Komatsu A29501, Shop Manual

Page 1: ...olicy 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 o...

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Page 3: ...00 INDEX AND FOREWORD PC290LL 11 00 1 Find manuals at https best manuals com...

Page 4: ...NECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 00 66 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 67 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROT...

Page 5: ...WORK EQUIPMENT SYSTEM 10 251 SWING SYSTEM 10 267 LAYOUT DRAWING OF SWING SYSTEM 10 267 SWING CONTROL SYSTEM DIAGRAM 10 271 COMPONENT PARTS OF SWING SYSTEM 10 277 TRAVEL SYSTEM 10 291 LAYOUT DRAWING OF...

Page 6: ...6 TEST SWING CIRCLE BEARING CLEARANCE 30 86 UNDERCARRIAGE AND FRAME 30 88 TEST AND ADJUST TRACK TENSION 30 88 HYDRAULIC SYSTEM 30 90 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30 90 TEST AND ADJ...

Page 7: ...FAILURE CODE 879EMC Ventilation Damper Malfunction 40 179 FAILURE CODE 879FMC Air Mix Damper Malfunction 40 180 FAILURE CODE 879GKX Refrigerant Pressure Input Signal Out of Range 40 181 FAILURE CODE 9...

Page 8: ...ne Controller Internal Failure 40 268 FAILURE CODE CA351 Injectors Drive Circuit Error 40 269 FAILURE CODE CA352 Sensor 1 Supply Voltage Low Error 40 270 FAILURE CODE CA356 MAF Sensor High Error 40 27...

Page 9: ...gh Error 2 40 377 FAILURE CODE CA1942 Crankcase Pressure Sensor In Range Error 40 382 FAILURE CODE CA1993 KDPF Differential Pressure Low Error 40 383 FAILURE CODE CA2185 Throttle Sensor Supply Voltage...

Page 10: ...emperature Sensor Low Error 40 508 FAILURE CODE CA3322 KDPF Outlet Temperature Sensor In Range Error 40 510 FAILURE CODE CA3419 MAF Sensor Supply Voltage High Error 40 512 FAILURE CODE CA3421 MAF Sens...

Page 11: ...4166 SCR Temperature Sensor ECU High Temperature Error 40 649 FAILURE CODE CA4168 DEF Pump Heater ON Stuck Error 40 651 FAILURE CODE CA4169 DEF Pump Heater OFF Stuck Error 40 654 FAILURE CODE CA4171 D...

Page 12: ...ensor Frozen 40 776 FAILURE CODE DHPAMA Front Pump Pressure Sensor Defective Function 40 778 FAILURE CODE DHPBMA Rear Pump Pressure Sensor Defective Function 40 781 FAILURE CODE DHS3MA RB Arm IN LL Ar...

Page 13: ...olenoid Short Circuit 40 903 FAILURE CODE DXE6KA Merge divider LS Solenoid Open Circuit 40 905 FAILURE CODE DXE6KB Merge divider LS Solenoid Short Circuit 40 907 FAILURE CODE DXE7KA Attachment Flow Re...

Page 14: ...DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40 987 E 22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEM PERATURE 40 989 E 23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 40...

Page 15: ...N MENTIONED IN TROUBLESHOOTING TABLE H MODE 40 1041 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 40 1042 FAILURE MODE AND CAUSE TABLE 40 1044 H 1 ANY OF WORK EQUIPMENT SWING AND TRAVEL DOES NOT WO...

Page 16: ...ARTABILITY IS POOR 40 1110 S 5 ENGINE DOES NOT PICK UP SMOOTHLY 40 1112 S 6 ENGINE STOPS DURING OPERATION 40 1114 S 7 ENGINE RUNS ROUGH OR IS UNSTABLE 40 1116 S 8 ENGINE LACKS POWER 40 1117 S 9 KDPF G...

Page 17: ...NSTALL AIR CLEANER ASSEMBLY 50 272 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 50 275 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 50 280 POWER TRAIN 50 282 REMOVE AND INSTALL TRAV...

