Komatsu PC490LC-11 Hydraulic Excavator Service Manual (FEN02769-00)

FOREWORD ……………………………………………………………………………………………………………………………………………………………. 
FIG No. PAGE
ENGINE CYLINDER HEAD AND ITS RELATED PARTS
Cylinder Head …………………………………………………………………………………………………………………………..(X-)
A- 
Cylinder Head Cover …………………………………………………………………………………………………………………(X-)
A- 
Head Cover Accessory ……………………………………………………………………………………………………………..(X-)
A- 
Air Intake Manifold …………………………………………………………………………………………………………………….(X-)
A- 
Air Cleaner ………………………………………………………………………………………………………………………………(X-)
B- 
Exhaust Manifold ………………………………………………………………………………………………………………………(X-)
A- 
Komatsu Variable Geometry Turbocharger (KVGT) ………………………………………………………………………(X-)
Mounting …………………………………………………………………………………………………………………………..A- 
Oil Piping …………………………………………………………………………………………………………………………..A- 
Water Piping ………………………………………………………………………………………………………………………A- 
Komatsu Diesel Particulate Filter (KDPF) Connector ………………………………………………………………A- 
EPC Piping ………………………………………………………………………………………………………………………..A- 
Heat Shield ………………………………………………………………………………………………………………………………(X-)
A- 
Exhaust Gas Re-circulation (EGR) Valve …………………………………………………………………………………….(X-)
Inner Parts, EGR Valve ……………………………………………………………………………………………………….A- 
EGR Valve and Cooler Mounting ………………………………………………………………………………………….A- 
Inner Parts, EGR Oil Pump ………………………………………………………………………………………………….A- 
EGR Piping and Cooler ……………………………………………………………………………………………………….A- 
EGR Cooler Piping and Air Vent …………………………………………………………………………………………..A- 
EGR Valve Lubricating Oil Piping …………………………………………………………………………………………A- 
Komatsu Closed Crankcase Ventilation (KCCV) …………………………………………………………………………..(X-)
Related Parts …………………………………………………………………………………………………………………….A- 
Komatsu Closed Crankcase Ventilation (KCCV) …………………………………………………………………………..(X-)
B- 
Damper ……………………………………………………………………………………………………………………………………(X-)
A- 
Komatsu Diesel Particulate Filter (KDPF) and SCR Assembly ………………………………………………………..(X-)
Komatsu Diesel Particulate Filter (KDPF) ………………………………………………………………………………B- 
Komatsu Diesel Particulate Filter (KDPF) Mounting ………………………………………………………………..B- 
SCR Assembly …………………………………………………………………………………………………………………..B- 
SCR Assembly Mounting …………………………………………………………………………………………………….B- 
AdBlue/DEF Mixing Tube …………………………………………………………………………………………………….B- 
AdBlue/DEF Supply System ………………………………………………………………………………………………………(X-)
B- 
ENGINE CYLINDER BLOCK AND ITS RELATED PARTS
Camshaft Related Parts …………………………………………………………………………………………………………….(X-)
Camshaft …………………………………………………………………………………………………………………………..A- 
Rocker Arm and Housing …………………………………………………………………………………………………….A- 
Cam Follower Cover ………………………………………………………………………………………………………………….(X-)
A- 
Front Cover Accessory ………………………………………………………………………………………………………………(X-)
A- 
Front Cover ……………………………………………………………………………………………………………………………..(X-)
A- 

