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Komatsu PC490LC-10 Shop Manual
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Komatsu PC490LC-10 Shop Manual

Hydraulic excavator
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Manual
PC490LC
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.
March 2016
PC490LC-10 A40001
6D125E-6
-10
and up
Copyright 2016 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM025304

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Summary of Contents for Komatsu PC490LC-10

  • Page 1 6D125E-6 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 DIAGRAMS AND DRAWINGS ..........90-1 00-2 PC490LC-10 Find manuals at https://best-manuals.com...
  • Page 3 01-10 10-26 00-9 ● 00-39 01-11 10-27 00-10 ● 00-40 01-12 10-28 00-11 ● 00-41 10-29 00-12 ● 00-42 10-1 10-30 00-13 ● 00-43 10-2 10-31 00-14 ● 00-44 10-3 10-32 00-15 00-2-1 e PC360/390LC-10 PC490LC-10 Find manuals at https://best-manuals.com...
  • Page 4 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● ● ● 10-33 10-66 10-99 10-132 ● ● ● ● 10-34 10-67 10-100 10-133 ● ● ● ● 10-35 10-68 10-101 10-134 ● ● ● ● 10-36 10-69 10-102 10-135 ●...
  • Page 5 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● ● ● 10-165 10-198 10-231 10-264 ● ● ● ● 10-166 10-199 10-232 10-265 ● ● ● ● 10-167 10-200 10-233 10-266 ● ● ● ● 10-168 10-201 10-234 10-267 ●...
  • Page 6 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-9 30-42 30-75 30-108 30-10 30-43 30-76 30-109 30-11 30-44 30-77 30-110 30-12 30-45 30-78 30-111 30-13 30-46 30-79 30-112 30-14 30-47 30-80 30-113 30-15 30-48 30-81 30-114 30-16 30-49 30-82 30-115 30-17 30-50...
  • Page 7 FOREWORD Mark Page Mark Page Mark Page Mark Page ● 30-141 30-174 30-207 40-25 30-142 30-175 30-208 40-26 30-143 30-176 30-209 40-27 30-144 30-177 30-210 40-28 30-145 30-178 30-211 40-29 30-146 30-179 30-212 40-30 30-147 30-180 30-213 40-31 30-148 30-181 30-214 40-32 30-149...
  • Page 8 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-58 40-91 40-124 40-157 40-59 40-92 40-125 40-158 ● 40-60 40-93 40-126 40-159 40-61 40-94 40-127 40-160 40-62 40-95 40-128 40-161 40-63 40-96 40-129 40-162 40-64 40-97 40-130 40-163 40-65 40-98 40-131 40-164 40-66...
  • Page 9 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-190 40-223 40-256 40-289 40-191 40-224 40-257 40-290 40-192 40-225 40-258 40-291 40-193 40-226 40-259 40-292 40-194 40-227 40-260 40-293 40-195 40-228 40-261 40-294 40-196 40-229 40-262 40-295 40-197 40-230 40-263 40-296 40-198 40-231...
  • Page 10 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-322 40-355 40-388 40-421 40-323 40-356 40-389 40-422 40-324 40-357 40-390 40-423 40-325 40-358 40-391 40-424 40-326 40-359 40-392 40-425 40-327 40-360 40-393 40-426 40-328 40-361 40-394 40-427 40-329 40-362 40-395 40-428 40-330 40-363...
  • Page 11 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-454 40-487 40-520 40-553 40-455 40-488 40-521 40-554 40-456 40-489 40-522 40-555 40-457 40-490 40-523 40-556 40-458 40-491 40-524 40-557 40-459 40-492 40-525 40-558 40-460 40-493 40-526 40-559 40-461 40-494 40-527 40-560 40-462 40-495...
  • Page 12 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-586 40-619 40-652 40-685 40-587 40-620 40-653 40-686 40-588 40-621 40-654 40-687 40-589 40-622 40-655 40-688 40-590 40-623 40-656 40-689 40-591 40-624 40-657 40-690 40-592 40-625 40-658 40-691 40-593 40-626 40-659 40-692 40-594 40-627...
  • Page 13 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-718 40-751 50-7 50-40 40-719 40-752 50-8 50-41 40-720 40-753 50-9 50-42 40-721 40-754 50-10 50-43 40-722 40-755 50-11 50-44 40-723 40-756 50-12 50-45 40-724 40-757 50-13 50-46 40-725 40-758 50-14 50-47 40-726 40-759...
  • Page 14 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-73 50-106 50-139 50-172 50-74 50-107 50-140 50-173 50-75 50-108 50-141 50-174 50-76 50-109 50-142 50-175 50-77 50-110 50-143 50-176 50-78 50-111 50-144 50-177 50-79 50-112 50-145 50-178 50-80 50-113 50-146 50-179 50-81 50-114...
  • Page 15 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-205 50-238 50-271 60-17 50-206 50-239 50-272 60-18 50-207 50-240 50-273 60-19 50-208 50-241 50-274 60-20 50-209 50-242 50-275 60-21 50-210 50-243 50-276 60-22 50-211 50-244 50-277 60-23 50-212 50-245 50-278 60-24 50-213 50-246...
  • Page 16 FOREWORD Mark Page Mark Page Mark Page Mark Page 60-50 80-6 80-39 80-72 60-51 80-7 80-40 80-73 60-52 80-8 80-41 80-74 60-53 80-9 80-42 80-75 60-54 80-10 80-43 80-76 60-55 80-11 80-44 80-77 60-56 80-12 80-45 80-78 60-57 80-13 80-46 80-79 60-58 80-14...

