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Komatsu PC390LL-10 Log Loader, Logging Road Builder Excavator Shop Manual A50601 and up – DOWNLOAD
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Komatsu PC390LL-10 Log Loader, Logging Road Builder Excavator Shop Manual
SERIAL NUMBERS : PC390LL-10 A50601 and up
Book Code: CEBM027501
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Description
Komatsu PC390LL-10 Log Loader, Logging Road Builder Excavator Shop Manual
FILE DETAILS:
Komatsu PC390LL-10 Log Loader, Logging Road Builder Excavator Shop Manual
Brands: Komatsu
Equipment Type: Log Loader, Logging/Road Builder Excavator
Manuals Type: Shop Manual
Machine Model: PC390LL-10
Serial Number: A50601 and up
Book Code: CEBM027501
Language: English
Pages: 352
File Format: Portable Document Format (PDF)
KOMATSU PC390LL-10 LOG LOADER, LOGGING ROAD BUILDER EXCAVATOR SHOP MANUAL A50601 AND UP – DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC390LL-10 Log Loader, Logging Road Builder Excavator Shop Manual
1 GENERAL :
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
01 GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
10 STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, 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 checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
40 TROUBLESHOOTING:
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
50 DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
60 MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
80 AIR CONDITIONING:
This section explains the air conditioning system, structure and function, troubleshooting, disassembly, and assembly.
90 DIAGRAMS AND SCHEMATICS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC390LL-10 Log Loader, Logging Road Builder Excavator Shop Manual
CEBM027501 PC390LL-10 S/N A50601-....................................................................... 1 CONTENTS............................................................................................ 3 00 - FOREWORD....................................................................................... 4 SAFETY.......................................................................................... 4 Safety Notice............................................................................... 4 Important Safety Notice................................................................. 4 General Precautions..................................................................... 4 Preparations For Work................................................................... 5 Precautions During Work................................................................. 5 GENERAL......................................................................................... 8 HOW TO READ THE SHOP MANUAL..................................................................... 10 Volumes..................................................................................... 10 Distribution and Updating................................................................... 10 Filing Method............................................................................... 10 Revised Edition Mark........................................................................ 10 Revisions................................................................................... 10 Symbols..................................................................................... 10 HOISTING INSTRUCTIONS........................................................................... 11 Hoisting.................................................................................... 11 Making Signs................................................................................ 11 Precautions................................................................................. 11 Precautions for Sling Work.............................................................. 11 Precautions for Using Mobile Crane...................................................... 12 Precautions for Using Overhead Hoist Crane.............................................. 12 Selecting Wire Ropes........................................................................ 13 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS............................................ 14 Points to Remember When Handling Electric Equipment......................................... 14 Points to Remember When Handling Hydraulic Equipment........................................ 26 PUSH PULL COUPLER............................................................................... 28 Type 1...................................................................................... 28 Disconnection........................................................................... 28 Connection.............................................................................. 28 Type 2...................................................................................... 29 Disconnection........................................................................... 29 Connection.............................................................................. 29 Type 3...................................................................................... 30 Disconnection........................................................................... 30 Connection.............................................................................. 30 EXPLANATION OF MAINTENANCE STANDARD TERMS....................................................... 31 HANDLING OF FUEL SYSTEM DEVICES................................................................. 32 HANDLING OF INTAKE SYSTEM PARTS................................................................. 33 STANDARD TIGHTENING TORQUE...................................................................... 34 Bolts And Nuts.............................................................................. 34 Tightening Torque Of Hose Nuts.............................................................. 35 Tightening Torque Of Split Flange Bolts..................................................... 35 Tightening Torque For Flared Nuts........................................................... 35 Tightening Torques for Split Flanged Bolts.................................................. 36 Tightening Torques For O-ring Boss Piping Joints............................................ 36 Table Of Tightening Torques For O-ring Boss Plugs........................................... 36 Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)............................ 37 Tightening Torque For Face Seal Joints.................................................. 37 For 102, 107, and 114 Engine Series (Bolts and Nuts).................................... 37 For 102, 107, and 114 Engine Series (Eye Joints)........................................ 38 For 102, 107, and 114 Engine Series (Taper Screws)...................................... 38 ELECTRIC WIRE CODE.............................................................................. 39 Classification By Thickness................................................................. 39 Classification By Color And Code............................................................ 39 How To Read Electric Wire Code.............................................................. 40 PRECAUTIONS FOR OPERATIONS...................................................................... 43 Precautions When Carrying Out Removal Work.................................................. 43 Precautions When Carrying Out Installation Work............................................. 44 Precautions When Completing the Operation................................................... 45 CONVERSION TABLES............................................................................... 46 Method Of Using The Conversion Table........................................................ 46 COATING MATERIALS............................................................................... 52 LIST OF ABBREVIATIONS........................................................................... 54 List of Abbreviations Used in the Shop Manual............................................... 54 List of Abbreviations Used in the Circuit Diagrams.......................................... 58 01 - GENERAL........................................................................................ 60 SPECIFICATIONS.................................................................................. 61 Dimension Drawings.......................................................................... 61 Road Builder............................................................................ 61 Log Loader.............................................................................. 61 Dimensions.................................................................................. 62 Working Ranges.............................................................................. 63 Road Builder............................................................................ 63 Log Loader.............................................................................. 64 Engine...................................................................................... 