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Komatsu PC390LL-10 Log Loader Road Builder Operation & Maintenance Manual SN A50601 and up – PDF DOWNLOAD
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Komatsu PC390LL-10 Log Loader Road Builder Operation & Maintenance Manual
Book Code: CEAM027101
SERIAL NUMBER PC390LL-10 A50601 and up
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Description
Komatsu PC390LL-10 Log Loader Road Builder Operation & Maintenance Manual
FILE DETAILS:
Komatsu PC390LL-10 Log Loader Road Builder Operation & Maintenance Manual
Brands: Komatsu
Equipment Type: Log Loader Road Builder
Manuals Type: Operation & Maintenance Manual
Machine Model: PC390LL-10
Serial Number: A50601 and up
Book Code: CEAM027101
Language: English
Pages: 428
File Format: Portable Document Format (PDF)
KOMATSU PC390LL-10 LOG LOADER ROAD BUILDER OPERATION & MAINTENANCE MANUAL SN A50601 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC390LL-10 Log Loader Road Builder Operation & Maintenance Manual
FOREWORD:
- This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines.
- Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance. Read, understand and follow all precautions and warnings in this manual and on the machine before operating and performing maintenance. Failure to do so may result in serious injury or death. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death.
TABLE OF CONTENTS:
Komatsu PC390LL-10 Log Loader Road Builder Operation & Maintenance Manual
CEAM027101 PC390LL-10 S/N A50601 and UP..................................................................................... 1 INTRODUCTION............................................................................................................ 3 FORWARD............................................................................................................. 4 SAFETY INFORMATION.................................................................................................. 5 Safety Labels................................................................................................... 6 INTRODUCTION........................................................................................................ 7 Intended Use.................................................................................................... 7 Directions of Machine........................................................................................... 7 Structure to Protect the Operator........................................................................... 7 Breaking-In the New Machine..................................................................................... 8 Product Information............................................................................................. 9 Product Identification Number (Pin)/Machine Serial No. Plate................................................ 9 EPA* Regulations, Engine Number Plate....................................................................... 9 Service Meter Location.......................................................................................... 10 Your Machine Serial Numbers and Distributor..................................................................... 10 Engine Acronyms................................................................................................. 10 TABLE OF CONTENTS................................................................................................... 11 SAFETY.................................................................................................................. 21 SAFETY LABELS....................................................................................................... 22 Location of Safety Labels....................................................................................... 22 Safety Labels................................................................................................... 23 Unique Safety Decals for Log Loader and Road Builder Excavators................................................. 31 GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE............................................................. 36 Precautions Before Starting Operation........................................................................... 36 Ensuring Safe Operation..................................................................................... 36 Understanding the Machine................................................................................... 36 Preparations for Safe Operation................................................................................. 36 Precautions Regarding Safety-Related Equipment.............................................................. 36 Inspecting Machine.......................................................................................... 36 Clothing and Personal Protective Items.......................................................................... 36 Keep Machine Clean.............................................................................................. 37 Keep Operator's Compartment Clean............................................................................... 37 Fire Extinguisher and First Aid Kit............................................................................. 37 Safety Equipment................................................................................................ 37 If Problems are Found........................................................................................... 37 Fire Prevention and Explosion Prevention........................................................................ 38 Action if Fire Occurs........................................................................................... 39 Handrails and Steps............................................................................................. 40 Mounting and Dismounting........................................................................................ 40 No Persons on Attachments....................................................................................... 40 Leaving Operator's Seat with Lock............................................................................... 41 Emergency Exit from Operator's Cab.............................................................................. 41 Do Not Get Caught in Work Equipment............................................................................. 42 Precautions Related to Protective Structures.................................................................... 42 Falling Objects, Flying Objects and Intruding Objects Prevention................................................ 42 Unauthorized Modification....................................................................................... 43 Precautions Related to Attachments and Options.................................................................. 43 Precautions Related to Cab Glass................................................................................ 43 Precautions When Running Engine Inside Building................................................................. 43 Safety at Job Site.............................................................................................. 44 Working on Loose Ground......................................................................................... 44 Distance to High Voltage Cables................................................................................. 44 Ensure Good Visibility.......................................................................................... 45 Signalman's Signal and Signs.................................................................................... 45 Asbestos Dust Hazard Prevention................................................................................. 46 SAFETY MACHINE OPERATION............................................................................................ 47 Starting Engine................................................................................................. 47 Checks Before Starting Engine............................................................................... 47 Safety Rules for Starting Engine............................................................................ 48 Starting Engine in Cold Weather............................................................................. 