Dimension (t): 15 mm
a Apply adhesive (15) thicker than dam rubber
(6).
a Apply the adhesive evenly in height.
3) Set adhesive cartridge (12) to caulking gun

[7].
a An electric caulking gun is more efficient.
a Apply adhesive (15) adjacent to additional

dam rubber (6a) for right side window glass
and additional dam rubber (6b) for lower door
window glass.
PC290LC-10 50-191
a After installing front window glass (4) fill

the clearances between the window glass
and center trim seal (16) with caulking
material in range (s) with dimensions (t)
and (u).
a After applying the primer to the part of
window glass (4) shown in section A-A,
apply the adhesive as caulking material.
• Caulking dimension (t): 2 mm
• Caulking dimension (u): 5 mm
a When caulking, apply masking to the
7. Install the window glass. window glass and form the adhesive with
1) Install window glass (9) while aligning the a rubber spatula as shown in the figure.
lines drawn on the positioning tapes in step a Wipe off the squeezed adhesive.
5.
2 Primer for glass:
a Since the window glass cannot be
Sunstar Primer 580 Super for
removed and installed again, install it with
glass
utmost caution.
2 Adhesive:
a Install the window glass within 5 minutes
after applying the adhesive. Sikaflex 250-2
2) After installing window glass (9), press entire
circumferential area until it adheres firmly to
the dam rubber.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently by

pulling window glass (9) from inside of the
operator's cab using suction cup X2.
50-192 PC290LC-10
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass to the dam
rubber to bond them completely.
9. After installing the window glass, remove any

excess of the primer and adhesive on the
operator's cab and window glass.
a Use white gasoline to wipe off the remaining
adhesive before it dries up.
a When cleaning the glass, do not give an
impact to it.
10.Cure the stuck window glass.
1) Keep the stopper rubbers, styrene foam
8. Fix the glass. blocks, and rubber bands installed for ten
1) After installing right side window glass (1) to hours as a curing period. (at temperature of
the operator's cab, install stopper rubbers X3 20℃ and humidity of 60%)
to 2 places (v) at the bottom of the window 2) After removing the stopper rubbers, styrene
glass to fix it. foam blocks, and rubber bands, wait at least
fourteen hours, at least twenty four hours in
total, before operating the machine actually.
PC290LC-10 50-193
Removal and installation of front window assembly

the engine.
k Removal and installation must be done by a

pair of two workers.
a To replace the front window glass, the front

window assembly must be removed from the
operator's cab.
Removal
1. Pull up front window assembly (1) to the ceiling
and lock it. 4. Release the lock of front window asembly (1).
a Make sure that the assembly is certainly

locked.
2. Remove front lower window (2).
3. Remove bracket (3) at the left corner (two

screws) and bracket (4) at the right corner (two
screws). [*1]
a Leave mounting screws (5) and washers (6)
for bracket (3) at the left corner in position.
They are used to hook the pull-up assist
cable in Step 6.
5. Carefully slide front window assembly (1) down

until the lower part of front window assembly (1)
is detached from the operator's cab through the
ends from which the corner brackets are
removed in Step 2 (rail missing ends) and
support the lower part of the front window
assembly.
a Right and left rollers (8) and (7) are insertion-
fitted, so they easily become detached.
Handle them carefully.
50-194 PC290LC-10
7. Lower front window assembly (1) completely.

a Take care not to let front window assembly
(1) touch machine monitor (12).
6. Remove pin (9). [*2]

a Removal of pin (9) allows plate (11) at the
end of pull-up assist cable (10) to come off.
a Hook plate (11) on screw (5) of left corner 8. Carefully slide front window assembly (1) down
bracket (3) to hold the plate (used washer (6) to detach the top of the front window assembly
as well). from the operator's cab through the ends from
which the left and right corner brackets are
removed in Step 2 (rail missing ends).
k Pull-up assist cable (10) is under a return
load of 58.8 N {6 kg} that is working a Right and left rollers (14) and (13) are
toward the rear of the operator's cab. So insertion-fitted, so they easily become
be fully careful when removing pin (9) detached. Handle them carefully.
during the disconnection of the cable.
Installation
• Perform installation in the reverse order to
removal.
[*1]
PC290LC-10 50-195
• Adjust opening and closing of front window

assembly (1) according to the following
procedure.
1. Open and close front window assembly (1) to
check that it does not interfere with the rails and
that the rollers are not caught.
2. If there is any problem in opening or closing of
front window assembly (1), loosen mounting
bolts (16) of roller adjustment bracket (15) and
adjust the condition of the front window, and
then tighten the mounting bolts again.
a Make sure that bracket (15) is not slanted
when mounted.
3 Mounting bolt (16) of bracket (15):
19.6 to 25.0 Nm {2.0 to 2.5 kgm}
5. Install left corner bracket (3).

a Tighten lightly for the meantime. Bolts are
tightened to the specified torque after
adjusting the locks for the front window
3. Pull up front window assembly (1) to the ceiling
assembly (1) in its "closed" position in the
and lock it.
following step 6.
a Install left corner bracket (3) so that
locked.
clearance (b) between rail (18) and left
4. Install right corner bracket (4).
corner bracket (3) becomes 0 to 2.0 mm.
a Tighten lightly for the meantime. Bolts are
a There must be no level difference on rolling
tightened to the specified torque after
surface (R) for the roller (same as the right
adjusting the locks for the front window
corner bracket).
assembly (1) in its "closed" position in the
following step 6.
a Install right corner bracket (4) so that
clearance (a) between rail (17) and right
corner bracket (4) becomes 0 to 2.0 mm.
a There must be no level difference on rolling
surface (R) for the roller.
6. Adjust the locks for the front window assembly

(1) in its "closed" position according to the
1) Install right and left corner brackets (4) and
(3) in roughly right positions so that front
50-196 PC290LC-10
window glass (19) is closely attached to cab-

side trim seal (20).
7. After the adjustment, splash water heavily over

the front window glass and check that the water
does not leak into the cab.
2) Check the working condition of right and left
8. Adjust the locks for front window assembly (1) in
locks (22) and (21) when opening and
its "open" position.
closing front window assembly (1).
1) After adjusting the locks for the front window
a If right and left locks (22) and (21) rattle; assembly (1) in its "closed" position in steps
1] Loosen lock fixing bolt (23) inside the 6 and 7, pull up front window assembly (1) to
cover, move lock (21) forward, and then the ceiling.
tighten the bolt again. (The same applies 2) Check the locks at the rear right and left of
to the right side.) the operator's cab on the following items with
2] After moving the lock, check the contact front window assembly (1) in its "open"
between front window glass (19) and cab- position.
side trim seal (20) which was checked in • Check the working condition of right and
step 1). left locks (22) and (21) (as explained
3] Repeat the work in 1] and 2] until the above).
contact of front window glass (19) and the • Front window assembly (1) must be in
working condition of right and left locks contact with the right and left rubber
(22) and (21) are both acceptable, and stoppers (24), and furthermore, must be
then tighten the mounting bolts of the pushing them backward by 1.5 to 3.0
right and left corner brackets (tighten to mm.
the specified torque). • Check that limit switch (25) is pushed
back 4 to 7 mm by front window assembly
(1).
a Since the position of limit switch (25)
cannot be adjusted, the "open" position of
front window assembly (1) is decided
within the functioning range of this switch.
a Limit switch (25) prohibits wiper operation
if the wiper switch is turned ON by
mistake while the front window assembly
is "open".
a The wiper falls into the operator's cab and
breaks if operated when front window
assembly (1) is open.
a To check whether limit switch (25) is
working, turn the starting switch to ON
position and see that, even if the wiper
switch is turned on, the wiper does not
operate when front window assembly (1)
is in the "open" position.
PC290LC-10 50-197
• When adjustment is needed after 6) Adjustment of right and left rubber stoppers
performing check in step 8; (24)
3) Close front window assembly (1). • Bring right and left rubber stoppers (24)
4) Loosen locknuts (26) of right and left rubber into contact with front window assembly
stoppers (24) and move the stoppers (1) (locked in "open" position).
backward so that front window assembly (1)
does not touch the stoppers when it is locked
in its "open" position.
• Close front window assembly (1).

• Turn right and left rubber stoppers (24) to
the left one and a half rotation.
5) Loosen lock nut (27) at both sides, and
adjust the position of striker bolt (28). a One turn of rubber stopper (24) to the left
is equivalent t o squashing the rubber by
• Striker bolt (28): M10
approximately1.5 mm.
• Diameter of hole in plate (29): 14.5 mm
a When front window assembly (1) is
locked in "open" position, front window
assembly (1) must be pushing right and
left rubber stoppers (24) by 1.5 to 3.0
mm.
• Front window assembly (1) (locked in

"open" position) must be pushing the limit
switch (25) backward by 4 to 7 mm.
• Working condition of lock (31).
• Tighten lock nuts (26) of right and left

rubber stoppers (24).
50-198 PC290LC-10
9. Adjust anti-vibration stoppers (30) of front

a Also check the latching efforts of right and
window assembly (1).
left locks (33) and (34) for the front window
1) Adjust and lock anti-vibration stopper (30) at assembly in its "closed" position (at front side
both sides so that surface (d) of stopper (D) of the operator's cab).
is in contact with surface (c) of anti-vibration
stopper (30) when front window assembly (1)
is pulled up.
[*2]
3 Pin (9):
27 to 34 Nm {2.8 to 3.5 kgm}
2 Thread portion of pin (9):
Adhesive (LT-2)
10.Check the latching efforts of front window

assembly (1).
a After finishing the adjustment of steps 6 to 9,
check that latching efforts of both right and
left locks (32) and (31) are even.
PC290LC-10 50-199
Removal and installation of floor frame assembly

k Park the machine on a level ground, lower a Refrigerant to be collected:
the work equipment to the ground, and stop 930 ± 50 g
the engine. 3. Remove cover (2).

hydraulic circuit".

k If you drain the coolant or disconnect the

heater hose when the radiator coolant
temperature is high, you may be scalded. In
such case, wait until the coolant temperature
lowers and then drain the coolant or 4. Loosen drain valve (3) to drain coolant. (Drain
disconnect the heater hose. hose: inside diameter f7 mm)
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches 6 Coolant:
your skins, you may suffer from frostbite. 36 l
Accordingly, put on the protective
eyeglasses, gloves and working suits with
long sleeves while you are collecting or
filling refrigerant (R134a).
a Never release the refrigerant (R134a) to the

atmosphere.
a Ask a qualified person for collecting, adding, and
filling operations of the refrigerant (R134a).
a Note the connector numbers and installed
positions before disconnecting wiring and hoses.
a Fit a plug or flange to the disconnected hydraulic 5. Remove cover (4).
hose ends to prevent oil from flowing out.
Removal
1. Remove operator's cab assembly (1), referring
to " Removal and installation of operator's cab
6. Disconnect ground cables (5).
2. Collect the refrigerant (R134a) from the air

conditioner circuit. [*1]
50-200 PC290LC-10

• Hose (18): Black (port (P1))
• Hose (19): Brown (port (P2))
7. Disconnect connectors (7) to (10) from travel

PPC valve (6).
• Connector (7): L.H. travel reverse oil
pressure sensor (P10)
11.Disconnect connectors (21) and (22) from 1-way
• Connector (8): L.H. travel forward oil
attachment PPC valve (20). (for machines
pressure sensor (P09)
• Connector (9): R.H. travel forward oil
pressure sensor (P11) • Connector (21): Pedal rear inclination oil
• Connector (10): R.H. travel reverse oil pressure switch (P14)
pressure sensor (P12) • Connector (22): Pedal front inclination oil
8. Disconnect hoses (11) to (14) from travel PPC pressure switch (P15)
valve (6). 12.Disconnect hoses (23) and (24) from 1-way
a The hose bands are colored as follows: equipped with attachment)
• Hose (11): Red (L.H. travel forward port
(P2))
• Hose (12): Without band (L.H. travel • Hose (23): Yellow (port (P1))
reverse port (P1)) • Hose (24): Without band (port (P2))
• Hose (13): Blue (R.H. travel reverse port 13.Disconnect connectors (25) and (26). (for
(P3)) machines equipped with attachment)
• Hose (14): Green (R.H. travel forward • Connector (25): Attachment oil flow rate
port (P4)) adjuster EPC valve (V30)
• Connector (26): Intermediate connector
(P13) of attachment oil pressure switch
a Cut all cable ties that hold the harnesses to
the floor frame.
9. Disconnect connectors (16) and (17) from 2-way

• Connector (16): Pedal front inclination oil
pressure switch (P16) 14.Disconnect clamps (27) (two bolts).
• Connector (17): Pedal rear inclination oil
pressure switch (P30)
10.Disconnect hoses (18) and (19) from 2-way
PC290LC-10 50-201
15.Disconnect ground cables (28). 19.Disconnect hose (35).

a Ground cable arrangement (from left to right): • Hose (35): Port (T) (drain circuit to the
(T04), (T05), (T06), (T07), (T09), (T10) hydraulic tank)
16.Remove clamps (29) and (30). 20.Disconnect connector (36).
• Connector (36): Dual pressure switch (P17)
of air conditioner
a Cut all cable ties that hold the harnesses to
the floor frame.
21.Remove bolt (37), then disconnect tubes (38) of
the air conditioner. [*2]
22.Remove clamp (39) (one bolt) fastening tubes
(38).
23.Disconnect heater core hoses (40). [*3]
24.Remove clamp (41) (one bolt) (with a spacer)
fastening hoses (40).
17.Pull connectors (31) to (33) out of the clips.

(A41) (for machines equipped with a 2nd
camera)
(A42) (for machines equipped with a 3rd
camera)
(A08) (for machines equipped with
attachment)
• Hose (34): Port (P) (circuit from PPC 25.Remove clamps (42) and (43) (two bolts each).
hydraulic lock solenoid valve) 26.Cut cable tie (44).
27.Remove clamp (45) (one bolt). (for machines
a Disconnect work equipment PPC valve
hoses (P) from the relay block. (See Step
34.)
50-202 PC290LC-10
28.Disconnect connector (46) and remove air

conditioner controller (B) from the main harness.
(AC04)
32.Open the engine hood, then remove cover (52)

(four bolts).
29.Disconnect connectors (47) to (49).

• Connector (47): R.H. console intermediate
harness (H14)
harness (H15)
• Connector (49): L.H. console intermediate
harness (H16)
33.Remove clamps (53) to (55) fastening the

hoses.
a Move the hoses toward the control valve to
allow disconnecting the work equipment
PPC valve hoses from the relay block.
a Cut the cable tie that bundles the hoses.
34.Disconnect work equipment PPC valve hoses

(57) to (64) from relay block (56).
a Be sure to place a container to receive
30.Disconnect ground cable (T01) (50).
hydraulic oil before disconnecting the hoses.
31.Disconnect all clamps that fasten main harness
(51) to the floor frame.
a Separate the pump controller assembly and
main harness from the floor frame and move
them toward the boom.
PC290LC-10 50-203

• Hose (57): White (bucket CURL circuit)
• Hose (58): Brown (boom LOWER circuit)
• Hose (59): Without band (swing RIGHT
circuit)
• Hose (60): Blue (arm IN circuit)
• Hose (61): Black (bucket DUMP circuit)
• Hose (62): Green (boom RAISE circuit)
• Hose (63): Red (swing LEFT circuit)
• Hose (64): Yellow (arm OUT circuit)
Reference: Precautions for removing work

equipment lever
Using a flat-head screwdriver and the like, push lock
(69) of resin frame (68) in boot (67) to remove boot
(67) from console resin cover (70).
a Do not forcibly pull out any parts other than lock
(69) of resin frame (68) when carrying out this
operation. Doing so may damage the resin
frame.
35.Open the left side cover of the machine and pull

out hose assembly (65).
36.Sling and remove floor frame assembly (66).

a Lift the assembly little by little while checking
that every hose, connector, and clamp is
disconnected.
4 Floor frame assembly (66):

250 kg
Installation
[*1]
• Filling air conditioner circuit with refrigerant
(R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
50-204 PC290LC-10
a Filling quantity: a Cab mounts must be installed with the mount

930 ± 50 g rubber groove (1) oriented as shown in the figure.
• Refilling of air compressor oil (Top view. Left side of figure is the front side of
For details, see Others, "Filling compressor oil". machine)
• Refilling of coolant (radiator)
Supply the coolant through the coolant filler port
to the specified level. Run the engine to circulate
the coolant through the system. Then, check the
5 Coolant (engine coolant):

36 l (For details, see "Table of fuel,
coolant and lubricants".)
[*2]
a When installing the air conditioner hoses and
tubes, take care so that dust, dirt, or water does
not enter them.
a When connecting the air conditioner hoses and
tubes, check that O-rings are fitted to their joints.
a Do not reuse an O-ring since it is deformed and
deteriorated once it is used.
a When removing O-rings, use a soft tool to avoid
damaging hoses and tubes.
a Check that there is no defect or deterioration on
the O-ring.
a Apply compressor oil (Denso: ND-OIL8) for
R134a refrigerant to O-rings.
3 Hose clamp (M6 bolt):

8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
a When installing the hoses of heater core, make
white line (marking) of heater hoses straight to
prevent kink of heater hoses.
Reference: Precautions for installing cab mount

a The type of damper differs by the installed
position. Note the identification labels before
removing them. (See Structure and
Function,“Cab mount and cab tipping stopper“.)
PC290LC-10 50-205
Removal and installation of air conditioner unit assembly

k Park the machine on a level ground, swing 3. Pull up front window assembly (1) to the ceiling
the upper structure by 45 deg., lower the and lock it.
stop the engine.
locked.
4. Remove front lower window (2) .
5. Remove floor mat (3) .
k If you drain the coolant or disconnect the

heater hose when the coolant temperature is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then drain the coolant or disconnect the
heater hose.

you may lose your sight. And if it touches
your skins, you may suffer from frostbite.
long sleeves while you are collecting or 6. Remove box (8) (five bolts) .
filling the refrigerant (R134a). a Disconnect the hose located under box (8) .
7. Remove box (9) (three bolts).
atmosphere. a Be careful about connectors (10) and (11)
located behind box (9) (for machines
a Ask a qualified person for collecting, adding, and equipped with 12 V power socket) .
a Note connector numbers and installed positions intermediate harness (M13A)
before disconnecting wiring and hoses. • Connector (11): 12 V power socket
a Positions of the controllers are shown below. intermediate harness (M13B)
8. Pull up cover (12) (three bolts) to remove.
• A: Pump controller assembly
• B: Air conditioner controller assembly a The connectors and harnesses at the rear
must not be caught.
Removal
a Refrigerant to be collected:
930 ± 50 g
2. Drain the coolant.
6 Coolant:
36 l
50-206 PC290LC-10
9. Remove cover (13) (seven bolts) . 12.Remove plate (19) .

13.Pull up lock pin (20) to unlock and remove duct
a Disconnect connector (14) located behind
(21) .
cover (13) .
14.Remove ducts (24) to (28) .
10.Remove duct (15) . a Cut the cable ties holding the ducts.
11.Remove cover (16) .
a Disconnect connectors (17) and (18) located
behind cover (16) .
harness (H14)
harness (H15)
15.Remove cable tie (39) of the left console wiring

harness.
PC290LC-10 50-207
16.Remove cable tie (40) of the floor wiring 19.Disconnect connectors (42) to (45).
harness. • Connector (42): Communication antenna
(GPS)
(CK01).
(CK02).
20.Remove KOMTRAX terminal (C) (four bolts).
17.Remove four bolts (29) and remove pump

controller assembly (A). Arrange the assembly
neatly and place it on the floor apart from the
operator's cab.
21.Remove cover (33) .
18.Disconnect connectors (30) to (32) from air

conditioner controller assembly (B) .
(AC01)
• Connector (31): Machine main harness 22.Remove bolt (34), then disconnect tubes (35) of
(AC02) the air conditioner. [*2]
• Connector (32): Machine main harness 23.Disconnect hoses (36) of the heater core.
(AC04)
50-208 PC290LC-10
24.Remove six mounting bolts (37), then remove [*3]

air conditioner unit assembly (38) .
a When installing air conditioner hoses and tubes,
take care so that dust, dirt or water does not
enter them.
a When connecting the air conditioner hoses and
tubes, check that O-rings are fitted to their joints.
deteriorated once it is used.
the O-ring.
Installation a Apply compressor oil (Denso: ND-OIL8) for
[*1]
• Filling air conditioner circuit with refrigerant
(R134a)
(R134a).
a Filling quantity:
930 ± 50 g
• Refilling of air compressor oil
For details, see Others “Refilling compressor oil“.
• Refilling of coolant (radiator)
Supply the coolant through the coolant filler port
to the specified level. Run the engine to circulate
the coolant through the system. Then, check the 3 Hose clamp (M6 bolt):
coolant level again. 8 to 12 Nm {0.8 to 1.2 kgm}
[*4]
5 Coolant (engine coolant):
a When installing the hoses of heater core, make
36 l (For details, see"Table of fuel,
white line (marking) of heater hoses straight to
coolant and lubricants".)
prevent kink of heater hoses.
[*2]
Removing cover (48) makes easier to install ducts
(24) and (26) .
a Since the mounting bolts of cover (48) are
hidden by cover (47), remove cover (47) first.
PC290LC-10 50-209
Removal and installation of operator's seat

stop the engine.

k Removal and installation work must be done

by a pair of two workers.

