Komatsu Hydraulic Excavator Pc490lc 10 F Shop Manual

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GEN00109-02

Field Assembly Instruction

HYDRAULIC PC490LC -10

EXCAVATOR
SERIAL NUMBERS 80001 and up

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FOREWORD

3INCETHISMACHINEISLARGEINSIZEITISDIVIDEDINTOSOMEUNITSTOMEET
THETRANSPORTATIONCONDITIONSANDREGULATIONSAPPLIEDTOTHETRANSPORTA
TIONROUTEWHENSHIPPEDFROMOURFACTORY
4HIS MANUAL DESCRIBES HOW TO ASSEMBLE THE UNITS INTO THE COMPLETE
MACHINEINTHEFIELD7EHOPETHATTHISMACHINEWILLDISPLAYITSQUALITY
ANDYOUWILLUSEITSAFELYACCORDINGTOTHEOPERATIONMANUAL

-ANYUNITSARELARGEINSIZEANDHEAVYINWEIGHTANDMAYBEHANDLED
INADANGEROUSPLACEORPOSTUREANDMANYWORKERSMAYHAVETOWORK
TOGETHERTOSLINGTHEMWITHCRANES
!CCORDINGLYBEFORESTARTINGTHEASSEMBLYWORKTHEWORKSUPERVISORIS
REQUIREDTOHOLDASAFETYMEETINGTOOBLIGETHEWORKERSTOPUTONPRO
TECTIVEGEARANDAPPOINTAWORKLEADERANDACRANEWORKSIGNALMAN
ANDALLOTROLESTOALLTHEWORKERSFORSAFEWORK
)NPARTICULARTHEABOVEMEETINGISMOREIMPORTANTWHENWORKEROFDIF
FERENTLANGUAGESANDCUSTOMSWORKTOGETHER
4HEFOLLOWINGISAREFERENCESUPERVISIONSYSTEMDIAGRAM

(Instruction system)
Work leader
Director
Work supervisor Crane director and
deputy director

Operator for assembly

Liaison man

Mechanics Sharing of work

Interpreter

.OTETHATTHISMANUALDOESNOTDESCRIBETHEWHOLESPECIFICATIONOFTHE
MACHINEBUTDESCRIBESONLYTHEBASICSPECIFICATION
)FYOUHAVEANYQUESTIONWHENDIVIDINGANDTRANSPORTINGTHEMACHINE
BYYOURSELFINFUTUREASKONEOFOURDISTRIBUTORS
 CONTENTS
Specifications ...................................................................................................................... 1
Precautions for field assembly ............................................................................................ 2
Disposal of removed parts................................................................................................... 3
Assembling procedures, applicable equipment and schedule ............................................ 4
Flow of field assembly ......................................................................................................... 5
Kit layout diagram................................................................................................................ 6
Transportation ..................................................................................................................... 7
Tool list for field assembly ................................................................................................... 10
Tightening torque ................................................................................................................ 11
Coating materials ................................................................................................................ 16
Selection of wire ropes used for assembly.......................................................................... 20
Selection of nylon slings used for assembly........................................................................ 21

A. Assembly of chassis ....................................................................................................... 23

A- 1. Installation of climbing step .................................................................................... 24
A- 2. Installation of handrail ............................................................................................ 25
A- 3. Installation of mirror................................................................................................ 27

B. Assembling of work equipment ....................................................................................... 31

B- 1. Installation of boom cylinder................................................................................... 32
B- 2. Releasing remaining pressure in hydraulic circuit .................................................. 34
B- 3. Installation of boom cylinder hoses ........................................................................ 35
B- 4. Installation of boom cylinder top pin ....................................................................... 36
B- 5. Installation of boom assembly ................................................................................ 37
B- 6. Installation of hoses from chassis along top of boom............................................. 40
B- 7. Connection of boom cylinder head......................................................................... 41
B- 8. Installation of arm assembly................................................................................... 42
B- 9. Installation of bucket cylinder hoses between boom and bucket cylinder .............. 44
B-10. Installation of bucket.............................................................................................. 46
B-11. Connection of work equipment grease piping ....................................................... 49
B-12. Connection of work equipment wiring ................................................................... 52
B-13. Greasing after completion of work equipment....................................................... 53
B-14. Bleeding air from work equipment circuit .............................................................. 54

