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Komatsu PC490-11E0 manual available for free PDF download: Operation & Maintenance Manual
Komatsu PC490-11E0 Operation & Maintenance Manual (540 pages)
HYDRAULIC EXCAVATOR
Brand:
Komatsu
| Category:
Excavators
| Size: 36 MB
Table of Contents
Read this Manual
4
Komatsu Machine Operator Privacy Policy
5
Safety Information
8
Safety Labels
9
Noise
10
Vibration Levels
11
Vibration - Operating Condition
11
Guide to Reduce Vibration Levels on Machine
11
Introduction
13
Main Use of Machine
13
Directions of Machine
13
Visibility from Operator's Seat
14
Engine Technology to Conform Exhaust Gas Emission
15
Product Information
16
Location of Product Identification Number (Pin)/Machine Serial No. Plate
16
Location of Engine Number Plate
16
Fluorinated Greenhouse Gases
17
Service Meter Location
17
Your Machine Serial Numbers and Distributor
17
Serial Plate
18
Method for Checking Engine Type
19
Declaration of Conformity
21
Table of Contents
22
Safety
27
Safety Labels
30
Location of Safety Labels
31
Contents of Safety Labels
33
General Precautions Common to Operation and Maintenance
45
Precautions before Starting Operation
45
Preparations for Safe Operation
45
Ensure Safe Operation
45
Understand the Machine
45
Precautions for Safety-Related Equipment
45
Inspect Machine
45
Wear Well-Fitting Clothes and Protective Equipment
45
Precautions to Prevent Fire
46
Keep Machine Clean
46
Precautions for Inside Operator's Compartment
46
Provide Fire Extinguisher and First Aid Kit
46
If any Problem Is Found
46
Actions if Fire Occurs
46
Prevent Fire
47
Precautions When Getting on or off Machine
48
Use Handrails and Steps When Getting on or off Machine
48
No Jumping on or off Machine
49
Lifting of Personnel Prohibited
49
No People on Attachments
49
Precautions When Standing up from Operator's Seat
49
Precautions When Leaving Machine
49
Do Not Get Caught in Work Equipment
50
Precautions Related to Protective Structures
50
Emergency Exit from Operator's Cab
50
Electromagnetic Interference
50
Protection against Falling, Flying or Intruding Objects
51
Actions in the Event of Damage to Safety Structures
52
Unauthorized Modification
53
Precautions Related to Attachments and Options
53
Quick Coupler Attachment
53
Large Attachments and Combinations
53
Precautions Related to Cab Glass
54
Precautions When Running Engine Inside Building
54
Precautions for Operation
55
Precautions for Jobsite
55
Investigate and Confirm Jobsite Conditions
55
Precautions When Working on Loose Ground
55
Do Not Go Close to High-Voltage Cables
55
Ensure Good Visibility
56
Check Signs and Signalman's Signals
56
Start Engine
57
Beware of Asbestos Dust
57
Use Warning Tags
57
Checks and Adjustment before Starting Engine
57
Precautions When Starting Engine
58
In Cold Weather
58
Start Engine with Jumper Cables
58
Precautions for Operation
59
Checks before Operation
59
When Travelling in Forward or Reverse and Swinging
60
Precautions When Travelling
60
Precautions When Traveling on Slopes
61
Precautions When Operating on Slopes
62
Prohibited Operations
62
Precautions for Transportation
64
Precautions When Operating on Snow or Frozen Surfaces
64
Precautions When Parking Machine
64
Precautions When Loading and Unloading
65
Towing and Being Towed
66
Lifting Operations
66
Precautions for Towing and Being Towed
66
General Precautions for Lifting Operations
66
Precautions for Maintenance
68
Precautions before Starting Inspection and Maintenance
68
Display Warning Tag During Inspection and Maintenance
68
Keep Work Place Clean and Tidy
68
Select Suitable Place for Inspection and Maintenance
68
Only Authorized Personnel
68
Appoint Leader When Working with Others