3. Pull lever (1) again and move operator's seat (2)

Removal forward and fold the backrest forward.
1. Pull lever (1) and move operator's seat (2) 4. Remove two bolts (5) (with hexagonal socket)
backward. and two reinforcing plates (7), on the seat rail at
the rear side of operator's seat.[*1]
5. Disconnect connector (6) of the operator's seat.
• Connector (6): Seat belt caution switch (S19)
2. Remove two bolts (3) (with hexagonal socket)

and two reinforcing plates (4), on the seat rail at
the front side of operator's seat.[*1]
a For the heated seat

Remove wiring harness fixing band (8) and
disconnect connector (9).
(Connector (9) is located under the seat rail
mounting frame.)
• Connector (9): Heated sheet (M35)
50-210 PC290LC-10
4. Slide adjusters (11) and (12) backward and

forward approximately three times to make sure
that they slide smoothly.
5. Make sure that they are locked at the midpoint of
the sliding move, then tighten four bolts (13).
49 Nm {5.0 kgm}
6. Slide the seat assembly backward and forward
approximately three times. After making sure
that they are locked in the rearmost position,
tighten two bolts (15) of the front side.
6. Remove the operator's seat. 3 Mounting bolt (15) (front side):

49 Nm {5.0 kgm}
4 Operator's seat: 7. Slide the seat assembly backward and forward
21 kg approximately three times again. After making
sure that they are locked in the rearmost position,
Installation tighten two bolts (15) of the rear side.
3 Mounting bolt (15) (rear side):
perform installation in the reverse order to removal. 49 Nm {5.0 kgm}
[*1] 8. If a large operating effort is required (target is
max.15 kg), repeat adjustment and make sure
3 Mounting bolts (3) and (5) of operator's
right and left locks work properly at respective
seat (hexagonal socket head):
positions.
25.5 Nm {2.6 kgm}
Reference: Assembly and adjustment procedure

for operator’s seat adjuster
1. Using four bolts (13), install adjusters (11) and
(12) loosely to frame (10). At the same time,
install two wires (14) for releasing slide lock.
a Check that right and left locks work properly.
2. Slide adjusters (11) and (12) backward and

install them loosely to base (16) using two bolts
(15).
a Place washer (17) between adjusters (11),
(12) and base (16).
3. Slide adjusters (11) and (12) forward and install
them loosely to base (16) using two bolts (15).
49 Nm {5.0 kgm}
PC290LC-10 50-211
Removal and installation of seat belt

the engine.

k Removal and installation work must be done

by a pair of two workers.

6. Remove operator seat (2).

Removal
1. Pull lever (1) and move operator's seat (2) 4 Operator's seat (2):
backward. 21 kg
7. Remove mounting bolt (6) of seat belt (7) (one
on each side) to remove seat belt (7).[*2]
2. Remove two hexagonal socket head bolts (3)

from the seat rails. [*1]
3. Pull lever (1) again and move operator's seat (2)

forward and fold the backrest forward.
4. Remove two hexagonal socket head bolts (4)
Installation
from the seat rails. [*1]
5. Disconnect connector (5). Perform installation in the reverse order to removal.
• Connector (5): Seat belt caution switch (S19) [*1]
3 Mounting bolts (hexagonal socket head)
(3) and (4) of operator's seat (2):
25.5 Nm {2.6 kgm}
[*2]
50-212 PC290LC-10
3 Mounting bolt (6) of seat belt (7):

19.6 – 29.4 Nm {2.0 – 3.0 kgm}
PC290LC-10 50-213
Removal and installation of front wiper assembly

the engine.
k Set the work equipment lock lever in the

LOCK position.

Removal
1. Check that wiper blade (1) is at stowed position
(to the R.H. stay).
2. Pull lever (3) to release the lock while holding

handle (2) at right and left of upper part of front
window.
3. Hold lower handle (4) with left hand and upper

handle (5) with right hand, and pull up the front
window, and push it against lock cap (6) at the
rear of cab to lock.
4. Check lever (3) is securely locked.

a Check that the position of arrows on lock
case (7) and lever (3) match.
50-214 PC290LC-10
8. Disconnect connector P31 (14) inside cover

(12).
5. Remove lower window (9) by pulling up at knobs

(8).
9. Remove covers (15) and (16).
6. Remove cover (10) and floor mat (11).

a Insert a flat-head screwdriver in slit (18) at
left bottom, and pull it upward to remove
cover (9) while releasing lug (19).

a One of four mounting screws is covered with
cap (13).
PC290LC-10 50-215
11.Remove duct (20). 14.Open cap (25), remove nut (26) and remove
wiper arm (27).
15.Remove cap (28), nut (29), washer (30) and
packing (31).
12.Remove the mounting bolts of bracket (21) and

keep the bracket with machine monitor (22) at
rear side.
16.Remove six mounting bolts (32) and remove
a Ii is not necessary to disconnect the
wiper motor assembly (33).
connectors of machine monitor.
13.Move wiring harness (23) and remove connector Installation

M05 (24).
1. Install wiper motor assembly (33).
Adhesive (LT-2)
50-216 PC290LC-10
2. Install packing (31), washer (30) and tighten nut

(29) to the specified torque.
a Install washer (30) with its chamfered face
toward cab front.
3 Nut (29):
10.8 to 12.7 Nm {1.10 to 1.30 kgm}
5. Check the operation of the wiper arm according

1) Connect connector M05 (24) and P31 (14).
3. Install cap (28) and wiper arm (27).

a Install wiper arm (27) so that clearance "a"
between washer nozzle (34) and wiper blade
(35) becomes following dimension.
• Dimension "a": 7 mm
4. Tighten nut (26) and close cap (25).
3 Nut (26):
11.8 to 15.7 Nm {1.20 to 1.60 kgm}
2) Install lower window (9) by holding knobs (8).
PC290LC-10 50-217
5) When the bottom of front window touches the

top of lower window, push the upper portion
of front window against lock catcher (36) at
the front of the cab to lock.
3) Pull lever (3) down to release the lock while

holding handle (2) at right and left of front
window stowed in the ceiling.
6) Check lever (3) is securely locked.

a Check that the position of arrows on lock
case (7) and lever (3) match.
4) Hold lower handle (4) with left hand and

upper handle (5) with right hand securely,
and push down the window forward slowly.
7) Turn the battery disconnect switch to the ON

position.
8) Check that the work equipment lock lever is
in the LOCK position, and then start the
engine.
9) Check the operation of wiper arm while the
front window is dry.
1] Push wiper switch (37) 3 times
consecutively, check that wiper arm (27)
makes one round trip and then be stowed
to the R.H. stay.
2] Repeat Step 1] again.
a Rotating direction of motor crank
defers between Step 1} and Step 2}.
Accordingly, check twice.
3] Push wiper switch (37), and check
clearance "b" with trim seal (38) becomes
following dimension when the tip of wiper
blade (35) reaches to the highest point.
• Dimension "b": 130 mm or less
50-218 PC290LC-10
highest point. (If interferes, click

sound is heard.)
• No interference between wiper blade
(35) and front window seal (42) when
the tip of wiper blade (35) reaches to
the lowest point.
10)Check the operation of wiper arm while the

front window is wet with washing fluid.
1] Keep pushing window washer switch (39)
for few seconds to wet the front window
throughout, then hand off the switch.
2] Check that wiper arm (27) makes two
round trips and then be stowed to the R.H. 11)If any abnormality is found in the above
stay checks, perform the installation adjustment
3] Repeat Step 1] again. of wiper arm in Step 3.
4] Check that wiper arm (27) makes round 6. Perform the subsequent installation in the
trips in odd number and then be stowed reverse order to removal.
to the R.H. stay
5] Keep pushing window washer switch (39)
to operate the wiper, and check following.
• No interference between wiper slider
(40) and stopper (41) when the tip of
wiper blade (35) reaches to the
PC290LC-10 50-219
Electric system
Electric system
Removal and installation of air conditioner compressor assembly

filling the refrigerant (R134a).

atmosphere.
4. Disconnect two air conditioner hoses (5) and (6).
a Ask a qualified person for collecting, adding, and [*3]
Removal

930 ± 50 g
2. Open the engine hood and remove fan guards
(1), (2), and (3).
a Plug the hose to prevent any dirt, dust and

water from entering.
a Take care not to damage or lose the O-rings.
5. Disconnect magnetic clutch connector AC03 (7)
for the air conditioner compressor.
6. Remove air conditioner compressor belt (12)
3. Remove air hose (4). [*2] compressor (11) in the direction of loosening
belt tension.
a Put marks on the hose end and tube to 4) Loosen the tension on air conditioner
indicate their fitting positions. compressor belt (12) and remove the belt.
50-220 PC290LC-10
Electric system

Lubricant (THREEBOND PANDO 18B)
Install the clamp to the clamp mark put on the
hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
Tighten the clamp so that BDG dimension is as
follows.
7. Remove four air conditioner compressor BDG: 7 to 10 mm
mounting bolts (13) and remove air conditioner
compressor (11). [*5]
[*3]
a When installing air conditioner hoses and tubes,
Installation take care so that dust, dirt or water does not
enter them.
Perform installation in the reverse order to removal. a When connecting the air conditioner hoses and
[*1] tubes, check that O-rings are fitted to their joints.
• Filling air conditioner circuit with refrigerant a Do not reuse an O-ring since it is deformed and
(R134a) deteriorated once it is used.
(R134a).
a Filling quantity:
930 ± 50 g the O-ring.
• Refilling of air compressor oil
For details, see Others, " Filling compressor oil". a Apply compressor oil (Denso: ND-OIL8) for
[*2] R134a refrigerant to O-rings.
Reconnect the disconnected air tubes according to 3 Hose clamp (M6 bolt):
the following procedure. 8 to 12 Nm {0.8 to 1.2 kgm}
a Use new MIKALOR clamps.
1. Set the hose to the original (marked) position.
a Reference
Air hose fitting length:
80 mm (both R.H. and L.H. sides)
2. With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) laps over
with the band by dimension (b) indicated below.
Dimension (b): Min. 5 mm
PC290LC-10 50-221
Electric system
[*4]
a See Testing and adjusting, " Checking and
adjusting air compressor belt tension".
3 Lock nut (9):
108 to 132 Nm {11 to 13.5 kgm}
59 to 74 Nm {6.0 to 7.5 kgm}
[*5]
3 Air conditioner compressor assembly
mounting bolt :
24.5 to 29.4 Nm {2.5 to 3.0 kgm}
50-222 PC290LC-10
Electric system
Removal and installation of air conditioner condenser assembly


filling the refrigerant (R134a).

atmosphere.
a Ask a qualified person for collecting, adding, and
Installation
filling operations of the refrigerant (R134a). Perform installation in the reverse order to removal.
[*1]
Removal • Filling air conditioner circuit with refrigerant
(R134a)
(R134a).
a Filling quantity:
930 ± 50 g
930 ± 50 g
• Addition of air compressor oil
2. Open the left rear cover and disconnect hoses
For details, see Others, "Refilling compressor
(1) and (2) from air conditioner condenser
oil".
assembly (4). [*2]
[*2]
3. Remove mounting bolts (3) and open air
conditioner condenser (4). a When installing air conditioner hoses, take care
so that dust, dirt or water does not enter the
hose.
a Make sure before the installation that there is an
O-ring in the piping connector of the air
conditioner hose.
deteriorated after the first time it was used.
damaging hoses.
the O-ring.
4. Remove 4 mounting bolts (5) for the air
a Apply compressor oil (Denso: ND-OIL8) for
conditioner condenser and then remove air
conditioner condenser (4). [*3]
3 Hose clamp (M6 bolt):
a In this removal operation, take care not to
damage the core part. 8 to 12 Nm {0.8 to 1.2 kgm}
PC290LC-10 50-223
Electric system
[*3]
a Mount the air conditioner condenser assembly
by inserting cushions in place.
2 Air conditioner condenser assembly
mounting bolt threads:
Adhesive (LT-2)
3 Air conditioner condenser assembly
mounting bolt:
10 to 15 Nm {1.2 to 1.5 kgm}
50-224 PC290LC-10
Electric system
Removal and installation of engine controller assembly

2) Grab the connector (5) and pull it down while
pressing locking tab (8) to disconnect the
connector.
a Locking tab (8) is provided on the farther
Removal side of connector (5).
2. Remove two mounting nuts (2), disconnect

harness clamp (3), and remove bracket (4). [*1]
4. Disconnect connectors ECM (9) and CE03 (10)

from the engine controller.
3. Disconnect connector E24 (5) from the engine and other contamination to prevent them
controller according to the following procedure. from entering the connector hole.
a Clean the surrounding area to remove mud a The connectors are locked with hexagonal
and other contamination to prevent them socket head bolts (11) (4 mm). [*2]
from entering the connector hole. 5. Remove four mounting bolts (12) and remove
1) Roll up rubber cover (6) and slide red lever engine controller (13). [*3]
(7) downward to unlock. a Ground cable (14) is tightened together.
PC290LC-10 50-225
Electric system
Installation
[*1]
When installing bracket (4), tighten harness clamp
(3) together.
3 Bracket mounting nut:
10 ± 2 Nm {1.0 ± 0.2 kgm}
[*2]
3 Hexagon socket head bolt (11):
3 ± 1 Nm {0.31 ± 0.1 kgm}
[*3]
When installing mounting bolt (12), tighten ground
cable (14) together.
3 Engine controller mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
50-226 PC290LC-10
Electric system
Removal and installation of pump controller assembly

the engine.


a The position of the pump controller is shown in
the figure.
• A: Pump controller
3. Disconnect connectors (4) and (5) according to
the following procedure.
a While pressing lock (L1), move lock (L2) to
the other side.
a Slider (B) comes out and the lock is
released.
• Connector (4): Pump controller (CP01)
• Connector (5): Pump controller (CP02)
4. Remove four bolts (6) to remove pump controller
(A).
Removal
1. Pull up cover (1) (three bolts) to remove.
a The connectors and harnesses at the rear
must not be caught.
2. Remove bolts (2) to remove plate (3).
Installation
Reference: Procedure for removing connector
cover (1)
1. Cut and remove cable tie (2).
2. Move lever (3) upward.
PC290LC-10 50-227
Electric system
3. Lightly press part (A) on both sides of connector

a Right and left sliders (4) are pushed in as far
cover (1) to release tabs (B).
as they go. (See the left figure shown below.)
4. Arc connector cover (1) around tab (C) to
2. Move lever (3) on connector cover (1) from the
remove the cover.
top position to the left position (locked position)
as shown in the following figure..
a (B) and (C): Tab
a If the sliders and lever are not set as shown
in the following figure, the connector is not
disconnected or locked securely with the
lever. Accordingly, check their positions
again.
a The figure below shows the connector

without connector cover (1).
3. Set tab (C) to the connector and place connector

cover (1).
a Take care that wiring harness (5) be not
caught.
Reference: Procedure for installing connector

cover (1)
1. Push in right and left sliders (4) as far as they
go.
4. Put tabs (B) in to install connector cover (1).
50-228 PC290LC-10
Electric system
5. Using a new cable tie (2), bind connector cover

(1) and harness (6).
PC290LC-10 50-229
Electric system
Removal and installation of machine monitor assembly

the engine.


Removal
1. Pull up front window assembly (1) to the ceiling 5. Remove connector (6) and then remove cover
and lock it. (4).
• Connector (6): Sunlight sensor (P31)
a Check that the front window is securely
locked.
6. Remove duct (10) (one bolt).
3. Remove rubber panel (3) (two bolts).
7. Insert a flat-head screwdriver in slit (7) and pull it

upward to remove cover (9) while releasing lug
(8).
4. Remove three mounting screws of cover (4).
a One of the three screws is covered with cap
(5).
50-230 PC290LC-10
Electric system
10.Disconnect connectors (13) to (16).

a Hook (17) beneath cover (9) unites cover (9).
a Disconnecting connector (15) first makes
easier to disconnect the other connectors.
• Connector (13): Machine monitor (CM01)
• Connector (14): Machine monitor (CM02)
• Connector (15): Machine monitor (not used)
(CM03)
• Connector (16): Machine monitor (for camera
connection) (CM04)
8. Loosen mounting bolts (19) of cover and duct

assembly (18).
a Loosening mounting bolts (19) first makes
easier to remove machine monitor mounting
bolts.
9. Remove four mounting bolts (11) of machine

monitor (12).
Installation
PC290LC-10 50-231
Electric system
Removal and installation of pump swash plate sensor

the engine.


Removal
lined cover (1) (five bolts).
Installation
3 Pump swash plate sensor mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a Adjust the pump swash plate sensor. For details,
see Testing and adjusting, "Special function of
machine monitor", "Adjustment (Cal F pump
swash plate sensor)" and "Adjustment (Cal R
pump swash plate sensor)".
2. Remove harness (2) from clip (3).

3. Disconnect connectors (4) and (5).
• Connector (4): Front pump swash plate
sensor (P27)
• Connector (5): Rear pump swash plate
sensor (P28)
4. Remove clamp (6) (one bolt) holding the swash

plate sensor harness.
5. Remove two swash plate sensor mounting bolts
(7), then remove front pump swash plate sensor
(8) and rear pump swash plate sensor (9).
50-232 PC290LC-10
Electric system
Removal and installation of Mass air flow and temperature sensor

Removal
1. Open the engine hood and remove cover (1).
2. Disconnect connector P55 (3) of intake air flow/

temperature sensor.
3. Remove intake air flow/temperature sensor (2).
[*1]
a Be careful about dust from entering into air
cleaner.
Installation
[*1]
3 Screw (4) for air intake flow/temperature
sensor:
0.98 to 1.27 Nm {0.1 to 0.13 kgm}
PC290LC-10 50-233
Electric system
Removal and installation of KOMTRAX terminal assembly

the engine.


a The position of the KOMTRAX terminal is shown
below.
• C: KOMTRAX terminal
a Be careful about connector (7) located
behind cover (6).
Removal
1. Remove box (1) (five bolts).
a Disconnect the hose located under box (1).
5. Disconnect connectors (8) to (11).
2. Remove box (2) (three bolts).
a Be careful about connectors (3) and (4) (GPS)
located behind box (2) (for machines • Connector (9): Machine main harness
equipped with 12 V power socket). (CK01).
• Connector (3): 12 V power socket • Connector (10): Machine main harness
intermediate harness (M13A) (CK02).
• Connector (4): 12 V power socket • Connector (11): Communication antenna
intermediate harness (M13B) 6. Remove KOMTRAX terminal (C) (four bolts).
Installation
50-234 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
60 Maintenance standard
8 60 Maintenance standard
PC290LC-10 60-1
Table of contents
Table of contents
60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Swing circle ......................................................................................................................... 60-5
Swing machinery ................................................................................................................. 60-6
Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Truck frame and idler cushion ............................................................................................. 60-12
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-18
Truck shoe ........................................................................................................................ 60-19
Hydraulic tank.................................................................................................................... 60-22
Main pump ........................................................................................................................ 60-23
Control valve ..................................................................................................................... 60-24
Swing motor ...................................................................................................................... 60-32
Travel motor ...................................................................................................................... 60-34
PPC valve ......................................................................................................................... 60-37
Solenoid valve ................................................................................................................... 60-46
Attachment circuit selector valve (for high-pressure circuit) .................................................... 60-47
Attachment circuit selector valve (for low-pressure circuit) ..................................................... 60-48
Center swivel joint .............................................................................................................. 60-49
Work equipment................................................................................................................. 60-50
60-2 PC290LC-10
Engine mount
Engine mount
PC290LC-10 60-3
Cooling system
Cooling system
60-4 PC290LC-10
Swing circle
Power train system
Swing circle
Unit: mm
No. Item Criteria Remedy
Axial clearance of bearing Standard clearance Allowable clearance
1 Replace
(when installed on machine) 0.5 – 1.6 3.2
PC290LC-10 60-5
Swing machinery
Swing machinery
60-6 PC290LC-10
Swing machinery
Unit mm
Backlash between Standard clearance Allowable clearance
1 swing motor shaft and
No.1 sun gear 0.18 to 0.28 —
Backlash between No.
2 1 sun gear and No. 1 0.16 to 0.50 1.00
planetary gear
Backlash between No.1
3 planetary gear and ring 0.18 to 0.59 1.10
gear
4 planetary carrier and 0.35 to 0.64 1.20
No. 2 sun gear
5 2 sun gear and No. 2 0.12 to 0.44 0.90
planetary gear
Replace
6 2 planetary gear and 0.16 to 0.56 1.00
ring gear
7 2 planetary carrier and 0.08 to 0.23 —
swing pinion
Backlash between
8 swing pinion and swing 0.23 to 1.37 2.00
circle
Clearance between
9 plate and No. 2 1.1 ± 0.52 —
planetary carrier
Clearance between
10 plate and No. 2 sun 3.2 ± 0.64 —
gear
Standard Repair by
Outside diameter of oil Tolerance Allowable dimension
dimension hard chrome-
11 seal contact surface of
0 plating or
spacer 125 —
-0.100 replace
PC290LC-10 60-7
Final drive
Final drive
60-8 PC290LC-10
Final drive
Unit:mm
Backlash between Standard clearance Allowable clearance
1 travel motor and No. 2
planetary carrier 0.06 to 0.25 —
ring gear
No. 2 sun gear
Replace
4 planetary gear and ring 0.18 to 0.62 1.20
gear
No. 1 sun gear shaft
6 planetary carrier and 0.39 to 0.80 1.60
No. 2 sun gear
Amount of wear on Build-up
7 Repair limit 6
sprocket tooth welding for
Standard dimension Repair limit rebuilding or
8 Width of sprocket tooth replace
87 81
PC290LC-10 60-9
Sprocket
Sprocket
Unit mm
Standard dimension Repair limit
1 Wear of tooth tip
336.5 324.5 Build-up
2 Thickness of tooth root 20 14 welding for
3 Width of tooth 87 81 rebuilding or
Repair limit 6 replace
4 Wear of tooth shape
(use a full-scale drawing of sprocket tooth shape to judge)
Full-scale drawing of sprocket tooth shape