48 Starting Engine with Booster Cables......................................................................... 48 Operation....................................................................................................... 49 Checks Before Operation..................................................................................... 49 Safety Rules for Changing Machine Directions................................................................ 49 Safety Rules for Traveling.................................................................................. 50 Traveling on Slopes......................................................................................... 51 Operations on Slopes........................................................................................ 52 Prohibited Operations....................................................................................... 53 Operations on Snow or Frozen Surfaces....................................................................... 55 Parking Machine............................................................................................. 55 TRANSPORTATION...................................................................................................... 56 Loading and Unloading........................................................................................... 56 Shipping the Machine............................................................................................ 57 TOWING.............................................................................................................. 57 Safety Rules for Towing......................................................................................... 57 LIFTING OBJECTS WITH BUCKET......................................................................................... 58 Safety Rules for Lifting Objects................................................................................ 58 SAFETY MAINTENANCE INFORMATION...................................................................................... 59 Warning Tag..................................................................................................... 59 Keep Work Place Clean and Tidy.................................................................................. 59 Select Suitable Place for Inspection and Maintenance............................................................ 59 Only Authorized Personnel....................................................................................... 59 Appoint Leader When Working with Others......................................................................... 59 Stop Engine Before Carrying Out Maintenance..................................................................... 60 Precautions When Working at High Places......................................................................... 60 Two Workers for Maintenance When Engine is Running.............................................................. 61 Attachments..................................................................................................... 61 Work on Machine................................................................................................. 62 Work Under the Machine.......................................................................................... 62 Proper Tools.................................................................................................... 62 Battery Disconnect Switch....................................................................................... 63 Removing Battery Terminals...................................................................................... 63 Welding......................................................................................................... 63 Battery......................................................................................................... 63 Battery Hazard Prevention................................................................................... 63 When Using Hammer............................................................................................... 64 Precautions with High Temperature Coolant....................................................................... 64 Precautions with High Temperature Oil........................................................................... 65 Safety Rules for High-Pressure Oil.............................................................................. 65 Precaution for High Fuel Pressure........................................................................... 65 Safety Handling High-Pressure Hoses or Piping............................................................... 65 Precaution for High Voltage..................................................................................... 66 Noise........................................................................................................... 66 Safety First When Using High-Pressure Grease to Adjust Track Tension............................................ 66 Do Not Disassemble Recoil Springs............................................................................... 67 Accumulator..................................................................................................... 67 Handling Gas Spring............................................................................................. 67 Precautions When Using...................................................................................... 67 Precautions When Discarding................................................................................. 68 Compressed Air.................................................................................................. 68 Air Conditioner Maintenance..................................................................................... 68 Waste Materials................................................................................................. 68 Select Window Washer Fluid...................................................................................... 68 Personnel....................................................................................................... 68 Periodic Replacement of Safety Critical Parts................................................................... 69 OPERATION............................................................................................................... 71 MACHINE VIEW ILLUSTRATIONS.......................................................................................... 72 General View of Log Loader Machine.............................................................................. 72 General View of Road Builder Machine............................................................................ 73 General View of Cab............................................................................................. 75 CONTROLS AND GAUGES................................................................................................. 76 Machine Monitor................................................................................................. 77 EXPLANATION OF COMPONENTS........................................................................................... 78 Machine Monitor................................................................................................. 78 Basic Operation of Machine Monitor.......................................................................... 79 Warning Display............................................................................................. 84 Meter Display............................................................................................... 