  • Page 17: Important Safety Notice

    Before starting work, warm up your body thoroughly to start work under good conditions. Avoid continuous work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places. 00-3 b PC490LC-10...
  • Page 18 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 used to or work with which you are too familiar 00-4 PC490LC-10...

  • Page 19: Preparations For Work

    12. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 00-5 b PC490LC-10...
  • Page 20 When tightening nuts of the air conditioner hoses and tubes, be sure to use two wrenches; one to fix the nut and the other to tighten the nut to the specified torque (Use a torque wrench for tightening). 00-6 PC490LC-10...
  • Page 21 18. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the machine. 00-7 b PC490LC-10...
  • Page 22 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 DRAWINGS This section has the foldout drawings for the machine. 00-8 PC490LC-10...
  • Page 23 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 b PC490LC-10...

  • Page 24: How To Read The Shop Manual

    Example: 10-4 10-4-1 Added pages 10-4-2 10-5 Revised Edition Mark When a manual is revised, an edition mark (…) is recorded on the bottom outside corner of the pages. 00-10 b PC490LC-10...

  • Page 25: 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. 00-11 b PC490LC-10...
  • Page 26 Precautions for Using Mobile Crane Remember the position of the main switch so that you can Read the Operation & Maintenance Manual provided with turn off the power immediately in an emergency. the crane in advance and operate the crane safely. 00-12 b PC490LC-10...
  • Page 27 Do not leave the sling installed to the hook. 11.2 13.7 12.5 15.7 21.6 27.5 35.3 43.1 22.4 54.9 98.1 10.0 176.5 18.0 274.6 28.0 392.2 40.0 The allowable load value is 1/6 of the breaking strength of the rope used. Safety coefficient: 6 00-13 b PC490LC-10...
  • Page 28 The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. 00-14 PC490LC-10...
  • Page 29 ★ If there is oil or water in the compressed air, the contacts will become even dirtier, so completely remove the oil and water from the compressed air before cleaning with compressed air. 00-15 b PC490LC-10...
  • Page 30 ★ If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector. 00-16 PC490LC-10...
  • Page 31 Since the DT 8-pin and 12-pin heavy duty wire connectors have 2 latches respectively, push them in until they click 2 times. Male connector Female connector ★ Normal locking state (Horizontal):a, b, d ★ Incomplete locking state (Diagonal):c 00-17 b PC490LC-10...
  • Page 32 ★ Mainly, following engines are object for following connectors. • 95E-5 • 107E-1, 107E-2 • 114E-3, 114E-5 • 125E-5, 125E-6 • 140E-5, 140E-6 • 170E-5 • 12V140E-3 Slide, lock type (Type 1) (FRAMATOME-3, FRAMATOME-2) • 95/107/114/125/140/170/12V140 Series • Various pressure sensors and Ne speed sensor. Examples: 00-18 PC490LC-10...
  • Page 33 Slide, lock type (Type 2) (FRAMATOME-24) • 107/114/125 Series • Intermediate connector between machine wiring harness and engine wiring harness. Examples: Intermediate connector (engine wiring harness): OEM CONNECTION (107/114/125 series) A. Disconnection Slide down lock (red) (L1). 00-19 b PC490LC-10...
