Komatsu A40001 Operation & Maintenance Manual Download | Manualshive

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INTRODUCTION

PC490LC-10

0-17

MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

Maintenance Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Maintenance Interval for Hydraulic Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

MAINTENANCE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Initial 10 Hours Maintenance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-22
Initial 250 Hours Maintenance (Only After the First 250 Hours)  . . . . . . . . . . . . . . . . . . . . . . . . .  3-22
Initial 500 Hours Maintenance (Only After the First 500 Hours)  . . . . . . . . . . . . . . . . . . . . . . . . .  3-22
When Required   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-23

Check, Clean and Replace Air Cleaner Element  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-23
Clean Inside of Cooling System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-29
Check and Tighten Track Shoe Bolts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-35
Check and Adjust Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-36
Replace Bucket Teeth (Vertical Pin Type)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-38
Replace Bucket Teeth (Horizontal Pin Type)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-41
Replace Bucket Side Cutter, Shroud  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-43
Adjust Bucket Clearance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-44
Check Window Washer Fluid Level, Add Fluid  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-45
Check and Maintain Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-46
Wash Washable Floor   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-47
Set Machine at Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-49
Check Gas Spring   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-50
Bleeding Air from Hydraulic System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-51
Clean Line Filter, Remove Dirt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-53

Check Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Every 50 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Every 250 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Check Level of Battery Electrolyte  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-56
Check Air Conditioner Compressor Belt Tension, Adjust   . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-58
Check and Tighten Connecting Bolt Between Center Frame and Track Frame . . . . . . . . . . .  3-59
Lubricate Swing Circle   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-59

Every 500 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-60
Change Oil in Engine Oil Pan  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Replace Engine Oil Filter Cartridge   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-62
Replace Fuel Pre-filter Cartridge  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Check Swing Pinion Grease Level, Add Grease  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-65
Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins,
Fuel Cooler Fins, and Condenser Fins   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-66
Clean Air Conditioner Fresh/Recirc Filters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-68
Replace Breather Element in Hydraulic Tank  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-70
Check Oil Level in Swing Machinery Case, Add Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-71
Check Oil Level in Final Drive Case, Add Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-72

Every 1000 Hours Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73

Replace Hydraulic Oil Filter Element  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-73
Change Oil in Swing Machinery Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-74
Check Oil Level in Damper Case, Add Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-75
Replace Fuel Main Filter Cartridge  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-76
Check All Tightening Points of Engine Exhaust Pipe Clamps  . . . . . . . . . . . . . . . . . . . . . . . .  3-79

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Summary of Contents for A40001

Page 1: ...is our policy to improve our products whenever it is possible and practical to do so We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously Due to this continuous program of research and development revisions may be made to this publication It is recommended that customers contact their distributor for i...

Page 2: ...Find manuals at https best manuals com ...

Page 3: ...Find manuals at https best manuals com ...

Page 4: ...0 1 INTRODUCTION 0 PC490LC 10 Find manuals at https best manuals com ...

Page 5: ...r together with the machine If this manual is lost or damaged contact your distributor immediately to arrange for its replacement For details regarding the machine serial No you will need to provide your Komatsu distributor See Your Machine Serial Numbers and Distributor on page 0 9 Before beginning operation or maintenance operators and maintenance personnel must always observe the following poin...

Page 6: ...uation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Remark This word is used for precautions that must be taken to avoid actions which could shorten the life of the machine Safety precautions are described in SAFETY Section 1 ...

Page 7: ...iangle and the method of avoiding the hazardous condition is shown inside a circle Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance Therefore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used it ...

Page 8: ...ee RECOMMENDED APPLICATIONS on page 2 197 for further details Directions of Machine In this manual the terms front rear left and right refer to the travel direction as seen from the operator s seat when the operator s seat is facing the front and the sprocket is at the rear of the machine A Front C Left E Operator s Seat B Rear D Right F Sprocket Find manuals at https best manuals com ...

Page 9: ...12 m The figure below shows visibility on the machine at a circumference of a 12 m radius Shaded area A in the figure shows an area whose view is blocked when the machine is equipped with the mirrors and other visibility assistant devices Operate the machine with enough awareness that the machine has a dead angle in which an operator cannot see Structure to Protect the Operator This machine is equ...

Page 10: ...d on the service meter Make sure that you fully understand the content of this manual and pay careful attention to the following points when breaking in the machine Run the engine at idle for 15 seconds after starting it During this time do not operate the control levers or fuel control dial Idle the engine for five minutes after starting it up Avoid operation with heavy loads or at high speeds Im...

