Komatsu PC390LC-8MO Hydraulic Excavator Shop Manual SEN06613-01 PDF

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Komatsu PC390LC-8MO Hydraulic Excavator Shop Manual SEN06613-01 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu PC390LC-8MO Hydraulic Excavator Shop Manual SEN06613-01 –  PDF DOWNLOAD

Language : English
Pages : 1108
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC390LC-8MO Hydraulic Excavator Shop Manual SEN06613-01 –  PDF DOWNLOAD

• Serial Numbers 80699 and up

COVER 1
00 Index and foreword 3
Table of contents 4
Foreword and general information . 13
Foreword, safety and general information . 13
How to read the shop manual 20
Explanation of terms for maintenance standard 22
Handling equipment of fuel system devices 24
Handling of intake system parts 25
Handling of hydraulic equipment 26
Method of disconnecting and connectingof push-pull type coupler 28
Handling of electrical equipment . 31
How to read electric wire code . 40
Precautions when performing operation 43
Practical use of KOMTRAX . 46
Standard tightening torque table . 47
List of abbreviation . 51
Conversion table . 56
01 Specification . 61
Specification and technical data . 63
Specification dimension drawings . 63
Specifications . 65
Weight table . 68
Table of fuel, coolant and lubricants 69
10 Structure, function and maintenance standard 71
Engine and cooling system 73
Engine related parts . 73
Radiator, oil cooler and aftercooler . 74
Power train 75
Power train 75
Swing circle . 76
Swing machinery 78
Final drive 80
Sprocket . 82
Undercarriage and frame 84
Track frame and recoil spring 84
Idler 86
Carrier roller . 88
Track roller . 89
Track shoe . 90
Hydraulic system . 94
Hydraulic equipment layout drawing . 94
Hydraulic tank and filter 96
Hydraulic pump . 98
Control valve 122
CLSS . 134
Functions and operation by valve . 138
Attachment circuit selector valve 177
Hydraulic drift prevention valve . 180
Valve control 186
PPC valve 187
Solenoid valve . 206
PPC accumulator 208
Center swivel joint 209
Travel motor . 211
Swing motor 223
Work equipment cylinder 231
Work equipment . 234
Work equipment . 234
Dimensions of components . 236
Electrical system 240
Engine control system 240
Electronic control system 249
Machine monitor system . 274
Sensor . 294
KOMTRAX system . 297
20 Standard value table 305
Standard service value table . 307
Standard value table for engine related parts 307
Standard value table for chassis related parts . 308
30 Testing and adjusting . 319
Related information on testing and adjusting . 321
Tools for testing, adjusting and troubleshooting . 321
Sketches of special tools 325
Engine and cooling system 326
Testing engine speed . 326
Testing air boost pressure . 327
Testing exhaust gas color 328
Adjusting valve clearance 330
Testing compression pressure . 332
Testing blowby pressure 336
Testing engine oil pressure 337
Testing fuel pressure 338
Handling during cylinder cutout operation 343
Handling during no-injection cranking operation 343
Testing fuel return rate and leakage . 344
Bleeding air from fuel circuit . 346
Checking fuel circuit for leakage 347
Testing and adjusting air compressor belt tension 348
Replacing fan belt . 349
Replacing alternator belt 350
Power train 351
Testing clearance in swing circle bearings . 351
Undercarriage and frame 352
Testing and adjusting track tension 352
Hydraulic system . 353
Testing and adjusting oil pressure in work equipment, swing and travel circuit . 353
Testing control circuit oil pressure . 357
Testing and adjusting pump PC control circuit oil pressure . 358
Testing and adjusting pump LS control circuit oil pressure . 361
Testing solenoid valve output pressure . 366
Testing PPC valve output pressure 370
Adjusting play of work equipment and swing PPC valves 371
Inspecting locations of hydraulic drift of work equipment 372
Releasing remaining pressure in hydraulic circuit 374
Testing oil leakage amount . 375
Bleeding air from various parts 377
Electrical sysytem . 380
Special functions of machine monitor . 380
Handling voltage circuit of engine controller 430
Preparation work for troubleshooting of electrical system 431
Procedure for testing diodes . 435
Pm clinic 436
Pm clinic service 436
40 Troubleshooting . 445
General Information on troubleshooting . 451
Symptom and troubleshooting numbers 451
Sequence of events in troubleshooting 453
Checks before troubleshooting 455
Classification and procedures for troubleshooting 457
Symptom and troubleshooting numbers 459