94 Gauges and Meter............................................................................................101 Monitor Switches Portion....................................................................................104 Handling Function Switches..................................................................................114 User Menu Selector Switch...................................................................................118 User Menu...................................................................................................119 Machine Settings............................................................................................131 Maintenance Screen Setting..................................................................................136 Monitor Setting.................................................................................................138 Screen Adjustment...........................................................................................138 Screen Adjustment (Camera)..................................................................................139 Clock Adjustment............................................................................................139 Time........................................................................................................141 SWITCHES............................................................................................................146 Starting Switch.................................................................................................147 Fuel Control Dial...............................................................................................147 Cigarette Lighter...............................................................................................147 Swing Lock Switch...............................................................................................148 Lamp Switch.....................................................................................................148 Room Lamp Switch................................................................................................149 Soft Swing Switch...............................................................................................150 Emergency Pump Drive Switch.....................................................................................151 Swing Brake Cancel Switch.......................................................................................151 Seat Heater Switch..............................................................................................152 Engine Shutdown Secondary Switch................................................................................153 CONTROL LEVERS AND PEDALS...........................................................................................154 Lock Lever......................................................................................................154 Travel Levers...................................................................................................155 Work Equipment Control Lever....................................................................................156 EMERGENCY ESCAPE....................................................................................................157 ENGINE HOOD.........................................................................................................158 When Opening (Normal Case: Intermediate Lock Position)..........................................................158 When Closing (Normal Case: Intermediate Lock Position)..........................................................160 CAPS AND COVERS WITH LOCK...........................................................................................162 Open and Close Caps with Lock...................................................................................162 Opening the Cap.............................................................................................162 Locking the Cap.............................................................................................162 Open and Close Covers with Lock.................................................................................163 Opening the Cover (Locked Cover)............................................................................163 Locking the Cover...........................................................................................163 Lock and Unlock Engine Hood.....................................................................................163 Opening the Hood (Locked Hood)..............................................................................163 Locking the Hood............................................................................................163 Lock and Unlock Cab Door........................................................................................164 Opening the Door (Locked Door)..............................................................................164 Locking the Door............................................................................................164 DRINK BOX...........................................................................................................165 MAGAZINE BOX........................................................................................................165 CUP HOLDER..........................................................................................................165 ASHTRAY.............................................................................................................166 AIR CONDITIONER CONTROLS............................................................................................167 Air Conditioner Control Panel...................................................................................167 Method of Operation.............................................................................................172 Automatic Operation.........................................................................................172 Stopping Automatic Operation................................................................................173 Manual Operation............................................................................................173 Stop Manual Operation.......................................................................................175 Operation with Cold Air to Face and Warm Air to Feet........................................................175 Defroster Operation.........................................................................................177 Rules for Using Air Conditioner.................................................................................179 Air Conditioner Maintenance.....................................................................................179 RADIO...............................................................................................................180 Control Panel...................................................................................................180 Operation Method................................................................................................182 Frequency Adjustment........................................................................................182 Frequency Adjustment (Auto Presetting)......................................................................182 Preset Call.................................................................................................182 Preset Memory...............................................................................................182 Sound Adjustment (Balance)..................................................................................182 Sound Adjustment (Treble)...................................................................................183 Sound Adjustment (Bass).....................................................................................183 Time Adjustment.............................................................................................183 Stowing Radio Antenna.......................................................................................183 AUXILIARY ELECTRIC POWER............................................................................................184 24 V Power Source...............................................................................................184 12 V Power Source...............................................................................................184 FUSE................................................................................................................185 FUSIBLE LINK........................................................................................................187 TOOL BOX............................................................................................................187 GREASE GUN HOLDER...................................................................................................187 BATTERY DISCONNECT