Beruflich Dokumente
Kultur Dokumente
2010 Caterpillar
All Rights Reserved
SEBU8301-02
June 2010
Operation and
Maintenance
Manual
390D Excavator
WAG1-Up (Machine)
BYP1-Up (Machine)
WAP1-Up (Machine)
WBT1-Up (Machine)
KCZ1-Up (Machine)
SAFETY.CAT.COM
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Maintenance Section
Maintenance Interval Schedule
i03984417
When Required
Air Conditioner/Cab Heater Filter (Recirculation) Inspect/Replace ................................................ 259
Battery - Recycle ................................................ 259
Battery or Battery Cable - Inspect/Replace ........ 259
Bucket Linkage - Inspect/Adjust ......................... 262
Bucket Tips - Inspect/Replace ............................ 263
Cab Air Filter (Fresh Air) - Clean/Replace .......... 266
Camera - Clean/Adjust ....................................... 266
Circuit Breakers - Reset ...................................... 268
Counterweight Removal Chain - Clean .............. 273
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 274
Engine Air Filter Secondary Element - Replace .. 277
Engine Air Precleaner - Clean ............................ 277
Ether Starting Aid Cylinder - Replace ................. 282
Fuel System - Prime ........................................... 284
Fuses - Replace .................................................. 287
High Intensity Discharge Lamp (HID) - Replace .. 289
Hydraulic Tank Screen - Clean ........................... 300
Oil Filter - Inspect ................................................ 302
Radiator Core - Clean ......................................... 303
Track Adjustment - Adjust ................................... 309
Window Washer Reservoir - Fill ........................... 311
Window Wiper - Inspect/Replace ........................ 312
Window - Check .................................................. 312
Windows - Clean ................................................. 312
281
282
290
293
295
296
305
272
273
279
283
258
Maintenance Section
Maintenance Interval Schedule
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293
295
281
281
282
303
308
Every Year
278
279
284
285
286
290
293
295
259
259
274
296
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Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
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Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
A battery supplier
An authorized battery collection facility
Recycling facility
i00934872
Illustration 275
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Battery - Clean
SMCS Code: 1401-070
Clean the battery surface with a clean cloth. Keep the
terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat
the terminal post with petroleum jelly.
260
Maintenance Section
Belt - Inspect/Adjust/Replace
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Belt - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510;
1397-025; 1397-040; 1397-510
Note: This engine is equipped with a belt tightener
that automatically adjusts the belt to the correct
tension.
1. Unlatch the engine hood and raise the engine
hood.
2. Inspect the belt for wear and for cracking.
Illustration 276
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Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate
Illustration 277
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Illustration 280
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Illustration 278
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Illustration 281
Illustration 279
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262
Maintenance Section
Bucket Linkage - Inspect/Adjust
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Illustration 282
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Illustration 283
(13)
(14)
(15)
(16)
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Illustration 284
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(1) No gap
(2) Stick boss
(3) Bucket clearance
(4) Shims
(5) Plate
(6) Pin
(7) Plate
(8) Bolts
(9) Washers
(10) Bolts
(11) Washers
(12) Location
(13) Flange
(14) Bucket boss
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Maintenance Section
Bucket Tips - Inspect/Replace
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Illustration 286
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(1) Usable
(2) Replace
(3) Overworn
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
Removal
Illustration 287
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264
Maintenance Section
Bucket Tips - Inspect/Replace
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Illustration 288
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Illustration 290
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Installation
1. Clean the adapter and the area around the latch,
if necessary.
2. Install the new bucket tip onto the adapter with a
slight clockwise rotation.
Illustration 291
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Illustration 292
265
Maintenance Section
Bucket Tips - Inspect/Replace
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Illustration 294
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Illustration 295
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(12)
(13)
(14)
(15)
(16)
Side protector
Pin
Retainer
Side plate
Shim
Illustration 293
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266
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace
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Camera - Clean/Adjust
SMCS Code: 7348
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(1) Bolt
(2) Filter cover
In order to avoid possible machine movement, move the hydraulic lockout control to the
LOCKED position and attach a Special Instruction, SEHS7332, Do Not Operate or similar
warning tag to the hydraulic lockout control.
g00730032
4. After you clean the air filter, inspect the air filter.
If the air filter is damaged or badly contaminated,
use a new air filter.
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267
Maintenance Section
Camera - Clean/Adjust
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(1) Cover
(2) Bolt
Illustration 300
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(3) Bolt
Display
Illustration 301
WAVS display
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268
Maintenance Section
Circuit Breakers - Reset
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Camera
The main circuit breaker has a capacity of 80 Amp.
