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PC490LC
Komatsu PC490LC User Manual
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SER
VICE METER LOCA
TION
This is displayed on the machine monitor
.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUT
OR
Machine serial No.
Engine serial No.
Product identification
number (PIN)
Manufacturers name:
Address:
KOMA
TSU UK Ltd
Durham Road
Birtley
Chester-le-Street
County Durham DH3 2QX
United Kingdom
Distributor name
Address
Service Personnel
Phone/Fax
PRODUCT INFORMA
TION
FOREWORD
1-12
13
15
Table of Contents
Table of Contents
17
Safety Information
5
Safety Labels
6
Noise
7
Vibration - Operating Condition
8
Guide to Reduce Vibration Levels on Machine
8
Vibration Levels
8
Introduction
10
Main Use of Machine
10
Directions of Machine
10
Visibility from Operator's Seat
11
Engine Technology to Conform Exhaust Gas Emission
12
Location of Engine Number Plate
13
Product Information
13
Location of Product Identification Number (Pin)/Machine Serial No. Plate
13
Service Meter Location
14
Your Machine Serial Numbers and Distributor
14
Serial Plate
15
Declaration of Conformity
16
Table of Contents
17
Safety Labels
24
Location of Safety Labels
25
Contents of Safety Labels
27
General Precautions Common to Operation and Maintenance
38
Preparations for Safe Operation
38
Ensure Safe Operation
38
Understand the Machine
38
Precautions for Safety-Related Equipment
38
Inspect Machine
38
Wear Well-Fitting Clothes and Protective Equipment
38
Keep Machine Clean
38
Precautions before Starting Operation
38
If any Problem Is Found
39
Actions if Fire Occurs
39
Precautions to Prevent Fire
39
Provide Fire Extinguisher and First Aid Kit
39
Precautions for Inside Operator's Compartment
39
Prevent Fire
40
Precautions When Getting on or off Machine
41
Use Handrails and Steps When Getting on or off Machine
41
No Jumping on or off Machine
41
Emergency Exit from Operator's Cab
42
Precautions When Leaving Machine
42
Precautions When Standing up from Operator's Seat
42
Lifting of Personnel Prohibited
42
No People on Attachments
42
Do Not Get Caught in Work Equipment
43
Precautions Related to Protective Structures
43
Electromagnetic Interference
43
Protection against Falling, Flying or Intruding Objects
44
Actions in the Event of Damage to Safety Structures
44
Unauthorized Modification
44
Precautions Related to Attachments and Options
44
Precautions When Running Engine Inside Building
45
Precautions Related to Cab Glass
45
Precautions for Operation
46
Precautions for Jobsite
46
Investigate and Confirm Jobsite Conditions
46
Precautions When Working on Loose Ground
46
Do Not Go Close to High-Voltage Cables
46
Ensure Good Visibility
47
Check Signs and Signalman's Signals
49
Use Warning Tags
50
Checks and Adjustment before Starting Engine
50
Beware of Asbestos Dust
50
Start Engine
50
Precautions When Starting Engine
51
In Cold Weather
51
Start Engine with Jumper Cables
51
Precautions for Operation
52
Checks before Operation
52
When Travelling in Forward or Reverse and Swinging
53
Precautions When Travelling
53
Precautions When Travelling on Slopes
54
Prohibited Operations
55
Precautions When Operating on Slopes
55
Precautions When Operating on Snow or Frozen Surfaces
57
Precautions When Parking Machine
57
Precautions for Transportation
58
Precautions When Loading and Unloading
58
Towing and Being Towed
59
Lifting Operations
59
Precautions for Towing and Being Towed
59
General Precautions for Lifting Operations
59
Only Authorized Personnel
61
Stability
61
Appoint Leader When Working with Others
61
Precautions for Maintenance
61
Select Suitable Place for Inspection and Maintenance
61
Precautions before Starting Inspection and Maintenance
61
Keep Work Place Clean and Tidy
61
Display Warning Tag During Inspection and Maintenance
61
Guards
62
End of Service Life
62
Stop Engine before Carrying out Inspection and Maintenance
62
Two Workers for Maintenance When Engine Is Running
62
Precautions When Installing, Removing, or Storing Attachments
63
Precautions for Working at High Places
63
Precautions When Working on Machine
63
Precautions for Check and Maintenance
64
Precautions When Working under Machine or Work Equipment
64
Use Proper Tools
64
Turn Battery Disconnect Switch to off Position
64
Precautions for Welding
64
Handle Battery
65
Precautions When Using Hammer
65
Precautions for High-Pressure Oil
66
Precautions for High-Temperature Parts
66
Precautions for High-Temperature Oil
66
Precautions for High-Temperature Coolant
66
Precautions for High-Pressure Fuel
67
Handle High-Pressure Hoses and Piping