68
Stability
69
Guards
69
End of Service Life
69
Stop Engine before Carrying out Inspection and Maintenance
69
Two Workers for Maintenance When Engine Is Running
69
Precautions When Installing, Removing, or Storing Attachments
70
Precautions for Working at High Places
70
Precautions When Working on Machine
70
Precautions for Check and Maintenance
71
Precautions When Working under Machine or Work Equipment
71
Use Proper Tools
71
Turn Battery Disconnect Switch to off Position
71
Precautions for Welding
72
Handle Battery
72
Precautions When Using Hammer
73
Precautions for High-Temperature Coolant
73
Precautions for High-Temperature Oil
73
Precautions for High-Temperature Parts
73
Precautions for High-Pressure Oil
73
Precautions for High-Pressure Fuel
74
Handle High-Pressure Hoses and Piping
74
Precautions for High Voltage
74
Precautions for Noise
74
Precautions for High-Pressure Grease When Adjusting Track Tension
75
Do Not Disassemble Recoil Spring
75
Handle Accumulator and Gas Spring
75
Precautions for Compressed Air
76
Maintenance of Air Conditioner
76
Chemical Hazard
76
Precautions for Disposing of Waste Materials
76
Method for Selecting Window Washer Fluid
76
Periodic Replacement of Defined Life Parts
76
Precautions for Def
78
General Character and Precautions for Handling
78
Precautions for Adding
78
Safety Rules for Storage
78
Precautions for Fire Hazard and Leakage
78
Other Precautions
78
Operation
79
General View
80
Machine Equipment Name
80
Cab Equipment Names
82
Controls and Gauges Names
83
Explanation of Components
86
Explanation of Machine Monitor Equipment
86
Warning Display
95
Pilot Display
111
Message Display
114
Hydraulic Oil Temperature Gauge
118
Fuel Gauge
119
Eco Gauge
120
Monitor Switches
121
Wiper Switch
128
Air Conditioner Switch
130
Function Switches
130
Change Display Setting
142
Machine Settings
147
Monitor Settings
160
Screen Adjustment
161
Clock Adjustment
162
Calendar Setting
163
Time Setting
164
Language Settings
168
Check Message
170
Reply to Message
171
Switches
172
Starting Switch
173
Fuel Control Dial
173
Cigarette Lighter
173
Lamp Switch
174
Horn Switch
174
Breaker Switch
179
Other Equipment
180
Emergency Escape Hammer
186
Drink Box
188
Magazine Box
188
Cup Holder
188
Fusible Link
191
Grease Pump Holder
192
Fire Extinguisher
192
Battery Disconnect Switch
192
Control Levers and Pedals
239
Lock Lever
240
Travel Lever
241
Machine Operations and Controls
243
Checks and Adjustment before Starting Engine
243
Refuelling Pump
244
Adjust Seat Height
258
Method for Starting Engine
275
Method for Operations and Checks after Starting Engine
279
Method for Stopping Engine
289
Method for Starting Machine (Travel Forward and Reverse) and Stopping Machine
292
Method for Steering Machine
295
Pivot Turn
295
Method for Swinging Machine
297
Method for Operating Work Equipment
298
Handle Working Mode
299
Prohibited Operations
301
Precautions for Operation
305
Precautions for Working on Slope
307
Method for Escaping from Mud
308
Recommended Applications
309
Shovel Work
310
Ditching Work
310
Loading Work
310
Effective Use of Hydraulic Excavator
310
Method for Replacing and Inverting Bucket
311
Method for Parking Machine
315
Method for Checking after Finishing Work
317
Lock
317
Handle Air Conditioner
323
Explanation of Air Conditioner Equipment
324
Off Switch
324
Fan Switch
324
Auto Switch
327
Display Monitor
327
Sunlight Sensor
328
Method for Operating Air Conditioner
328
Handling Radio
337
Explanation of Radio Equipment
337
Preset Button
338
Method for Controlling Radio
339
Stow Antenna
342
Space for Radio Cassette
342
Komvision
343
PRECAUTIONS WHEN USING Komvision
343
Monitor Display
343
Transportation
