Komatsu PC490-10 PC490LC-10 Hydraulic Excavator Shop Manual 2013 PDF

Description

Komatsu PC490-10 & PC490LC-10 Shop Manual

This Komatsu PC490-10 PC490LC-10 Hydraulic Excavator Shop Manual is the complete workshop reference for the PC490-10 and PC490LC-10 models, covering serial numbers 80001 and up and K60001 and up. Across 1,677 pages, the manual takes a technician from general safety and specifications through to full hydraulic and electrical diagnostics, component disassembly and assembly, and maintenance standards. Every major system on the machine is documented: the SAA6D125E-6 engine, the CLSS hydraulic system, the main pump and control valve, swing and travel motors, the electrical control system including the machine monitor and KOMTRAX, and the work equipment. Whether you are servicing a single fault or rebuilding an entire assembly, this shop manual provides the procedures, specifications, torque values and circuit diagrams needed to do the job correctly.

File Details

• Manual type: Shop Manual (workshop service and repair reference)
• Brand: Komatsu
• Models covered: PC490-10, PC490LC-10
• Serial numbers: 80001 and up, K60001 and up
• Engine: Komatsu SAA6D125E-6 diesel engine
• Document number: UEN05622-02
• Date: January 2013
• Language: English
• Page count: 1,677
• File format: PDF

Chapters Covered

• 00 Index and foreword — Important safety notice, how to read the shop manual, explanation of terms for maintenance standard, handling of fuel system devices, handling of intake system parts, handling of hydraulic equipment, push-pull coupler method, handling of electrical equipment, electric wire code, precautions when performing operation, practical use of KOMTRAX, standard tightening torque table, list of abbreviations, conversion table
• 01 Specifications — Specification drawings, working range drawings, machine specifications, weight table, table of fuel, coolant and lubricants
• 10 Structure and function — Engine and cooling system, power train, swing circle, swing machinery, final drive, undercarriage and frame, hydraulic component layout, valve control, hydraulic tank, CLSS, main pump, control valve, swing motor, travel motor, PPC valve, solenoid valve, attachment circuit selector valve, variable pressure compensation valve, center swivel joint, accumulator, hydraulic drift prevention valve, ATT EPC valve assembly, return oil filter, quick coupler control valve, work equipment, work equipment shims, cab and its attachments, electrical control system, machine monitor system, KOMTRAX system, sensors, PPC levers, auto grease system
• 20 Standard value table — Standard service value table, standard value table for engine, standard value table for machine
• 30 Testing and adjusting — Tools for testing and adjusting, engine and cooling system, power train, undercarriage and frame, hydraulic system, cab and its attachments, electrical system, Pm clinic and check sheet
• 40 Troubleshooting — General information, checks before troubleshooting, failure codes table, troubleshooting by failure code, electrical system (E-mode), hydraulic and mechanical system (H-mode), engine (S-mode), auto grease system
• 50 Disassembly and assembly — Engine and cooling system, power train system, undercarriage and frame, hydraulic system, work equipment, cab and its attachments, electrical system
• 60 Maintenance standard — Engine and cooling system, power train system, undercarriage and frame, hydraulic system, work equipment
• 80 Appendix — Air conditioner components, refrigeration cycle, testing and troubleshooting procedures, failure codes related to air conditioner, gauge pressure troubleshooting, compressor oil handling
• 90 Diagrams and drawings — Hydraulic circuit diagram, electric circuit diagram, electric circuit diagram for air conditioner unit

The manual is structured so that a technician can move from a symptom to a repair without guesswork. The troubleshooting chapter is split into failure-code-based diagnostics and symptom-based diagnostics for the electrical, hydraulic, mechanical and engine systems. The testing and adjusting chapter supplies the measurement procedures and standard values needed to confirm whether a component is within specification. The disassembly and assembly chapter documents the order of work, special tools, coating materials, tightening torques and capacities required for each major assembly. The maintenance standard chapter provides the wear limits, clearances and repair criteria used to decide whether a part can be reused or must be replaced. Altogether, this gives a complete working reference for the PC490-10 and PC490LC-10, not just an overview.

What This Shop Manual Covers in Practice

The PC490-10 and PC490LC-10 are large hydraulic excavators, and the systems on board reflect that: a common rail diesel engine with EGR, KVGT turbocharger and KDPF aftertreatment, a closed-center load-sensing hydraulic system with two main pumps, electronic proportional control for pump and valve regulation, and a machine monitor network that ties the engine, pump and monitor controllers together over CAN communication. This manual documents each of those systems in detail.

For the engine and cooling system, the manual covers the SAA6D125E-6 in the context of the machine, including the supply pump, injectors, cylinder head, radiator, hydraulic oil cooler, aftercooler, cooling fan and fan motor, KDPF assembly, KCCV assembly and air cleaner. Procedures for measuring boost pressure, exhaust gas temperature and color, valve clearance, compression pressure, blowby pressure, engine oil pressure, EGR valve and KVGT oil pressure, fuel pressure, and fuel leakage and return are all included, along with the compensation value writing procedure when injectors or the engine controller are replaced.