C. Increasing and decreasing of track frame gauge, assembling of counterweight............ 55

C- 1. Increasing and decreasing of track frame gauge ................................................... 56
C- 2. Installation of steps ................................................................................................ 62
C- 3. Installation of travel piping covers ......................................................................... 63
C- 4. Adjustment of track tension ................................................................................... 67
C- 5. Sticking sheet to counterweight ............................................................................. 70
C- 6. Installation of camera ............................................................................................. 71
C- 7. Installation of counterweight................................................................................... 77

M. Procedure for inspection and maintenance after completion of assembly ..................... 81

M- 1. Replacement of return filter (Standard filter to flushing filter) ................................ 82
M- 2. Flushing of hydraulic circuit ................................................................................... 83
M- 3. Replacement of return filter (Standard filter to flushing filter) ................................ 85
M- 4. Check of oil/coolant level at each part ................................................................... 87
M- 5. Inspection of oil level in hydraulic tank and refill.................................................... 89
M- 6. Parts to be touched up after field assembly........................................................... 91
M- 7. Error code .............................................................................................................. 92

Mounting bolt torque check sheet

Field assembly inspection report (Backhoe)
Specifications
Machine model PC490LC-10
Weight of machine kg 46,600
Bucket capacity m3 1.9
Engine model — KOMATSU SAA6D125E-6
Flywheel horsepower kW/rpm {HP/rpm} 268/1,900{359/1,900}
Min. ground clearance mm 700
Travel speed (Low/High) km/h 3.0/4.2/5.5
Swing speed rpm 9.1

PC490LC-10

1
Precautions for field assembly
1. Selection of work place
1) When selecting a work place, consider the following.
• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout drawing.)
• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
• Is the ground flat? (The ground surface must not be uneven or sloping.)
• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.

2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read and
understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the work
place so that all the workers will observe the precautions.

3. Preparation and check of protective gear, slings and tools

The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear? If special
protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without problem.
In particular, check wooden blocks for internal decay and cracking.

4. k Check during actual work

The work supervisor or the work leader must check the following items constantly and make all the workers ob-
serve them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked that
work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel control
lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?

5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.

2
Disposal of removed parts
As described in "FOREWORD", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic
devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and
dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading and crane work.

The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after comple-
tion of the machine. Since they are useful when the machine needs to be transported in future, however, we rec-
ommend you to keep them as long as possible.

3
 Days

Backhoe · Inspection of oil level and

coolant level
· Air bleeding from work
equipment cylinder 3 Division
· Flushing of hydraulic
Assembly unit circuit
· Adjustment of track
Unloading parts Assembly of work Increasing of track Installation of tension
Step equipment frame gauge counterweight · Performance test
Handrail and mirror
Assembling procedures,

Crane
45t

4
applicable equipment and schedule

Air compressor

Worker

Leader + 3 mechanics

Start of assembling

· Completion of general
· Meeting with all workers assembling
Komatsu Hydraulic Excavator Pc490lc 10 F Shop Manual
Full download: http://manualplace.com/download/komatsu-hydraulic-excavator-pc490lc-10-f-shop-manual/

Flow of field assembly

*1 Installation of accessories

*2 Installation of boom cylinder

*2•*3 Installation of boom

*2•*4 Installation of arm

*2 Installation of bucket

Greasing of work equipment

Air bleeding (work equipment)

Increasing of gauge

*5 Installation of sub
Installation of counterweight counterweight

*6 Installation of accessories

Flushing

Check of oil and coolant levels

– Completion inspection

Precautions
*1: Installation of grip, handrail, and rear view mirror
*2: Adjustment of shim
*3: Installation of working lamp
*4: Bucket cylinder and link are installed before shipment
*5: Installation of sound absorbing material, backup lamp, and rear view
monitoring camera
*6: Installation of track frame step and travel piping cover

5
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