SWITCH...........................................................................................188 SYSTEM OPERATING LAMP...............................................................................................189 HANDLING KOMATSU DIESEL PARTICULATE FILTER (KDPF)...................................................................190 Operation Procedure of Manual Stationary Regeneration...........................................................195 Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Procedure.....................................198 While Regeneration is Being Performed: Stopping Regeneration................................................199 Handling Komatsu Closed Crankcase Ventilation (KCCV)........................................................200 HANDLING MACHINES EQUIPPED WITH KOMTRAX.............................................................................201 Basic Precautions...............................................................................................201 MACHINE OPERATIONS AND CONTROLS.....................................................................................202 Before Starting Engine..........................................................................................202 Walk-Around Checks..........................................................................................202 Checks Before Starting......................................................................................204 Adjustment..................................................................................................214 Seat Belt Inspection............................................................................................223 Seat Belt.......................................................................................................224 Operations Before Starting Engine...............................................................................225 STARTING ENGINE.....................................................................................................227 Turbo Protect Function..........................................................................................230 AFTER STARTING ENGINE...............................................................................................231 Engine Warm Up..................................................................................................233 Hydraulic System Warm-Up........................................................................................235 Operation After Completion of Warming-Up Operation..............................................................241 STOPPING THE ENGINE.................................................................................................243 MACHINE OPERATION...................................................................................................244 Preparations for Moving the Machine.............................................................................244 Moving Machine Forward..........................................................................................245 Moving Machine Backward.........................................................................................246 Stopping Machine................................................................................................247 STEERING THE MACHINE................................................................................................248 Steering........................................................................................................248 Steering the Machine When Stopped...........................................................................248 Changing Direction of the Machine...........................................................................249 Counter-Rotation Turn (Spin Turn)...........................................................................249 SWINGING............................................................................................................250 WORK EQUIPMENT CONTROLS AND OPERATIONS..............................................................................251 WORKING MODE........................................................................................................253 Working Mode Switch.............................................................................................253 One-Touch Power Max. Switch.....................................................................................255 PROHIBITED OPERATIONS...............................................................................................256 GENERAL OPERATION INFORMATION.......................................................................................259 Traveling.......................................................................................................259 High Speed Travel...............................................................................................259 Permissible Water Depth.........................................................................................260 TRAVELING ON SLOPES.................................................................................................261 ESCAPE FROM MUD.....................................................................................................263 Track on One Side Stuck.........................................................................................263 Tracks on Both Sides Stuck......................................................................................263 RECOMMENDED APPLICATIONS............................................................................................264 Backhoe Work....................................................................................................264 Shovel Work.....................................................................................................264 Ditching Work...................................................................................................264 Loading Work....................................................................................................265 BUCKET REPLACEMENT AND INVERSION....................................................................................266 Replacement.....................................................................................................266 Inversion.......................................................................................................268 PARKING MACHINE.....................................................................................................270 MACHINE INSPECTION AFTER DAILY WORK.................................................................................272 LOCKING.............................................................................................................272 TRANSPORTATION......................................................................................................272 Transportation Procedure........................................................................................272 Loading and Unloading with Trailer..............................................................................273 Loading.....................................................................................................274 Securing Machine............................................................................................277 Stowing Radio Antenna.......................................................................................281 Rear View Mirrors...........................................................................................281 Unloading...................................................................................................284 LIFTING MACHINE.....................................................................................................286 Standard Specification Machines.................................................................................286 COLD WEATHER OPERATION..............................................................................................288 Cold Weather Operation Information..............................................................................288 Fuel and Lubricants.........................................................................................288 Coolant.....................................................................................................288 