Page 18: ...T 60 8 MAINTENANCE STANDARD OF COOLING SYSTEM 60 9 POWER TRAIN 60 10 MAINTENANCE STANDARD OF SWING CIRCLE 60 10 MAINTENANCE STANDARD OF SWING MACHINERY 60 11 MAINTENANCE STANDARD OF FINAL DRIVE 60 13...

Page 19: ...ECIRC AIR CHANGEOVER 80 47 TEST SUNLIGHT SENSOR 80 48 TEST DUAL PRESSURE SWITCH FOR REFRIGERANT 80 49 TEST RELAYS 80 50 AIR CONDITIONER TROUBLESHOOTING CHART 1 80 51 AIR CONDITIONER TROUBLESHOOTING CH...

Page 20: ...CIRCUIT DIAGRAM 1 3 90 8 HYDRAULIC CIRCUIT DIAGRAM 2 3 90 10 HYDRAULIC CIRCUIT DIAGRAM 3 3 90 12 ELECTRICAL CIRCUIT DIAGRAM 90 13 SYMBOLS IN ELECTRICAL CIRCUIT DIAGRAMS 90 13 ELECTRICAL CIRCUIT DIAGR...

Page 21: ...n auto matically applies the retarder with a constant braking force HD HM ARSC Automatic Retarder Speed Control Travel and brake When the accelerator pedal is released while the machine is traveling d...

Page 22: ...raulic system This mechanism allows actuators to be operated in proportion to the current supplied FOPS Falling Object Protective Structure Cab and canopy This structure protects the operator s head f...

Page 23: ...the opti mum force and at the same time activates the in ter axle differential lock when the wheels idle while the machine travels on the soft ground road HM KVGT Komatsu Variable Ge ometry Turbochar...

Page 24: ...essure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pump and motor D PC etc PTO Power Take Off Power train system Power take off mechanism PTP Power Tilt and power Pitch dozer Work...

Page 25: ...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...

Page 26: ...adjusting and troubleshooting Use the standard values table to check the standard values for testing and adjusting and judge troubles in troubleshooting 30 TESTING AND ADJUSTING This section describe...

Page 27: ...ing posture for slinging work Tightening torque This signal indicates the tightening torque for portions which requires spe cial care in assembling work Coat This signal indicates a place to be coated...

Page 28: ...in good physical condition and good preparation Always be alert and careful General precautions k If the machine is handled incorrectly it is dangerous Read and understand what is described in the ope...

Page 29: ...levers and hang UNDER REPAIR warning tag on them When performing the disassembling or assembling work support the machine securely with blocks jacks or stands before starting the work Remove all mud...

Page 30: ...caught in ro tating parts or moving parts When raising a heavy component heavier than 25 kg use a hoist or crane Before starting work check that the slings wire ropes webbing slings chains and hooks a...

Page 31: ...workers must communicate with each other fre quently The appointed signaler must make specified signals clearly at a place where he is well seen from the operator s seat and where he can see the worki...

Page 32: ...ok is maximum at its central part Never use a wire rope which has breaks in strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Precautions f...

Page 33: ...o work and passage After operating the hoist do not swing the control switch Remember the position of the main switch so that you can turn off the power immediately in an emer gency If the hoist stops...

Page 34: ...to use 2 wrenches use one wrench to fix and use the other one to loosen the nut Precautions for air conditioner piping When installing the air conditioner piping be careful so that dirt dusts and wate...

Page 35: ...An O ring is fitted to every joint of the air conditioner piping For tightening torques see PRECAUTIONS FOR DISCON NECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 80 85 00 INDEX AND...

Page 36: ...umulated or attached to or around the engine exhaust manifold muffler or battery or on the undercovers To prevent fires from being caught remove any flammable materials such as dry leaves chips pieces...

Page 37: ...ee the Operation and Maintenance Manual for the setting procedure Explosion caused by lighting equipment When checking fuel oil battery electrolyte or coolant always use lighting equipment with anti e...

Page 38: ...hen they are inhaled Do not breathe the fumes After a fire there may be harmful compounds left If they touch your skin they may have a bad influence on your body Be sure to wear rubber gloves when han...