345
Precautions for Transporting Machine
345
Select Transportation Method
345
Loading and Unloading with Trailer
346
Method for Lifting Machine
356
Spread and Narrow Track Frame Gauge
357
Cold Weather Operation
360
Cold Weather Operation Information
360
Fuel and Lubricants
360
Precautions after Daily Work Completion in Cold Weather
361
After Cold Weather Season
362
Precautions for Long-Term Storage
363
Preparation for Long-Term Storage
363
Maintenance During Long-Term Storage
363
Starting Machine after Long-Term Storage
363
Troubles and Actions
365
Actions When Running out of Fuel
365
Phenomena that Are Not Failures
366
Precautions for Towing Machine
366
Precautions for Severe Job Condition
367
Precautions for Discharged Battery
368
Other Trouble
371
Maintenance
377
Precautions for Maintenance
378
Check Service Meter Reading
378
Komatsu Genuine Replacement Parts
378
Komatsu Genuine Lubricants
378
Always Use Clean Washer Fluid
378
Fresh and Clean Lubricants
378
Check Drained Oil and Used Filter
378
Precautions for Refilling Oil or Fuel
378
Precautions for Adding Def
378
Welding Instructions
378
Precautions for Kdpf
379
Precautions for Scr Assembly
379
Dusty Jobsites
379
Avoid Mixing Oil
379
Lock Inspection Covers
379
Bleed Air from Hydraulic Circuit
379
Precautions When Installing Hydraulic Hoses
379
Checks after Inspection and Maintenance
379
Fuel and Lubricants to Match the Ambient Temperature
380
Close Engine Hood Securely
380
Precautions When You Clean Work Equipment Control Lever
380
Outline of Maintenance
381
Handle Oil, Fuel, Coolant, and Performing Oil Clinic
381
Coolant and Water for Dilution
384
Handle Electrical Components
387
Standard Tightening Torque for Bolts and Nuts
388
Maintenance Schedule
390
Maintenance Schedule Table
390
Maintenance Interval for Hydraulic Breaker
391
Maintenance Procedure
393
When Required
393
Method for Checking, Cleaning and Replacing Air Cleaner
393
Method for Cleaning Inside of Cooling System
398
Method for Checking Looseness and Tightening Track Shoe Bolts
404
Method for Checking and Adjusting Track Tension
404
Method for Replacing Bucket Teeth (Vertical Pin Type)
405
Method for Replacing Bucket Teeth (Horizontal Pin Type)
408
Method for Replacing Bucket Side Cutter and Shroud
409
Method for Adjusting Bucket Clearance
410
Method for Checking Window Washer Fluid Level, Adding Fluid
411
Method for Checking and Maintenance Air Conditioner
411
Check Level of Refrigerant (Gas)
412
Method for Washing Washable Floor
413
Method for Checking Gas Spring
416
Method for Bleeding Air from Hydraulic Circuit
417
Method for Cleaning Line Filter and Removing Dirt
419
Method for Checking Camera Visibility
419
Checks before Starting
420
Every 50 Hours Maintenance
420
Method for Lubricating Work Equipment
420
Every 250 Hours Maintenance
421
Method for Checking Battery Electrolyte Level
421
Method for Checking and Adjusting Air Conditioner Compressor Belt Tension
423
Method for Checking Looseness and Tightening Connecting Bolt between Centre Frame and Track Frame
424
Every 500 Hours Maintenance
425
Method for Lubricating Swing Circle
425
Method for Lubricating
425
Method for Replacing Fuel Prefilter Cartridge
428
Method for Checking Swing Pinion Grease Level, Add Grease
432
Method for Checking and Cleaning Radiator Fins, Oil Cooler Fins, Aftercooler Fins, and Air Conditioner Condenser Fins
433
Method for Cleaning Air Conditioner Fresh/Recirc Filters
434
Method for Checking Oil Level in Swing Machinery Case, Adding Oil
436
Method for Checking Oil Level in Final Drive Case, Adding Oil
437
Every 1000 Hours Maintenance
438
Check Structures for Cracks
438
Method for Replacing Hydraulic Oil Filter Element