  • Page 34 Oil temperature sensor: TOIL iv. Coolant temperature sensor: TWTR and other. A. Disconnection Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward. B. Connection Insert the connector straight in until it “clicks.” 00-20 PC490LC-10...
  • Page 35 [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with the flat- head screwdriver [1], pull out connector (3) in the direction of the arrow. B. Connection Insert the connector straight until it “clicks.” 00-21 b PC490LC-10...
  • Page 36 While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. • Example: Fuel pressure sensor in common rail PFUEL etc. (AMP-3) • Example: Injection pressure control valve of supply pump: PCV (SUMITOMO-2)) 00-22 PC490LC-10...
  • Page 37 ★ Housing (H1) is left on the wiring harness. B. Connection Insert the connector to the end, while aligning its groove to the other. ii. Turn housing (H1) in the direction of the arrow until it “clicks.” 00-23 b PC490LC-10...
  • Page 38 D. When performing troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. • If there is any change, there is probably a defective contact in that circuit. 00-24 PC490LC-10...
  • Page 39 If any old oil is left, contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 00-25 b PC490LC-10...
  • Page 40 The oil cleaning equipment is used to remove the ultra fine {about 3 (10 ft)} particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device. 00-26 PC490LC-10...
  • Page 41 After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality. 00-27 b PC490LC-10...
  • Page 42 Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it. Connection Hold the connector of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it. 00-28 PC490LC-10...
  • Page 43 (2) to disconnect it. Connection Hold the connector of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it. 00-29 b PC490LC-10...
  • Page 44 (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. • After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. 00-30 PC490LC-10...
  • Page 45 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 46 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 47: Standard Tightening Torque

    Thread diameter of bolt Width across flats Tightning torque N•m lbf-ft 5.9 - 9.8 4.35 - 7.22 13.7 - 23.5 10.10 - 17.33 34.3 - 46.1 25.29 - 34.00 74.5 - 90.2 54.94 - 66.52 Figure A Figure B 00-33 b PC490LC-10...
  • Page 48 36.1 ± 14.4 78.5 ± 19.6 57.8 ± 14.4 137.3 ± 29.4 101.2 ± 21.6 176.5 ± 29.4 130.1 ± 21.6 196.1 ± 49 144.6 ± 36.1 245.2 ± 49 180.8 ± 36.1 294.2 ± 49 216.9 ± 36.1 00-34 PC490LC-10...
  • Page 49 107.8 (79.50) – 107.8 - 147.0 (79.50 - 108.42) 124.4 (91.75) 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03) – 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40) – 274.4 - 367.5 (202.38 - 271.05) 323.4 (238.52) 00-35 b PC490LC-10...
  • Page 50 45 [4.6] {33.19} 13/16-16UN 20.6 15 (16) 30 (32) 60 – 68 [6.1 – 6.8] {44.25 – 50.15} 64 [6.5] {47.20} 1-14UN 25.4 22 (20) 90 – 95 [9.2 – 9.7] {66.38 – 70.07} 92.5 [9.4] {68.22} 1-3/16-12UN 30.2 00-36 PC490LC-10...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

A40001