Circuit Breaker Reset Push in the button in order
to reset the circuit breaker. If the electrical system is
working properly, the button will remain depressed.
If the button does not remain depressed, check the
appropriate electrical circuit. Repair the electrical
circuit, if necessary.
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Illustration 304
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The circuit breaker is located behind the front left access door.
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Maintenance Section
Cooling System Coolant (ELC) - Change
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 305
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270
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
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NOTICE
Mixing Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar products or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or concentrate coolants. Use only Caterpillar Extender with
Caterpillar ELC. Failure to follow these recommendations could result in the damage to cooling systems
components.
Illustration 306
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Coolant reservoir
(1) FULL
(2) LOW
Illustration 307
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Maintenance Section
Cooling System Coolant Level - Check
Illustration 309
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Illustration 308
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Coolant reservoir
(1) FULL
(2) LOW
Illustration 310
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272
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
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Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
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274
Maintenance Section
Counterweight Removal Chain - Lubricate
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Illustration 313
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Illustration 314
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Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Illustration 315
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NOTICE
Do not clean the air filter elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets, or seals. Damaged elements will allow dirt to pass through. Engine
damage could result.
of a primary filter.
Pressurized air
Vacuum cleaning
276
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
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Illustration 317
Illustration 316
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Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
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Illustration 318
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Maintenance Section
Engine Air Filter Secondary Element - Replace
Date of cleaning
Number of cleanings
Illustration 319
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Illustration 320
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278
Maintenance Section
Engine Crankcase Breather - Clean
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Illustration 321
(1)
(2)
(3)
(4)
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Outlet hose
Hose clamp
Clamp for the breather
Breather cover
Illustration 322
(1) Dipstick for the engine oil
(2) Filler plug for the engine oil
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Maintenance Section
Engine Oil Sample - Obtain
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Illustration 323
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Illustration 324
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NOTICE
Operating your engine when the oil level is above the
FULL mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating characteristics and could result in the loss of power.
6. Add oil until the oil level is between the ADD and
FULL marks on the ENGINE STOPPED side
of the dipstick.
7. Clean the filler plug and install the filler plug.
8. Close the engine hood and latch the engine hood.
280
Maintenance Section
Engine Oil and Filter - Change
Illustration 325
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The drain hose for the engine crankcase is located under the rear
of the upper structure.
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Illustration 327
(1) Dipstick
(2) Filter
(3) Filler plug
Illustration 326
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Illustration 328
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Maintenance Section
Engine Valve Lash and Fuel Injector Timing - Check
i00707053
15. Wait for 30 minutes so that the oil can drain back
into the crankcase, before you check the oil.
16. Remove the dipstick (1). Wipe the oil off the
dipstick and reinsert the dipstick.
Illustration 329
g01100724
17. Remove the dipstick again. Make sure that the oil
level is between the ADD and FULL marks on
the ENGINE STOPPED side of the dipstick.
18. Close the engine hood and latch the engine hood.
19. Install the crankcase drain valve access cover
with the bolts and the washers.
Illustration 330
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282
Maintenance Section
Ether Starting Aid Cylinder - Replace
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Illustration 332
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Maintenance Section
Final Drive Oil Level - Check
Note: If the oil fills slowly, the fill hole may be blocked
by the planetary gear. Rotate the final drive in order
to move the planetary gear away from the fill hole.
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Illustration 333
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g00822278
284
Maintenance Section
Fuel System - Prime
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
Illustration 335
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Illustration 336
(1)
(2)
(3)
(4)
g02144267
Shutoff valve
Bowl
Filter
Drain valve
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Maintenance Section
Fuel System Secondary Filter - Replace
Illustration 337
(2)
(3)
(5)
(6)
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Bowl
Filter
Cap
Seal
Illustration 338
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286
Maintenance Section
Fuel System Water Separator - Drain
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Illustration 341
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Maintenance Section
Fuel Tank Water and Sediment - Drain
Illustration 343
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Fuses - Replace
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288
Maintenance Section
Fuses - Replace
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Maintenance Section
High Intensity Discharge Lamp (HID) - Replace
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290
Maintenance Section
Hydraulic System Filter Element (Fine Filtration) - Replace
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Illustration 347
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6. Remove four bolts (1) and cover (2) from the fine
filtration filter.
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Illustration 346
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Maintenance Section
Hydraulic System Oil - Change
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Illustration 348
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Illustration 351
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Illustration 349
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292
Maintenance Section
Hydraulic System Oil - Change
Illustration 352
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12. Remove the plug from the tube. Allow the oil to
drain into a container.