a The above drawing is reduced to 62%. Enlarge it to 160% to return it to the full scale and make a copy on
an OHP sheet.
60-10 PC290LC-10
Sprocket
PC290LC-10 60-11
Truck frame and idler cushion
60-12 PC290LC-10
Unit:mm
Standard dimension Tolerance Repair limit
+3
Height of idler Track 123 127
1 guide frame -1
Build-up
Idler
120 ±0.5 118 welding for
support
rebuilding or
Track +4 replace
266 271
Width of idler frame -1
2 guide Idler
261 — 259
support
Free length Load at Load at
Installed
x Outside installed Free length installed
3 Recoil spring length Replace
diameter length length
811.5 × 208.7 kN 167.0 kN
655 —
261 {21,287 kg} {17,024 kg}
PC290LC-10 60-13
Idler
Idler
Unit:mm
Outside diameter of Standard dimension Repair limit
1 protrusion 635 —
Outside diameter of Build-up
2 590 578
tread welding for
3 Thickness of tread 22.5 28.5 rebuilding or
4 Depth of tread — — replace
5 Ovevall width 190 —
6 Width of tread 44 —
60-14 PC290LC-10
Idler
Unit:mm
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
7 shaft and bushing -0.225 + 0.130 0.201 to
80 —
-0.325 - 0.024 0.455
Tolerance Standard Allowable
Standard
interfer- interfer- Replace
Interference between dimension Shaft Hole
8 ence ence bushing
idler and bushing
+ 0.087 - 0.027 0.064 to
87.6 —
+ 0.037 - 0.079 0.166
Clearance between Standard dimension Repair limit
9 bushing and support
0.68 to 1.22 —
(Total of both sides)
PC290LC-10 60-15
Track roller
Track roller
60-16 PC290LC-10
Track roller
Unit: mm
Outside diameter of outer Standard dimension Repair limit
1 flange 216 –
Outside diameter of inner
2 210 –
flange (double flange)
3 Outside diameter of tread 180 168
4 Thickness of tread 54 48
5 Overall width 250 –
Single Rebuild by
49 – build-up welding
flange
6 Width of tread or replace
Double
47.7 –
flange
Single
27 –
flange
7 Width of flange
Double
27 –
flange
Width of inner flange (double
8 20 –
flange)
Clearance between bushing Standard dimension Repair limit
9 and collar Replace
0.44 – 0.97 –
(Total of both sides)
Clearance between shaft dimension Shaft Hole clearance clearance
10 and bushing
-0.250 +0.186 0.186 to
65 –
-0.350 -0.064 0.536 Replace
Tolerance Standard Allowable bushing
Standard
interfer- interfer-
Interference between roller dimension Shaft Hole
11 and bushing ence ence
+0.108 -0.006 0.014 to
72 –
+0.008 -0.036 0.144
PC290LC-10 60-17
Carrier roller
Carrier roller
Unit mm
Outside diameter of Standard dimension Repair limit
1 flange 179 —
Outside diameter of
2 152 138
tread
3 Width of tread 50.3 —
4 Thickness of tread 32 25
5 Width of flange 19 —
Clearance between dimension Shaft Hole clearance clearance Replace
6 shaft and bushing -0.250 +0.100 0.214 to
54 —
-0.280 +0.036 0.380
Tolerance Standard Allowable
Standard
interfer- interfer-
Interference between dimension Shaft Hole
7 ence ence
roller and bushing
+0.117 +0.030 0.057 to
61 —
+0.087 0 0.117
End play of roller (play Standard clearance Allowable clearance
8 of shaft end) 0.5 to 0.7 —
60-18 PC290LC-10
Truck shoe
Truck shoe
a Portion P shows the link on the side where the bushing is press-fitted.
PC290LC-10 60-19
Truck shoe
Unit: mm
1 Link pitch Turn 180
216.3 219.3
deg. or
2 Outside diameter of bushing 66.9 61.9 replace
3 Thickness of bushing 10.8 5.8
4 Link height 116 107
Repair or
Thickness of link (bushing replace
5 press fit part) 30.7 21.7
6 178.4
7 Shoe bolt pitch 140.4
8 76.2
9 Inside width 102
10 Link Overall width 47.8
Adjust or
11 Tread width 42.6
replace
12 Protrusion of pin 4.2
13 Protrusion of regular bushing 5.25
14 Overall length of pin 242
15 Overall length of bushing 158.9
16 Thickness of spacer –
17 Bushing 98 to 264.6 kN {10 to 27 ton}
18 Press fitting Regular pin 147 to 362.6 kN {15 to 37 ton}
–
(*1) force
Master pin 98 to 314 kN {10 to 32 ton}
19
Tightening torque Retightening angle
a. Regular (Nm {kgm}) (deg.)
link Triple grouser 393 ± 39
120 ± 10
shoe {40 ± 4}
20 Shoe bolt Retighten
Tightening Lower limit
torque Retightening angle torque
b. Master link (deg.)
(Nm {kgm}) (Nm {kgm})
– – –
Standard Tolerance Standard
Interference between bushing dimension Shaft Hole interference
21
and link +0.464 +0.074
66.5 0.350 to 0.464
+0.424 0
Interference between regular +0.235 -0.188
22 pin and link 44.6 0.273 to 0.485
+0.085 -0.250
Clearance between regular pin dimension Shaft Hole clearance
23 and bushing
+0.235 +0.915 Adjust or
44.6 0.180 to 0.830 replace
+0.085 +0.415
(*1) Interference between master dimension Shaft Hole interference
24 pin and link +0.030 -0.0188
44.6 0.188 to 0.280
0 -0.250
(1*) Clearance between master pin dimension Shaft Hole clearance
25 and bushing +0.050 +0.915
44.3 0.365 to 0.965
-0.050 +0.415
*1: For the dry type truck shoe
60-20 PC290LC-10
Truck shoe
Triple grouser shoe
Unit:mm
Grouser overall
1 height 36 24
* 30 18
Shoe overall 47 35
2 height * 41 29
3 Plate thickness 11
32 Build-up
4 welding for
Grouser base * 29 rebuilding or
length 26 replace
5
* 24
24
6
* 22
18
7 Grouser tip length
* 16
18
8
* 22
*: For 600 mm shoe
PC290LC-10 60-21
Hydraulic tank
Hydraulic system
Hydraulic tank
60-22 PC290LC-10
Main pump
Main pump
PC290LC-10 60-23
Control valve
Control valve
60-24 PC290LC-10
Control valve
PC290LC-10 60-25
Control valve
Unit: mm
Free length Installed Load at Load at
1 Spool return spring length
407 N 326 N
55.2 x 34.4 51.2 — If damaged
{41.5 kg} {33.2 kg} or deformed,
393 N 315 N replace
2 Spool return spring 54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg} spring
375 N 300 N
{38.2 kg} {30.6 kg}
421 N 336 N
{42.9 kg} {34.3 kg}
60-26 PC290LC-10
Control valve
PC290LC-10 60-27
Control valve
Unit: mm
x Outside installed Free length installed If damaged
1 Suction valve spring length
diameter length length or deformed,
5.5 N 4.4 N replace
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg} spring
1.5 N 1.2 N
2 Check valve spring 11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg}
60-28 PC290LC-10
Control valve
Unit: mm
Variable back pressure x Outside installed Free length installed
1 length
valve return spring diameter length length
14.7 N 11.8 N
59.3 x 14.4 43 —
{1.5 kg} {1.2 kg}
13.7 N 11 N
2 Check valve spring 33.8 x 6 29 — If damaged
{1.4 kg} {1.12 kg} or deformed,
Quick return valve 170 N 135 N replace
3 60.2 x 20 36 —
spring {17.3 kg} {13.8 kg} spring
Regeneration circuit 5.9 N 4.71 N
4 31.5 x 10.3 19.5 —
check valve spring {0.6 kg} {0.48 kg}
Cooler check valve 157 N 126 N
5 88.2 x 28.4 65 —
spring {16 kg} {12.8 kg}
52.7 N 42.2 N
6 Pilot piston spring 22.35 x 9.3 13.4 —
{5.37 kg} {4.30 kg}
PC290LC-10 60-29
Control valve
60-30 PC290LC-10
Control valve
Unit: mm
Merge-divider valve x Outside installed Free length installed
1 length
spring (for LS) diameter length length
121 N 96.5 N
36.4 x 21.8 33.0 —
{12.3 kg} {9.84 kg}
250 N 200 N
2 Sequence valve spring 70.9 x 18.0 56.0 —
{25.5 kg} {20.4 kg}
Merge-divider valve 178 N 142 N If damaged
3 64.5 x 32.3 63.0 — or deformed,
spring (main) {18.1 kg} {14.5 kg}
replace
Hydraulic drift 35.3 N 28.2 N spring
4 prevention valve check 33.0 x 12.0 26.0 —
valve spring {3.6 kg} {2.88 kg}
13.7 N 11.0 N
{1.4 kg} {1.12 kg}
Regeneration circuit 5.9 N 4.71 N
6 31.5 x 10.3 19.5 —
check valve spring {0.6 kg} {0.48 kg}
Travel junction valve 50.0 N 40.0 N
7 30.7 x 20.5 23 —
spring {5.1 kg} {4.08 kg}
PC290LC-10 60-31
Swing motor
Swing motor
60-32 PC290LC-10
Swing motor
Unit: mm
1 Check valve spring length
3.53 N 2.84 N replace
57.2 x 19.0 30.0 —
{0.36 kg} {0.29 kg} spring
13.7 N 11.0 N
2 Shuttle valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}
PC290LC-10 60-33
Travel motor
Travel motor
60-34 PC290LC-10
Travel motor
PC290LC-10 60-35
Travel motor
Unit: mm
1 Regulator piston spring length
221 N 177 N
61.1 x 23.2 43.9 —
{22.5 kg} {18.0 kg}
If damaged
118 N 94.1 N or deformed,
2 Regulator piston spring 65.3 x 16.2 52.9 —
{12 kg} {9.6 kg} replace
98.1 N 78.5 N spring
3 Regulator valve spring 29.6 x 9.0 26.0 —
{10.0 kg} {8.0 kg}
1.27 N 0.98 N
{0.13 kg} {0.10 kg}
58.43 x 427 N 341 N
5 Spool return spring 42.0 —
30.0 {43.5 kg} {34.8 kg}
60-36 PC290LC-10
PPC valve
PPC valve
Work equipment and swing PPC valve
PC290LC-10 60-37
PPC valve
60-38 PC290LC-10
PPC valve
Unit:mm
Centering spring x Outside installed Free length installed
1 length
(for ports P3 and P4) diameter length length
If damaged
17.7 N 14.1 N or deformed,
42.5 x 15.5 34.0 —
{1.80 kg} {1.44 kg} replace
Centering spring 29.4 N 23.5 N spring
2 44.5 x 15.5 34.0 —
(for ports P1 and P2) {3.0 kg} {2.40 kg}
16.7 N 13.3 N
3 Metering spring 26.5 x 8.15 24.9 —
{1.70 kg} {1.36 kg}
Travel PPC valve

PC290LC-10 60-39
PPC valve
60-40 PC290LC-10
PPC valve
Unit:mm
1 Centering spring length
48.57 x 108 N 86.3 N replace
32.5 —
15.5 {11 kg} {8.8 kg} spring
26.53 x 16.7 N 13.3 N
2 Metering spring 24.9 —
8.15 {1.7 kg} {1.36 kg}
1st-line attachment PPC valve (with EPC valve)

(if equipped)
PC290LC-10 60-41
PPC valve
60-42 PC290LC-10
PPC valve
Unit:mm
125 N 100 N replace
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg} spring
16.7 N 13.3 N
{1.70 kg} {1.36 kg}
EPC valve
(if equipped)
PC290LC-10 60-43
PPC valve
Unit:mm
Load at Load at If damaged
Installed or deformed,
Free length installed Free length installed
1 Metering spring length replace the
length length
EPC valve
3.24 N assembly
9.5 8.4 — —
{0.33 kg}
2nd-line attachment PPC valve

(if equipped)
60-44 PC290LC-10
PPC valve
Unit:mm
125 N 100 N replace
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg} spring
16.7 N 13.3 N
{1.70 kg} {1.36 kg}
PC290LC-10 60-45
Solenoid valve
Solenoid valve
a The figure shows the type for a machine ready for installing attachments.
60-46 PC290LC-10
Attachment circuit selector valve (for high-pressure
circuit)
Attachment circuit selector valve (for high-pressure circuit)

(if equipped)
Unit mm
Free length Installed Load at Load at If damaged
x Outside installed Free length installed or deformed,
diameter length length replace
28.7 N 22.9 N spring
33.4 x 11.2 27.3 —
{2.93 kg} {2.34 kg}
PC290LC-10 60-47
Attachment circuit selector valve (for low-pressure
circuit)
Attachment circuit selector valve (for low-pressure circuit)

(if equipped)
Unit mm
Free length Installed Load at Load at If damaged
x Outside installed Free length installed or deformed,
diameter length length replace
834 N 667 N spring
132 x 29 114.5 —
{85.0 kg} {68.0 kg}
60-48 PC290LC-10
Center swivel joint
Center swivel joint
Unit: mm
Allowable
Clearance between Standard dimension Standard clearance
1 clearance Replace
rotor and shaft
80 0.056 to 0.105 0.111
PC290LC-10 60-49
Work equipment
Work equipment
Work equipment cylinder
Work equipment
60-50 PC290LC-10
Work equipment
PC290LC-10 60-51
Work equipment
Unit:mm
Criteria
No. Item Standard Tolerance Standard Allowable Remedy
dimension Shaft Hole clearance clearance
Clearance between pin
and bushing connecting -0.036 +0.138 0.114 to
1 100 1.0
revolving frame and -0.071 +0.078 0.209
boom
Clearance between pin -0.036 +0.137 0.113 to
2 and bushing connecting 90 1.0
-0.071 +0.077 0.208
boom and arm
Clearance between pin -0.030 +0.337 0.303 ～
3 and bushing connecting 80 1.0 Replace pin
-0.076 +0.273 0.413
arm and link and bushing
-0.076 +0.270 0.400
arm and bucket
-0.076 +0.273 0.413
link and bucket
-0.076 +0.273 0.413
links
60-52 PC290LC-10
Work equipment
Unit:mm
Criteria
Greasing Width of boss Width of hinge Remedy
No. Item Standard
interval Standard Standard
Tolerance Tolerance clearance
dimension dimension
Connecting 0 +1 Adjust shim
625.5 632 4.5 to 8.0
part of -0.5 -2 so that
7 revolving L7: Adjust with the combination of shim thickness 2.0 mm (2), clearance will
(*2) 2.5 mm (1), 3.0 mm (1), and 3.5 mm (1).
frame and be 1.0 mm or
boom 500 hours R7: Insert 2.0 mm thickness shim (1). less
(*1) +1.5
96 ±1.2 99.3 2.1 to 6.0
Connecting 0 Adjust shim
part of so that
8 revolving L8: Adjust with the combination of shim thickness 1.0 mm (1) clearance will
(*2) and 2.0 mm (2).
frame and be 1.5 mm or
boom 500 hours R8: Insert 1.0 mm thickness shim (1). less
cylinder
+3
695 ±2.9 701 2.1 to 11.9
Connecting -1 Adjust shim
part of L9-1: Adjust with the combination of shim thickness 1.0 mm (1) so that
9 boom and and 2.0 mm (2). clearance will
boom (*2) L9-2: Insert 1.0 mm thickness shim (1). be 1.5 mm or
cylinder 500 hours R9-1: Insert 1.0 mm thickness shim (1). less
R9-2: Insert 1.0 mm thickness shim (1).
+1.5 Adjust shim
Connecting 106 ±1.2 109.3 2.1 to 6.0
0 so that
part of
10 L10: Insert 1.0 mm thickness shim (1). clearance will
boom and (*2)
arm cylinder 500 hours R10: Adjust with the combination of shim thickness 1.0 mm (1) be 1.5 mm or
and 2.0 mm (2). less
0 +0.5 Adjust shim
Connecting 305.5 310 4.5 to 6.5
-0.5 0 so that
part of L11: Insert 2.0 mm thickness shim (1).
11 clearance will
boom and (*2)
R11: Adjust with either shim thickness 2.0 mm (1) or 2.5 mm be 1.0 mm or
arm 500 hours (1) or 3.0 mm (1). less
Connecting +1.5
106 ±1.2 109.3 2.1 to 6.0
part of arm 0 Replacement
12 L12: Insert 1.0 mm thickness shim (1).
cylinder and (*2) of shim
arm 500 hours R12: Insert 1.0 mm thickness shim (1).
+1.5 Adjust shim
Connecting 96 ±1.2 99.3 2.1 to 6.0
0 so that
part of arm
13 L13: Insert 1.0 mm thickness shim (1). clearance will
and bucket (*2)
cylinder R13: Adjust with the combination of shim thickness 1.0 mm (1) be 1.5 mm or
500 hours and 2.0 mm (2). less
Connecting 325 ±0.5 326.5 ±1 0 to 3.0
14 part of link (*3) L14: — —
and bucket 100 hours R14: —
Connecting 96 ±1.2 100.2 ±0.5 2.5 to 5.9
part of
15a bucket (*3) L15a: — —
cylinder and 100 hours R15a: —
link
0 Adjust shim
280 — — —
Connecting -0.5 so that
15b part of link L15b: — clearance will
(*3)
and link R15b: Adjust with the combination of shim thickness 0.8 mm be 1.5 mm or
100 hours (1) and 1.5 mm (4). less
PC290LC-10 60-53
Work equipment
Unit:mm
Criteria
Greasing Width of boss Width of hinge Remedy
No. Item Standard
interval Standard Standard
Tolerance Tolerance clearance
dimension dimension
0 Adjust shim
280 — — —
Connecting - 0.5 so that
16 part of arm L16: Adjust with the combination of shim thickness 0.8 mm (1) clearance will
(*3)
and link and 1.5 mm (3). be 1.5 mm or
100 hours less
R16: —
0 +2.2 Adjust shim
325 327.5 2.3 to 5.2
Connecting -0.5 -0.2 so that
17 part of arm L17: — clearance will
(*4)
and bucket R17: Adjust with the combination of shim thickness 0.5 mm (4) be 0.5 to 1.0
100 hours and 1.0 mm (12). mm
*1: The criteria indicates the L.H. boom cylinder. The position for shim adjustment of R.H. boom cylinder
becomes opposite to that of L.H. boom cylinder.
*2: Use plastic shims (with flange).
*3: Use iron shims (without flange).
*4: Use separated iron shims.
a The number in ( ) next to the shim thickness shows the quantity of shims to be prepared.
Dimensions of arm
60-54 PC290LC-10
Work equipment
PC290LC-10 60-55
Work equipment
Unit: mm
PC240LC–10
No. Tolerance
Measurement point Standard dimension
Shaft Hole
-0.030 +0.100
1 — 80
-0.076 0
+1.5
Arm side 109.3
2 0
Cylinder head side 106 ±1.2
+0.5
Boom side 310
0
3
0
Arm side 305.5
-0.5
-0.036 +0.054
4 — 90
-0.071 0
5 — 419.9 ±1.0
6 — 206.1 ±0.5
7 — 918.6 ±1.0
8 — 3,037.6 —
9 — 2,562.8 ±1.0
10 — 465 ±1.0
11 — 585 ±0.2
12 — 600 ±0.5
13 — 446.3 —
14 — 1,551.7 —
-0.030 +0.100
15 — 80
-0.076 0
Link side 325 ±0.5
16
Bucket side 326.5 ±1.0
-0.030 +0.100
17 — 80
-0.076 0
0
(without bushing) 311
-0.5
18
(with bushing press-
325 —
fitted)
(Min.) 1,605 —
19
(Max.) 2,625 —
60-56 PC290LC-10
Work equipment
Dimensions of bucket
PC290LC-10 60-57
Work equipment
Unit: mm
PC240LC–10
No.
Measurement point Standard dimension Tolerance
1 — 442.4 ±0.5
2 — 59.2 ±0.5
3 — 97°37′ —
4 — 446.3 —
5 — 1540.5 —
6 — 185.6 —
7 — — —
8 — 7°48′ —
+0.1
9 — 80
0
10 — 326.5 ±1.0
11 — 59 —
12 — 104 —
13 — 470 —
14 — 23.5 —
15 — 140 —
16 — 190 —
17 — 156.3 —
18 — 133.1 —
19 — 107 —
20 — 82 —
+2.0
21 — 348.5
0
22 — 37 —
Boom cylinder
Unit:mm
1 piston rod and bushing bushing
-0.036 +0.257 0.084 to
90 0.447
-0.090 +0.048 0.347
Clearance between -0.030 +0.190
piston rod support shaft 0.100 to
2 80 1.0
and bushing -0.060 +0.070 0.250
Replace pin
Clearance between and bushing
-0.030 +0.190 0.100 to
3 cylinder bottom support 80 1.0
shaft and bushing -0.060 +0.070 0.250
60-58 PC290LC-10
Work equipment
Unit:mm
Tightening torque of
4 270 ± 39.0 Nm {27.5 ± 4.0 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston fix 58.9 - 73.6 Nm {6.0 - 7.5 kgm}
screw
Boom cylinder (large diameter piston)
Unit:mm
-0.036 +0.222 0.083 to
95 0.412
-0.090 +0.047 0.312
Clearance between
-0.030 +0.190 0.100 to
2 piston rod support shaft 80 1.0
and bushing -0.060 +0.070 0.250
Replace pin
-0.030 +0.190 0.100 to
4 373 ± 54.0 Nm {38.0 ± 5.5 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston fix 58.9 - 73.6 Nm {6.0 - 7.5 kgm}
screw
Arm cylinder
PC290LC-10 60-59
Work equipment
Unit:mm
– 0.036 + 0.257 0.083 to
100 0.447
– 0.090 + 0.047 0.347
Clearance between – 0.030 + 0.190
piston rod support shaft 0.100 to
2 80 1.0
and bushing – 0.076 + 0.070 0.266
Replace pin
– 0.030 + 0.190 0.100 to
shaft and bushing – 0.076 + 0.070 0.266
4 373 ± 54.0 Nm {38.0 ± 5.5 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston fix 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
screw
Bucket cylinder
Unit:mm
-0.036 +0.257 0.084 to
90 0.447
-0.090 +0.048 0.347
Clearance between
-0.030 +0.457 0.400 to
2 piston rod support shaft 80 1.0
and bushing -0.076 +0.370 0.533
Replace pin
-0.030 +0.190 0.100 to
4 373 ± 54.0 Nm {38.0 ± 5.5 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston fix 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
screw
60-60 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up
80 Appendix
9 80 Appendix
PC290LC-10 80-1
80 Appendix
Table of contents
Table of contents
80 Appendix...................................................................................................................................... 80-1
Air conditioner ............................................................................................................................ 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-6
Outline of refrigeration cycle.................................................................................................. 80-7
Air conditioner unit ............................................................................................................... 80-9
Dual pressure switch .......................................................................................................... 80-15
Air conditioner controller ..................................................................................................... 80-16
Air conditioner compressor ................................................................................................. 80-17
Air conditioner condenser ................................................................................................... 80-18
Sunlight sensor .................................................................................................................. 80-20
Outside air temperature sensor ........................................................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-26
Input and output signals of the air conditioner controller ......................................................... 80-27
Parts and connectors layout................................................................................................ 80-29
Layout of air conditioner related parts and connectors ........................................................... 80-30
Testing air leakage (duct) .................................................................................................... 80-33
Testing with self-diagnosis function ...................................................................................... 80-36
How to enter air conditioner "Electrical Systems" screen in service mode of the machine
monitor................................................................................................................. 80-37
Testing vent (mode) changeover.......................................................................................... 80-39
Testing FRESH/RECIRC air changeover.............................................................................. 80-41
Testing sunlight sensor ....................................................................................................... 80-42
Testing (dual) pressure switch for refrigerant......................................................................... 80-43
Testing relays .................................................................................................................... 80-45
Failure code list related to air conditioner.............................................................................. 80-51
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-52
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-53
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-54
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-56
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-58
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-59
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-60
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-62
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-63
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-64
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-65
A-2 Troubleshooting of compressor system (Air is not cooled)................................................ 80-67
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-70
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-72
Troubleshooting with gauge pressure................................................................................... 80-74
Testing refrigerant pressure................................................................................................. 80-77
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-80
Handling of compressor oil.................................................................................................. 80-82
Desiccant replacement ....................................................................................................... 80-84
80-2 PC290LC-10
80 Appendix
Precautions for refrigerant
Air conditioner
Precautions for refrigerant
k Although the refrigerant (refrigerantgas:R134a) used on the machine's air conditioner is less
destructive to the ozone layer for environmentally friendliness, it is not allowed to be released into
the atmosphere as is. Whenever disconnecting the air conditioner gas circuit, be sure to recover
the refrigerant gas to reuse it.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k Wear safety glasses, gloves and a working suit with long sleeves when you collect or fill
refrigerant gas (R134a). Otherwise, you may lose your sight if the gas gets in your eyes, or you
may suffer from frostbite if your skin is exposed to the gas.
PC290LC-10 80-3
80 Appendix
Air conditioner component
1. Sunlight sensor
2. Machine monitor
3. Hot water supply pipe
80-4 PC290LC-10
80 Appendix
4. Condenser (with modulator)

