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Komatsu PC390LC-10 Shop Manual

Hydraulic excavator
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Manual
PC360LC
PC390LC
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
November 2015
PC360LC-10 A32001
PC360LC-10 K64001
PC390LC-10 A30001
6D114E-5
Copyright 2015 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM025205
-10
-10
and up
and up
and up

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  • Page 1 6D114E-5 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 FOREWORD CONTENTS CONTENTS GENERAL ............. 01-1 STRUCTURE AND FUNCTION .
  • Page 3 FOREWORD The affected pages are indicated by using the following Mark Indication Action marks. It is requested that necessary actions be taken to ❍ New page to be added these pages according to the table below. ● Page to be replaced Replace Page to be deleted Discard...
  • Page 4 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● ● ● 10-29 10-62 10-95 10-128 ● ● ● ● 10-30 10-63 10-96 10-129 ● ● ● ● 10-31 10-64 10-97 10-130 ● ● ● ● 10-32 10-65 10-98 10-131 ●...
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  • Page 19: Important Safety Notice

    FOREWORD SAFETY SAFETY Safety Notice Important Safety Notice Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose.
  • Page 20 FOREWORD SAFETY Safety Points Good arrangement Correct work clothes Following work standard Making and checking signs Prohibition of operation and handling by unlicensed workers Safety check before starting work Wearing protective goggles (for cleaning or grinding work) Wearing shielding goggles and protectors (for welding work) Good physical condition and preparation Precautions against work which you are not...

  • Page 21: Preparations For Work

    FOREWORD SAFETY Preparations For Work Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling.
  • Page 22 FOREWORD SAFETY 13. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.
  • Page 23 FOREWORD SAFETY ★ Example of O-ring (Fitted to every joint of hoses and tubes) ★ For tightening torque, see the precautions for installation in each section of “Disassembly and assembly”. 18. When jump starting the machine, only use a machine of similar size and voltage.
  • Page 24 FOREWORD GENERAL 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.
  • Page 25 FOREWORD GENERAL NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information. 00-9 PC360/390LC-10...

  • Page 26: How To Read The Shop Manual

    FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL Volumes Revisions Shop manuals are issued as a guide to performing repairs. Revised pages are shown at the LIST OF REVISED PAGES They are divided as follows: between the title page and SAFETY page.

  • Page 27: Hoisting Instructions

    When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. PC390LC-10 00-11...
  • Page 28 FOREWORD HOISTING INSTRUCTIONS Apply wire ropes from the middle portion of the hook. Precautions for Using Overhead Hoist Crane • Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a WARNING! Heavy parts (25 kg (55 lb) or serious accident can result.
  • Page 29 FOREWORD HOISTING INSTRUCTIONS 12. If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault protection circuit breaker, check that the devices related to that switch are not in operational state. 13.
  • Page 30 FOREWORD HOISTING INSTRUCTIONS Selecting Wire Ropes Use adequate ropes depending on the weight of parts to be hoisted. Refer to the following table. Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter Allowable load tons 11.2 13.7 12.5 15.7 21.6...
  • Page 31 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs.
  • Page 32 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS C. Disconnections in wiring. • If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
  • Page 33 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Removing, installing, and drying connectors and wiring harnesses A. Disconnecting connectors. • Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, completely loosen the screw, then hold the male and female connectors in each hand and pull apart.
  • Page 34 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Connecting connectors A. Check the connector visually. • Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins.
  • Page 35 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS E. Drying wiring harness • If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high- pressure water or steam directly on the wiring harness.
  • Page 36 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Charge (boost) pressure sensor in the air intake manifold: PIM (125/170/12V140 series) ii. Oil pressure sensor: POIL (125/170/12v140 series) iii. Oil pressure switch (95/107/114 series) iv. Ne speed sensor on flywheel housing: Ne (95/107/114/125/140/170/12v140 series) Ambient pressure sensor: PAMB (125/170/12V140 series) A.
  • Page 37 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS ii. While pressing lock (L2), pull out connector (1). ★ Lock (L2) is located in the back of connector (1). B. Connection Insert the connector straight until it “clicks.” Pull lock type (PACKARD-2) •...
  • Page 38 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Push lock type (1) • 95/107/114 series. • Examples: Fuel pressure sensor in common rail (BOSHCH-3) A. Disconnection While pressing lock (C), pull out connector (3) in the direction of the arrow. • 114 series •...
  • Page 39 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS 10. Push lock type (2) • 107/114 series • Examples: Charge (boost) pressure sensor in the air intake manifold (SUMITOMO-4) A. Disconnection While pressing lock (D), pull out connector (4) in the direction of the arrow. B.
  • Page 40 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS • Example: Speed sensor of supply pump: G (SUMITOMO -3) ★ Pull the connector straight up. B. Connection Insert the connector straight in until it “clicks.” 12. Turn-housing type (Round green connector) • 140 series •...
  • Page 41 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS 13. Handling controller A. The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. B. Do not place objects on top of the controller. C.
  • Page 42 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Points to Remember When Handling Hydraulic Equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
  • Page 43 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Flushing operations • After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is performed twice: primary flushing is performed with flushing oil, and secondary flushing is performed with the specified hydraulic oil.
  • Page 44 FOREWORD PUSH PULL COUPLER PUSH PULL COUPLER WARNING! Before performing the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
  • Page 45 FOREWORD PUSH PULL COUPLER Type 2 Disconnection Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end. Hold in the condition in Step 1, and turn the lever (4) to the right - clockwise.
  • Page 46 FOREWORD PUSH PULL COUPLER Type 3 Disconnection Hold the connector of the tightening portion and push the body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end. Hold in the condition in Step 1, and push until the cover (3) contacts surface a of the hexagonal portion at the male end.
  • Page 47 FOREWORD EXPLANATION OF MAINTENANCE STANDARD TERMS EXPLANATION OF MAINTENANCE STANDARD TERMS ● The maintenance standard values necessary for judgment of products and parts are described by the following terms. Standard Size And Tolerance • To be accurate, the finishing size of parts is a little different from one to another.
  • Page 48 Wash the system carefully with clean fuel if dusts enter the system. Precautions for replacing fuel filter cartridge ● Be sure to use the Komatsu genuine fuel filter cartridge. ● Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzles, it employs a high-efficiency special filter to prevent foreign matter from entering it.
  • Page 49 HANDLING OF INTAKE SYSTEM PARTS ● The Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable mechanism) than the conventional turbocharger. If foreign matter enters this system, it can cause a problem. Use special care to prevent entry of foreign matter when servicing the air intake system.