Flywheel Housing ……………………………………………………………………………………………………………………..(X-)
A- 
Flywheel ………………………………………………………………………………………………………………………………….(X-)
A- 
Engine Oil Pan …………………………………………………………………………………………………………………………(X-)
A- 
Crank Pulley …………………………………………………………………………………………………………………………….(X-)
A- 
Engine Mounting ………………………………………………………………………………………………………………………(X-)
A- 
Cylinder Block ………………………………………………………………………………………………………………………….(X-)
A- 
Cylinder Block Accessory …………………………………………………………………………………………………………..(X-)
A- 
Crankshaft ……………………………………………………………………………………………………………………………….(X-)
A- 
Vibration Damper ……………………………………………………………………………………………………………………..(X-)
A- 
Piston and Connecting Rod ……………………………………………………………………………………………………….(X-)
A- 
Idler Gear ………………………………………………………………………………………………………………………………..(X-)
A- 
ENGINE LUBRICATION SYSTEM
Engine Oil Cooler Mounting ……………………………………………………………………………………………………….(X-)
A- 
Engine Oil Pump ………………………………………………………………………………………………………………………(X-)
A- 
Engine Oil Filter ………………………………………………………………………………………………………………………..(X-)
Oil Filter …………………………………………………………………………………………………………………………….A- 
Piping ……………………………………………………………………………………………………………………………….A- 
Engine Oil Cooler ……………………………………………………………………………………………………………………..(X-)
A- 
ENGINE FUEL SYSTEM
Fuel Supply Pump …………………………………………………………………………………………………………………….(X-)
Inner Parts, Pump ………………………………………………………………………………………………………………A- 
Inner Parts, Feed Pump ………………………………………………………………………………………………………A- 
Pump Mounting ………………………………………………………………………………………………………………….A- 
Common Rail …………………………………………………………………………………………………………………….A- 
Piping ……………………………………………………………………………………………………………………………….A- 
Fuel Supply Pump Drive ……………………………………………………………………………………………………………(X-)
A- 
Fuel Injection Nozzle …………………………………………………………………………………………………………………(X-)
A- 
Fuel Return ………………………………………………………………………………………………………………………………(X-)
A- 
Fuel Filter Cartridge …………………………………………………………………………………………………………………..(X-)
Service Only ………………………………………………………………………………………………………………………A- 
Fuel Filter ………………………………………………………………………………………………………………………………..(X-)
Fuel Filter and Piping ………………………………………………………………………………………………………….A- 
Priming Pump …………………………………………………………………………………………………………………….A- 
Priming Pump and Piping ……………………………………………………………………………………………………A- 
Timer Switch …………………………………………………………………………………………………………………………….(X-)
B- 
Fuel Supply Pump Bracket and Piping …………………………………………………………………………………………(X-)
Piping and Bracket ……………………………………………………………………………………………………………..A- 
Cover ………………………………………………………………………………………………………………………………..A- 

Fuel Prefilter Cartridge ………………………………………………………………………………………………………………(X-)
B- 
ENGINE COOLING SYSTEM
Water Pump Mounting and Air Vent …………………………………………………………………………………………….(X-)
A- 
Thermostat Housing ………………………………………………………………………………………………………………….(X-)
A- 
ENGINE ELECTRICAL SYSTEM
Alternator (Amp) ……………………………………………………………………………………………………………………(X-)
Inner Parts …………………………………………………………………………………………………………………………A- 
Related Parts …………………………………………………………………………………………………………………….A- 
Starting Motor (KW) ……………………………………………………………………………………………………………….(X-)
Inner Parts …………………………………………………………………………………………………………………………A- 
Mounting Parts …………………………………………………………………………………………………………………..A- 
Wiring Harness …………………………………………………………………………………………………………………………(X-)
(/) ………………………………………………………………………………………………………………………………….A- 
(/) ………………………………………………………………………………………………………………………………….A- 
Sensor and Wiring Harness Mounting …………………………………………………………………………………..A- 
ENGINE ACCESSORIES AND OTHERS
Water Drain Valve …………………………………………………………………………………………………………………….(X-)
A- 
Engine Controller (For North America EPA th Regulations) ………………………………………………………….(X-)
A- 
Engine Controller (For EU Exhaust Emissions th Regulations) ……………………………………………………..(X-)
A- 
ENGINE MARKS AND PLATES
Name Plate and Caution Plate (For North America EPA th Regulations) ………………………………………..(X-)
A- 
Name Plate and Caution Plate (For EU Exhaust Emissions th Regulations) …………………………………..(X-)
A- 
ENGINE RELATED PARTS
Engine Mounting Parts ………………………………………………………………………………………………………………(X-)
B- 
Air Cleaner ………………………………………………………………………………………………………………………………(X-)
Air Cleaner Related Parts ……………………………………………………………………………………………………B- 
Komatsu Closed Crankcase Ventilation (KCCV) Mounting ………………………………………………………B- 
Exhaust …………………………………………………………………………………………………………………………………..(X-)
Komatsu Diesel Particulate Filter (KDPF) and SCR Assembly Mounting ……………………………………B- 
Pipe and Hose ……………………………………………………………………………………………………………………B- 
SCR Piping ………………………………………………………………………………………………………………………..B- 
Tube and Bracket ……………………………………………………………………………………………………………….B- 
COOLING SYSTEM
Cooling System ………………………………………………………………………………………………………………………..(X-)
Radiator …………………………………………………………………………………………………………………………….C- 
Oil Cooler ………………………………………………………………………………………………………………………….C- 
Shroud (/) ………………………………………………………………………………………………………………………C- 
Aftercooler and Condenser ………………………………………………………………………………………………….C- 
Stay and Air Piping ……………………………………………………………………………………………………………..C- 
Reservoir Tank Piping …………………………………………………………………………………………………………C- 
Fan Motor (/) ………………………………………………………………………………………………………………….C- 
Fan Motor (/) ………………………………………………………………………………………………………………….C- 
Fan Motor (/) ………………………………………………………………………………………………………………….C- 
Fan Mounting …………………………………………………………………………………………………………………….C- 
Fan Motor Piping ………………………………………………………………………………………………………………..C- 
Guard ……………………………………………………………………………………………………………………………….C- 
Stay ………………………………………………………………………………………………………………………………….C- 
Sub-tank ……………………………………………………………………………………………………………………………C- 

