Komatsu PC490LC-10 Hydraulic Excavator Shop Manual SEN05622-02 – Full PDF Service & Repair Guide
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Complete Komatsu PC490LC-10 shop manual (SEN05622-02) covering specifications, disassembly and assembly, testing and adjusting, troubleshooting, hydraulic and electrical diagrams for serial numbers 80001 and up. Instant PDF download.
Description
Komatsu PC490LC-10 Shop Manual – SEN05622-02
This is the complete Komatsu PC490LC-10 hydraulic excavator shop manual, document number SEN05622-02. It is the same comprehensive workshop reference used by professional technicians to service, diagnose, repair, and rebuild the PC490LC-10, covering machines from serial number 80001 and up. The manual is presented as a single, fully linked PDF that runs to well over 1,600 pages of procedures, specifications, and diagrams.
The Komatsu PC490LC-10 Shop Manual SEN05622-02 is organized into clearly separated chapters — each covering a major system or stage of the repair process — so you can move directly to the information you need whether you are adjusting a relief valve, removing a final drive, or tracing an electrical fault.
File Details
- Manual type: Shop Manual (Workshop / Service and Repair)
- Brand: Komatsu
- Model: PC490LC-10 Hydraulic Excavator
- Document number: SEN05622-02
- Serial number coverage: 80001 and up
- Language: English
- Format: PDF
- Page count: Approximately 1,659 pages
- Publication date: June 2013 (06-13)
Chapters Covered
The manual follows Komatsu’s standard chapter numbering system. The main chapters and their primary sub-sections are:
- 00 – Index and Foreword
- Important safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of fuel system devices, intake system parts, hydraulic equipment, electrical equipment
- Method of disconnecting and connecting push-pull type coupler
- How to read electric wire code
- Precautions when performing operation
- Standard tightening torque table
- List of abbreviations, conversion tables
- 01 – Specification
- Specification drawing
- Working range drawing
- Specifications
- Table of weight
- Table of fuel, coolant and lubricants
- 10 – Structure and Function
- Engine and cooling system (cooling fan pump, cooling fan motor)
- Power train (swing circle, swing machinery, final drive)
- Undercarriage and frame (track frame, idler cushion)
- Hydraulic system (main pump, control valve, swing motor, travel motor, PPC valve, solenoid valve, CLSS, center swivel joint, accumulator)
- Work equipment and shims
- Cab and its attachments, ROPS cab
- Electrical control system (engine controller, machine monitor, KOMTRAX, sensors)
- 20 – Standard Value Tables
- Standard value table for engine
- Standard value table for machine
- Posture of machine for measuring performance
- 30 – Testing and Adjusting
- Engine and cooling system tests (speed, boost pressure, exhaust color, valve clearance, compression pressure, blowby, oil pressure, EGR/KVGT, fuel pressure, fuel leakage)
- Power train (swing circle bearing clearance)
- Undercarriage and frame (track tension)
- Hydraulic system (releasing remaining pressure, work equipment/swing/travel circuit pressures, pump PC and LS control circuits, solenoid valve output, PPC valve output, fan speed, fan pump circuit, oil leakage, bleeding air)
- Cab and attachments (tipping stopper, mirrors)
- Electrical system (special functions of machine monitor, camera angle, diodes)
- Pm clinic check sheet
- 40 – Troubleshooting
- Failure codes table (engine, electrical, hydraulic, mechanical)
- Troubleshooting by failure code (CA, D, E, B@ codes)
- Troubleshooting of electrical system (E-mode)
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Troubleshooting of engine (S-mode)
- Connector list and layout
- T-branch box and adapter table
- Fuse box connection table
- 50 – Disassembly and Assembly
- Engine and cooling system (supply pump, injector, cylinder head, radiator, oil cooler, aftercooler, cooling fan, engine and main pump, seals, hood, KDPF, KCCV, air cleaner)
- Power train (travel motor and final drive, swing motor and machinery, swing circle)
- Undercarriage and frame (track shoe, sprocket, idler, idler cushion, track roller, carrier roller, revolving frame, counterweight)
- Hydraulic system (center swivel joint, hydraulic tank, main pump, control valve, PPC valves)
- Work equipment (assembly, cylinder)
- Cab and attachments (operator’s cab, glass, front window, floor frame, air conditioner unit, seat, wiper)
- Electrical system (A/C compressor, condenser, engine controller, pump controller, machine monitor, sensors, KOMTRAX)
- 60 – Maintenance Standard
- Engine mount, cooling system, cooling fan pump and motor
- Power train (swing circle, swing machinery, final drive)
- Undercarriage and frame (sprocket, track frame, idler, track roller, carrier roller, track shoe)
- Hydraulic system (main pump, control valve, swing motor, travel motor, PPC valve, solenoid valve, center swivel joint)
- Work equipment and cylinders
- 80 – Appendix
- Air conditioner components
- Refrigeration cycle configuration and function
- Air conditioner unit, dual pressure switch, controller, compressor, condenser, receiver drier, sensors
- Testing and troubleshooting procedures (self-diagnosis, air leakage, vent changeover, pressure switch, relays)
- Failure codes related to air conditioner
- 90 – Diagrams and Drawings
- Hydraulic circuit diagram (with symbols)
- Electric circuit diagram (with symbols)
- Air conditioner unit electrical circuit diagram
Altogether, the Komatsu PC490LC-10 Shop Manual SEN05622-02 provides a full service and repair framework for the machine: structure and function explanations that tell you how each system works, standard value tables that give you the exact tolerances and repair limits, testing and adjusting procedures that let you verify and tune the machine, and disassembly/assembly instructions that guide you through component removal and rebuild. It also contains a complete troubleshooting section keyed to failure codes so you can move from a symptom to a precise cause and remedy.