67
Precautions for High Voltage
67
Precautions for Noise
67
Precautions for High-Pressure Grease When Adjusting Track Tension
68
Do Not Disassemble Recoil Spring
68
Handle Accumulator and Gas Spring
68
Precautions for Compressed Air
69
Maintenance of Air Conditioner
69
Chemical Hazard
69
Precautions for Disposing of Waste Materials
69
Method for Selecting Window Washer Fluid
69
Periodic Replacement of Defined Life Parts
69
Safety Rules for Storage
71
Other Precautions
71
Precautions for Fire Hazard and Leakage
71
Precautions for Adding
71
General Character and Precautions for Handling
71
Precautions for Def
71
Operation
73
General View
74
Machine Equipment Name
74
Cab Equipment Names
76
Controls and Gauges Names
77
Explanation of Components
81
Explanation of Machine Monitor Equipment
81
Switches
162
Control Levers and Pedals
170
Other Equipment
173
Machine Operations and Controls
216
Checks and Adjustment before Starting Engine
216
Method for Starting Engine
245
Method for Operations and Checks after Starting Engine
248
Method for Stopping Engine
258
Method for Starting Machine (Travel Forward and Reverse) and Stopping Machine
261
Method for Steering Machine
264
Method for Swinging Machine
265
Method for Operating Work Equipment
266
Handle Working Mode
267
Prohibited Operations
269
Precautions for Operation
273
Precautions for Working on Slope
275
Method for Escaping from Mud
276
Recommended Applications
277
Effective Use of Hydraulic Excavator
278
Method for Replacing and Inverting Bucket
279
Method for Parking Machine
282
Method for Checking after Finishing Work
284
Lock
284
Handle Air Conditioner
290
Explanation of Air Conditioner Equipment
291
Method for Operating Air Conditioner
295
Handling Radio
303
Explanation of Radio Equipment
303
Method for Controlling Radio
305
Stow Antenna
308
Space for Radio Cassette
308
Select Transportation Method
309
Precautions for Transporting Machine
309
Transportation
309
Loading and Unloading with Trailer
310
Method for Lifting Machine
320
Spread and Narrow Track Frame Gauge
321
Cold Weather Operation
324
Cold Weather Operation Information
324
Precautions after Daily Work Completion
325
After Cold Weather Season
326
Precautions for Long-Term Storage
327
Preparation for Long-Term Storage
327
Maintenance During Long-Term Storage
327
Starting Machine after Long-Term Storage
327
Troubles and Actions
329
Actions When Running out of Fuel
329
Phenomena that Are Not Failures
330
Precautions for Towing Machine
330
Precautions for Severe Job Condition
331
Precautions for Discharged Battery
332
Other Trouble
335
Maintenance
341
Welding Instructions
342
Check Drained Oil and Used Filter
342
Precautions for Adding Def
342
Precautions for Refilling Oil or Fuel
342
Check Service Meter Reading
342
Fresh and Clean Lubricants
342
Always Use Clean Washer Fluid
342
Komatsu Genuine Lubricants
342
Komatsu Genuine Replacement Parts
342
Precautions for Maintenance
342
Precautions for Scr Assembly
343
Dusty Jobsites
343
Avoid Mixing Oil
343
Lock Inspection Covers
343
Bleed Air from Hydraulic Circuit
343
Precautions When Installing Hydraulic Hoses
343
Checks after Inspection and Maintenance
343
Fuel and Lubricants to Match the Ambient Temperature
343
Close Engine Hood Securely
344
Outline of Maintenance
345
Handle Oil, Fuel, Coolant, and Performing Oil Clinic
345
Handle Electrical Components
349
Standard Tightening Torque for Bolts and Nuts
350
Maintenance Schedule
352
Maintenance Schedule Table
352
Maintenance Interval for Hydraulic Breaker
353
Maintenance Procedure
355
Method for Checking, Cleaning and Replacing Air Cleaner
355
When Required
355
Method for Cleaning Inside of Cooling System
360
Method for Checking and Adjusting Track Tension
366
Method for Checking Looseness and Tightening Track Shoe Bolts
366
Method for Replacing Bucket Teeth (Vertical Pin Type)
367
Method for Replacing Bucket Teeth (Horizontal Pin Type)
370
Method for Replacing Bucket Side Cutter and Shroud
371
Method for Adjusting Bucket Clearance
372
Method for Checking and Maintenance Air Conditioner
373
Method for Checking Window Washer Fluid Level, Adding Fluid
373
Method for Washing Washable Floor
375
Method for Checking Gas Spring
378
Method for Bleeding Air from Hydraulic Circuit
379
Check Automatic Grease System
381
Method for Cleaning Line Filter and Removing Dirt
381
Periodic Checks
381
Greasing Procedure
382
Refilling Grease
382
System Test
382
Checks before Starting
383
Every 50 Hours Maintenance
384
Method for Lubricating Work Equipment
384
Every 250 Hours Maintenance
385