5. Hot water return pipe
6. Fresh air temperature sensor
7. Fresh air filter
8. Recirculation air filter
9. Compressor
10. Refrigerant piping
11. Sight glass
12. Air conditioner controller
14. Dual pressure switch
A: Front vent
B: Rear vent
C: Foot vent
D: Defroster vent
E: Recirculation air inlet
F: Fresh air inlet
Specification
Refrigerant R134a
Refrigerant refilling level (g) 930 ± 50
PC290LC-10 80-5
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle

Cycle Compression Condensation Expansion Evaporation
(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
Location Engine Front of radiator In operator cab In operator cab
compartment (Built in air conditioner (Built in air conditioner
unit) unit)
Function Circulates Condenses Lowers temperature and Evaporates refrigerant
refrigerant gas and refrigerant to pressure of refrigerant to absorb heat from air
increases its discharge heat liquid and gas for easy around evaporator,
temperature and absorbed in evaporation with throttle. and cool the air.
pressure so that it evaporator. Controls flow rate, too. (Evaporation of
can be liquefied (condensation of (Throttle of refrigerant) refrigerant)
easily in condenser. refrigerant)
(Compression of
refrigerant)
State of Gas o Gas Gas o Liquid Liquid o Liquid and gas Liquid and gas o Gas
refrigerant Adiabatic Constant pressure Adiabatic expansion Constant pressure
compression change change
80-6 PC290LC-10
80 Appendix
Outline of refrigeration cycle

• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
Compression (Compressor)
• The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
• The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
• The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
• The heat released to the outside from the condenser is called condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency.
• In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
(The condensation pressure varies depending on the condensation temperature of the refrigerant)
Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
• The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
*1: Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
• The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
• The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
Relationship between refrigerant and defective air conditioning

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
PC290LC-10 80-7
80 Appendix
• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
• If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.
80-8 PC290LC-10
80 Appendix
Air conditioner unit

a This air conditioner unit is auto temperature control type.
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
PC290LC-10 80-9
80 Appendix
C: Hot water inlet

D: Hot water outlet
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan, blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor (MODES)
Vent (mode) changeover door
8. Rear door
9. Foot door
10. Defroster door
11. FRESH/RECIRC air changeover servomotor (R/FS)
12. FRESH/RECIRC air changeover door
13. Power transistor
14. Evaporator temperature sensor
15. Insidel air temperature sensor
Function
• The air conditioner unit consists of the evaporator (1) and heater core (2), and is used to cool down or
warm up the air in the cab.
Temperature control
• Whenever a temperature control switch is operated on the machine monitor, temperature setting data is
sent to the air conditioner controller, which is located behind the operator seat. The air conditioner
controller controls the air mix servomotor (5) and changes the angle of the air mix door (6) in order to
adjust the temperature.
Over-cooling (Freezing) prevention

• Evaporator temperature sensor (14) varies its electrical resistance according to temperature.
• The air conditioner controller detects the temperature of the evaporator (1) by converting the changes in
the resistance of the evaporator temperature sensor (14) into voltage changes.
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: See "Parts and connectors layout" for details regarding the compressor clutch relay.
Air flow adjustment

• Whenever an air flow control switch is operated on the machine monitor, air flow setting data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) using power transistor
(13) in order to adjust the air flow.
Vent (mode) changeover

• Whenever a vent switch is operated on the machine monitor, mode data is sent to the air conditioner
controller. The air conditioner controller controls mode changeover servomotor (7) to adjust the opening
angle of mode changeover doors (8) to (10) and thus perform vent changeover.
FRESH/RECIRC air changeover

• Whenever a FRESH/RECIRC air changeover switch is operated on the machine monitor, FRESH/
RECIRC air changeover setting data is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (11) to open and close FRESH/RECIRC air
changeover door (12).
80-10 PC290LC-10
80 Appendix
Automatic air conditioner

• Inside air temperature sensor (15) detects the internal temperature based on changes in resistance. The
air conditioner controller detects the internal temperature by converting the changes in the resistance of
inside air temperature sensor (15) into voltage changes.
The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the
internal temperature so that it matches the setting made on the machine monitor.
Data from the sunlight sensor and the outside air temperature sensor is also taken into consideration
when adjusting the internal temperature.
a The door is the same as the damper.
Changeover pattern of the vent (mode) changeover door
Rear door (8) Foot door (9) Defroster door (10)
Opening Opening Opening
and closing Angle and closing Angle and closing Angle
door door door
Front Close 0 Close 0 Close 0
Front and rear Open 25 Close 0 Close 0
Front, rear and Open Open
25 35 Close 0
Air vent foot
mode Foot Open 25 Open 53 Close 0
Foot and Open Open Open
25 23 38
defroster
Defroster Open 25 Open 0 Open 38
Selection pattern of air mix door (6)
Set temperature Opening and closing door Angle
Max. Cool Close 0
Max. Hot Open 80
PC290LC-10 80-11
80 Appendix
Functions of major components

Evaporator
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3). Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.
Heater core
• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through the heater core fins.
Evaporator temperature sensor

• Evaporator temperature sensor (12) is installed on evaporator (1) with the holder. Its resistance changes
in response to the temperature change of the evaporator. The air conditioner controller monitors the
evaporator temperature to prevent its from freezing.
Servomotors
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.
• Whenever a switch on the machine monitor is operated, the air conditioner controller delivers power to the
servomotor by raising the voltage between terminals (6) and (7) to 24 V. (The rotation direction changes
based on the supply polarity.)
• The servomotor contains a variable resistance, and its resistance value changes as the motor turns.
• The air conditioner controller delivers voltage at 5 V to the variable resistance and detects motor rotation
angle based on the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the potential difference fails to reach a predefined voltage for control of the servomotor, the air
conditioner controller notifies the machine monitor of an abnormality. [879EMC] or [879FMC] is displayed
on the "Electrical Systems" screen of the electrical system on the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
a When attempting to operate a servomotor during inspecting, do not supply power directly between
servomotor terminals (6) and (7).
80-12 PC290LC-10
80 Appendix
Expansion valve
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Outline
• The expansion valve converts high-pressure and high-temperature liquid refrigerant from the receiver drier
to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).
Structure
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).
• The opening level of needle valve (1a) is determined based on the balance between the reaction force
exerted by spring (1b) in a rightward direction, and force (Fg) of refrigerant gas (2) pushing needle valve
(1a) through diaphragm (1a-1) in a leftward direction.
PC290LC-10 80-13
80 Appendix
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).
Operation
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve
(1a) is moved rightward by the reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)
80-14 PC290LC-10
80 Appendix
Dual pressure switch

a The dual pressure switch is mounted on the air conditioner hose under the floor.
• The dual pressure switch turns “OFF“ when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay “OFF“. As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC290LC-10 80-15
80 Appendix
Air conditioner controller
Air conditioner controller
a See "System Diagrams" for details regarding input/output signals.
80-16 PC290LC-10
80 Appendix
Air conditioner compressor
Air conditioner compressor
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Specification
Number of cylinder – Bore × Stroke (mm) 10 – 32 × 20.8
Piston capacity (cc/rev) 157.3
Allowable maximum speed (rpm) 6,000
Compressor oil Denso: ND-OIL8 (for R134a)
Compressor oil refill capacity (cc) 180
Function
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When the magnetic clutch is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.
PC290LC-10 80-17
80 Appendix
Air conditioner condenser
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to air conditioner unit)
1. Condenser
2. Modulator
3. Desiccating agent
4. Filter
5. Seal cap
6. O-ring
7. Snap ring
Specification
Fin pitch (mm) 4.0
Total heat dissipation surface (m2) 3.58
Max. working pressure (MPa{kg/cm2}) 3.53{36}
Weight of desiccating agent (g) 290
Function
• The condenser cools and liquefies the high pressure and high temperature misty refrigerant sent from the
compressor.
• The sub-cool section of condenser (1) further cools liquefied refrigerator, which came to this section after
passing through modulator (2), to increase the cooling efficiency.
• Modulator (2) stores the high-pressure and high-temperature liquefied refrigerant from the condenser. It is
capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to
the condenser condition in heat dissipation.
• Filter (4) and desiccating agent (3) contained in modulator (2) eliminate foreign substances in the
circulation circuit and water in the refrigerant.
80-18 PC290LC-10
80 Appendix
a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction
of refrigerant becomes impossible. Since increase of pressure in the refrigerant circulation circuit applies
extra load to the engine and reduces the cooling effect, you must take care not to crush or damage the fins
when handling them or during daily inspection.
a For the replacement procedure of desiccating agent (3) in modulator (2), see "Desiccant replacement".
PC290LC-10 80-19
80 Appendix
Sunlight sensor
Sunlight sensor
1. Connector
2. Sensor
Function
• The sunlight sensor is mounted on top of the machine monitor.
• It detects the strength of incident sunlight and sends signals to the air conditioner controller.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
80-20 PC290LC-10
80 Appendix
Outside air temperature sensor
Outside air temperature sensor
1. Connector
2. Sensor
Function
• The outside (air) temperature sensor is installed in the cooling unit.
• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller detects the ambient temperature by converting the changes in the resistance
of the outside air temperature sensor into voltage changes.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the outside (air) temperature sensor in order to adjust the
temperature and air flow.
PC290LC-10 80-21
80 Appendix
Procedure for testing and troubleshooting

The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air
conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air
conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with
the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
80-22 PC290LC-10
80 Appendix
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no
refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC290LC-10 80-23
80 Appendix
Circuit diagram and arrangement of connector pins
80-24 PC290LC-10
80 Appendix
a The diffuser servomotor means the vent (mode) changeover servomotor.

a The Fresh/recirculated air servomotor means the FRESH/RECIRC air changeover servomotor.
a The frost sensor means the evaporator temperature sensor.
PC290LC-10 80-25
80 Appendix
System diagram
System diagram
a This air conditioner unit is auto temperature control type.
80-26 PC290LC-10
80 Appendix
Input and output signals of the air conditioner controller

Controller connector: AMP 025 - 32PM
Wiring harness connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply (5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA Fresh/recirculated air servomotor terminal A Output
14 MRFB Fresh/recirculated air servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
Function
• Operation of air conditioner controller
1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
PC290LC-10 80-27
80 Appendix
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the air conditioner controller controls the inside (air)
temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor,
the outside air temperature sensor, and the inside air temperature sensor.
8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the controller
notifies it to the machine monitor by the CAN communication. Then, failure code [879***] is displayed on
the "Electrical Systems" screen of the electrical system on the machine monitor.
80-28 PC290LC-10
80 Appendix
Parts and connectors layout
Parts and connectors layout

• Three fuses related to the air conditioner are in the fuse box at the right rear of the operator's seat.
• The air conditioner unit is mounted inside the rear cover of at the rear cover of the operator's seat.
k Park the machine on a level surface, swing the upper structure by 90 degrees, lower the work
equipment to the ground so that it is stable, and stop the engine.
k Turn the battery disconnect switch to the "OFF" position and pull out the key.
a Note the connector numbers and installed positions before disconnecting wiring and hoses.
Connector Reference
Remarks Location
No. item
AC01 Intermediate connector Right rear of cab 2.
AC02 Intermediate connector Right rear of cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Air conditioner controller Rear of cab 2.
CM01* Machine monitor Front of cab 5.
CM02 Machine monitor Front of cab 5.
F01 Fuse box Right rear of cab 1.
P17 Under cab 6.
a Swing upper structure 90 deg.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear of cab 2.
[2] Power transistor Air conditioner unit 3.
[5]* FRESH/RECIRC air changeover
Air conditioner unit 3.
servomotor
[6]* Inside air temperature sensor Air conditioner unit 3.
Evaporator temperature sensor
[7]* Air conditioner unit 3.
(Frost sensor)
*: Connector that does not appear during troubleshooting
PC290LC-10 80-29
80 Appendix
Layout of air conditioner related parts and connectors

1. Each fuse in fuse box F01: Open the cover of the fuse box at the right rear of the operator's cab.
• No. 10 (20 A): Fuse for power supply of blower (fan) and air conditioner compressor
• No. 14 (5 A): Fuse for primary power supply of air conditioner unit, air conditioner controller, and air
conditioner compressor electromagnetic clutch relay
• No. 19 (5 A): Fuse for power supply (backup power supply) of air conditioner controller
2. Air conditioner controller: *1

• AC01: Intermediate connector
• AC02: Intermediate connector
• ACECU: Air conditioner controller connector
• R21: Connector for air conditioner compressor electromagnetic clutch relay

a Connectors [2], [5], [6], and [7] do not have labels.
80-30 PC290LC-10
80 Appendix
a Rear side of air conditioner unit (only connector [2] can be removed while installed on machine)
[2]: Power transistor (*2) connector
[5]: FRESH/RECIRC air changeover servomotor connector
[6]: Inner sensor (inside air temperature sensor) connector
[7]: Evaporator temperature sensor connector
*2: Power transistor
4. Sunlight sensor
P31: Sunlight sensor connector
5. Machine monitor
• CM01 to CM04: Machine monitor connector
a Connector CM03: (Not used)
a Connector CM04: (For camera connection)
6. Dual pressure switch

a Rotate cab undercover 90 degrees and remove it.
• P17: Dual pressure switch connector
PC290LC-10 80-31
80 Appendix
7. Air conditioner compressor

a Open up the engine hood.
• AC03: Air conditioner compressor connector
8. Outside (air) temperature sensor

P18: Outside (air) temperature sensor connector
80-32 PC290LC-10
80 Appendix
Testing air leakage (duct)

k Park the machine on a level place, lower the work equipment to the ground stably, and stop the
engine.
k Turn the battery disconnect switch to the “OFF“ position and remove the key.
a Note connector numbers and installed positions when disconnecting wiring and hoses.
Check
1. Lift front window assembly (1) to the ceiling and lock it.
a Check that the front window is securely locked.
3. Remove floor mat (3).
4. Remove cover (4) first, and then remove cover (5).
6. Remove cap (7-1).

a Disconnect the sunlight sensor connector from the rear of cover (7).
8. Remove drink box (8) (five bolts).

a Disconnect the hose under drink box (8).
9. Remove magazine box (9) (three bolts).
a Be careful about connectors (10) and (11) behind magazine box (9). (for machines equipped with 12 V
power socket)
• Connector (10): 12 V power socket intermediate harness (M13A)
• Connector (11): 12 V power socket intermediate harness (M13B)
10.Pull up cover (12) (three bolts) to remove.
a The connectors and wiring harnesses at the rear must not be caught.
PC290LC-10 80-33
80 Appendix
11.Remove cover (13) (seven bolts).

a Be careful about connector (14) behind cover (13).
12.Check the following ducts and pins for disconnection.