Information in troubleshooting table . 461
Connector list and layout 463
Connection table for connector pin numbers . 474
T- branch box and T- branch adapter table 510
Troubleshooting method for open circuit in wiring harness of pressure sensor system 513
Failure codes table 515
Fuse locations . 521
Troubleshooting by failure code 523
Failure code [879AKA] A/C Inner Sensor Open Circuit 523
Failure code [879AKB] A/C Inner Sensor Short Circuit . 523
Failure code [879BKA] A/C Outer Sensor Open Circuit 523
Failure code [879BKB] A/C Outer Sensor Short Circuit . 523
Failure code [879CKA] Ventilating Sensor Open Circuit 523
Failure code [879CKB] Ventilating Sensor Short Circuit . 524
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit 524
Failure code [879EMC] Ventilation Damper Abnormality . 524
Failure code [879FMC] Air Mix Damper Abnormality . 524
Failure code [879GKX] Refrigerant Abnormality 524
Failure code [989L00] Engine Controller Lock Caution1 525
Failure code [989M00] Engine Controller Lock Caution2 526
Failure code [989N00] Engine Controller Lock Caution3 527
Failure code [AA10NX] Air Cleaner Clogging . 528
Failure code [AB00KE] Charge Voltage Low . 530
Failure code [B@BAZG] Eng Oil Press Low 532
Failure code [B@BAZK] Engine Oil Level Low . 533
Failure code [B@BCNS] Eng Water Overheat . 534
Failure code [B@BCZK] Radiator Coolant Level Low . 536
Failure code [B@HANS] Hyd Oil Overheat . 538
Failure code [CA111] ECM Critical Internal Failure . 539
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 539
Failure code [CA122] Chg Air Press Sensor High Error . 540
Failure code [CA123] Chg Air Press Sensor Low Error 542
Failure code [CA131] Throttle Sensor High Error 544
Failure code [CA132] Throttle Sensor Low Error . 546
Failure code [CA144] Coolant Temp Sens High Error 548
Failure code [CA145] Coolant Temp Sens Low Error . 550
Failure code [CA153] Chg Air Temp Sensor High Error 552
Failure code [CA154] Chg Air Temp Sensor Low Error . 554
Failure code [CA155] Chg Air Temp High Speed Derate 556
Failure code [CA187] Sens Supply 2 Volt Low Error 558
Failure code [CA221] Ambient Press Sens High Error . 560
Failure code [CA222] Ambient Press Sens Low Error 562
Failure code [CA227] Sens 2 Supply Volt High Error . 564
Failure code [CA234] Eng Overspeed . 564
Failure code [CA238] Ne Speed Sens Supply Volt Error . 565
Failure code [CA271] IMV/PCV1 Short Error 566
Failure code [CA272] IMV/PCV1 Open Error . 568
Failure code [CA281] Abnormal supply pump pressure balance . 570
Failure code [CA322] Inj #1(L#1) Open/Short Error 572
Failure code [CA323] Inj #5(L#5) Open/Short Error 574
Failure code [CA324] Inj #3(L#3) Open/Short Error 576
Failure code [CA325] Inj #6(L#6) Open/Short Error 578
Failure code [CA331] Inj #2(L#2) Open/Short Error 580
Failure code [CA332] Inj #4(L#4) Open/Short Error 582
Failure code [CA342] Calibration Code Incompatibility 584
Failure code [CA351] Injectors Drive Circuit Error . 585
Failure code [CA352] Sens Supply 1 Volt Low Error 586
Failure code [CA386] Sens Supply 1 Volt High Error . 588
Failure code [CA428] Water in Fuel Sensor High Error . 590
Failure code [CA429] Water in Fuel Sensor Low Error 592
Failure code [CA435] Eng Oil Press Sw Error 594
Failure code [CA441] Battery Voltage Low Error . 596
Failure code [CA442] Battery Voltage High Error 598
Failure code [CA449] Rail Press Very High Error 599
Failure code [CA451] Rail Press Sensor High Error 600
Failure code [CA452] Rail Press Sensor Low Error . 602
Failure code [CA488] Chg Air Temp High Torque Derate . 604
Failure code [CA553] Rail Press High Error . 605
Failure code [CA559] Rail Press Low Error 606
Failure code [CA689] Eng Ne Speed Sensor Error . 608
Failure code [CA731] Eng Bkup Speed Sens Phase Error . 612
Failure code [CA757] All Continuous Data Lost Error 613
Failure code [CA778] Eng Bkup Speed Sensor Error . 614
Failure code [CA2185] Throt Sens Sup Volt High Error . 617
Failure code [CA2186] Throt Sens Sup Volt Low Error 618
Failure code [CA2249] Rail Press Very Low Error 619
Failure code [CA2265] Fuel Feed Pump Open Error 620
Failure code [CA2266] Fuel Feed Pump Short Error . 622
Failure code [CA2311] lMV Solenoid Error . 623
Failure code [CA2555] Grid Htr Relay Open Circuit Error 624
Failure code [CA2556] Grid Htr Relay Short Circuit Error . 626
Failure code [D110KB] Battery Relay Drive Short Circuit 628
Failure code [D19JKZ] Personal Code Relay Abnormality 630
Failure code [D811MC] KOMTRAX Error 632
Failure code [D862KA] GPS Antenna Open Circuit . 633
