PDF Service Manual Komatsu PC290LC-10 Hydraulic Excavator - 7 MB
Maintain your Komatsu PC290LC-10 hydraulic excavator at peak performance with this complete service and repair manual.
This essential guide contains detailed factory procedures for everything from standard maintenance to complex overhauls.
Technicians can access comprehensive diagrams, system specifications, and troubleshooting charts.
Following the manufacturer's recommended procedures ensures safety and significantly extends the life of your valuable equipment.
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--- Page 1 ---
CEBM025103
Shop
Manual
PC290LC-10
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC290LC-10 A25001 and up
ENGINE 6D107E-2
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2013 Komatsu
Printed in U.S.A.
Komatsu America Corp.
July 2013
--- Page 3 ---
FOREWORD SAFETY
12
SAFETY 00
Safety Notice 00
Important Safety Notice 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying
this symbol should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety,
and take the necessary actions to deal with the situation.
General Precautions 00
6. Keep all tools in good condition and learn the correct
way to use them. Before starting work, thoroughly
Mistakes in operation are extremely dangerous. Read the check the tools, machine, forklift truck, service car, etc.
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine. 7. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
1. Before performing any greasing or repairs, read all the correct places. Always keep the work area clean and
precautions given on the decals which are fixed to the make sure that there is no dirt or oil on the floor. Smoke
machine. only in the areas provided for smoking. Never smoke
while working.
2. When performing any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or 8. Before starting work, warm up your body thoroughly to
clothes with buttons missing. start work under good conditions. Avoid continuous
β’ Always wear safety glasses when hitting parts with work for long hours and take rests at proper intervals to
a hammer. keep your body in good condition. Take rests in
β’ Always wear safety glasses when grinding parts specified safe places.
with a grinder, etc.
Safety Points
3. If welding repairs are needed, always have a trained,
experienced welder perform the work. When perform-
1 Good arrangement
ing welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work. 2 Correct work clothes
3 Following work standard
WARNING! Never modify, weld, cut, or 4 Making and checking signs
drill on any part of a ROPS
Prohibition of operation and handling by
structure. Doing so may 5
unlicensed workers
weaken the structure which
could lead to possible failure 6 Safety check before starting work
in a rollover situation.
Wearing protective goggles
7
(for cleaning or grinding work)
4. When performing any operation with two or more Wearing shielding goggles and protectors
workers, always agree on the operating procedure 8
(for welding work)
before starting. Always inform your fellow workers
before starting any step of the operation. Before starting 9 Good physical condition and preparation
work, hang UNDER REPAIR signs on the controls in Precautions against work which you are not
the operator's compartment. 10 used to or work with which you are too
familiar
5. Only qualified workers must perform the work and
operation which require license or qualification.
PC290LC-10 00-3
--- Page 4 ---
FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
β’ Example: Speed sensor of supply pump: G (SUMITOMO -3)
β
Pull the connector straight up.
B. Connection
i. Insert the connector straight in until it βclicks.β
12. Turn-housing type (Round green connector)
β’ 140 series
β’ Example: Charge (boost) pressure sensor in the air intake manifold: PIM (CANNON-4), etc.
A. Disconnection
i. Turn housing (H1) in the direction of the arrow.
β
When the connector is unlocked, housing (H1) becomes heavy to turn.
ii. Pull out housing (H1) in the direction of the arrow.
β
Housing (H1) is left on the wiring harness.
B. Connection
i. Insert the connector to the end, while aligning its groove to
the other.
ii. Turn housing (H1) in the direction of the arrow until it
βclicks.β
PC290LC-10 00-21
--- Page 5 ---
FOREWORD ELECTRIC WIRE CODE
12
3. 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
β 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.
Example: βGWβ means that the background is Green and marking is White.