• Front duct (15)
• Defroster duct (16)
• Rear duct (17)
• Fresh air inlet duct (18) and pin (19)
80-34 PC290LC-10
80 Appendix
PC290LC-10 80-35
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function

Outline
On the air conditioner operation screen of the machine monitor, the system performs self-diagnosis to the
communication with the air conditioner controller, FRESH/RECIRC air temperature sensor, outside (air)
temperature sensor, evaporator temperature sensor, temperature control, vent (mode) changeover, and
refrigerant pressure with the pressure switch, and if a problem is detected, the "Air conditioner system
condition monitor" is displayed.
a Even if the cause of a detected problem is restored to normal, the self-diagnosis failure condition will not
automatically be reset. To reset the failure condition, the starter switch must be set to OFF.
a On the "Electrical System" screen in the service mode of the machine monitor, the system performs self-
diagnosis for various sensors. If a problem is detected, failure information is displayed.
a FRESH/RECIRC air changeover servomotor is not checked with self-diagnosis function.
80-36 PC290LC-10
80 Appendix
How to enter air conditioner "Electrical Systems" screen
in service mode of the machine monitor.
How to enter air conditioner "Electrical Systems" screen in service mode

of the machine monitor.
• Overview of machine monitor operating procedure
Normal screen
O While pressing [4], press [1], [2], and [3] in this order.
Service menu (Mode)
O Press [F3] twice. Press [F6].
03 Abnormality record
O Press [F3] once. Press [F6].
02 Electrical Systems screen
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. On the service menu screen, press [F3] twice, and then select "03 Abnormality Record".
3. Press [F6] to confirm.
4. On the Abnormality Record screen, press [F3] once, and then select "02 Electrical Systems".
5. Press [F6] to confirm.
a For details, see the failure code list related to air conditioner
PC290LC-10 80-37
80 Appendix
How to enter air conditioner "Electrical Systems" screen
in service mode of the machine monitor.
Failure code Failure (Displayed on screen) Remarks

879AKA A/C Inner Sensor Open Circuit
*
879AKB A/C Inner Sensor Short Circuit
879BKA A/C Outer Sensor Open Circuit
879BKB A/C Outer Sensor Short Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
879DKZ Sunlight Sensor Open or Short Circuit
879EMC Ventilation Dumper Abnormality *
879FMC Air Mix Dumper Abnormality *
879GKX Refrigerant Abnormality
DAZ9KQ A/C Model Selection Abnormality See Chapter 40, "Troubleshooting by
failure code"
DAZQKR CAN2 Discon (Aircon ECU)
**
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector
cannot be checked.
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The vent damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
80-38 PC290LC-10
80 Appendix
Testing vent (mode) changeover

k Park the machine on a level surface, lower the work equipment to the ground so that it is stable,
k Turn the battery disconnect switch to the “OFF“ position and pull out the key.
Testing
1. Remove drink box (1) (five bolts).
a Disconnect the hose under drink box (1).
2. Remove magazine box (2) (three bolts).
a Be careful about connectors (3) and (4) behind magazine box (2). (for machines equipped with 12 V
power socket).
• Connector (3): 12 V power socket intermediate harness (M13A)
• Connector (4): 12 V power socket intermediate harness (M13B)

a Be careful about connector (7) behind box (6).
PC290LC-10 80-39
80 Appendix
5. Remove ducts (8) and (9).
6. Turn the battery disconnect switch to the “ON“ position.

7. Start the engine and turn the air conditioner power “ON“.
8. Operate the vent changeover switch on the machine monitor.
9. Check the opening/closing operation of rear door (11) and defroster door (12) of air conditioner unit (10).
10.After finishing the inspection, turn the starting switch to the OFF position.
80-40 PC290LC-10
80 Appendix
Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover

• FRESH/RECIRC air is selected by changing the door (damper) angle in the air conditioner unit with the
servo motor. Check the opening and closing operations of the door (damper) visually.
a The system does not have self-diagnosis function for FRESH/RECIRC air changeover servo motor.
Testing
1. Open outside air filter cover (1) and remove outside air filter (2).
2. Start the engine and turn the air conditioner power "ON".
3. Operate the FRESH/RECIRC air selector switch on the machine monitor.
4. Check the opening/closing operation of FRESH/RECIRC air changeover rear door (3) through the fresh
air inlet on the left side of the cab.
5. After finishing the inspection, turn the starting switch to the OFF position.
PC290LC-10 80-41
80 Appendix
Testing sunlight sensor
Testing sunlight sensor

• When [879DKZ] "Sunlight Sensor Open or Short Circuit" is displayed by the self-diagnosis (on "03 Air-
conditioning System" screen of "Abnormality Record" in the machine monitor), test sunlight sensor
connector SLS.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
a If the sunlight sensor is measured with the resistance range of the tester, the sunlight sensor may be
destroyed, so do not measure with the resistance range of the tester.
Testing
1. Remove the machine monitor cover. For details, see "Testing air leakage (duct)", Steps 6 and 7.
2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.)
3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals
on the sensor side using a circuit tester in voltage range.
• Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
80-42 PC290LC-10
80 Appendix
Testing (dual) pressure switch for refrigerant

• If [879GKX] "Refrigerant Abnormality" is displayed by the self-diagnosis (on "03 Air-conditioning System"
screen of "Abnormality Record" in the machine monitor), test the dual pressure switch connector P17.
• To reset the self-diagnosis system (detection of abnormality), the starting switch must be turned OFF.
• The dual pressure switch is ON when the refrigerant pressure is normal, and OFF when it is abnormal.
a As the refrigerant pressure will drop when the ambient temperature is below 0 °C, there is a possibility
that the dual pressure switch is OFF. In such a case, the dual pressure switch is actually normal (i.e.,
not defective).
Testing
1. Swing by 90 deg..
2. Remove the cab undercover.
3. Disconnect the dual pressure switch connector P17.
4. Ensure that the resistance between the switch-side terminals from connector P17 is shorted (ON). (If not
shorted (OFF), the dual pressure switch will detect a refrigerant pressure abnormality.)
a When the dual pressure switch is OFF, connect a pressure gauge to the high-pressure side of the air
conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and
"Troubleshooting with gauge pressure."
a If the refrigerant pressure is normal, the dual pressure switch is defective.
• (Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC290LC-10 80-43
80 Appendix
k When replacing the dual pressure switch, refrigerant must be collected in advance.
a If resistance between the switch-side terminals from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant system".
80-44 PC290LC-10
80 Appendix
Testing relays
Testing relays
a If the air conditioner compressor is normal (air is cooled), omit this test since the relays are normal.
• Compressor clutch relay R21:
Turns the air conditioner compressor (clutch) ON/OFF.
a See Step 2 on "Parts and connectors layout".
Testing
1. Check contact R21 of connector (for disconnection).
2. Turn the starting switch ON (do not start the engine), turn the main power of the air conditioner ON, and
turn the air conditioner switch. If the compressor relay is normal, it is turned ON. Check whether its clicks.
a The air conditioner controller will not turn on the compressor clutch relay in the following cases.
1) When the evaporator temperature is below 3 °C (depending on the input voltage from the evaporator
temperature sensor).
2) When the pressure switch detects abnormality (it is turned OFF).
• Checking relay unit

a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil
actually.
Compressor clutch relay (CCRL), connector (AC04)
1. The coil resistance between terminals (1) and (2) is approximately 300 to 500 z.
2. While voltage (DC 20 to 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are
connected.
3. While voltage (DC 20 to 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (5) are
connected.
PC290LC-10 80-45
80 Appendix
Troubleshooting chart 1
The numbers in the boxes are the item numbers in the troubleshooting table.
1. Cooling trouble
2. Heating trouble
80-46 PC290LC-10
80 Appendix
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check the connector for disconnection. Repair broken parts
Wire breakage or defective and connect
connection See "Parts and connectors layout". correctly
Operate the fan switches in order and check the fan
Defective blower fan motor speed. Replace
See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check duct joints.
Repair
joints See "Testing air leakage (duct)".
Obstruction at evaporator Check evaporator for stain and obstruction Remove obstruction
inlet and clean
Defective evaporator Evaporator is frozen.
temperature sensor, Sensor fixing clip inspection, sensor contaminated
defective contact of Repair or replace
evaporator temperature Inspect the air conditioner hose around the pressure
switch for frost.
sensor, defective expansion
valve* (when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass. refrigerant again
Specifically, perform checking with the gauge manifold Collect refrigerant,
connected. then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2 }
Judgment by pressure at See Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 - 1.7 MPa {15 – 17 kg/cm2 } with gauge pressure
Temperature in operator's cab: 30 to 35 °C , Engine
speed: Approx. 1,500 rpm
PC290LC-10 80-47
80 Appendix
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
part
Deflection of belt is large.
Compressor See "Testing and adjusting of Air
belt
Slack of belt conditioner compressor belt tension" in Adjust tension
the "Testing and adjusting" in Chapter
30 of the shop manual.
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 - 20 z) Replace
Magnet
Check ground cable and joints.
clutch Wire breakage or defective
connection of ground wire See "Troubleshooting for compressor Repair
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging.
engine coolant Bleed air and correct
(Hose, pipe and core)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
See "Testing and adjusting of fan belt and alternator belt
Fan speed is low tension" in "Testing and adjusting" in Chapter 30 of the Correct
shop manual.
80-48 PC290LC-10
80 Appendix
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Select manual mode and change temperature setting.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible. and heating
FRESH/RECIRC air cannot
See "Testing FRESH/RECIRC air changeover".
be changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
PC290LC-10 80-49
80 Appendix

Information in troubleshooting table
a The following information is summarized in the troubleshooting table and the related circuit diagram.
Before performing troubleshooting, understand that information fully.
Failure Problem on machine
Related information Information related to the detected failure or troubleshooting
[Contents of description]
• Procedure
• Measuring location
1
a "Between A and B" means "Measure voltage or resistance and so
Probable causes for on between A and B".
trouble
• Criteria to judge probable causes
(Perform troubleshooting • Remarks required for judgement
according to these.)
[Notes on troubleshooting]
2 (1) Description sequence of pin number and handling of tester lead
For troubleshooting, connect the plus (+) and minus (–) tester leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (–) lead to a pin or harness indicated in the
rear.
3 Defective component
(2) Example of troubleshooting by inspection of multiple items
a Normal in 1 but abnormal in 2
At this time “ - " defective shown at left is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into contact with the power (24 V) circuit
accidentally.
• Short circuit
An independent wire in the harness contacts with other wire. (poor insulation at connector and others)
Circuit diagram related

This is the excerpted circuit diagram related to failure.
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location.
• The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
• N.C.: Normally closed (Normally ON)
• [1], [2], ··· are numbers of unlabeled connectors.
• Arrow (io): Roughly indicates their mounting place on the machine.
80-50 PC290LC-10
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner

Compo-
Failure Failure (Displayed on screen) nent in Action Category
Remarks
code charge level of record
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON –
Circuit system performed while the controller
is mounted on the machine
A/C Inner Sensor Short Electrical
879AKB MON – since the connector cannot
Circuit system
be checked.
A/C Outer Sensor Open Electrical
879BKA MON –
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON –
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot
Circuit system
be checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Short Circuit system
Ventilation Dumper Electrical Troubleshooting cannot be
879EMC Abnormality MON L01 system performed while the controller
Electrical
879FMC Air Mix Dumper Abnormality MON L01 since the connector cannot
system
be checked.
Electrical
879GKX Refrigerant Abnormality MON L01 system
A/C Model Selection Electrical
DAZ9KQ Abnormality MON –
system See Chapter 40,
"Troubleshooting by failure
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01 code"
system
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The vent damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes is explained after failure code
[879GKX].
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover
PC290LC-10 80-51
80 Appendix
Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKA] A/C Inner sensor Open Circuit

Action Air conditioner inside air temperature sensor disconnection
Failure code
level Failure
— (Machine monitor system)
879AKA
Details of • Air conditioner controller detected disconnection in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a disconnection in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
Related electrical system in the service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
Defective air If no failures are found by the above checks, the air conditioner controller may be
1 conditioner defective.
controller (Since this is an internal defect, troubleshooting cannot be performed.)
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
2
conditioner unit
(Since this is an internal defect, troubleshooting cannot be performed.)
80-52 PC290LC-10
80 Appendix
Failure code [879AKB] A/C Inner sensor Short Circuit
Failure code [879AKB] A/C Inner sensor Short Circuit

Action Air conditioner inside air temperature sensor short circuit
Failure code
level Failure
879AKB
Details of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
2
conditioner unit
PC290LC-10 80-53
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit

Action Air conditioner outside air temperature sensor disconnection
Failure code
level Failure
879BKA
Details of • Air conditioner controller detected disconnection in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since the air conditioner outside temperature sensor has a disconnection, outside
Problem on temperature is not counted in automatic mode.
machine (The air conditioner is not affected in manual mode)
electrical system in the service mode of the machine monitor.
• For connectors and other parts, see "Parts and connectors layout(PAGE 80-29)".
• Since connector ACECU of the air conditioner controller has small pins and does not
Related have a T-adapter, carry out troubleshooting by using the intermediate connector
information (Although the intermediate connector does not have a T-adapter either, it does have large
pins).
• If the air conditioner wiring harness between connector ACECU of the air conditioner
controller and the intermediate connector needs to be replaced, the air conditioner unit
must be replaced.
1. Turn starting switch to “OFF“ position.
Defective outside
1 air temperature
sensor Between P18
Resistance (male) (1) and (2) 25°C 1.7 kz

Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
Resistance (female) (7) and (8) 25°C 1.7 kz
a If cause 2 is not the cause for the failure, this check is not required.
harness 2. Disconnect connectors P18 and AC01.
3 (Wire breakage or Between AC01 (female) (7) and P18
Between AC01 (female) (8) and P18
5
conditioner unit
80-54 PC290LC-10
80 Appendix
Circuit diagram related to air conditioner outside air temperature sensor
PC290LC-10 80-55
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit

Action Air conditioner outside air temperature sensor short circuit
Failure code
level Failure
879BKB
Details of • Air conditioner controller detected short circuit in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since air conditioner outside temperature sensor has short circuit, outside temperature is
Problem on not counted in automatic mode.
pins).
must be replaced.
1. Turn starting switch to “OFF“ position.
Defective outside
1 air temperature
sensor Between P18
Resistance (male) (1) and (2) 25°C 1.7 kz

Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
Resistance (female) (7) and (8) 25°C 1.7 kz
a If cause 2 is not the cause for the failure, this check is not required.
3 2. Disconnect connectors P18 and AC01.
harness
Between AC01 (female) (7) and (8), or
Resistance between P18 (female) (1) and (2) Min. 1 Mz
harness 2. Disconnect connectors P18 and AC01.
4
(Contact with GND Between ground and AC01 (female) (8)
circuit) Resistance or P18 (female) (1) Min. 1 Mz
6
conditioner unit
80-56 PC290LC-10
80 Appendix
Circuit diagram related to air conditioner outside air temperature sensor
PC290LC-10 80-57
80 Appendix
Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKA] Ventilating sensor Open Circuit

Action Evaporator temperature (frost) sensor disconnection
Failure code
level Failure
879CKA
Details of • Air conditioner controller detected disconnection in evaporator temperature (frost) sensor.
failure
• Th air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a disconnection in the evaporator
machine temperature (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
2
conditioner unit
80-58 PC290LC-10
80 Appendix
Failure code [879CKB] Ventilating sensor Short Circuit
Failure code [879CKB] Ventilating sensor Short Circuit

Action Evaporator temperature (frost) sensor short circuit
Failure code
level Failure
879CKB
Details of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
2
conditioner unit
PC290LC-10 80-59
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit

Action Sunlight sensor disconnection or short circuit
Failure code
level Failure
879DKZ
Details of • Air conditioner controller detected disconnection or short circuit in sunlight sensor.
failure
• The air conditioner controller sends information about sunlight sensor disconnection or
Action of short circuit to the machine monitor via CAN communication.
controller • Continues control of the air conditioner in automatic mode, ignoring sunlight sensor data.
• Since the air conditioner sunlight sensor has a disconnection or short circuit, sunlight
Problem on strength is not counted in automatic mode.
pins).
must be replaced.
1. See "Testing sunlight sensor(PAGE 80-42)".
Defective sunlight Direct sunlight Approx. 0.55 V
1 Between sunlight
sensor Voltage Cloudy Approx. 0.45 V
sensor terminals
Indoor Approx. 0.4 V
Breaking of 2. Disconnect connector P31.
harness a See "Testing sunlight sensor(PAGE 80-42)".
2 (Wire breakage or Between P31 (female) (1) and AC01
Between P31 (female) (2) and AC01
4
conditioner unit
80-60 PC290LC-10
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
PC290LC-10 80-61
80 Appendix
Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879EMC] Ventilating Damper Abnormality

Action Abnormality in vent (mode) changeover damper servomotor
Failure code
level Failure
L01 879EMC
Details of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
2
conditioner unit
80-62 PC290LC-10
80 Appendix

Action Abnormality in air mix (temperature regulation) damper
Failure code
level Failure servomotor
L01 879FMC (Machine monitor power train control system)
Details of • The air conditioner controller judged from the potentiometer voltage of the servomotor
failure that the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
• Method of reproducing failure code: Turn starting switch ON position.
Related
information
• Troubleshooting cannot be performed since the connector part of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
2
conditioner unit
PC290LC-10 80-63
80 Appendix

Action Refrigerant (dual) pressure switch abnormality
Failure code
level Failure
L01 879GKX
Details of • Air conditioner controller detected that dual pressure switch was OFF (abnormal).
failure
• The air conditioner controller sends information about the refrigerant pressure
abnormality to the machine monitor via CAN communication.
Action of • The air conditioner controller turns OFF compressor clutch relay, since refrigerant
controller pressure is abnormal.
(The air conditioner compressor stops)
Problem on • The air conditioner (cooling) does not operate.
machine
• For each connector and other parts, see "Parts and connectors layout(PAGE 80-29)".
pins).
must be replaced.
Defective 1. See "Testing (dual) pressure switch for refrigerant(PAGE 80-43)".
1 refrigerant (dual)
k When replacing the dual pressure switch, be sure to collect refrigerant in
pressure switch
advance. See "Precautions for refrigerant(PAGE 80-3)".
Breaking of
2. Disconnect connector AC01 and AC05.
harness
Between P17 (female) (1) and AC01
2 (Wire breakage or (female) (6) Max. 1 z
defective contact of Resistance Between P17 (female) (2) and ground
connectors) Max. 1 z
a Looseness and rust of T06
4
conditioner unit
Circuit diagram related to (dual) pressure switch for refrigerant
80-64 PC290LC-10
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)
A-1 Troubleshooting for power supply system (Air conditioner does not
operate)
Failure • Trouble: Air conditioner does not operate due to power supply system failure.
• If failure code [DAZQKR] is displayed on machine monitor, perform this troubleshooting
first.
a The machine monitor, engine controller, pump controller, and air conditioner controller are
connected via CAN communication.
• "DAZQKR" is displayed on operation screen of machine monitor in the following cases. In
this section, 1) and 2) of the following are explained.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is malfunctioning.
3) No communication is possible between the air conditioner controller and the machine
monitor.
a For 3), see failure code [DAZQKR].
• Turn starting switch to ON position and check whether failure code [DAZQKR] is
displayed on machine monitor and whether CAN communication condition is abnormal.
Related This type of abnormal status indicates that CAN communication cannot be performed
information between the air conditioner controller above the air conditioner unit and the machine
monitor.
• Referring to "Parts and connectors layout(PAGE 80-29)", check fuse No. 14 (5 A) in fuse
box F01 for breakage.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system."
have a T-adapter, carry out troubleshooting by using the intermediate connector
(Although the intermediate connector does not have a T-adapter either, it does have large
pins).
must be replaced.
Defective wiring 2. Set battery disconnect switch to OFF position.
1 harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on harness side of
Resistance connector AC02 and chassis ground Max. 1 z

2 Blown fuse 2. Referring to "Parts and connectors layout(PAGE 80-29)", check fuse No. 14 (5
A) in fuse box F01 for breakage.
a If fuse described in related information is broken, replace it.
2. Set battery disconnect switch to OFF position.
Defective wiring 3. Disconnect connector AC02.
3
harness 4. Set battery disconnect switch to ON position.
Between connector AC02 (female) (4) 20 to 30 V
Voltage
(red) and (1) (black)
PC290LC-10 80-65
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

a If the fuse is blown again during the above test, carry out the following
procedure.
Ground fault in
machine wiring
2. Set battery disconnect switch to OFF position.
4 harness
3. Disconnect connector AC02.
(Contact with GND 4. Remove fuse No. 14 of fuse box F01.
circuit) Between connector AC02 (female) (4)
Resistance (red) and ground, or between F01-14 Min. 1 Mz
and ground
Breaking of 1.Turn starting switch to OFF position.
harness 2.Set battery disconnect switch to OFF position.
3.Disconnect connector AC02.
5 (Wire breakage or
4.Remove fuse No. 14 of fuse box F01.
Between connector AC02 (female) (4)
connectors) Resistance Max. 1 Mz
(red) and F01-14
Defective air Replace air conditioner controller.
6 conditioner
controller
7
conditioner unit
Defective machine If no abnormality is found in the checkup of potential causes 1 - 7, the machine
8
monitor monitor is defective.
Circuit diagram related to power supply
80-66 PC290LC-10
80 Appendix
A-2 Troubleshooting of compressor system (Air is not
cooled)
A-2 Troubleshooting of compressor system (Air is not cooled)

Failure • Trouble: Air is not cooled due to compressor or refrigerant system failure.
• Referring to "Testing with self-diagnosis function", display "Electrical Systems" screen on
the machine monitor and check to see if the refrigerant pressure is abnormal by checking
whether failure code [879GKX] is displayed. If the refrigerant pressure is abnormal, the
compressor will not be turned ON and air will not subsequently not be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the
dual pressure switch is not grounded".
• In certain cases, the air conditioner will not turn on at 3°C or lower (normal).
• If no air comes out, see "Troubleshooting for blower motor system".
• For each connector and fuse, see "A-3 Troubleshooting for blower motor system (No air
Related comes out or air flow is abnormal)(PAGE 80-70)" and "Parts and connectors layout(PAGE
information 80-29)".
a A T-adapter is provided only for the connector AC03.
pins).
must be replaced.
a Perform this check when failure code [879GKX] is displayed on "Electrical
Systems" screen of machine monitor.
See failure code [879GKX].
Defective dual a In certain cases, the dual pressure switch may be operating normally and set to
1 pressure switch OFF, therefore, if abnormality is indicated (i.e., switch OFF), attach a pressure
system gauge to the air conditioner compressor and check the refrigerant pressure.
(See "Troubleshooting with gauge pressure(PAGE 80-74)".)
k If the pressure switch is to be replaced, refrigerant must be collected in
advance.
2. Disconnect the connector AC03 from the air conditioner compressor and
connect a T-adapter to the male side.
Defective air
2 conditioner a Ensure connection of air conditioner compressor ground cable (E).
compressor (See "Parts and connectors layout(PAGE 80-29)".)
Between connector AC03 (male) (1) and
Resistance the chassis ground (i.e., air conditioner Approx. 15 z
compressor coil resistance)
• Referring to "Testing relays", check sound when compressor clutch relay is
turned ON.
Click is heard.————————————————————————— A
a When A above is abnormal and B below is abnormal and C is normal (if the
relay is normal), go to cause 4.
Defective 2. Disconnect connector R21.
compressor clutch 3. Use a wire to short-circuit (3) (white) and (5) (red on yellow) of connector R21
3 relay(Does not turn (wiring harness side). (This forces the compressor to operate without using the
ON) relay.)
Air is cooled.————————————————————————— B
2. Disconnect connector R21 and troubleshoot in that condition.
Between R21
(male) (1) and (2) (i. Approx. 300 to 500
Resistance C
e., coil resistance) z
PC290LC-10 80-67
80 Appendix
cooled)