For the hydraulic system, the manual describes the CLSS (Closed-center Load Sensing System), the HPV210+210 main pump, the control valve with its pressure compensation, merge-divider, travel junction and relief functions, the swing motor with its 2-stage relief and reverse prevention valves, the travel motor with counterbalance and safety valves, the PPC valves for work equipment, swing and travel, the solenoid valve block, the attachment circuit selector valve, the variable pressure compensation valve, the center swivel joint, the accumulator and the hydraulic drift prevention valves. Testing and adjusting procedures cover work equipment, swing and travel circuit oil pressures, control circuit pressure, pump PC and LS control circuit pressures, solenoid valve output pressures, PPC valve output pressures, fan pump circuit pressure and fan pump EPC current.

For the electrical system, the manual documents the machine monitor system, the engine controller, the pump controller, the KOMTRAX system, the sensors (ambient pressure, engine oil pressure, charge pressure, charge temperature, coolant temperature, Ne and Bkup speed, common rail pressure, EGR valve lift, KVGT speed and position, mass air flow and temperature, dosing fuel pressure, KDPF differential and outlet pressure, KDOC inlet and outlet temperature, KDPF outlet temperature, crankcase pressure, engine oil level, fuel level, coolant level, hydraulic oil temperature, front and rear pump oil pressure, PPC oil pressure, front and rear pump swash plate, cooling fan speed, quick coupler low pressure warning, auto grease pressure switch), the PPC levers and the auto grease system. Special functions of the machine monitor, including service mode, monitoring, abnormality record, maintenance record, maintenance mode setting, default settings, diagnostic tests and adjustments, are described in full.

For troubleshooting, the manual provides a failure codes table and detailed troubleshooting procedures for each code, covering air conditioner sensors, engine controller lock cautions, KDPF regeneration requests, air cleaner clogging, charge voltage, engine oil pressure and level, engine coolant temperature and level, hydraulic oil overheat, engine speed sensor errors, charge air pressure and temperature sensor errors, throttle sensor errors, coolant temperature sensor errors, sensor supply voltage errors, ambient pressure sensor errors, engine overspeed, injection and PCV errors, injector open/short errors, ECM internal failures, battery voltage errors, rail pressure errors, crankcase pressure errors, turbo speed errors, intake temperature errors, ECM internal temperature errors, backup speed sensor errors, persistent data loss, KDOC malfunction, regeneration ineffective, sensor supply 5 V errors, crankcase pressure sensor errors, KDPF delta pressure errors, KDPF soot load errors, dosing fuel valve errors, dosing fuel pressure sensor errors, KDPF outlet pressure errors, fuel doser degradation, KDOC and KDPF temperature errors, mass air flow sensor power supply errors, battery relay drive, personal code relay, KOMTRAX errors, GPS antenna, system operating lamp, CAN communication errors, pump controller errors, pump solenoid power, 5 V sensor power, model selection errors, monitor ROM and error, camera power supply, hydraulic oil temperature sensor errors, air cleaner clogging sensor, pump pressure sensor errors, PPC pressure sensor errors, pump swash plate sensor errors, fan speed sensor errors, travel alarm, travel speed solenoid, swing holding brake solenoid, fan reverse solenoid, travel junction solenoid, attachment solenoid, 2-stage relief solenoid, variable back pressure solenoid, swing cut-off solenoid, fan pump EPC solenoid, PC-EPC solenoids, LS-EPC solenoid, service current EPC, merge-divider solenoids, wiper working and parking, and wiper drive short circuits.

IMAGES PREVIEW

For the hydraulic and mechanical systems, the manual provides symptom-based troubleshooting for low speed or power across all functions, engine speed drop or stall, no movement in any function, unusual noise from the hydraulic pump, poor fine control, low boom, arm or bucket speed or power, no movement in single operation, large hydraulic drift, large time lag, other functions moving when one is relieved, one-touch power maximizing function not working, machine push-up function not working, combined operation issues, travel deviation, low travel speed, steering and travel power issues, travel speed change issues, one track not running, swing issues including no swing, poor acceleration, overrun, shock and noise on stop, swing drift on slope, attachment circuit change and oil flow control issues, fan speed and noise issues, and quick coupler cylinder issues.

For engine troubleshooting, the manual provides symptom-based procedures for no cranking, no exhaust smoke, no start despite injection, poor startability, poor pickup, engine stopping during operation, rough or unstable running, lack of power, black exhaust, excessive oil consumption, early oil contamination, excessive fuel consumption, oil in coolant, oil pressure drop, fuel in oil, water in oil, overheating, unusual noise, excessive vibration, air bleeding problems, frequent active regeneration, long active regeneration and white smoke during active regeneration.

Who This Manual Is For

This shop manual is written for professional technicians and mechanics who service Komatsu PC490-10 and PC490LC-10 excavators, as well as for owners and operators who need a reliable technical reference for maintenance, repair and diagnostics. The procedures assume access to ordinary workshop tools and, where necessary, Komatsu special tools, which are listed with part numbers in the relevant chapters.

Get Instant Access

With this Komatsu PC490-10 PC490LC-10 Hydraulic Excavator Shop Manual in PDF form, you can carry the complete factory reference on a laptop, tablet or phone, print only the pages you need for the job, and search across the full text for the specification, torque value or procedure you are looking for. No shipping, no waiting — the file is delivered immediately after purchase. Having the correct procedures and specifications on hand is what separates a repair that lasts from one that comes back, and this manual gives you that information directly from the manufacturer.