13. Inspect the O-ring. Replace the O-ring if wear or
damage is evident.
14. Clean the plug. Install the plug and the O-ring into
the drain port.
Illustration 354
g01137588
(5) Spring
(6) Screen
Note: Do not allow spring (5) to fall back into the tank.
16. Remove spring (5) and screen (6).
Note: Refer to Operation and Maintenance, General
Hazard Information for information on containing
fluid spillage.
17. Wash the screen in a clean nonflammable solvent.
Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
Illustration 353
g01137582
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Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
Illustration 356
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Illustration 355
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294
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
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Illustration 357
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Illustration 358
Illustration 359
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Illustration 360
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Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace
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Illustration 361
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Illustration 362
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Illustration 363
Illustration 364
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296
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
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Illustration 367
(1)
(2)
(3)
(4)
(5)
g00102211
Bolts
Washers
Cover
Plug
Filter cartridge
Illustration 365
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Illustration 368
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Illustration 366
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Illustration 369
297
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
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Illustration 370
Illustration 371
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(4) Plug
(8) Plate
(18) O-ring
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(7) O-ring
Illustration 372
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(8) Plate
(9) Spiral retaining ring
Illustration 373
(8) Plate
(10) Shell
(11) O-ring
(12) Filter element
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298
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
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Illustration 375
Illustration 374
(13)
(14)
(15)
(19)
g00104511
Slide plate
Pads
Screws
Port
g00104512
(8) Plate
(10) Shell
(16) Boss
(17) Notch
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Illustration 376
299
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
g00102220
(B) Port
(C) Slide plate
Illustration 378
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(F) O-rings
Illustration 379
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(1) Bolts
Illustration 377
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300
Maintenance Section
Hydraulic System Oil Level - Check
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NOTICE
Never remove the fill/vent plug from the hydraulic tank
if the oil is hot.
Air can enter the system and cause pump damage.
Illustration 382
Illustration 380
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Illustration 381
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Illustration 383
301
Maintenance Section
Hydraulic Tank Screen - Clean
g01137376
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(1) Spring
(2) Screen
Note: Do not allow spring (1) to fall back into the tank.
5. Remove spring (1) and screen (2).
Note: Refer to Operation and Maintenance, General
Hazard Information for information on containing
fluid spillage.
Illustration 384
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302
Maintenance Section
Indicators and Gauges - Test
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Illustration 386
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Illustration 387
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Maintenance Section
Radiator Core - Clean
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Illustration 388
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304
Maintenance Section
Seat Belt - Inspect
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Illustration 389
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Typical example
Illustration 390
(1)
(2)
(3)
(4)
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Maintenance Section
Swing Drive Oil - Change
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Illustration 391
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Illustration 393
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This swing drive is located next to the cab under the boom.
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Illustration 394
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306
Maintenance Section
Swing Drive Oil Level - Check
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Illustration 397
Illustration 395
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6. Pull out the end of the drain hose (1) from the
upper frame. Face the end of the hose toward
the container.
g01137328
Illustration 398
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4. Check the oil that has been drained for metal chips
or metal particles. Consult your Caterpillar dealer
if any metal chips or metal particles are found.
Note: Dispose of drained materials according to local
regulations.
i02270202
Illustration 396
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Maintenance Section
Swing Drive Oil Sample - Obtain
Illustration 399
Illustration 400
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Illustration 402
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Illustration 403
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Illustration 401
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Maintenance Section
Swing Gear - Lubricate
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Illustration 406
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(5) Plug
(6) O-ring
Illustration 404
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Illustration 407
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Illustration 405
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Maintenance Section
Track Adjustment - Adjust
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Illustration 409
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Illustration 408
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Illustration 410
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Typical example
310
Maintenance Section
Track Adjustment - Inspect
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Illustration 413
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Illustration 412
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Maintenance Section
Undercarriage - Check
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Undercarriage - Check
SMCS Code: 4150-535
Illustration 414
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Illustration 416
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312
Maintenance Section
Window Wiper - Inspect/Replace
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Windows - Clean
SMCS Code: 7310-070; 7340-070
Clean the outside of the windows from the ground,
unless handholds are available.
Illustration 417
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Illustration 418
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Typical example
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Cleaning Methods
Aircraft Window Cleaner
Window - Check
SMCS Code: 7310-535
Check the polycarbonate windows of the cab for the
following conditions.
yellow or haze
scratches on either side of the window that can be
felt with a fingernail
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Maintenance Section
Windows - Clean