Page 11: ... following items Product Identification Number Pin Machine Serial No Plate The plate is located on the bottom right of the operator s cab The design of the nameplate differs according to the territory EPA Regulations Engine Number Plate The plate is located on the top side of the engine cylinder head cover EPA Environmental Protection Agency U S A ...

Page 12: ...hine Serial Numbers and Distributor Engine Acronyms Machine serial No Engine serial No Product identification number PIN Distributor name Address Service Personnel Phone Fax Acronym Stands for KDPF Komatsu Diesel Particulate Filter KVGT Komatsu Variable Geometry Turbo KCCV Komatsu Closed Crankcase Ventilation ...

Page 13: ...rting Operation 1 13 Ensuring Safe Operation 1 13 Understanding the Machine 1 13 Preparations for Safe Operation 1 13 Precautions Regarding Safety related Equipment 1 13 Inspecting Machine 1 13 Clothing and Personal Protective Items 1 13 Keep Machine Clean 1 14 Keep Operator s Compartment Clean 1 14 Fire Extinguisher and First Aid Kit 1 14 Safety Equipment 1 14 If Problems are Found 1 14 Fire Prev...

Page 14: ...s on Snow or Frozen Surfaces 1 32 Parking Machine 1 32 TRANSPORTATION 1 33 Loading and Unloading 1 33 Shipping the Machine 1 33 TOWING 1 34 Safety Rules for Towing 1 34 LIFTING OBJECTS WITH BUCKET 1 35 Safety Rules for Lifting Objects 1 35 SAFETY MAINTENANCE INFORMATION 1 36 Warning Tag 1 36 Keep Work Place Clean and Tidy 1 36 Select Suitable Place for Inspection and Maintenance 1 36 Only Authoriz...

Page 15: ...eriodic Replacement Of Safety Critical Parts 1 46 MACHINE VIEW ILLUSTRATIONS 2 2 Overall Machine View 2 2 General View of Cab 2 4 CONTROLS AND GAUGES 2 5 Machine Monitor 2 6 EXPLANATION OF COMPONENTS 2 7 Machine Monitor 2 7 Basic Operation of Machine Monitor 2 8 Warning Display 2 13 Meter Display 2 23 Gauges and Meter 2 30 Monitor Switches Portion 2 33 User Menu Selector Switch 2 46 User Menu 2 47...

Page 16: ...the Cover 2 95 Lock and Unlock Engine Hood 2 95 Opening the Hood Locked Hood 2 95 Locking the Hood 2 95 Lock and Unlock Cab Door 2 96 Opening the Door Locked Door 2 96 Locking the Door 2 96 DRINK BOX 2 97 MAGAZINE BOX 2 97 CUP HOLDER 2 97 ASHTRAY 2 98 AIR CONDITIONER CONTROLS 2 99 Air Conditioner Control Panel 2 99 Method of Operation 2 104 Automatic Operation 2 104 Stopping Automatic Operation 2 ...

Page 17: ... 2 131 Re enabling KDPF Regeneration 2 132 Handling Komatsu Closed Crankcase Ventilation KCCV 2 132 HANDLING MACHINES EQUIPPED WITH KOMTRAX 2 133 Basic Precautions 2 134 MACHINE OPERATIONS AND CONTROLS 2 135 Before Starting Engine 2 135 Walk around Checks 2 135 Checks Before Starting 2 137 Adjustment 2 144 Seat Belt Inspection 2 153 Seat Belt 2 154 Operations Before Starting Engine 2 155 STARTING ...

Page 18: ...T AND INVERSION 2 199 Replacement 2 199 Inversion 2 201 PARKING MACHINE 2 203 MACHINE INSPECTION AFTER DAILY WORK 2 205 LOCKING 2 205 TRANSPORTATION 2 205 Transportation Procedure 2 205 Loading and Unloading with Trailer 2 206 Loading 2 207 Securing Machine 2 210 Stowing Radio Antenna 2 212 Installation and Removal of Mirrors 2 212 Remove and Install Handrail 2 214 Unloading 2 215 LIFTING MACHINE ...