2. Disconnect connector R21 and carryout troubleshooting without turning
starting switch ON.
a Ensure that test result for cause 2 (air conditioner compressor is normal) is
normal.
Between connector R21 (female) (5) and
Breaking of F01-10 Max. 1 z
4 (Pressure switch is turned ON)
harness
Resistance the chassis ground
Approx. 15 z
(Air conditioner compressor coil
resistance)
Between F01-14 and AC01 (female) (4)
300 to 500 z
a Relay coil resistance
a If the fuse is not blown, skip troubleshooting.
Ground fault in
harness
5 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the female
(Contact with GND side of AC03.
circuit) Between AC03 (female) (1) and chassis
Resistance ground Min. 1 Mz

2. Disconnect connectors AC01, AC02, and R21.
Short-circuiting of a Ensure that test result for cause 2 is normal.
6
harness Between wiring harness side (2) of
Resistance connector R21 and AC02 (female) (2), Min. 1 Mz
(3), and (4)
2. Disconnect connector R21.
Defective air 3. Turn starting switch to ON position.
7 conditioner 4. Display the air conditioner operation screen on the machine monitor and press
controller the A/C switch.
Voltage Max. 1 V
ground
Defective machine 2. Display the air conditioner operation screen on the machine monitor.
8
monitor
Press A/C switch. "A/C ON" is displayed.
9
conditioner unit
80-68 PC290LC-10
80 Appendix
cooled)
Circuit diagram related to compressor and refrigerant system
PC290LC-10 80-69
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
• This failure is not checked with self-diagnosis function.
• In cases where the blown-air volume begins to behave in an unpredictable manner after a
certain while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1. Defective compressor clutch relay (i.e., stuck in ON position) (see item 3 A from
"Troubleshooting for compressor and refrigerant system")
2. Detachment of the evaporator temperature sensor's mounting holder (Replace the air
conditioner unit)
3. Incorrect adjustment of expansion valve (Replace air conditioner unit)
• If air comes out, fuse and motor are normal, and also wiring harness is normal.
• For connectors and power transistor, see "Parts and connectors layout(PAGE 80-29)".
Related
information a The power transistor is on the rear side of the air conditioner unit.
• If air comes out but its flow is abnormal in heating mode, replace power transistor. (When
no air comes out, the power transistor may also be defective.)
a The blower motor cannot be replaced unless the air conditioner unit is removed once.
pins).
must be replaced.
Defective fuse No. If fuse is blown, circuit probably has ground fault.
1
10 in fuse box F01
Defective power 2. Replace power transistor.
2
transistor a If air comes out and air flow can be adjusted, the original power transistor is
defective.
harness 2. Disconnect connector AC02.
3 (Wire breakage or 3. Remove fuse No. 10 of fuse box F01.
Resistance Between AC02 (female) (2) and F01-10 Max. 1 z
connectors)
harness 2. Disconnect connectors AC02 and AC04.
4 3. Remove fuse No. 10 of F01.
(Contact with GND
Between AC02 (female) (2) or F01-10
circuit) Resistance Max. 1 z
and ground
5 conditioner defective. (Since this is an internal defect, troubleshooting cannot be performed.)
controller
6
conditioner unit
80-70 PC290LC-10
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
Circuit diagram related to blower motor system
PC290LC-10 80-71
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover

Failure • Trouble: FRESH/RECIRC air cannot be selected
• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Referring to "Testing FRESH/RECIRC air selector", operate the FRESH/RECIRC air
selector switch and check operation of FRESH/RECIRC air changeover door (damper).
• For connectors, see "Parts and connectors layout(PAGE 80-29)".
a The T-adapter is not prepared for the connector.
Related (Although the intermediate connector does not have a T-adapter either, it does have large
information pins).
must be replaced.
• Troubleshooting cannot be performed since the connector portion of the servomotor
cannot be checked while it is installed on machine.
Defective fuse No. If fuse is blown, circuit probably has ground fault.
1
19 in fuse box F01
Breaking of a Connector [5] installed on machine cannot be disconnected since it is on the
harness rear side of the air conditioner unit.
2 (Wire breakage or 1. Turn starting switch to OFF position.
defective contact of 2. Disconnect connector AC02.
connectors) 3. Remove fuse No. 19 of F01.
Resistance Between F01-19 and AC02 (female) (3) Max. 1 z
harness 2. Disconnect connector AC02.
3 3. Remove fuse No. 19 of F01.
(Contact with GND
Between F01-19 and ground, or
circuit) Resistance Max. 1 z
between AC02 (female) (3) and ground
4 conditioner defective. (Since this is an internal defect, troubleshooting cannot be performed.)
controller
5
conditioner unit
2. Display the air conditioner operation screen on the machine monitor.
Defective machine
6 Press FRESH/
monitor
RECIRC air Display of Recirc/Fresh changes.
selector switch.
80-72 PC290LC-10
80 Appendix
Circuit diagram related to FRESH/RECIRC air changeover
PC290LC-10 80-73
80 Appendix
Troubleshooting with gauge pressure

Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• High-pressure line pressure is too high: Above approx. 2.5 MPa {25 kg/cm 2}
• High-pressure line pressure is too low: Below approx. 1 MPa {10 kg/cm 2}
• Low-pressure line pressure is too high: Above approx. 0.3 MPa {3 kg/cm2}
• Low-pressure line pressure is too low: Below approx. 0.05 MPa {0.5 kg/cm2}
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-perssure line is abnormal.
<Measurement condition for pressure>
Item Condition value
Ambient temperature 25 – 50 °C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Full cool
• Dual pressure switch
a The swiths is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
80-74 PC290LC-10
80 Appendix
Indicated gauge
Cause Check method Remedy
pressure
Air conditioner cycle is operating normally.
Pressure is If there is any trouble (cooling trouble), there is another cause.
–
normal High-pressure: Approx. 1.5 - 1.7 MPa {15 - 17 kg/cm2}
Low-pressure: Approx. 0.13 - 0.2 MPa {1.3 - 2.0 kg/cm2}
Collect refrigerant,
then fill up with
Bubble can be seen through sight
Insufficient refrigerant proper quantity of
glass. *1, *3
refrigerant again
*2
There is a temperature difference
between inlet and outlet pipes of Replace
Clogging of receiver drier receiver drier. *2
Tank is frosty
Both high- Clean or replace
Clogging of expansion valve Expansion valve is frosted
pressure and *2
low-pressure Gas leakage at thermoprobe of Low-pressure gauge reads Replace
are too low> expansion valve vacuum *2
Low-pressure Repair or replace
gauge reads Evaporator is frozen Replace receiver
vacuum Defective evaporator temperature drier
Flow rate of refrigerant is reduced
sensor or defective contact of Collect refrigerant,
due to freezing.
sensor (coming off of mounting then fill up with
clip) (At Cool Max. and HI speed of fan, proper quantity of
later it becomes not to cold.)
refrigerant again
*2
Piping between receiver drier and
compressor is clogged or crushed. Clean or replace
Clogged or crushed piping
If clogged completely, low- *2
pressure gauge reads vacuum
Collect refrigerant,
then fill up with
Filling too much with refrigerant Connect gauge manifold proper quantity of
refrigerant again
*2
Clean, repair fins,
Dirty condenser, clogging or
or repair or replace
<Both high- Defective cooling of condenser crushing of fins, or defective
condenser
pressure and rotation of cooling fan
low-pressure *2
are too high> Improper adjustment of
Bubble can be seen through sight Replace
expansion valve (Valve is opened
glass. *3 *2
too wide)
Evacuate and then
fill up with proper
Bubble can be seen through sight
Air in cycle parts quantity of
glass. *3
refrigerant again
*2
<High-pressure Clean inside of
Clogged or crushed piping There is a remarkable temperature
is too high and cycle or replace
between compressor and difference across clogged part
low-pressure is
condenser *2
too low>
Both high-pressure and low-
<High-pressure pressure are balanced while
Defective compressor Replace
is too low and compressor is in operation.
(Compression trouble of
low-pressure is *2
compressor) Compressor has seized and is
too high>
extremely hot.
PC290LC-10 80-75
80 Appendix
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks, too. So perform the check
mainly on pipe joints and dirty parts with oil.
*2:
k When replacing a cooling cycle part, see “Caution about refrigerant” and collect refrigerant. After
replacing it, fill up the air conditioner system with refrigerant again.
*3: Sight glass is on the receiver drier.
80-76 PC290LC-10
80 Appendix
Testing refrigerant pressure

• The troubled portion can be narrowed by checking the gauge pressures on the high- and low-pressure
sides of the refrigeration cycle and checking the combination of the indicated pressures on the high- and
low-pressure sides.
a Component to be checked
a The service tool kit shown below is for R134a.
Symbol Part No Part Name
X 799-703-1200 Service tool kit
k Turn the battery disconnect switch to the “OFF“ position and pull out the key.
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the following conditions.
• Outside air temperature: 25 to 50°C
• Engine speed: 1,500 rpm
• Air conditioner switch: ON
• Fan switch: High
• Set temperature: Max. cooling (18.0°C)
Check
PC290LC-10 80-77
80 Appendix
1. Close the high-pressure valve (6) and low-pressure valve (7) of gauge manifold (1).
2. Connect red high-pressure charging hose (2) to the HI side of gauge manifold (1) and blue low-pressure
charging hose (3) to the LO side of the gauge manifold.
3. Connect quick joint (4) to red high-pressure charging hose (2).
a Quick joint (4) has larger diameter than the other.
a As threaded portion (a) is coarse and loosened easily, take care.
4. Connect quick joint (5) to blue low-pressure charging hose (3).
a Quick joint (5) has smaller diameter than the other.
a As threaded portion (a) is coarse and loosened easily, take care.
5. Connect quick joint (4) to service valve (8) of the high-pressure refrigerant piping and connect quick joint
(5) to service valve (9) of the low-pressure refrigerant piping.
6. Check the pressures indicated on high-pressure side (HI) and low-pressure side (LO) of gauge manifold
(1).
• The pressures indicated on the high- and low-pressure sides are judged as follows.
Indicated gauge pressure
Criterion
(MPa {kg/cm2})
High Min. approx. 2.5 {25}
High-pressure side
Low Max. approx. 1 {10}
High Min. approx. 0.3 {3}
Low-pressure side
Low Max. approx. 0.05 {0.5}
Reference: Dual pressure switch turns “OFF“ to protect the refrigerant circuit if the pressure of the
high-pressure or low-pressure line is abnormal.
a For operation of dual pressure switch, see "Dual pressure switch(PAGE 80-15)".
Troubleshooting table with gauge pressure indicated by gauge manifold

Indicated gauge
Probable cause Check method Remedy (*1)
pressure
• Refrigerant cycle is operating normally
Pressure on high-pressure side: Approx. 1.5 to 1.7 MPa
Reference: Pressure is {15 to 17 kg/cm2}
—
normal Pressure on low-pressure side: Approx. 0.13 to 0.2 MPa
{1.3 to 2.0 kg/cm2}
• If there is any trouble, there is another cause.
• Insufficient refrigerant (*2) and (*3) • Collect refrigerant,
• Bubbles are seen in the sight then fill up with
glass proper quantity of
refrigerant again
• Clogged modulator of • There temperature difference
condenser between outlet and inlet of
modulator of condenser • Replace
• Modulator of condenser is
• Both high-pressure frosted
and low-pressure • Clogging of • Expansion valve is frosted
• Clean or replace
are too low expansion valve
• Pressure on low- • Gas leakage at • Low-pressure gauge reads
pressure side thermoprobe of vacuum • Replace
becomes vacuum expansion valve
• Defective evaporator • Evaporator is frozen • Repair or replace
temperature sensor Refrigerant flow decreases • Replace
• Defective contact of because of freezing condenser
sensor (Coming off of (If air flow is set maximum at (modulator)
fixing clip) maximum cooling level for a • Collect refrigerant,
while, air is not cooled) then fill up with
proper quantity of
refrigerant again
80-78 PC290LC-10
80 Appendix
Indicated gauge
Probable cause Check method Remedy (*1)
pressure
• Clogged or crushed • Clogged or crushed
piping refrigerant piping between
condenser and compressor • Clean or replace
If clogged completely, low-
pressure gauge reads
vacuum
• Overcharge with • Connect gauge manifold • Collect refrigerant,
refrigerant then fill up with
proper quantity of
refrigerant again
• Defective cooling of • Dirty condenser, clogging or
condenser crushing of fins • Clean, repair, or
• Defective rotation of cooling replace
• Both high-pressure
fan
and low-pressure
• Improper adjustment (*3)
are too high
of expansion valve • Bubbles are seen in the sight • Replace
(Value is opened too glass
wide)
• Air in refrigeration (*3) • Evacuate, then fill
cycle • Bubbles are seen in the sight up with proper
glass quantity of
refrigerant again
• Clogged or crushed • There is a remarkable
• Pressure on high-
refrigerant piping temperature difference
pressure is too high • Clean or replace
between compressor between before and after
and that on low- refrigerant piping
and condenser clogged part of refrigerant
pressure is too low
piping
• Defective compressor • Pressures on high- and low-
• Pressure on high- (Defective pressure sides are balanced
pressure is too low compression by while compressor is in
• Replace
and that on low- compressor) operation
pressure is too high • Compressor has seized and is
extremely hot.
k *1: When replacing a refrigeration cycle part, see “Precautions for disconnecting and connecting
air conditioner piping(PAGE 80-80)” and collect refrigerant. After replacing the part, fill up the
refrigerant circuit with refrigerant again.
*2: If refrigerant leaks, compressor oil circulating in the refrigerant circuit always leaks, too. So perform the
check mainly on pipe joints and oil leaking parts.
*3: The sight glass is installed to the refrigerant piping on the refrigerant outlet side of the condenser.
PC290LC-10 80-79
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
Precautions for disconnecting and connecting air conditioner piping

Precautions for disconnecting
k Collect the refrigerant (Air conditioner gas: R134a) from air conditioner circuit before
disconnecting air conditioner hose to replace air conditioner unit, air conditioner compressor or
receiver drier and so on.
a Ask a qualified person for collecting, adding and filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Accordingly, put on protective eyeglasses, gloves and working cloth
with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
• When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches.
Use one wrench to fix and use the other one to loosen the nuts.
Precautions for connecting
• When connecting piping, apply compressor oil (ND-OIL8) for R134a to its O-rings. (See item 4 of
"Handling compressor oil")
Do not apply oil to the threads of a bolt, nut or union, however.
• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it. When removing it,
use a soft tool (such as a toothpick) so that the piping will not be damaged.
• Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers.
• Be sure to use two wrenches to tighten each nut. Use one wrench to fix and tighten the nut with the other
wrench to the specified torque (Use a torque wrench for tightening).
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
3.9 - 6.9 {0.4 - 0.7} (Receiver drier)
M6 x 1.0
8 - 12 {0.8 - 1.2} (Air conditioner unit and compressor)
M16 x 1.5 12–15(1.2–1.5)
M22 x 1.5 20–25 {2.0–2.5}
M24 x 1.5 30–35 {3.1–3.6}
80-80 PC290LC-10
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
1. Engine
2. Compressor
3. Condenser
4. Receiver drier
PC290LC-10 80-81
80 Appendix
Handling of compressor oil

1. Compressor oil management (DENSO: ND-OIL8 for R134a)
Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following
types of problem can occur if the amount in the system is too high or too low.
Condition Content
Insufficiency of oil Lubrication trouble and seizure of compressor
Cooling trouble (Excessive oil stick to parts and lower heat exchange
Excess of oil performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2. Filling compressor oil

k Refrigerant is potentially hazardous to health and to the environment. Before disconnecting air
conditioner hoses, therefore, refrigerant should be collected in accordance with "Precautions for
disconnecting and connecting air conditioner piping(PAGE 80-80)"
a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized.
Be sure to use an oil suitable for R134a (DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic, and therefore, the cap must be immediately closed after
use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (except
a baked finish) as it may dissolve these plastics.
Check compressor oil in the following cases, and then add new oil if necessary.
• When much refrigerant is discharged because of leakage.
• When the compressor is troubled and replaced.
(See 3 below)
• When a cycle parts such as condenser, receiver drier, evaporator unit, etc. is replaced.
• Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser Approx. 40
Receiver drier Approx. 20
Hose (between M24 joint and cab) Approx. 30
Hose (between condenser and M22 joint) Approx. 35
Hose (between condenser and M16) Approx. 10
Hose (between cab and M16) Approx. 20
3. Replacement of compressor
• In case of compressor seizure or breakage.
Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
80-82 PC290LC-10
80 Appendix
In this case, flush the air conditioner circuit and replace the compressor and receiver drier.
The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new
compressor with the oil of the specified quantity (180 cc) filled in it.
• Other cases
a New compressor contains compressor oil of 180 cc in it.
1. Prepare an oil container and drain oil from the old compressor.
2. Measure the quantity of the drained oil with a measuring cylinder, and note the quantity or mark the level.
3. Drain below-mentioned quantity of oil from the new compressor.

Quantity to be drained = 180 cc - "Noted quantity"
Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new
compressor would be 150 cc (i.e., 180 - 30 cc).
4. Applying compressor oil to O-rings

Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in order to
prevent the leakage of refrigerant.
PC290LC-10 80-83
80 Appendix
Desiccant replacement
a Prepare desiccating agent replacement kit (20Y-810-1250).
k When replacing the desiccating agent, be sure to collect the refrigerant from the air conditioning
cycle. If the desiccating agent is replaced without collecting the refrigerant, the refrigerant may
blind you or cap (C) may fly out and injure you because of the refrigerant pressure in the cycle.
1. Condenser
2. Modulator
a The desiccanting agent is in modulator (2).
Taking out desiccanting agent (D)

1. Remove snap ring (SR) from modulator (2).
2. Hold boss (B) of cap (C) with pliers etc. to remove it from modulator (2).
a Cap (C) may be hard to remove. When removing it, exercise care not to damage or deform the seal or
modulator (2).
3. Remove filter (F) from modulator (2).
4. Remove desiccanting agent (D) from modulator (2).
a Replace snap ring (SR), cap (C), O-ring (OR), filter (F), and desiccanting agent (D) with the new parts
in the desiccanting agent replacement kit.
80-84 PC290LC-10
80 Appendix
Installing new desiccanting agent (D)

1. Apply compressor oil (ND-OIL8) to the periphery of O-ring (OR) of cap (C).
2. Install filter (F) to cap (C).
3. Insert desiccanting agent (D) in modulator (2).