Battery.....................................................................................................289 AFTER DAILY WORK COMPLETION.........................................................................................290 AFTER COLD WEATHER SEASON...........................................................................................290 LONG TERM STORAGE...................................................................................................291 Before Storage..................................................................................................291 During Storage..................................................................................................291 After Storage...................................................................................................292 Starting Machine After Long-Term Storage........................................................................292 TROUBLES AND ACTIONS................................................................................................293 Running Out of Fuel.............................................................................................293 Phenomena that are Not Failures.................................................................................293 Towing the Machine..............................................................................................294 Lightweight Towing Hole.........................................................................................295 Severe Job Condition............................................................................................295 Discharged Battery..............................................................................................296 Battery Removal and Installation............................................................................296 Battery Charges.............................................................................................297 Starting Engine with Booster Cables.........................................................................298 OTHER TROUBLE.......................................................................................................300 Electrical System...............................................................................................300 Chassis.........................................................................................................301 Engine..........................................................................................................302 Electronic Control System.......................................................................................304 Point of Contact to Telephone When Error Occurs.............................................................304 MAINTENANCE.............................................................................................................305 MAINTENANCE INFORMATION.............................................................................................306 OUTLINE OF SERVICE..................................................................................................308 Handling Oil, Fuel, Coolant, and Performing Oil Clinic..........................................................308 Oil.........................................................................................................308 Fuel........................................................................................................309 Coolant and Water for Dilution..............................................................................309 Grease......................................................................................................310 Carrying Out KOWA (Komatsu Oil Wear Analysis)...............................................................310 Storing Oil and Fuel........................................................................................311 Filters.....................................................................................................311 Electric System Maintenance.....................................................................................311 WEAR PARTS..........................................................................................................312 Wear Parts List.................................................................................................312 RECOMMENDED FUEL, COOLANT, AND LUBRICANT............................................................................313 Lubrication Chart...............................................................................................313 Fuel, Coolant, and Lubricants to Match the Ambient Temperature..................................................315 KDPF (Komatsu Diesel Particulate Filter)........................................................................315 Recommended Brands, Recommended Quality for Products Other than Komatsu Genuine Oil.............................316 TORQUE SPECIFICATIONS...............................................................................................317 Torque List.....................................................................................................317 Torque of Bolts.............................................................................................317 Torque of Hose Nuts.........................................................................................318 Torque of Split Flange Bolts................................................................................318 Torque for Flared Nuts......................................................................................318 Torque for O-Ring Boss Piping Joints........................................................................320 Torque for O-Ring Boss Plugs................................................................................320 Torque for Hoses (Taper Seal Type and Face Seal Type).......................................................321 SAFETY CRITICAL PARTS...............................................................................................322 Safety Critical Parts List......................................................................................323 MAINTENANCE SCHEDULE................................................................................................324 Maintenance Schedule Table......................................................................................324 MAINTENANCE PROCEDURE...............................................................................................326 Initial 10 Hours Maintenance....................................................................................326 Initial 250 Hours Maintenance (Only After the First 250 Hours)..................................................326 Initial 500 Hours Maintenance (Only After the First 500 Hours)..................................................326 When Required...................................................................................................327 Check, Clean and Replace Air Cleaner Element................................................................327 Clean Inside of Cooling System..............................................................................334 Check and Tighten Track Shoe Bolts..........................................................................340 Check and Adjust Track Tension..............................................................................341 Replace Bucket Teeth (Vertical Pin Type)....................................................................343 Replace Bucket Teeth (Horizontal Pin Type)..................................................................346 Replace Bucket Side Cutter, Shroud..........................................................................348 Adjust Bucket Clearance.....................................................................................349 Check Window Washer Fluid Level, Add Fluid..................................................................350 Check and Maintain Air Conditioner..........................................................................351 Wash Washable Floor.........................................................................................352 Set Machine at Angle........................................................................................354 Check Gas