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 634
Failure code [DA22KK] Pump Solenoid Power Low Error 636
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 638
Failure code [DA26KP] 5V Sensor 2 Power Abnormality 640
Failure code [DA29KQ] Model Selection Abnormality 642
Failure code [DA2QKR] CAN2 Discon (Pump Con) . 644
Failure code [DAF0MB] Monitor ROM Abnormality 647
Failure code [DAF0MC] Monitor Error 648
Failure code [DAF8KB] Camera Power Supply Short Circuit 650
Failure code [DAF9KQ] Model Selection Abnormality 652
Failure code [DAFGMC] GPS Module Error . 653
Failure code [DAFQKR] CAN2 Discon 654
Failure code [DAZ9KQ] A/C Model Selection Abnormality 655
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) . 656
Failure code [DB2QKR] CAN2 Discon (Engine Con) . 658
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit . 662
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit . 664
Failure code [DHPAMA] F Pump Press Sensor Abnormality 666
Failure code [DHPBMA] R Pump Press Sensor Abnormality 668
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 670
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality . 672
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 674
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality 676
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 678
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 680
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality 682
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality . 684
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality . 686
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality . 688
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality . 690
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality . 692
Failure code [DHX1MA] Overload Sensor Abnormality 694
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality 696
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality 698
Failure code [DV20KB] Travel Alarm Short Circuit . 700
Failure code [DW43KA] Travel Speed Sol Open Circuit 702
Failure code [DW43KB] Travel Speed Sol Short Circuit . 704
Failure code [DW45KA] Swing Brake Sol. Valve Open Circuit 706
Failure code [DW45KB] Swing Brake Sol Short Circuit 708
Failure code [DW91KA] Travel Neutral Sol Open Circuit 710
Failure code [DW91KB] Travel Neutral Sol Short Circuit . 712
Failure code [DWA2KA] Attachment Sol Open Circuit 714
Failure code [DWA2KB] Attachment Sol Short Circuit . 716
Failure code [DWJ0KA] Merge-divider Sol. Open Circuit 718
Failure code [DWJ0KB] Merge-divider Sol. Short Circuit . 720
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 722
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit . 724
Failure code [DWK2KA] Variable Back Press Sol Open Circuit . 726
Failure code [DWK2KB] Variable Back Press Sol Short Circuit 728
Failure code [DXA8KA] PC-EPC Sol Open Circuit 730
Failure code [DXA8KB] PC-EPC Sol Short Circuit . 732
Failure code [DXE0KA] LS-EPC Sol Open Circuit 734
Failure code [DXE0KB] LS-EPC Sol Short Circuit . 736
Failure code [DXE4KA] Attachment Flow EPC Open Circuit . 738
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 740
Failure code [DY20KA] Wiper Working Abnormality 742
Failure code [DY20MA] Wiper Parking Abnormality 744
Failure code [DY2CKB] Washer Drive Short Circuit . 746
Failure code [DY2DKB] Wiper Drive (Fwd) Short 748
Failure code [DY2EKB] Wiper Drive (Rev) Short 750
Troubleshooting of electrical system (E-mode) 752
Fuse locations . 752
Information contained in troubleshooting table . 754
E-1 Engine does not start (Engine does not crank) 756
E-2 Preheater does not operate . 761
E-3 When starting switch is turned to ON position, machine monitor displays nothing 765
E-4 When starting switch is turned to ON position (with engine stopped), basic check monitor lights up . 768
E-5 Precaution monitor lights up while engine is running . 769
E-6 Emergency stop monitor lights up while engine is running . 771
E-7 Fuel level gauge does not indicate properly 772
E-8 Engine coolant temperature gauge does not indicate properly 774
E-9 Hydraulic oil temperature gauge does not indicate properly . 775
E-10 Displays on machine monitor are different from those for actual machine . 778
E-11 Some areas of machine monitor screen are not displayed 779
E-12 Function switch does not operate 779
E-13 Automatic warm-up system does not operate (in cold season) 780
E-14 Auto-decelerator does not operate properly 781
E-15 Working mode does not change 782
E-16 Travel speed does not change 783