β
Types of circuits and color codes
(Table 4)
Type of wire AVS, AV, CAVS AEX
Charge R WG β β β β R β
Ground B β β β β β B β
Start R β β β β β R β
Light RW RB RY RG RL β D β
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB β L β
Type of
Br BrW BrR BrY BrB β β β
circuit
Lg LgR LgY LgB LgW β β β
O β β β β β β β
Others Gr β β β β β β β
P β β β β β β β
Sb β β β β β β β
Dg β β β β β β β
Ch β β β β β β β
PC290LC-10 00-39
--- Page 6 ---
01 GENERAL
SPECIFICATION DIMENSION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
PC290LC-10 01-1
--- Page 7 ---
STRUCTURE AND FUNCTION ENGINE AND COOLING SYSTEM
1. Reservoir tank 8. Fuel cooler outlet 14. Radiator inlet hose
2. Oil cooler 9. Condenser 15. Oil cooler intlet
3. Radiator cap 10. Air conditioner condenser 16. Aftercooler inlet hose
switching bracket
4. Radiator 17. Shroud
5. Aftercooler 11. Oil cooler outlet 18. Fan
6. Fuel cooler inlet 12. Aftercooler outlet hose 19. Radiator outlet hose
7. Fuel cooler 13. Fan guard 20. Radiator drain valve
Specifications
Radiator Oil cooler Aftercooler Fuel cooler
Aluminum wave Aluminum wave
Core type CF40-1 Drawn cup
type, 4 rows type
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
0.05 MPa
Pressure valve cracking pressure (0.5kg/cm2) β β β
{7 psi}
-0.005 MPa
Vacuum valve cracking pressure (-0.05 kg/cm2) β β β
{-1 psi}
PC290LC-10 10-7
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STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
Features
β Fine control not influenced by load
β Control performance that allows digging even when fine control operation is turned on
β Ease of combined operation enabled by the flow divider function that is determined by the opening areas of spools during
combined operations
β Energy saving by variable pump control
Configuration
β CLSS consists of variable capacity piston pump, control valve, and actuators.
β The main pump consists of pump itself, PC valve and LS valve.
Basic Principle
Pump swash plate angle control
β The pump swash plate angle (pump delivery) is controlled so that
LS differential pressure ( PLS), which is the difference between
pump delivery pressure (PP) and LS pressure (PLS) (load pressure
of actuator) at control valve outlet, is constant.
β [LS differential pressure ( PLS) = Pump delivery pressure (PP) -
LS pressure (PLS)]
β The pump swash plate angle shifts toward the maximum position if
LS differential pressure ( PLS) is lower than the set pressure of
the LS valve (when the actuator load pressure is high).
β 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 10-25
--- Page 9 ---
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
β Springs (4) and (6) extend according to the movement of servo piston (9), and the reaction force of spring decreases.
β 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).
β 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.
β 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
β 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.
β 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.
β When spool (3) moves to the left, the opening of ports (C) and (D) widens.
β The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
β Servo piston (9) stops at a position further to the right than the position when pump pressures (PP1) and (PP2) are low.
PC290LC-10 10-43
--- Page 10 ---
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
MEMORANDUM
PC290LC-10 10-61
--- Page 11 ---
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
Operation
β 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/cmΒ²) {0 psi}.
β Main spool (1) is pressed to the right by spring (2). As a result, port (E) and (F) are interconnected.
β 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.
β 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.
β 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.
PC290LC-10 10-79
--- Page 12 ---
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
3. In arm βINβ operation
β When arm is operated "IN", the pilot pressure from the PPC valve pushes pilot piston (2).
β The pressurized oil of the arm cylinder head flows from orifice (c) to drain port (T) through orifice (a) and
chamber (b).
β Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
β As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
β As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
PC290LC-10 10-97
--- Page 13 ---
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
Swing Motor Reverse Prevention Valve
MA: From control valve (left swing port) 1. Valve body 5. Spool (MB side)
MB: From control valve (right swing port) 2. Spool (MA side) 6. Spring (MB side)
T1: To hydraulic tank 3. Spring (MA side) 7. Plug (MB side)
T2: To hydraulic tank 4. Plug (MA side)
PC290LC-10 10-115
--- Page 14 ---
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
When control lever is in fine control range
(When returned to fine control range)
β When disc (5) begins to return, spool (1) is pushed up by the force
of centering spring (3) and the force exerted by the pressure in port
(P1).
β Fine control hole (f) is connected to drain chamber (D), and the
pressurized oil in port (P1) is released.
β If the pressure in port (P1) is excessively reduced, spool (1) is
depressed by metering spring (2).
β Fine control hole (f) is disconnected from drain chamber (D), and at
almost the same time, it is connected to pump pressure chamber
(PP).
β The pump pressure is supplied until the pressure at port (P1)
recovers to the level corresponding to the lever position.
β 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.
When control lever is moved to stroke end
β Disc (5) depresses piston (4), and retainer (9) depresses spool (1).
β Fine control hole (f) is disconnected from drain chamber (D), and it
is connected to pump pressure chamber (PP).
β 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.
β The oil returning from port (B) flows from port (P2) into drain
chamber (D) through fine control hole (f').
PC290LC-10 10-133
--- Page 15 ---
STRUCTURE AND FUNCTION HYDRAULIC SYSTEM
Attachment Circuit Selector Valve (For High Pressure Circuit) (If Equipped)
PI: From attachment circuit selector solenoid valve 1. Spool
ACC: To accumulator
ATT: To attachment
TS: To hydraulic tank
Function
β 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.
β 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
β Spool (1) is pressed to the left by the force of spring (2).
β Since port (ATT) is disconnected from port (ACC), no oil flows to
the accumulator.