Spring............................................................................................355 Bleeding Air From Hydraulic System..........................................................................356 Check Before Starting...........................................................................................358 Every 50 Hours Maintenance......................................................................................359 Lubricating Road Builder....................................................................................359 Lubricating Log Loader......................................................................................361 Every 250 Hours Maintenance.....................................................................................362 Check Level of Battery Electrolyte..........................................................................362 Check Air Conditioner Compressor Belt Tension, Adjust.......................................................364 Lubricate Swing Circle......................................................................................365 Check Oil Level in Swing Machinery Case, Add Oil............................................................366 Every 500 Hours Maintenance.....................................................................................367 Lubricating.................................................................................................367 Change Oil in Engine Oil Pan................................................................................369 Replace Engine Oil Filter Cartridge.........................................................................369 Replace Fuel Pre-Filter Cartridge...........................................................................371 Check Swing Pinion Grease Level, Add Grease.................................................................375 Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Condenser Fins....376 Clean Air Conditioner Fresh/Recirc Filters..................................................................378 Replace Breather Element in Hydraulic Tank..................................................................380 Replace Additional Breather Element in Hydraulic Tank.......................................................381 Check Oil Level in Final Drive Case, Add Oil................................................................382 Check Oil Level in Swing Machinery Case, Add Oil............................................................383 Every 1000 Hours Maintenance....................................................................................384 Replace Hydraulic Oil Filter Element........................................................................384 Change Oil in Swing Machinery Case..........................................................................385 Check Oil Level in Damper Case, Add Oil.....................................................................386 Replace Fuel Main Filter Cartridge..........................................................................387 Check All Tightening Points of Engine Exhaust Pipe Clamps...................................................389 Check Fan Belt Tension and Replace Fan Belt.................................................................389 Check Nitrogen Gas Charge Pressure in Accumulator (For Breaker).............................................389 Every 2000 Hours Maintenance....................................................................................390 Change Oil in Final Drive Case..............................................................................390 Clean Hydraulic Tank Strainer...............................................................................391 Check Charge Pressure of Nitrogen Gas in Accumulator (For Control Circuit)..................................392 Check Alternator............................................................................................396 Check Engine Valve Clearance, Adjust........................................................................396 Replace Komatsu Closed Crankcase Ventilation (KCCV) Filter Element..........................................397 Every 4000 Hours Maintenance....................................................................................401 Check Water Pump............................................................................................401 Check Vibration Damper......................................................................................401 Check Starting Motor........................................................................................401 Replace Accumulator (For Control Circuit)...................................................................402 Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber............................................403 Check Operating Condition of Compressor.....................................................................403 Every 4500 Hours Maintenance....................................................................................404 Clean Komatsu Diesel Particulate Filter (KDPF)..............................................................404 Replace Komatsu Closed Crankcase Ventilation (KCCV) Hose....................................................404 Every 5000 Hours Maintenance....................................................................................405 Change Oil in Hydraulic Tank................................................................................405 Every 8000 Hours Maintenance....................................................................................407 Replace Fuel Spray Prevention Cap...........................................................................407 Replace High-Pressure Piping Clamp..........................................................................407 SPECIFICATIONS..........................................................................................................409 SPECIFICATIONS......................................................................................................410 Dimensions......................................................................................................411 Working Range...................................................................................................414 Road Builder................................................................................................414 Log Loader..................................................................................................416 Lifting Capacity................................................................................................418 OPTIONS, ATTACHMENTS....................................................................................................421 GENERAL PRECAUTIONS FOR SAFETY......................................................................................422 Precautions When Selecting......................................................................................422 Read the Operation and Maintenance Manual Thoroughly............................................................422 Precautions When Removing or Installing.........................................................................422 Precautions When Using..........................................................................................422 BUCKET WITH HOOK....................................................................................................423 Hook Condition..................................................................................................423 Safety Rules for Lifting Operations.............................................................................423 Straight Travel (Option)............................................................................................424 TRACK SHOES SELECTION...............................................................................................426 BUCKET TEETH SELECTION..............................................................................................427 Selection Guide for Horizontal or Vertical Pin Type Tooth.......................................................427
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- This is the SAME exact manual used by your dealers to fix your vehicle.
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