Method for Checking Battery Electrolyte Level
385
Method for Checking and Adjusting Air Conditioner Compressor Belt Tension
386
Every 500 Hours Maintenance
388
Method for Checking Looseness and Tightening Connecting Bolt between Centre Frame and Track Frame
388
Method for Lubricating Swing Circle
388
Method for Lubricating
389
Method for Replacing Fuel Pre-Filter Cartridge
391
Method for Checking and Cleaning Radiator Fins, Oil Cooler Fins, Aftercooler Fins, and Air Conditioner Condenser Fins
393
Method for Checking Swing Pinion Grease Level, Add Grease
393
Method for Cleaning Air Conditioner Fresh/Recirc Filters
395
Method for Checking Oil Level in Final Drive Case, Adding Oil
397
Method for Checking Oil Level in Swing Machinery Case, Adding Oil
397
Check Structures for Cracks
398
Every 1000 Hours Maintenance
398
Method for Replacing Hydraulic Oil Filter Element
398
Method for Change Oil in Swing Machinery Case
400
Method for Checking and Adding Oil in Damper Case
400
Method for Replacing Fuel Main Filter Cartridge
401
Method for Checking All Tightening Points of Engine Intake Pipe Clamps
403
Method for Checking and Releasing Nitrogen Gas Charge Pressure in Accumula- Tor (for Breaker)
403
Method for Replacing Hydraulic Tank Breather Element
403
Method for Checking Alternator Belt Tension and Replacing Alternator Belt
404
Method for Replacing Def Tank Breather Element
404
Every 2000 Hours Maintenance
405
Method for Changing Oil in Final Drive Case
405
Method for Cleaning Hydraulic Tank Strainer
405
Method for Checking and Releasing Nitrogen Gas Charge Pressure in Accumula- Tor (for Control Circuit)
406
Method for Checking Alternator
410
Method for Checking and Adjusting Engine Valve Clearance
410
Method for Replacing Kccv Filter Element
410
Method for Replacing Def Filter
412
Every 4000 Hours Maintenance
415
Method for Checking Starting Motor
415
Method for Checking Water Pump
415
Replace Defined Life Parts
415
Method for Replacing Accumulator (for Control Circuit)
416
Method for Checking for Looseness of Engine High-Pressure Piping Clamp, Hard- Ening of Rubber
417
Check for Missing Fuel Spray Prevention Cap on Fuel Doser Piping, Hardening of Rubber
418
Every 4500 Hours Maintenance
418
Every 5000 Hours Maintenance
418
Method for Changing Oil in Hydraulic Tank
418
Method for Cleaning Def Tank
418
Method for Cleaning Fuel Doser
418
Method for Cleaning Kdpf
418
End of Service Life
420
Every 8000 Hours Maintenance
420
Every 9000 Hours Maintenance
420
Method for Replacing Def Hose
420
Method for Replacing Engine High-Pressure Piping Clamp
420
Method for Replacing Fuel Spray Prevention Cap
420
Method for Replacing Fuel Spray Prevention Cap on Fuel Doser Piping
420
Specifications
421
Explanation of Lift Capacity Chart (6.7M Boom)
424
Explanation of Lift Capacity Chart (7.1M Boom)
427
Attachments and Options
431
Precautions for Using Attachment and Options
432
Precautions When Removing and Installing
432
Precautions When Selecting
432
Precautions When Using
432
Read the Operation and Maintenance Manual Thoroughly
432
Handling Quick Coupler
434
Quick Coupler System
434
Automatic Grease System
437
Handling Automatic Grease System
437
Changing the Grease Interval with the In-Cab Display
438
Diagram of Automatic Greasing Points
438
System Operation
438
Indication on the In-Cab Display
439
Check Automatic Grease System
440
Handle Bucket with Hook
443
Precautions for Operation
443
Explanation of Components on Machine Equipped with Attachment
444
Handle Machine Ready for Installation of Attachment
444
Method for Change-Over and Connect Hydraulic Circuit for Machine Ready for Installation of Attachment
448
Method for Removing and Installing Attachment
451
Method for Operating Attachment
454
Long-Term Storage
458
Maintenance of Additional Filter for Breaker
459
Specifications
462
Arm/Pin Information
463
Attachments and Options
464
Install Attachment
464
Rock Bucket Selection
465
Tool Control System
466
Track Shoes Selection
467
Hydraulic Breaker
469
Recommended Attachment Operations
469
Replacement Parts
475
Defined Life Parts List
476
Periodic Replacement of Defined Life Parts
476
Consumable Parts
477
Lubrication Chart
479
Recommended Fuel, Coolant, and Lubricant
479
Use of Fuel, Coolant and Lubricants According to Ambient Temperature
480
Recommended Brands and Qualities Other than Komatsu Genuine Oils
482
Index
483
5
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Komatsu PC490LC Specifications
General
Brand
Komatsu
Model
PC490LC
Category
Excavators
Language
English
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