438
Method for Change Oil in Swing Machinery Case
440
Method for Checking and Adding Oil in Damper Case
440
Method for Replacing Fuel Main Filter Cartridge
441
Method for Checking All Tightening Points of Engine Intake Pipe Clamps
445
Method for Checking and Releasing Nitrogen Gas Charge Pressure in Accumula- Tor (for Breaker)
445
Method for Replacing Hydraulic Tank Breather Element
445
Method for Replacing Def Tank Breather Element
446
Method for Checking Alternator Belt Tension and Replacing Alternator Belt
446
Every 2000 Hours Maintenance
447
Method for Changing Oil in Final Drive Case
447
Method for Cleaning Hydraulic Tank Strainer
447
Check Function of Accumulator for Control Circuit and Release Internal Pressure in Hydraulic Circuit
448
Method for Checking Alternator
451
Method for Checking and Adjusting Engine Valve Clearance
451
Method for Replacing Kccv Filter Element
452
Method for Replacing Def Filter
454
Every 4000 Hours Maintenance
457
Replace Defined Life Parts
457
Method for Checking Water Pump
457
Method for Checking Starting Motor
457
Method for Replacing Accumulator (for Control Circuit)
458
Method for Checking for Looseness of Engine High-Pressure Piping Clamp, Hard- Ening of Rubber
459
Every 4500 Hours Maintenance
460
Method for Replacing Radiator Cap
460
Method for Cleaning Kdpf
460
Method for Cleaning Def Tank
460
Method for Replacing Def Tank Filler Port Filter
460
Every 5000 Hours Maintenance
461
Method for Cleaning Fuel Doser
461
Check for Missing Fuel Spray Prevention Cap on Fuel Doser Piping, Hardening of Rubber
461
Method for Changing Oil in Hydraulic Tank
461
Every 8000 Hours Maintenance
463
Every 9000 Hours Maintenance
463
Method for Replacing Engine High-Pressure Piping Clamp
463
Method for Replacing Fuel Spray Prevention Cap
463
Method for Replacing Def Hose
463
Method for Replacing Fuel Spray Prevention Cap on Fuel Doser Piping
463
End of Service Life
463
Specifications
465
Explanation of Lift Capacity Chart (6.7M Boom)
467
Explanation of Lift Capacity Chart (7.1M Boom)
470
Attachments and Options
475
Precautions for Using Attachment and Options
476
Precautions When Selecting
476
Read the Operation and Maintenance Manual Thoroughly
476
Precautions When Removing and Installing
476
Precautions When Using
476
Quick Coupler System
478
Handling Quick Coupler
478
Automatic Grease System
482
Handling Automatic Grease System
482
Diagram of Automatic Greasing Points
483
System Operation
483
Changing the Grease Interval with the In-Cab Display
484
Indication on the In-Cab Display
484
Check Automatic Grease System
485
System Test
486
Handle Bucket with Hook
489
Precautions for Operation
489
Handle Machine Ready for Installation of Attachment
490
Explanation of Components on Machine Equipped with Attachment
490
Stop Valve
490
Selector Valve
491
Control Pedal
492
Method for Change-Over and Connect Hydraulic Circuit for Machine Ready for Installation of Attachment
495
Method for Removing and Installing Attachment
497
Method for Operating Attachment
501
Long-Term Storage
506
Maintenance of Additional Filter for Breaker
506
Specifications
510
Arm/Pin Information
511
Attachments and Options
512
Install Attachment
512
Rock Bucket Selection
513
Track Shoes Selection
514
Recommended Attachment Operations
515
Hydraulic Breaker
515
Replacement Parts
521
Periodic Replacement of Defined Life Parts
522
Defined Life Parts List
522
Consumable Parts
523
Recommended Fuel, Coolant, and Lubricant
525
Lubrication Chart
527
Use of Fuel, Coolant and Lubricants According to Ambient Temperature
528
Recommended Brands and Qualities Other than Komatsu Genuine Oils
529
Index
531
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