Page 39: ...he cab and riser assembly when the machine is on a slope Do not tilt the cab and riser assembly in windy conditions When the tilt operation is being performed ensure that the work equipment is in an e...

Page 40: ...or lakes Obey appropriate laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters batteries and DEF Avoid exposure to burning rubber or plastics which produce a...

Page 41: ...R system Commercial DEF that is API approved and meets all the requirements defined in ISO 22241 1 This solution will be represented as DEF throughout this manual About DEF DEF is necessary for the ur...

Page 42: ...l up its con tainer for storage When opening the container perform it where there is good ventilation For storage see STORE DEF 00 41 Store DEF avoiding direct sunlight Always use the original contain...

Page 43: ...rage area Storage period Max 10 C Up to 36 months Max 25 C Up to 18 months Max 30 C Up to 12 months Max 35 C Up to 6 months Do not store DEF in the temperature of 35 C or above Handling DEF in cold we...

Page 44: ...aling of openings prevention of flowing out of oil Plug the openings of the piping and the device which have been removed to prevent foreign material from enter ing and oil from flowing out NOTICE Do...

Page 45: ...required to completely dislodge the contami nants and sludges and existing oil containing those inside the hydraulic circuit after disassembling and assembling and when replacing the oil with the new...

Page 46: ...ckness and number of shims when storing shims When hoisting the components prepare the slings with sufficient strength When using forcing screws to remove any component tighten the forcing screws unif...

Page 47: ...n of the split flange type hoses and tubes Nomi nal No Bolt pitch mm Hose side Tube side O ring 4 Bolt 5 Washer 6 a b Flange 1 Split flange 2 Sleeve head 3 04 38 1 17 5 07379 00400 07371 30400 07378 1...

Page 48: ...1643 51232 30 106 4 62 07379 03010 07371 13010 07378 13000 07000 12085 07372 51650 01643 51645 34 120 6 69 8 07379 03411 07371 13411 07378 13400 07000 12100 07372 51650 01643 51645 40 130 2 77 8 07379...

Page 49: ...ps of adhesive to the threaded portion When applying liquid gasket clean and degrease the surface and apply it uniformly after making sure that the surface is free from dust or damage Clean all of the...

Page 50: ...t of grease to the work equipment parts When the coolant is drained be sure that the drain valve is securely tightened then refill the coolant reser voir with the coolant Komatsu recommends to the spe...

Page 51: ...lation portion If there is any damage replace the part Check that there is no looseness on the exhaust equipment and mounting bolts nuts and clamps on the instal lation portion If there is any loosene...

Page 52: ...it is necessary to be extremely careful when handling and maintenance of the wiring harnesses If DEF is spilled over wiring harness and connectors it may cause corrosion and defective contact Be caref...

Page 53: ...icity Entry of water dirt or dust when disconnecting a con nector If any water mud or dust is stuck to the outside surface of a connector it can enter inside the connector when the connector is discon...

Page 54: ...y pollute the environ ment Do not discard the oil inconsiderately Ask the customer for disposal or bring it back to dispose it appropriately How to clean parts when dirt is stuck If any dirt or dust s...

Page 55: ...l when servicing the intake system Select an appropriate workplace Avoid the work of adding hydraulic oil replacing filters or repairing the machine in rainy or windy weather or in dusty environment S...

Page 56: ...undness of machine in addition to KOMTRAX function described above These data can be used on per sonal computer screens How to make a full use of KOMTRAX Making use of KOMTRAX enables the following ac...

Page 57: ...connection 1 Hold adapter 1 and push hose joint 2 into mating adapter 3 REMARK Push it in approximately 3 5 mm Do not hold rubber cap portion 4 2 While having adapter 3 inserted into hose side joint 2...

Page 58: ...isconnection 1 Hold the tightening adapter part and push body 2 straight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition...

Page 59: ...traight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition of step 1 push cover 3 straight until it contacts contact surface...

Page 60: ...ning adapter part and push body 2 straight un til sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end DISCONNECT AND CONNECT PUSH PULL TYPE COUPLER 00 INDEX AND...

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