Page 19: ... 2 OUTLINE OF SERVICE 3 4 Handling Oil Fuel Coolant and Performing Oil Clinic 3 4 Oil 3 4 Fuel 3 5 Coolant and Water for Dilution 3 5 Grease 3 6 Carrying Out KOWA Komatsu Oil Wear Analysis 3 6 Storing Oil and Fuel 3 7 Filters 3 7 Electric System Maintenance 3 7 WEAR PARTS 3 8 Wear Parts List 3 8 RECOMMENDED FUEL COOLANT AND LUBRICANT 3 9 Lubrication Chart 3 9 Fuel Coolant and Lubricants to Match t...

Page 20: ...t 3 53 Check Before Starting 3 54 Every 50 Hours Maintenance 3 55 Lubricating 3 55 Every 250 Hours Maintenance 3 56 Check Level of Battery Electrolyte 3 56 Check Air Conditioner Compressor Belt Tension Adjust 3 58 Check and Tighten Connecting Bolt Between Center Frame and Track Frame 3 59 Lubricate Swing Circle 3 59 Every 500 Hours Maintenance 3 60 Lubricating 3 60 Change Oil in Engine Oil Pan 3 6...

Page 21: ...ticulate Filter KDPF 3 92 Clean Fuel Doser 3 92 Check for Missing Fuel Spray Prevention Cap of Fuel Doser Piping Hardening of Rubber 3 92 Every 5000 Hours Maintenance 3 93 Change Oil in Hydraulic Tank 3 93 Every 8000 Hours Maintenance 3 95 Replace Fuel Spray Prevention Cap 3 95 Replace High pressure Piping Clamp 3 95 EVERY 9000 HOURS MAINTENANCE 3 95 Replacement of Fuel Spray Prevention Cap of Fue...

Page 22: ...chment Guide 5 29 Attachment Combinations 5 29 TRACK SHOES SELECTION 5 31 Selection Method of Track Shoe 5 31 HANDLING COUNTERWEIGHT REMOVER 5 32 Explanation of Components 5 32 Counterweight 5 32 Remover Link 5 32 Remover Link Cylinder 5 32 Counterweight Remover Control Lever 5 33 Remover Control Selector Valve 5 33 Operation of Counterweight Remover 5 34 Lowering Counterweight 5 35 Installing Cou...

Page 23: ...INTRODUCTION 0 20 PC490LC 10 MEMORANDUM ...

Page 24: ...d and make sure that you fully understand the precautions described in this manual and the safety labels on the machine Read and follow all safety precautions Failure to do so may result in serious injury or death PC490LC 10 ...

Page 25: ...nd always keep them clean When cleaning them do not use organic solvents or gasoline These may cause the labels to peel off There are also other labels in addition to the warning signs and safety labels Handle those labels in the same way If the labels are damaged lost or cannot be read properly replace them with new ones For details of the part numbers for the labels see this manual or the actual...

Page 26: ... To prevent SEVERE INJURY or DEATH do the following before moving machine or its attachments Honk horn to alert people nearby Be sure no one is on or near machine or in swing area Rotate cab for full view of travel path if it can be done safety Use spotter if view is obstructed Follow above even if machine is equipped with travel alarm and mirrors 3 Caution for leaving operator s seat 09654 03001 ...

Page 27: ...ments are not kept safe distance away from electric lines 5 Caution for operating pattern 09822 03000 WARNING In order to prevent an accident resulting in injury or death caused by error operation confirm the machine motion and indicated operating pattern when operating machine Pay attention to the circumference and operate slowly when confirming the machine motion ...

Page 28: ...rious injury 7 Caution when stowing front window 09803 03000 WARNING When raising window lock it in place with lock pins on both sides Falling window can cause injury 8 Caution for high temperature hydraulic oil 09653 03001 WARNING Hot oil hazard To prevent hot oil from spurting out Turn engine off Allow oil to cool Slowly loosen cap to relieve pressure before removing 9 Caution with high temperat...

Page 29: ...urning lubricator further could cause lubricator and grease to fly off and hurt you When loosening track shoe if it does not loosen after turning lubricator ONE TURN ask Komatsu dealer or distributor to disassemble 12 Caution when handling cable 09808 03000 WARNING Improper use of booster cables and battery cables can cause an explosion resulting in serious injury or death Follow instructions in m...

Page 30: ...UTION NEVER be on this hood 16 Warning when swinging or traveling in reverse 22B 00 21290 WARNING When swing or backing up excavator press button to change display mode in monitor so you can see rear and side of machine Before moving look around and at mirror and monitor to confirm that no one is around the machine Failure to do so can result in serious injury or death 17 Prohibited to enter swing...

Page 31: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com ...

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