4. Install cap (C) with filter (F) to modulator (2).
5. Fit snap ring (SR) to modulator (2) to fix cap (C).
a If snap ring (SR) is not fitted to the groove in modulator (2) securely, cap (C) may be come off.
PC290LC-10 80-85
80 Appendix
80-86 PC290LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC290LC - 10
Model Serial Number
PC290LC - 10 15001 and up

10 90 Diagrams and drawings
PC290LC-10 90-1
Table of contents
Table of contents
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electric circuit diagram........................................................................................................ 90-13
Electric circuit diagram for air conditioner unit ....................................................................... 90-25
90-2 PC290LC-10
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram

(Rev. 2010/03)
PC290LC-10 90-3
90-4 PC290LC-10
PC290LC-10 90-5
90-6 PC290LC-10
Hydraulic circuit diagram Hydraulic circuit diagram
PC290LC-10
PC290LC-10
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC290LC-10 90-7
Symbols in electric circuit diagram
Electric circuit diagram

(Rev. 2010/03)
PC290LC-10 90-9
90-10 PC290LC-10
PC290LC-10 90-11
90-12 PC290LC-10
Electrical circuit diagram (1/6) Electrical circuit diagram (1/6)
PC290LC-10
PC290LC-10
PC290LC-10 90-13
PC290LC-10
PC290LC-10
PC290LC-10 90-15
PC290LC-10
PC290LC-10
PC290LC-10 90-17
PC290LC-10
PC290LC-10
PC290LC-10 90-19
PC290LC-10
PC290LC-10
PC290LC-10 90-21
PC290LC-10
PC290LC-10
PC290LC-10 90-23
Electrical circuit diagram for air conditioner unit Electrical circuit diagram for air conditioner unit
PC290LC-10
PC290LC-10
a In the drawing, full line shows air conditioner wiring harness, and dashed line shows cab and chassis wiring harness. (For the detail of cab and chassis harness, see "Electrical circuit diagram")
a In the drawing, dot and dash line shows machine monitor wiring, and using twisted line (AVS 0.5 x 2, pitch 45 mm or less).
PC290LC-10 90-25
INDEX
INDEX
A Cooling system.......................................10-5, 60-4

A-1 Troubleshooting for power supply system
(Air conditioner does not operate) ................. 80-65 D
A-2 Troubleshooting for compressor and
Desiccant replacement.................................. 80-84
refrigerant system (Air is not cooled) ............. 80-67
Diagnostic procedure for wiring harness open
A-3 Troubleshooting for blower motor system
curcuit of pressure sensor system ................ 40-55
(No air comes out or air flow is abnormal) ...... 80-70
Disassembly and assembly of carrier roller ... 50-137
A-4 Troubleshooting for FRESH/RECIRC air
Disassembly and assembly of center swivel
changeover ................................................ 80-72
joint.......................................................... 50-147
Adjusting mirrors........................................... 30-71
Disassembly and assembly of control valve .. 50-163
Adjusting play of work equipment and swing
Disassembly and assembly of final drive....... 50-106
PPC valves ................................................ 30-62
Disassembly and assembly of idler............... 50-130
Adjustment (Pump calibration: Matching speed
Disassembly and assembly of idler cushion .. 50-133
calibration) ............................................... 30-136
Disassembly and assembly of KDPF .............. 50-92
Adjustment (Pump calibration: Matching speed
Disassembly and assembly of swing
check)...................................................... 30-131
machinery ................................................ 50-117
Air conditioner component ............................... 80-4
Disassembly and assembly of track roller ..... 50-135
Air conditioner compressor ............................ 80-17
Disassembly and assembly of travel PPC
Air conditioner condenser .............................. 80-18
valve ........................................................ 50-169
Air conditioner controller ................................ 80-16
Disassembly and assembly of work equipment
Air conditioner unit .......................................... 80-9
cylinder .................................................... 50-175
Angle adjustment of rear view camera .......... 30-142
Disassembly and assembly of work equipment
Attachment circuit selector valve (for high-
PPC valve ................................................ 50-167
pressure circuit) .......................................... 60-47
Dual pressure switch..................................... 80-15
Attachment circuit selector valve (for low-
pressure circuit) .......................................... 60-48
E
B E-1 Engine does not start (Engine does not
rotate) ...................................................... 40-539
Bleeding air from fuel system ......................... 30-34
E-2 Manual preheating system does not work .....40-
Bleeding air from hydraulic circuit ................... 30-68
545
E-3 Automatic preheating system does not
C work......................................................... 40-548
E-4 Preheating monitor does not light up when
Carrier roller ................................................. 60-18 preheater is operated ................................ 40-550
Center swivel joint......................................... 60-49 E-5 When starting switch is turned to ON
Checking and adjusting air conditioner position, machine monitor displays nothing.. 40-552
compressor belt tension............................... 30-39 E-6 When starting switch is turned to ON
Checking cab tipping stopper......................... 30-70 position (before starting engine), engine oil
Checking engine speed................................... 30-9 level monitor lights up in yellow .................. 40-555
Checking fuel circuit for leakage..................... 30-36 E-7 When starting switch is turned to ON
Checking oil pressure with sensor adapter position (before starting engine), radiator
(special tool) ............................................... 30-55 coolant level monitor lights up in yellow ....... 40-556
Circuit diagram and arrangement of connector E-8 Coolant temperature monitor lights up in
pins ........................................................... 80-24 white while engine is running...................... 40-557
Classification and procedure for E-9 Hydraulic oil temperature monitor lights up
troubleshooting ........................................... 40-46 in white while engine is running .................. 40-558
CLSS........................................................... 10-22 E-10 Charge level monitor lights up while
Coating materials list....................................... 50-6 engine is running....................................... 40-559
Configuration and function of refrigeration E-11 Fuel level monitor lights up in red while
cycle ............................................................ 80-6 engine is running....................................... 40-560
Connector contact identification ..................... 40-68 E-12 Air cleaner clogging monitor lights up in
Connector list and layout ............................... 40-57 yellow while engine is running .................... 40-561
Control valve ...................................... 10-51, 60-24
Conversion table .......................................... 00-51
PC290LC-10 1
INDEX
E-13 Water separator monitor lights up while E-41 One-touch power maximizing function
engine is running....................................... 40-562 cannot be released.................................... 40-596
E-14 Coolant temperature monitor lights up in E-42 Travel alarm does not sound when
red while engine is running......................... 40-563 machine travels ........................................ 40-597
E-15 Hydraulic oil temperature monitor lights E-43 Travel alarm does not stop sounding
up in red while engine is running................. 40-564 when machine stops.................................. 40-598
E-15 One-touch power maximizing function E-44 Horn does not sound ........................... 40-599
does not work ........................................... 40-650 E-45 Horn does not stop sounding ............... 40-601
E-16 Engine oil pressure monitor lights up in E-46 Wiper monitor does not light up or go out
red while engine is running......................... 40-565 when wipper switch is operated .................. 40-602
E-17 Fuel gauge indicate either full or empty E-47 Wiper does not operate when wipper
and does not move.................................... 40-566 switch is operated ..................................... 40-603
E-18 Fuel gauge indicates incorrect amount E-48 Window washer does not operate when
(indicates neither full nor empty) ................. 40-567 window washer switch is operated .............. 40-605
E-19 Coolant temperature gauge indicate E-49 BOOM LOWER indication is not
either Min or Max and does not move.......... 40-568 displayed properly with monitoring function . 40-606
E-20 Coolant temperature gauge indicates E-50 ARM DUMP indication is not displayed
incorrect temperature (indicates neither Min properly with monitoring function ................ 40-607
nor Max)................................................... 40-569 E-51 ARM IN indication is not displayed
E-21 Hydraulic oil temperature gauge indicate properly with monitoring function ................ 40-608
either Min or Max and does not move.......... 40-570 E-52 BOOM RAISE indication is not displayed
E-22 Hydraulic oil temperature gauge indicates properly with monitoring function ................ 40-609
incorrect temperature (indicates neither Min E-53 BUCKET CURL indication is not
nor Max)................................................... 40-572 displayed properly with monitoring function . 40-610
E-23 Content of display on machine monitor is E-54 BUCKET DUMP indication is not
different from that of actual machine ........... 40-573 displayed properly with monitoring function . 40-611
E-24 Machine monitor does not display some E-55 SWING indication is not displayed
items........................................................ 40-574 properly with monitoring function ................ 40-612
E-25 Function switch does not work ............. 40-575 E-56 TRAVEL indication is not displayed
E-26 Automatic preheating system does not properly with monitoring function ................ 40-613
work (In cold season) ................................ 40-576 E-57 Service is not displayed properly with
E-2 Manual preheating system does not work .....40- monitoring function.................................... 40-614
577 E-58 Attachment hydraulic circuit cannot be
E-28 Auto-deceleration is not actuated or changed ................................................... 40-617
canceled when lever is operated ................ 40-578 E-59 KOMTRAX system does not work
E-29 Working mode selector screen selection properly.................................................... 40-618
screen is not diplayed when working mode Electric circuit diagram .................................. 90-13
switch is operated ..................................... 40-580 Electric circuit diagram for air conditioner unit .. 90-25
E-30 Engine or hydraulic pump setting does Engine mount ................................................. 60-3
not change when working mode is changed 40-581 Engine related parts ........................................ 10-3
E-31 Travel speed monitor does not change Explanation of terms for maintenance standard ...00-
when travel speed switch is operated.......... 40-582 20
E-32 Travel speed does not change when
travel speed is shifted................................ 40-583
E-33 Alarm buzzer does not stop sounding ... 40-584
F
E-34 When starting switch is turned to OFF Failure code [879FMC] Air Mix Damper
position, service meter is not displayed ....... 40-585 Abnormality .................................... 40-132, 80-63
E-35 Service mode cannot be selected......... 40-586 Failure code [879AKA] A/C Inner sensor Open
E-36 Any of work equipment, swing and travel Circuit ........................................................ 80-52
does not work ........................................... 40-587 Failure code [879AKA] A/C Inner Sensor Open
E-37 Any of work equipment, swing and travel Circuit ...................................................... 40-124
can not be locked ...................................... 40-589 Failure code [879AKB] A/C Inner sensor Short
E-38 Machine can not swing while swing brake Circuit ........................................................ 80-53
cancel switch is canceled........................... 40-590 Failure code [879AKB] A/C Inner Sensor Short
E-39 Swing brake does not operate while Circuit ...................................................... 40-125
swing brake cancel switch is locked ............ 40-592 Failure code [879BKA] A/C Outer sensor Open
E-40 One-touch power maximizing function Circuit ........................................................ 80-54
does not work or monitor is not displayed .... 40-594 Failure code [879BKA] A/C Outer Sensor
Open Circuit ............................................. 40-126
2 PC290LC-10
INDEX
Failure code [879BKB] A/C Outer sensor Short Failure code [CA187] Sensor 2 Supply Volt
Circuit ........................................................ 80-56 Low Error ................................................. 40-168
Failure code [879BKB] A/C Outer Sensor Short Failure code [CA221] Ambient Press Sensor
Circuit ...................................................... 40-127 High Error................................................. 40-170
Failure code [879CKA] Ventilating sensor Failure code [CA222] Ambient Press Sensor
Open Circuit ............................................... 80-58 Low Error ................................................. 40-172
Failure code [879CKA] Ventilating Sensor Failure code [CA227] Sensor 2 Supply Volt
Open Circuit ............................................. 40-128 High Error................................................. 40-174
Failure code [879CKB] Ventilating sensor Failure code [CA234] Eng Overspeed........... 40-175
Short Circuit ............................................... 80-59 Failure code [CA238] Ne Speed Sensor
Failure code [879CKB] Ventilating Sensor Supply Volt Error ....................................... 40-176
Short Circuit ............................................. 40-129 Failure code [CA239] Ne Speed Sens Supply
Failure code [879DKZ] Sunlight sensor Open Volt High Error .......................................... 40-177
or Short Circuit............................................ 80-60 Failure code [CA271] IMV/PCV1 Short Error . 40-178
Failure code [879DKZ] Sunlight Sensor Open Failure code [CA295] Ambient Press Sens In
or Short Circuit.......................................... 40-130 Range Error.............................................. 40-181
Failure code [879EMC] Ventilating Damper Failure code [CA322] Inj #1(L#1) Open/Short
Abnormality ................................................ 80-62 Error ........................................................ 40-182
Failure code [879EMC] Ventilation Damper Failure code [CA323] Inj #5(L#5) Open/Short
Abnormality .............................................. 40-131 Error ........................................................ 40-184
Failure code [879GKX] Refrigerant Failure code [CA324] Inj #3(L#3) Open/Short
Abnormality .................................... 40-133, 80-64 Error ........................................................ 40-186
Failure code [989L00] Engine Controller Lock Failure code [CA325] Inj #6(L#6) Open/Short
Caution1 .................................................. 40-134 Error ........................................................ 40-188
Failure code [989M00] Engine Controller Lock Failure code [CA331] Inj #2(L#2) Open/Short
Caution2 .................................................. 40-135 Error ........................................................ 40-190
Failure code [989N00] Engine Controller Lock Failure code [CA332] Inj #4(L#4) Open/Short
Caution3 .................................................. 40-136 Error ........................................................ 40-192
Failure code [A1U0N3] HC desorb request1.. 40-137 Failure code [CA343] ECM Critical Internal
Failure code [A1U0N4] HC desorb request2.. 40-139 Failure ..................................................... 40-194
Failure code [AA10NX] Air Cleaner Clogging. 40-141 Failure code [CA351] Injectors Drive Circuit
Failure code [AB00KE] Charge Voltage Low . 40-143 Error ........................................................ 40-195
Failure code [B@BAZG] Engine Oil Pressure Failure code [CA352] Sensor 1 Supply Volt
Low ......................................................... 40-145 Low Error ................................................. 40-196
Failure code [B@BAZK] Eng Oil Level Low ... 40-146 Failure code [CA356] Mass Air Flow Sensor
Failure code [B@BCNS] Engine Coolant High Error................................................. 40-198
Overheat .................................................. 40-147 Failure code [CA357] Mass Air Flow Sensor
Failure code [B@BCZK] Radiator Coolant Low Error ................................................. 40-200
Level Low................................................. 40-148 Failure code [CA386] Sensor 1 Supply Volt
Failure code [B@HANS] Hyd Oil Overheat.... 40-150 High Error................................................. 40-202
Failure code [CA115] Eng Ne and Bkup Speed Failure code [CA428] Water in Fuel Sensor
Sens Error ................................................ 40-151 High Error................................................. 40-203
Failure code [CA122] Chg Air Press Sensor Failure code [CA429] Water in Fuel Sensor
High Error................................................. 40-152 Low Error ................................................. 40-205
Failure code [CA123] Chg Air Press Sensor Failure code [CA435] Eng Oil Press Sw Error......40-
Low Error ................................................. 40-154 207
Failure code [CA131] Throttle Sensor High Failure code [CA441] Battery Voltage Low
Error ........................................................ 40-156 Error ........................................................ 40-208
Failure code [CA132] Throttle Sensor Low Failure code [CA442] Battery Voltage High
Error ........................................................ 40-158 Error ........................................................ 40-210
Failure code [CA144] Coolant Temp Sens High Failure code [CA449] Rail Press Very High
Error ........................................................ 40-160 Error ........................................................ 40-211
Failure code [CA145] Coolant Temp Sens Low Failure code [CA451] Rail Press Sensor High
Error ........................................................ 40-162 Error ........................................................ 40-212
Failure code [CA153] Chg Air Temp Sensor Failure code [CA452] Rail Press Sensor Low
High Error................................................. 40-164 Error ........................................................ 40-214
Failure code [CA154] Chg Air Temp Sensor Failure code [CA515] Rail Press Sens Sup Volt
Low Error ................................................. 40-166 High Error................................................. 40-216
PC290LC-10 3
INDEX
Failure code [CA516] Rail Press Sens Sup Volt Failure code [CA2272] EGR Valve Pos Sens
Low Error ................................................. 40-218 Low Error ................................................. 40-275
Failure code [CA553] Rail Press High Error... 40-220 Failure code [CA2288] Turbo Speed High Error
Failure code [CA555] Crankcase Press High 1.............................................................. 40-278
Error 1...................................................... 40-221 Failure code [CA2311] IMV Solenoid Error .... 40-279
Failure code [CA556] Crankcase Press High Failure code [CA2349] EGR Valve Solenoid
Error 2...................................................... 40-222 Open Error ............................................... 40-280
Failure code [CA559] Rail Press Low Error ... 40-223 Failure code [CA2353] EGR Valve Solenoid
Failure code [CA687] Turbo Speed Low Error .....40- Short Error................................................ 40-282
226 Failure code [CA2357] EGR Differential
Failure code [CA689] Eng Ne Speed Sensor Pressure .................................................. 40-284
Error ........................................................ 40-228 Failure code [CA2373] Exh Manifold Press.
Failure code [CA691] Intake Air Temp Sens Sens Volt.................................................. 40-285
High Error................................................. 40-230 Failure code [CA2374] Exhaust Manifold Press
Failure code [CA692] Intake Air Temp Sens Sens Low Error ......................................... 40-287
Low Error ................................................. 40-232 Failure code [CA2376] EGR Orifice Temp Sens
Failure code [CA697] ECM Int Temp Sensor Low Error ................................................. 40-291
High Error................................................. 40-234 Failure code [CA2381] KVGT Pos Sens High
Failure code [CA698] ECM Int Temp Sensor Error ........................................................ 40-293
Low Error ................................................. 40-235 Failure code [CA2382] KVGT Pos Sens Low
Failure code [CA731] Eng Bkup Speed Sens Error ........................................................ 40-295
Phase Error .............................................. 40-236 Failure code [CA2383] KVGT Solenoid Open
Failure code [CA778] Eng Bkup Speed Sensor Error ........................................................ 40-297
Error ........................................................ 40-237 Failure code [CA2386] KVGT Solenoid Short
Failure code [CA1117] Persistent Data Lost Error ........................................................ 40-299
Error ........................................................ 40-241 Failure code [CA2387] KVGT Servo Error ..... 40-301
Failure code [CA1664] KDOC Malfunction .... 40-242 Failure code [CA2554] Exh Manifold Press
Failure code [CA1691] Regeneration Sens In Range Error.................................. 40-302
Ineffective................................................. 40-244 Failure code [CA2555] Grid Htr Relay Volt Low
Failure code [CA1695] Sensor 5 Supply Volt Error ........................................................ 40-303
Low Error ................................................. 40-246 Failure code [CA2556] Grid Htr Relay Volt High
Failure code [CA1696] Sensor 5 Supply Volt Error ........................................................ 40-306
High Error................................................. 40-248 Failure code [CA2637] KDOC Face Plugging 40-308
Failure code [CA1843] Crankcase Press Sens Failure code [CA2639] Manual Stationary
High Error................................................. 40-250 Regeneration Request............................... 40-310
Failure code [CA1844] Crankcase Press Sens Failure code [CA272] IMV/PCV1 Open Error . 40-180
Low Error ................................................. 40-252 Failure code [CA2961] EGR Orifice Temp High
Failure code [CA1879] KDPF Delta P Sensor Error 1...................................................... 40-312
High Error................................................. 40-254 Failure code [CA2973] Chg Air Press Sensor
Failure code [CA1881] KDPF Delta P Sensor In Range Error .......................................... 40-313
Low Error ................................................. 40-256 Failure code [CA3133] KDPF Outlet Press
Failure code [CA1883] KDPF Delta P Sens In Sens High Error ........................................ 40-314
Range Error.............................................. 40-258 Failure code [CA3134] KDPF Outlet Press
Failure code [CA1921] KDPF Soot Load High Sens Low Error ......................................... 40-316
Error 1...................................................... 40-261 Failure code [CA3135] KDPF Outlet Press
Failure code [CA1922] KDPF Soot Load High Sens In Range Error.................................. 40-318
Error 2...................................................... 40-263 Failure code [CA3251] DOC Inlet Temp High
Failure code [CA1942] Crankcase Press Sens Error ........................................................ 40-321
In Range Error .......................................... 40-268 Failure code [CA3253] KDOC Temp Error -
Failure code [CA1993] KDPF Delta Pressure Non Regeneration..................................... 40-324
Low Error ................................................. 40-269 Failure code [CA3254] KDOC Outlet Temp
Failure code [CA2185] Throt Sensor Sup Volt High Error 1 .............................................. 40-325
High Error................................................. 40-270 Failure code [CA3255] KDPF Temp Error - Non
Failure code [CA2186] Throt Sensor Sup Volt Regeneration............................................ 40-328
Low Error ................................................. 40-271 Failure code [CA3256] KDPF Outlet Temp
Failure code [CA2249] Rail Press Very Low High Error 1 .............................................. 40-329
Error ........................................................ 40-272 Failure code [CA3311] KDOC Outlet Temp
Failure code [CA2271] EGR Valve Pos Sens High Error 2 .............................................. 40-330
High Error................................................. 40-273
4 PC290LC-10
INDEX
Failure code [CA3312] KDPF Outlet Temp Failure code [DA2RKR] CAN1 Discon (Pump
High Error 2 .............................................. 40-331 Con) ........................................................ 40-394
Failure code [CA3313] KDOC Inlet Temp Failure code [DAF0MB] Monitor ROM
Sensor Low Error ...................................... 40-333 Abnormality .............................................. 40-395
Failure code [CA3314] KDOC Inlet Temp Sens Failure code [DAF0MC] Monitor Error ........... 40-396
High Error................................................. 40-336 Failure code [DAF8KB] Camera Power Supply
Failure code [CA3315] KDOC Inlet Temp Sens Short Circuit ............................................. 40-397
In Range Error .......................................... 40-340 Failure code [DAF9KQ] Model Selection
Failure code [CA3316] KDOC Outlet Temp Abnormality .............................................. 40-399
Sens Low Error ......................................... 40-344 Failure code [DAFGMC] GPS Module Error .. 40-400
Failure code [CA3317] KDOC Outlet Temp Failure code [DAFLKA] Operating Lamp Open
Sens High Error ........................................ 40-347 Circuit(Monitor) ......................................... 40-401
Failure code [CA3318] KDOC Inlet Temp Sens Failure code [DAFLKB] Operating Lamp Short
In Range Error .......................................... 40-351 Circuit(Monitor) ......................................... 40-403
Failure code [CA3319] KDPF Outlet Temp Failure code [DAFQKR] CAN2 Discon
Sens High Error ........................................ 40-355 (Monitor) .................................................. 40-404
Failure code [CA3321] KDPF Outlet Temp Failure code [DAZ9KQ] A/C Model Selection
Sens Low Error ......................................... 40-359 Abnormality .............................................. 40-405
Failure code [CA3322] KDPF Outlet Temp Failure code [DAZQKR] CAN2 Discon (Aircon
Sens In Range Error.................................. 40-362 ECU) ....................................................... 40-406
Failure code [CA3419] Mass Air Flow Sensor Failure code [DB2RKR] CAN1 Discon (Engine
Sup Volt High Error.................................... 40-366 Con) ........................................................ 40-415
Failure code [CA3421] Mass Air Flow Sensor Failure code [DGH2KB] Hyd Oil Sensor Short
Sup Volt Low Error .................................... 40-367 Circuit ...................................................... 40-419
Failure code [CA3741] Rail Press Valve Trip Failure code [DHA4KA] Air Cleaner Clog
Error ........................................................ 40-369 Sensor Open Circuit .................................. 40-421
Failure code [CA488] Chg Air Temp High Failure code [DHPAMA] F Pump Press Sensor
Torque Derate........................................... 40-215 Abnormality .............................................. 40-422
Failure code [CA595] Turbo Speed High Error Failure code [DHPBMA] R Pump Press Sensor
2.............................................................. 40-225 Abnormality .............................................. 40-425
Failure code [D110KB] Battery Relay Output Failure code [DHS3MA] Arm Curl PPC Press
Voltage..................................................... 40-370 Sensor Abnormality................................... 40-428
Failure code [D19JKZ] Personal Code Relay Failure code [DHS4MA] Bucket Curl PPC
Abnormality .............................................. 40-372 Press Sensor Abnormality ......................... 40-430
Failure code [D811MC] KOMTRAX Error ...... 40-375 Failure code [DHS8MA] Boom Raise PPC
Failure code [D862KA] GPS Antenna Open Press Sensor Abnormality ......................... 40-433
Circuit ...................................................... 40-376 Failure code [DHS9MA] Boom Lower PPC
Failure code [D8ALKA] Operating Lamp Open Press Sensor Abnormality ......................... 40-436
Circuit(KOMTRAX) Failure code [DHSAMA] Swing RH PPC Press
................................................................ 40-377 Sensor Abnormality................................... 40-439
Failure code [D8ALKB] Operating Lamp Short Failure code [DHSBMA] Swing LH PPC Press
Circuit (KOMTRAX)................................... 40-379 Sensor Abnormality................................... 40-442
Failure code [D8AQKR] CAN2 Discon Failure code [DHSCMA] Arm Dump PPC
(KOMTRAX) ............................................. 40-380 Press Sensor Abnormality ......................... 40-445
Failure code [DA20MC] Pump Controller ...... 40-381 Failure code [DHSDMA] Bucket Dump PPC
Failure code [DA22KK] Pump Solenoid Power Press Sensor Abnormality ......................... 40-448
Low Error ................................................. 40-382 Failure code [DHSFMA] Travel Fwd LH PPC
Failure code [DA25KP] 5V Sensor 1 Power Press Sensor Abnormality ......................... 40-451
Abnormality .............................................. 40-384 Failure code [DHSGMA] Travel Fwd RH PPC
Failure code [DA29KQ] Model Selection Press Sensor Abnormality ......................... 40-454
Abnormality .............................................. 40-387 Failure code [DHSHMA] Travel Rev LH PPC
Failure code [DA2LKA] Operating Lamp Open Press Sensor Abnormality ......................... 40-457
Circuit(Pump Con) .................................... 40-389 Failure code [DHSJMA] Travel Rev RH PPC
Failure code [DA2LKB] Operating Lamp Short Press Sensor Abnormality ......................... 40-460
Circuit(Pump Con) .................................... 40-391 Failure code [DKR0MA] F Pump Swash Plate
Failure code [DA2QKR] CAN2 Discon (Pump Sensor Abnormality................................... 40-463
Con) ........................................................ 40-392 Failure code [DKR1MA] R Pump Swash Plate
Failure code [DB2QKR] CAN2 Discon (Engine Sensor Abnormality................................... 40-466
Con) ........................................................ 40-410
PC290LC-10 5
INDEX
Failure code [DR21KX] Camera 2 Picture Rev. Failure code [DY20MA] Wiper Parking
Drive Abnormality...................................... 40-469 Abnormality .............................................. 40-531
Failure code [DR31KX] Camera 3 Picture Rev. Failure code [DY2CKB] Washer Drive Short
Drive Abnormality...................................... 40-471 Circuit ...................................................... 40-533
Failure code [DV20KB] Travel Alarm Short Failure code [DY2DKB] Wiper Drive (Fwd)
Circuit ...................................................... 40-473 Short Circuit ............................................. 40-535
Failure code [DW43KA] Travel Speed Sol Failure code [DY2EKB] Wiper Drive (Rev)
Open Circuit ............................................. 40-475 Short Circuit ............................................. 40-537
Failure code [DW43KB] Travel Speed Sol Failure code list related to air conditioner ........ 80-51
Short Circuit ............................................. 40-477 Failure codes table ..................................... 40-115
Failure code [DW45KA] Swing Brake Sol Open Failure mode and cause table ...................... 40-622
Circuit ...................................................... 40-479 Final drive ............................................10-12, 60-8
Failure code [DW45KB] Swing Brake Sol Short Fuse list and location ...................................40-111
Circuit ...................................................... 40-482
Failure code [DW91KA] Travel Junction Sol
Open Circuit ............................................. 40-485
G
Failure code [DW91KB] Travel Junction Sol General information on testing and adjusting..... 30-3
Short Circuit ............................................. 40-487
Failure code [DWA2KA] Attachment Sol Open
Circuit ...................................................... 40-489
H
Failure code [DWA2KB] Attachment Sol Short H-1 All of work equipment, swing and travel
Circuit ...................................................... 40-491 operation lacks speed or power .................. 40-630
Failure code [DWK0KA] 2-Stage Relief Sol H-2 Engine speed lowers significantly or
Open Circuit ............................................. 40-493 engine stalls ............................................. 40-633
Failure code [DWK0KB] 2-Stage Relief Sol H-3 Any of work equipment, swing and travel
Short Circuit ............................................. 40-495 does not work ........................................... 40-635
Failure code [DWK2KA] Variable Back Press H-4 Unusual sound is heard from around
Sol Open Circuit........................................ 40-497 hydraulic pump ......................................... 40-636
Failure code [DWK8KA] Swing Press C/O Sol H-5 Fine control performance or response is
Open Circuit ............................................. 40-501 poor ......................................................... 40-637
Failure code [DWK8KB] Swing Press C/O Sol H-6 Boom operation lacks speed or power .... 40-638
Short Circuit ............................................. 40-503 H-7 Arm operation lacks speed or power....... 40-640
Failure code [DXA8KA] PC-EPC (F) Sol Open H-8 Bucket operation lacks speed or power .. 40-642
Circuit ...................................................... 40-505 H-9 Work equipment does not move in single
Failure code [DXA8KB] PC-EPC (F) Sol Short operation.................................................. 40-643
Circuit ...................................................... 40-507 H-10 Hydraulic drift of boom is large ............. 40-644
Failure code [DXA9KA] PC-EPC (R) Sol Open H-11 Hydraulic drift of arm is large ................ 40-645
Circuit ...................................................... 40-509 H-12 Hydraulic drift of bucket is large............ 40-646
Failure code [DXA9KB] PC-EPC (R) Sol Short H-13 Time lag of work equipment is large...... 40-647
Circuit ...................................................... 40-511 H-14 When part of work equipment is relieved
Failure code [DXE0KA] LS-EPC Sol Open singly, other parts of work equipment move . 40-649
Circuit ...................................................... 40-513 H-16 In combined operation of work
Failure code [DXE0KB] LS-EPC Sol Short equipment, equipment having heavier load
Circuit ...................................................... 40-515 moves slower ........................................... 40-651
Failure code [DXE4KA] Attachment Flow EPC H-17 In combined operations of swing and
Open Circuit ............................................. 40-517 boom RAISE, boom rising speed is low....... 40-652
Failure code [DXE4KB] Attachment Flow EPC H-18 In combined operations of swing and
Short Circuit ............................................. 40-519 travel, travel speed drops largely ................ 40-653
Failure code [DXE5KA] Merge-divide Main Sol H-19 Machine does not travel straight........... 40-654
Open Circuit ............................................. 40-521 H-20 Travel speed is too low ........................ 40-655
Failure code [DXE5KB] Merge-divide Main Sol H-21 Machine is hard to steer or travel power
Short Circuit ............................................. 40-523 is low ....................................................... 40-657
Failure code [DXE6KA] Merge-divide LS Sol H-22 Travel speed does not change, or travel
Open Circuit ............................................. 40-525 speed is too low or high ............................. 40-659
Failure code [DXE6KB] Merge-divide LS Sol H-23 One of tracks dose not run................... 40-660
Short Circuit ............................................. 40-527 H-24 Upper structure does not swing to the
Failure code [DY20KA] Wiper Working right or left ................................................ 40-661
Abnormality .............................................. 40-529 H-25 Upper structure swing only to the right or
left ........................................................... 40-662
6 PC290LC-10
INDEX
H-26 Swing acceleration is poor or swing L