E-17 Alarm buzzer cannot be canceled . 784
E-18 When starting switch is turned OFF, service meter is not displayed 784
E-19 Service mode cannot be selected . 784
E-20 Any of work equipment, swing and travel do not operate or cannot be locked 785
E-21 Swing holding brake does not operate properly . 787
E-22 One-touch power maximizing function does not operate properly . 790
E-23 Travel alarm does not sound or does not stop sounding . 793
E-24 Horn does not sound or does not stop 794
E-25 Windshield wiper and window washer do not operate . 796
E-26 Machine push-up function cannot be canceled . 798
E-27 Machine push-up function does not operate . 800
E-28 BOOM DOWN indicator is not displayed properly with monitoring function 801
E-29 ARM DUMP indicator is not displayed properly with monitoring function . 801
E-30 ARM IN indicator is not displayed properly with monitoring function . 801
E-31 BOOM RAISE indicator is not displayed properly with monitoring function . 802
E-32 BUCKET CURL indicator is not displayed properly with monitoring function 802
E-33 BUCKET DUMP indicator is not displayed properly with monitoring function 802
E-34 SWING indicator is not displayed properly with monitoring function 803
E-35 TRAVEL indicator is not displayed properly with monitoring function . 803
E-36 ATTACHMENT indicator is not displayed properly with monitoring function . 804
E-37 Attachment hydraulic circuit cannot be changed 806
E-38 KOMTRAX system does not operate properly 807
Troubleshooting of hydraulic and mechanical system (H-mode) 808
System chart for hydraulic and mechanical system . 808
Information contained in troubleshooting table . 810
H-1 All work equipment lack power, or travel and swing speeds are slow . 812
H-2 Engine speed sharply drops or engine stalls 814
H-3 No work equipment, swing or travel move 815
H-4 Abnormal noise is heard from around hydraulic pump . 815
H-5 Auto-decelerator does not work . 816
H-6 Fine control mode does not function or responds slow . 816
H-7 Boom moves slowly or lacks power . 817
H-8 Arm moves slowly or lacks power 818
H-9 Bucket moves slowly or lacks power . 819
H-10 Work equipment does not move in its single operation 819
H-11 Work equipment has a bit too fast hydraulic drift . 820
H-12 Work equipment has big time lag . 822
H-13 Other work equipment moves when relieving single circuit 822
H-14 Power max. switch does not operate 823
H-15 In compound operation, work equipment with larger load moves slowly . 823
H-16 In swing + boom RAISE operation, boom moves slowly 824
H-17 In swing + travel operation, travel speed drops sharply . 824
H-18 Machine swerves in travel . 825
H-19 Machine travels slowly 826
H-20 Machine cannot be easily steered or lacks power . 827
H-21 Travel speed does not shift, or it is too slow or fast 828
H-22 Track shoe does not turn (on one side only) . 829
H-23 Machine does not swing 830
H-24 Swing acceleration is poor, or swing speed is slow 832
H-25 Excessive overrun when stopping swing . 834
H-26 There is big shock when stopping swing 835
H-27 Large sound is made when upper structure stops swinging . 835
H-28 Swing hydraulic drift is too big 836
Troubleshooting of engine (S-mode) . 837
Method of using troubleshooting charts . 837
S-1 Starting performance is poor . 840
S-2 Engine does not start 841
S-3 Engine does not pick up smoothly . 844
S-4 Engine stops during operations . 845
S-5 Engine does not rotate smoothly 846
S-6 Engine lacks output (or lacks power) . 847
S-7 Exhaust smoke is black (incomplete combustion) . 848
S-8 Oil consumption is excessive (or exhaust smoke is blue) 849
S-9 Oil becomes contaminated quickly . 850
S-10 Fuel consumption is excessive . 851
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 852
S-12 Oil pressure drops 853
S-13 Oil level rises (water, fuel in oil) 854
S-14 Coolant temperature becomes too high (overheating) 855
S-15 Abnormal noise is made 856
S-16 Vibration is excessive 857
50 Disassembly and assembly 859
Related information on disassembly and assembly 862
How to read this manual 862
Coating materials list . 864
Special tools list . 868
Sketches of special tools 871
Engine and cooling system 873
Removal and installation of supply pump assembly . 873
Removal and installation of engine front oil seal 877
Removal and installation of engine rear oil seal . 880
Removal and installation of cylinder head assembly . 885
Removal and installation of radiator assembly 899
Removal and installation of hydraulic oil cooler assembly 901