65 Undercarriage............................................................................... 65 Hydraulic System............................................................................ 66 Road Builder............................................................................ 66 Log Loader.............................................................................. 67 WEIGHT TABLE.................................................................................... 68 FUEL, COOLANT AND LUBRICANTS.................................................................... 70 Lubrication Chart........................................................................... 72 10 - STRUCTURE AND FUNCTION......................................................................... 74 ENGINE AND COOLING SYSTEM....................................................................... 77 Engine Related Parts........................................................................ 77 Cooling System.............................................................................. 79 POWERTRAIN SYSTEM............................................................................... 81 Powertrain.................................................................................. 81 Swing Circle................................................................................ 83 Final Drive................................................................................. 84 TRACK FRAME • RECOIL SPRING..................................................................... 85 HYDRAULIC SYSTEM................................................................................ 87 Hydraulic Component Layout.................................................................. 87 Valve Control............................................................................... 89 Hydraulic Tank.............................................................................. 91 Oil Filler Cap.............................................................................. 92 CLSS........................................................................................ 93 Structure of CLSS....................................................................... 93 Basic principle......................................................................... 94 Main Pump................................................................................... 97 Operation...............................................................................101 LS Valve................................................................................103 PC Valve................................................................................109 LS(PC)-EPC Valve........................................................................116 Control Valve...............................................................................119 Functions and Operation by Valve............................................................131 Hydraulic Circuit Diagram and Name of Valves............................................131 Unload Valve............................................................................133 Introduction of LS Pressure.............................................................134 LS By-Pass Plug.........................................................................135 Pressure Compensation Valve.............................................................136 Shuttle Valve In Pressure Compensation Valve............................................139 Boom Regeneration Circuit...............................................................141 Arm Regeneration Circuit................................................................143 Merge-Divider Valve.....................................................................145 LS Selector Valve.......................................................................148 Self-Pressure Reducing Valve............................................................149 Travel Junction Valve...................................................................152 Travel PPC Shuttle Valve................................................................155 Boom Hydraulic Drift Prevention Valve...................................................157 Arm Hydraulic Drift Prevention Valve (Road Builder).....................................160 Arm Drift Prevention Valve (Log Loader).................................................163 Operation...............................................................................164 Suction Safety Valve for Drift Prevention Valve.........................................166 Arm Quick Return Valve..................................................................167 Variable Back Pressure Valve............................................................169 Main Relief Valve.......................................................................171 Suction 2-Stage Safety Valve............................................................172 Swing Motor.................................................................................174 Swing Holding Brake.....................................................................176 Relief Valve............................................................................178 Swing 2-Stage Relief Valve..............................................................180 Swing Motor Reverse Prevention Valve....................................................181 Travel Motor - Type KMV200ADT-2.............................................................184 Operation of Travel Motor...............................................................187 Parking Brake...........................................................................189 Brake Valve.............................................................................191 Safety Valve............................................................................193 PPC Valve...................................................................................197 Work Equipment and Swing PPC Valve......................................................197 Travel PPC Valve........................................................................202 1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)............................207 EPC Valve (If Equipped).................................................................209 2nd-Line Attachment PPC Valve (If Equipped).............................................212 Solenoid Valve..............................................................................214 Attachment Solenoid Valve...................................................................216 Center Swivel Joint.........................................................................218 Accumulator.................................................................................219 PPC Accumulator.........................................................................219 WORK EQUIPMENT..................................................................................220 Work Equipment - Road Builder...............................................................220 Work Equipment - Log Loader.................................................................221 Work Equipment Shim.........................................................................222 Bucket Play Adjustment Shim.................................................................222 ELECTRICAL SYSTEM...............................................................................224 Electrical Control System...................................................................224 Machine Control System Diagram..........................................................224 Engine Control Function.................................................................226 Engine and Pump Combined Control Function...............................................228 Pump and Valve Control Function.........................................................234 One-Touch Power Maximizing Function.....................................................236 Machine Push-Up Function................................................................238 Auto-Deceleration Function..............................................................240 Engine Automatic Warm-Up Function.......................................................242 Overheat Prevention Function............................................................244 Turbocharger Protection Function........................................................245 Swing Control Function..................................................................246 Swing Control Function (with Soft Swing Option).........................................247 Quick Warm-Up Function..................................................................249 Swing 2-Stage Relief Function...........................................................249 Travel Control Function.................................................................250 PPC Lock Function.......................................................................252 Attachment Flow Control Function........................................................253 System Component Part.......................................................................254 Engine