PC290LC-10 10-151
--- Page 16 ---
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
Control method in each mode
P, E, L, ATT-P and ATT-E modes
Matching point
Working mode Matching point
P and ATT-P 127.1 kW/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}
β 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.
β 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]
β As the load increases further, the engine speed decreases further.
[See (2) in graph]
β The controller lowers the pump absorption upper limit torque (PT)
to reduce the load on the engine. [See (3) in graph]
β As the engine load decreases, the engine speed increases. [See (4)
in graph]
β The controller raises the pump absorption upper limit torque (PT) to
maintain it near the matching point. [See (5) in graph]
β To save fuel consumption, the controller lowers the engine
matching speed (Nmatch) at low loads (low delivery and torque).
[See (6) in graph]
PC290LC-10 10-169
--- Page 17 ---
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
Travel Control Function
1. Pump controller 12. Rear pump Input and output signals
2. Engine controller 12a. Servo
3. Machine monitor 12b. LS valve a. Oil pressure sensor signal
4. Fuel control dial 12c. PC valve b. CAN signal
5. Fuel supply pump 13. Control valve c. LS-EPC valve drive signal
6. Sensors 13a. Self-pressure reducing valve d. Solenoid valve GND
7. Front pump oil pressure sensor 13b. Merge-divider valve e. Travel junction solenoid valve
8. Rear pump oil pressure sensor 13c. Travel junction valve drive signal
9. Oil pressure sensor 14. Travel motor f. Travel speed increase solenoid
10. Travel alarm 15. Travel speed increase solenoid valve drive signal
11. Front pump valve g. Oil pressure sensor signal
11a. Servo 16. Travel junction solenoid valve h. Travel alarm buzzer operation
11b. LS valve 17. LS-EPC valve signal
11c. PC valve i. 1st throttle signal
j. Fuel supply pump control signal
k. Sensor signals
PC290LC-10 10-187
--- Page 18 ---
STRUCTURE AND FUNCTION ELECTRICAL SYSTEM
PPC Oil Pressure Switch
PPC: Abbreviation for Proportional Pressure Control
1. Plug
2. Switch
3. Connector
Specifications
Contact type: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normally open
Operating (ON) pressure: . . . . . . . . . . . . . . 490 Β±98.1 kPa (5.0 Β±1.0 kg/cmΒ²) {71 Β±14 psi}
Resetting (OFF) pressure: . . . . . . . . . . . . . . . 294 Β±49.0 kPa (3.0 Β±0.5 kg/cmΒ²) {43 Β±7 psi}
Function
β 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.
PC290LC-10 10-205
--- Page 19 ---
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
Switches
No. Name Function Operation
Switches the auto-deceleration function
β When working mode is "L", this switch is
Auto-deceleration switch ON/OFF.
1 always "OFF" after the engine is started.
[Numeric keypad: 1] Lights up: ON
OFF ON
Not lighting: OFF
P: Heavy-duty operation
E: Low-fuel operation
(*1) L: Fine operation
Displays the working mode selector
2 Working mode selector switch B: Breaker operation
screen.
[Numeric keypad: 2] ATT-P: Double-acting attachment operation
ATT-E: Double-acting attachment and
low-fuel operation
Changes the travel speed. β Speed is sequentially changed as
Travel speed selector switch Lo lights up: Low speed shown below.
3
[Numeric keypad: 3] Mi lights up: Medium speed Lo (Low speed) Mi (Medium speed)
Hi lights up: High speed Hi (High speed) Lo (Low speed)
β The alarm buzzer stops sounding.
Stops the alarm buzzer.
Buzzer cancel switch β The alarm buzzer sounds again if
4 (Some alarm buzzer does not stop
[Numeric keypad: 4] another error worth alarming is
sounding even if the switch is pressed.)
detected.
Operates the front glass wiper. β Pressing the switch sequentially
(*2)
INT: Intermittent operation changes the wiper operation.
5 Wiper switch
ON: Continuous operation INT (Intermittent) ON (Continuous)
[Numeric keypad: 5]
Not lighting: Holds in position OFF (Stop) INT (Intermittent)
PC290LC-10 10-223
--- Page 20 ---
STRUCTURE AND FUNCTION SENSORS
EGR Valve Lift Sensor
EGR: Abbreviation for Exhaust Gas Recirculation
1. O-ring (small) 3. Sensor
2. O-ring (large) 4. Connector
Function
β This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the corresponding variable
voltage.
Output characteristics
β The relation between stroke and output voltage is as shown in the
following graph.
PC290LC-10 10-241
--- Page 21 ---
20 STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Standard Value Table for Engine Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Standard Value Table for Chassis Related Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Control Valve Spool Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Control Lever Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
Operating Effort of Control Lever and Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-7