speed is low (both right and left) ................. 40-663
Layout of air conditioner related parts and
H-27 Swing acceleration is poor or swing
connectors ................................................. 80-30
speed is low (either right or left) .................. 40-664
List of abbreviation........................................ 00-47
H-28 Upper structure overruns excessively
when it stops swinging (both right and left) .. 40-665
H-29 Upper structure overruns excessively M
when it stops swinging (either right or left) ... 40-666
Machine monitor system.................. 10-166, 10-209
H-30 Shock is large when upper structure
Main pump ......................................... 10-27, 60-23
stops swinging .......................................... 40-667
Measuring and adjusting of oil pressure in work
H-31 Large unusual noise is heard when upper
equipment, swing, and travel circuits............. 30-44
structure stops swinging ............................ 40-668
Measuring and adjusting oil pressure in pump
H-32 Swing drift on a slope is large while swing
LS control circuit ......................................... 30-52
holding brake is applied ............................. 40-669
Measuring and adjusting oil pressure in pump
H-33 Swing drift on a slope is large while swing
PC control circuit......................................... 30-49
holding brake is released ........................... 40-670
Measuring and adjusting valve clearance........ 30-13
H-34 Attachment circuit cannot be changed
Measuring blowby pressure ........................... 30-20
while attachment is installed....................... 40-671
Measuring boost pressure ............................. 30-10
H-35 Oil flow in attachment circuit cannot be
Measuring compression pressure .................. 30-16
controlled ................................................. 40-672
Measuring EGR valve and KVGT oil pressure . 30-22
Handling cylinder cutout mode operation ........ 30-37
Measuring engine oil pressure ....................... 30-21
Handling no injection cranking operation......... 30-38
Measuring exhaust gas color ......................... 30-11
Handling of compressor oil ............................ 80-82
Measuring fuel delivery, return and leakage..... 30-29
Handling of electrical equipment .................... 00-29
Measuring fuel pressure ................................ 30-23
Handling of fuel system devices ..................... 00-22
Measuring oil leakage ................................... 30-65
Handling of hydraulic equipment .................... 00-24
Measuring oil pressure in control circuit .......... 30-48
Handling of intake system parts ..................... 00-23
Measuring PPC valve output pressure ............ 30-60
Handling voltage circuit of engine controller .. 30-144
Measuring solenoid valve output pressure ...... 30-57
How to enter air conditioner "Electrical
Method of disconnecting and connecting push-
Systems" screen in service mode of the
pull type coupler.......................................... 00-26
machine monitor.......................................... 80-37
How to proceed troubleshooting..................... 40-11
How to read electric wire code ....................... 00-37 O
How to read the shop manual ........................ 00-18
How to read this manual .................................. 50-4 Outline of refrigeration cycle ............................ 80-7
Hydraulic circuit diagram ................................. 90-7 Outside air temperature sensor ...................... 80-21
Hydraulic equipment layout drawing ............... 10-16
Hydraulic tank .................................... 10-20, 60-22 P
Parts and connectors layout .......................... 80-29
I Pm clinic .................................................... 30-147
Idler ............................................................. 60-14 Pm clinic service......................................... 30-147
Important safety notice .................................. 00-13 Power train..................................................... 10-7
Information mentioned in troubleshooting table....40- PPC valve........................................ 10-129, 60-37
52, 80-50 Precautions for cleaning and replacing KDPF
Information mentioned in troubleshooting table (KCSF, KDOC).......................................... 40-113
(H mode) .................................................. 40-619 Precautions for disconnecting and connecting
Information mentioned in troubleshooting table air conditioner piping ................................... 80-80
(S mode) .................................................. 40-673 Precautions for refrigerant ............................... 80-3
Instruction on troubleshooting .......................... 40-9 Precautions when performing operation.......... 00-40
Isolating the parts causing hydraulic drift in Preparation work for troubleshooting of
work equipment .......................................... 30-64 electrical system ......................................... 40-42
Procedure for testing and troubleshooting ....... 80-22
K
R
KOMTRAX system ..................................... 10-227
Releasing remaining pressure from hydraulic
circuit ......................................................... 30-43
PC290LC-10 7
INDEX
Removal and installation of air conditioner Removal and installation of radiator assembly . 50-51
compressor assembly ............................... 50-220 Removal and installation of revolving frame
Removal and installation of air conditioner assembly.................................................. 50-140
condenser assembly ................................. 50-223 Removal and installation of seat belt............. 50-212
Removal and installation of air conditioner unit Removal and installation of sprocket ............ 50-128
assembly.................................................. 50-206 Removal and installation of supply pump
Removal and installation of center swivel joint assembly.................................................... 50-17
assembly.................................................. 50-145 Removal and installation of swing circle
Removal and installation of control valve assembly.................................................. 50-125
assembly.................................................. 50-156 Removal and installation of swing motor and
Removal and installation of counterweight swing machinery assembly ........................ 50-114
assembly.................................................. 50-142 Removal and installation of travel motor and
Removal and installation of cylinder head final drive assembly................................... 50-105
assembly.................................................... 50-31 Removal and installation of work equipment
Removal and installation of engine and main assembly.................................................. 50-172
pump assembly .......................................... 50-58 Replacing fan belt ......................................... 30-40
Removal and installation of engine controller
assembly.................................................. 50-225
Removal and installation of engine front oil S
seal ........................................................... 50-70 S-1 When starting switch is turned to START
Removal and installation of engine hood position, engine does not crank .................. 40-674
assembly.................................................... 50-81 S-2 When engine cranks, smoke does not
Removal and installation of engine rear oil seal ...50- come out .................................................. 40-675
74 S-3 Engine does not start while fuel is injected
Removal and installation of floor frame (Incomplete combustion) ........................... 40-676
assembly.................................................. 50-200 S-4 Startability is poor ................................. 40-677
Removal and installation of front window S-5 Engine does not pick up smoothly .......... 40-679
assembly.................................................. 50-194 S-6 Engine stops during operation................ 40-680
Removal and installation of front wiper S-7 Engine runs rough or is unstable ............ 40-682
assembly.................................................. 50-214 S-8 Engine lacks power............................... 40-683
Removal and installation of fuel cooler S-9 Exhaust smoke is black (KDPF clogs up
assembly.................................................... 50-77 early) ....................................................... 40-685
Removal and installation of fuel tank assembly....50- S-10 Engine oil consumption is too much...... 40-687
78 S-11 Oil becomes contaminated early........... 40-688
Removal and installation of hydraulic oil cooler S-12 Fuel consumption is excessive............. 40-689
assembly.................................................... 50-53 S-13 Oil is in coolant (or coolant spurts or
Removal and installation of hydraulic tank coolant level goes down) ........................... 40-690
assembly.................................................. 50-148 S-14 Engine oil pressure drops .................... 40-691
Removal and installation of idler and idler S-15 Fuel is contaminated in engine oil......... 40-692
cushion assembly ..................................... 50-129 S-16 Coolant is contaminated in engine oil (Oil
Removal and installation of injector assembly . 50-22 becomes cloudy white) .............................. 40-693
Removal and installation of KCCV assembly . 50-100 S-17 Coolant temperature rises too high
Removal and installation of KDPF assembly ... 50-84 (Overheating) ........................................... 40-694
Removal and installation of KOMTRAX S-18 Unusual noise is heard ........................ 40-695
terminal assembly ..................................... 50-234 S-19 Vibration is excessive.......................... 40-696
Removal and installation of machine monitor S-20 Automatic regeneration is operated
assembly.................................................. 50-230 frequently ................................................. 40-697
Removal and installation of main pump S-21 Active regeneration is operated for long 40-698
assembly.................................................. 50-152 S-22 White smoke comes out in the process of
Removal and installation of Mass air flow and active regeneration.................................... 40-699
temperature sensor ................................... 50-233 Sensors ..................................................... 10-229
Removal and installation of operator cab glass Separation and connection of track shoe
(adhered glass)......................................... 50-186 assembly.................................................. 50-126
Removal and installation of operator's cab Sketch of tools for testing and adjusting ............ 30-7
assembly.................................................. 50-181 Sketches of special tools ............................... 50-14
Removal and installation of pump controller Solenoid valve.................................. 10-150, 60-46
assembly.................................................. 50-227 Special functions of machine monitor.............. 30-73
Removal and installation of pump swash plate Special tools list............................................ 50-10
sensor...................................................... 50-232
8 PC290LC-10
INDEX
Specification drawings .................................... 01-3

Specifications ................................................. 01-5
Sprocket ...................................................... 60-10
Standard tightening torque table .................... 00-43
Sunlight sensor............................................. 80-20
Swing circle............................................10-9, 60-5
Swing machinery ..................................10-10, 60-6
Swing motor ..................................... 10-104, 60-32
Symbols in electric circuit diagram.................... 90-9
Symbols in hydraulic circuit diagram................. 90-3
Symptom of probable failure and
troubleshooting No. ..................................... 40-49
System chart for hydraulic system ................ 40-620
System component part .............................. 10-198
System diagram ........................................... 80-26
T
Table of fuel, coolant and lubricants .................. 01-9
Testing (dual) pressure switch for refrigerant ... 80-43
Testing air leakage (duct)............................... 80-33
Testing and adjusting track shoe tension......... 30-42
Testing before troubleshooting ....................... 40-12
Testing diodes ............................................ 30-146
Testing FRESH/RECIRC air changeover ........ 80-41
Testing procedure before troubleshooting ....... 40-14
Testing pump swash plate sensor................... 30-63
Testing refrigerant pressure ........................... 80-77
Testing relays ............................................... 80-45
Testing sunlight sensor.................................. 80-42
Testing swing circle bearing clearance............ 30-41
Testing vent (mode) changeover .................... 80-39
Testing with self-diagnosis function................. 80-36
Tools for testing and adjusting, and
troubleshooting ............................................. 30-3
Track frame and idler cushion ........................ 10-14
Track roller ................................................... 60-16
Travel motor ..................................... 10-115, 60-34
Troubleshooting chart 1................................. 80-46
Troubleshooting chart 2................................. 80-47
Troubleshooting with gauge pressure ............. 80-74
Truck frame and idler cushion ........................ 60-12
Truck shoe ................................................... 60-19
T-branch box and T-branch adapter table...... 40-105
V
Valve control ................................................ 10-18
W
Weight table ................................................... 01-8
Work equipment ........................................... 60-50
Work equipment shim ................................. 10-162
PC290LC-10 9
PC290LC-10 HYDRAULIC EXCAVATOR
Form No. SEN05644–02
©2011 KOMATSU
All Rights Reserved
Printed in Japan 08–11

PC290LC 10

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SEN05644-02

HYDRAULIC PC290LC -10

PC290LC - 10 15001 and up

00 Index and foreword

Electrical system .................................................................................................................... 10-166

Pm clinic service .............................................................................................................. 30-147

Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-180

Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-533

S-5 Engine does not pick up smoothly ............................................................................... 40-679

Removal and installation of center swivel joint assembly ..................................................... 50-145

Air conditioner ............................................................................................................................ 80-3

Electric circuit diagram for air conditioner unit ....................................................................... 90-25

Foreword, safety and general information

General precautions wear welding gloves, apron, shielding goggles,

k Slinging with one rope may cause turning

Precautions for using mobile crane

the other wrench to the specified torque (Use a

a For tightening torques, see "Others",

How to read the shop manual

Composition of shop manual

Revision and distribution

Explanation of terms for maintenance standard

Standard dimension and tolerance

• The performance and function of products

Handling of fuel system devices

Be careful of the work environment

Cleaning off dusts

Precautions for replacing fuel filter cartridge

Handling of intake system parts

Be careful of the work environment

Handling of hydraulic equipment

Be careful of the work environment

Disassembly and maintenance work in the field

Method of disconnecting and connecting push-pull type coupler

Handling of electrical equipment

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

dry cloth or blow it with compressed air and

High-pressure water entering connector

Entry of water or mud or dirt when disconnecting a

• Check that connector pins are free from

3. Action to take after removing connectors

Deutsch connector (DT8-pin, DT12-pin)

2. Dry the inside of the connector with a dryer.

3. Perform a continuity test on the connector.

Drying wiring harness

a After completely drying the connector,

Slide, lock type (Type 2) (FRAMATOME-24)

Connection • 107 series

Pull lock type (PACKARD-2)

Push lock type (1)

Push lock type (3) Turn-housing type (Round green connector)

Example) Injection pressure control valve of

Example) Speed sensor of supply pump: G

connected to the controller.Fit an arc welding

Precautions for troubleshooting electrical