Controller.......................................................................254 Pump Controller.........................................................................258 Fuel Control Dial.......................................................................261 Resister for PC-EPC valve...............................................................262 CAN Terminating Resistor................................................................263 Engine Oil Pressure Switch..............................................................264 PPC Oil Pressure Switch.................................................................265 MACHINE MONITOR SYSTEM..........................................................................266 Machine Monitor.............................................................................268 Input and Output Signals................................................................269 Display.................................................................................271 Gauges..................................................................................273 Caution Monitor.........................................................................275 Pilot Monitor...........................................................................278 Switches....................................................................................281 Guidance ICON and Function Switch.......................................................283 Operator Mode Function..................................................................286 Service Mode Function...................................................................288 KOMTRAX SYSTEM..................................................................................289 KOMTRAX terminal............................................................................290 Input and Output Signals....................................................................291 SENSORS.........................................................................................293 Ambient Pressure Sensor.....................................................................293 Charge (Boost) Pressure and Temperature Sensor..............................................294 Coolant Temperature Sensor..................................................................295 Ne (Crankshaft) Speed Sensor................................................................295 Bkup (Camshaft) Speed Sensor................................................................296 Common Rail Pressure Sensor.................................................................296 Exhaust Manifold Pressure Sensor............................................................297 EGR Orifice Temperature Sensor..............................................................297 EGR Valve Lift Sensor.......................................................................298 Turbo Speed Sensor..........................................................................299 KVGT Position Sensor........................................................................300 Mass Air Flow and Temperature Sensor........................................................301 KDPF Differential Pressure and Outlet Pressure Sensor.......................................301 KDOC Inlet Temperature Sensor...............................................................302 KDOC Outlet Temperature Sensor..............................................................302 KDPF Outlet Temperature Sensor..............................................................303 Crankcase Pressure Sensor...................................................................303 Engine Oil Level Sensor.....................................................................304 Fuel Level Sensor...........................................................................305 Coolant Level Sensor........................................................................306 Hydraulic Oil Temperature Sensor............................................................306 Front Pump Oil Pressure Sensor..............................................................307 Rear Pump Oil Pressure Sensor...............................................................308 PPC Oil Pressure Sensor.....................................................................309 Air Cleaner Clogging Sensor.................................................................310 Front Pump Swash Plate Sensor...............................................................311 Rear Pump Swash Plate Sensor................................................................313 Water-In-Fuel Sensor........................................................................315 20- STANDARD VALUE TABLES...........................................................................316 STANDARD SERVICE VALUE TABLES...................................................................317 Standard Value Table for Engine Related Parts...............................................317 Standard Value Table for Chassis Related Parts..............................................319 Engine Speed............................................................................319 Travel of Control Valve Spool...........................................................319 Travel of Control Lever.................................................................320 Operating Effort of Control Lever and Pedal.............................................320 Hydraulic Pressure......................................................................321 Swing...................................................................................322 Travel..................................................................................323 Work Equipment..........................................................................324 Performance in Combined Operation.......................................................325 Pump Swash Plate Sensor.................................................................326 Main Pump...............................................................................326 Posture of Machine for Measuring Performance and Measurement Procedure......................328 Control Valve: Spool Stroke.............................................................328 Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing....328 Swing 2: Hydraulic Drift of Swing.......................................................328 Travel 1: Travel Speed, Idle Running (Without Load).....................................329 Travel 2: Travel Speed (Actual Run), Travel Deviation...................................329 Travel 3: Travel Deviation..............................................................330 Travel 4: Hydraulic Drift of Travel.....................................................330 Work Equipment 1: Hydraulic Drift of Work Equipment.....................................331 Work Equipment 2: Boom Speed............................................................331 Work Equipment 3: Arm Speed.............................................................331 Work Equipment 4: Bucket Speed/Heel Speed...............................................332 Work Equipment 5: Boom Time Lag.........................................................332 Work Equipment 6: Arm Time Lag..........................................................333 Work Equipment 7: Bucket Time Lag.......................................................333 HYDRAULIC CIRCUIT DIAGRAM................................................................... 0 Symbols in Hydraulic Circuit Diagram........................................................ 0 90- DIAGRAMS AND SCHEMATICS.........................................................................334 HYDRAULIC CIRCUIT DIAGRAM.......................................................................336 Symbols in Hydraulic Circuit Diagram........................................................336 Hydraulic Circuit Diagram (1/2).............................................................339 Hydraulic Circuit Diagram (2/2).............................................................340 ELECTRICAL SYSTEM...............................................................................341 Symbols in Electrical Circuit Diagrams......................................................341 Air Conditioner Electrical Circuit Diagram..................................................344 Electrical Circuit Diagram - Log Loader Unique..............................................345 Electrical Circuit Diagram (1/6)............................................................346 Electrical Circuit Diagram (2/6)............................................................347 Electrical Circuit Diagram (3/6)............................................................348 Electrical Circuit Diagram (4/6)............................................................349 Electrical Circuit Diagram (5/6)............................................................350 Electrical Circuit Diagram (6/6)............................................................351 Cab Diagram.................................................................................352
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