  • Page 50: Standard Tightening Torque

    FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE Bolts And Nuts ● Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using torque wrench) ★ The following table corresponds to the bolts in Figure A. Thread diameter of bolt Width across flats Tightening torque...
  • Page 51 FOREWORD STANDARD TIGHTENING TORQUE Tightening Torque Of Hose Nuts Use these torques for hose nuts. Thread diameter Width across flat Tightening torque Nominal No. N•m lbf-ft 19.6 - 29.4 14.5 - 21.7 29.4 - 68.6 21.7 - 50.6 58.9 - 98.1 44.4 - 72.4 107.9 - 166.7 79.6 - 123.0...
  • Page 52 FOREWORD STANDARD TIGHTENING TORQUE Tightening Torques for Split Flanged Bolts ★ Unless otherwise specified, tighten split flanged bolt to the torque shown in the following table. Thread Diameter Width across Flats Tightening Torque N•m lbf ft 59 – 74 59 – 74 43.51 –...
  • Page 53 FOREWORD STANDARD TIGHTENING TORQUE Tightening Torque For Hoses (Taper Seal Type And Face Seal Type) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Taper seal Tightening torque (N•m (lbf-ft)) Face seal type...
  • Page 54 FOREWORD STANDARD TIGHTENING TORQUE For 102, 107, and 114 Engine Series (Eye Joints) ★ Tighten the metric eye joints of the 102, 107, and 114 engine series to the torque in this table, unless there are special instructions. Thread size Tightening Torque N•m lbf in...
  • Page 55 FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe. Classification By Thickness Copper wire Nominal...

  • Page 56: How To Read Electric Wire Code

    FOREWORD ELECTRIC WIRE CODE How To Read Electric Wire Code ★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
  • Page 57 FOREWORD ELECTRIC WIRE CODE Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/ 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 Diameter of strand Conductor Sectional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
  • Page 58 FOREWORD ELECTRIC WIRE CODE Color Codes Table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...

  • Page 59: Precautions For Operations

    FOREWORD PRECAUTIONS FOR OPERATIONS PRECAUTIONS FOR OPERATIONS ★ When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given in this section when carrying out the operation. Precautions when Carrying Out Removal Work •...
  • Page 60 FOREWORD PRECAUTIONS FOR OPERATIONS • If the part is not under hydraulic pressure, the following corks can be used. Dimensions Nominal Part Number Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 11.5 07049-01620 13.5 07049-01822 07049-02025 07049-02228 18.5 07049-02430 07049-02734 22.5 Precautions when Carrying Out Installation Work •...
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