Engine, Hydraulics, and Under-Table Specifications
The specification chapter covers the Komatsu SAA6D125E-6 diesel engine — a 4-cycle, water-cooled, in-line, direct-injection unit with turbocharger and air-cooled aftercooler, 6 cylinders, 125 mm bore × 150 mm stroke, 11.045 L displacement, rated 268 kW (359 HP) net at 1,900 rpm. The machine itself has an operating weight of 46,660 kg, a standard bucket capacity of 1.9 m³, a 700 mm shoe width, and travels at 3.0 / 4.2 / 5.5 km/h in low, medium, and high. The hydraulic system uses two variable-displacement piston pumps (HPV210 + 210) with a set pressure of 37.2 MPa (380 kg/cm²) and a delivery of 347 L/min each.
These figures, plus fluid capacities (engine oil pan 42 L, hydraulic tank 248 L refill / 472 L specified, cooling system 44 L, fuel tank 650 L), tightening torques, and component weights, are all part of the specification and standard value chapters. The Komatsu PC490LC-10 Shop Manual also includes the working range drawing (max digging reach 12,030 mm, max digging depth 7,755 mm, max digging height 10,980 mm) and the specification drawing with overall dimensions.
What This Manual Enables You to Do
With this manual on hand, a technician or owner can perform the full range of service work on the PC490LC-10:
- Diagnose faults using the failure code tables and symptom-based troubleshooting charts — engine (S-mode), electrical (E-mode), and hydraulic/mechanical (H-mode).
- Test and adjust engine speed, boost pressure, valve clearance, compression pressure, oil pressure, hydraulic circuit pressures, pump control circuits, PPC valve output, and fan speed.
- Remove and install major components — engine, main pump, control valve, swing motor, travel motor, final drive, hydraulic tank, center swivel joint, work equipment cylinders, cab, and electrical controllers.
- Disassemble and assemble sub-components such as the final drive, swing machinery, idler, idler cushion, track roller, carrier roller, control valve, PPC valves, and work equipment cylinders.
- Check wear and tolerances against the maintenance standard values for pins, bushings, gears, sprockets, track components, and hydraulic parts.
- Understand the machine through the structure and function chapter — how the CLSS hydraulic system, the engine and pump combined control, the swing holding brake, the travel junction valve, and the fan control work.
- Follow the wiring with the full electrical circuit diagrams, connector layouts, and fuse box tables.
- Service the air conditioner using the appendix dedicated to the refrigeration cycle, self-diagnosis, and air conditioner failure codes.
Why Correct Procedures and Specifications Matter
The PC490LC-10 is a 46-tonne class excavator. Incorrect assembly torque, wrong hydraulic pressures, or a misdiagnosed electrical fault can lead to component failure, downtime, and expensive secondary damage. The Komatsu PC490LC-10 Shop Manual SEN05622-02 gives you the manufacturer’s own procedures and values, so you can tighten to the correct torque, set pressures to the specified range, identify the actual cause of a failure code, and rebuild components to the correct clearance. Whether you are maintaining a single machine or running a fleet, having the correct reference eliminates guesswork and reduces the risk of repeat repairs.
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Instant PDF Delivery
This Komatsu PC490LC-10 Shop Manual is delivered as an instant PDF download — no shipping, no waiting, no physical media. Once payment is complete you can download the file immediately and open it on any device: laptop, desktop, tablet, or smartphone. The PDF is printable, so you can produce paper copies of the sections you need for the workshop floor, or keep the entire manual on a tablet for quick reference. The file is yours to keep and use for the life of your machine.
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