Removal and installation of aftercooler assembly . 903
Removal and installation of engine and hydraulic pump assembly . 905
Power train system . 910
Removal and installation of travel motor and final drive assembly 910
Disassembly and assembly of final drive assembly . 911
Removal and installation of swing motor and swing machinery assembly . 920
Disassembly and assembly of swing motor and swing machinery assembly . 921
Removal and installation of swing circle assembly 929
Undercarriage and frame 930
Disassembly and assembly of carrier roller assembly 930
Disassembly and assembly of track roller assembly 932
Disassembly and assembly of idler assembly . 933
Disassembly and assembly of recoil spring assembly . 936
Removal and installation of sprocket . 938
Expansion and installation of track shoe assembly 939
Removal and installation of revolving frame assembly . 941
Removal and installation of counterweight assembly . 943
Hydraulic system . 946
Removal and installation of center swivel joint assembly . 946
Disassembly and assembly of center swivel joint assembly . 948
Removal and installation of hydraulic tank assembly 949
Removal and installation of control valve assembly . 951
Disassembly and assembly of control valve assembly . 954
Removal and installation of hydraulic pump assembly 959
Removal and installation of hydraulic pump input shaft oil seal 962
Disassembly and assembly of work equipment PPC valve assembly 963
Disassembly and assembly of travel PPC valve assembly 965
Disassembly and assembly of work equipment cylinder assembly . 967
Work equipment . 973
Removal and installation of work equipment assembly 973
Cab and its attachments 976
Removal and installation of operator’s cab assembly 976
Removal and installation of operator’s cab glass (adhered window glass) 979
Removal and installation of front window assembly 988
Removal and installation of floor frame assembly . 994
Electrical system 998
Removal and installation of air conditioner unit assembly 998
Removal and installation of KOMTRAX terminal assembly 1003
Removal and installation of machine monitor assembly .1005
Removal and installation of pump controller assembly .1007
Removal and installation of engine controller assembly .1009
80 Appendix 1011
Air conditioner 1013
Precautions for refrigerant 1013
Air conditioner component 1014
Configuration and function of refrigeration cycle 1016
Outline of refrigeration cycle .1017
Air conditioner unit .1019
Air conditioner controller .1025
Compressor .1026
Condenser 1027
Receiver drier .1028
Sensor .1029
Procedure for testing and troubleshooting 1030
Circuit diagram and arrangement of connector pins 1032
System diagram .1034
Parts and connectors layout 1036
Testing air leakage (duct) .1039
Testing with self-diagnosis function .1041
Testing vent (mode) changeover .1043
Testing FRESH/RECIRC air changeover 1044
Testing sunlight sensor 1045
Testing (dual) pressure switch for refrigerant .1046
Testing relays .1047
Troubleshooting chart 1 1048
Troubleshooting chart 2 1050
Information in troubleshooting table .1052
Failure code list related to air conditioner .1053
Failure code [879AKA] A/C Inner sensor Open Circuit 1054
Failure code [879AKB] A/C Inner sensor Short Circuit .1055
Failure code [879BKA] A/C Outer sensor Open Circuit 1056
Failure code [879BKB] A/C Outer sensor Short Circuit .1058
Failure code [879CKA] Ventilating sensor Open Circuit 1060
Failure code [879CKB] Ventilating sensor Short Circuit .1061
Failure code [879DKZ] Sunlight sensor Open or Short Circuit 1062
Failure code [879EMC] Ventilating Damper Abnormality .1064
Failure code [879FMC] Air Mix Damper Abnormality .1065
Failure code [879GKX] Refrigerant Abnormality 1066
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) .1068
Troubleshooting for compressor and refrigerant system (Air is not cooled) 1070
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) .1073
Troubleshooting for FRESH/RECIRC air changeover 1075
Troubleshooting with gauge pressure 1077
Connection of service tool .1079
Precautions for disconnecting and connecting air conditioner piping 1081
Handling of compressor oil .1083
90 Diagrams and drawings .1085
Hydraulic diagrams and drawings 1087
Symbols in hydraulic circuit diagram .1087
Hydraulic circuit diagram 1091
Electrical diagrams and drawings .1092
Symbols in electric circuit diagram 1092
Electrical circuit diagram .1096
Index 1101

DESCRIPTION:

Komatsu PC390LC-8MO Hydraulic Excavator Shop Manual SEN06613-01 –  PDF DOWNLOAD

• Serial Numbers 80699 and up

G.B 28/12/24