Shroud (/) ………………………………………………………………………………………………………………………C- 
Cooling Fan Guard ……………………………………………………………………………………………………………………(X-)
C- 
FUEL SYSTEM
Fuel Tank ………………………………………………………………………………………………………………………………..(X-)
D- 
Fuel Supply Piping ……………………………………………………………………………………………………………………(X-)
Fuel Piping ………………………………………………………………………………………………………………………..D- 
Bracket and Clip …………………………………………………………………………………………………………………D- 
Prefilter Bracket ………………………………………………………………………………………………………………….D- 
Related Parts …………………………………………………………………………………………………………………….D- 
AdBlue/DEF Tank ……………………………………………………………………………………………………………………..(X-)
Tank and sensor ………………………………………………………………………………………………………………..D- 
Suction Tube ……………………………………………………………………………………………………………………..D- 
Tank Mounting …………………………………………………………………………………………………………………..D- 
AdBlue/DEF Piping ……………………………………………………………………………………………………………………(X-)
Suction and Return Piping …………………………………………………………………………………………………..D- 
Supply Module Mounting …………………………………………………………………………………………………….D- 
AdBlue/DEF Pressure Hose ………………………………………………………………………………………………..D- 
AdBlue/DEF Tank Coolant Piping (/) …………………………………………………………………………………D- 
AdBlue/DEF Tank Coolant Piping (/) …………………………………………………………………………………D- 
Dosing Module Coolant Hose ………………………………………………………………………………………………D- 
ELECTRICAL SYSTEM
Battery …………………………………………………………………………………………………………………………………….(X-)
E- 
Electric Wiring Harness ……………………………………………………………………………………………………………..(X-)
Starting Wiring Harness Clamp …………………………………………………………………………………………….E- 
Main Wiring Harness Clamp (/) …………………………………………………………………………………………E- 
Main Wiring Harness Clamp (/) …………………………………………………………………………………………E- 
Main Wiring Harness Clamp (/) …………………………………………………………………………………………E- 
Main Wiring Harness Clamp (/) …………………………………………………………………………………………E- 
Main Wiring Harness Clamp (/) …………………………………………………………………………………………E- 
Main Wiring Harness Clamp (/) …………………………………………………………………………………………E- 
Main Wiring Harness Clamp (/) …………………………………………………………………………………………E- 
Main Wiring Harness Clamp (/) …………………………………………………………………………………………E- 
Battery Cable for Disconnect Switch ……………………………………………………………………………………..E- 
Working Lamp ……………………………………………………………………………………………………………………E- 
Electric Priming Pump Switch ………………………………………………………………………………………………E- 
Horn ………………………………………………………………………………………………………………………………………..(X-)
E- 
Travel Alarm …………………………………………………………………………………………………………………………….(X-)
E- 
Rearview Camera ……………………………………………………………………………………………………………………..(X-)
E- 
HYDRAULIC SYSTEM
Hydraulic Tank …………………………………………………………………………………………………………………………(X-)
Tank …………………………………………………………………………………………………………………………………H- 
Breather Mounting ……………………………………………………………………………………………………………..H- 
Control Valve (With -service Valve) …………………………………………………………………………………………..(X-)
-spool (/) …………………………………………………………………………………………………………………….H- 
-spool (/) …………………………………………………………………………………………………………………….H- 
-spool (/) …………………………………………………………………………………………………………………….H- 
-spool (/) …………………………………………………………………………………………………………………….H- 
-spool (/) …………………………………………………………………………………………………………………….H- 
-spool (/) …………………………………………………………………………………………………………………….H- 
-spool (/) …………………………………………………………………………………………………………………….H- 
-spool (/) …………………………………………………………………………………………………………………….H- 

Suction Piping ………………………………………………………………………………………………………………………….(X-)
H- 
Delivery Piping …………………………………………………………………………………………………………………………(X-)
H- 
Oil Cooler Piping ………………………………………………………………………………………………………………………(X-)
H- 
Return Piping ……………………………………………………………………………………………………………………………(X-)
H- 
Return Piping (With -additional Actuator Piping, Accumulator) ………………………………………………………(X-)
H- 
Drain Piping ……………………………………………………………………………………………………………………………..(X-)
H- 
Boom Piping …………………………………………………………………………………………………………………………….(X-)
H- 
Arm and Bucket Piping ………………………………………………………………………………………………………………(X-)
Piping ……………………………………………………………………………………………………………………………….H- 
Clamp ……………………………………………………………………………………………………………………………….H- 
Attachment Piping (With -additional Actuator Piping, Accumulator) ……………………………………………….(X-)
Piping, L.H. ………………………………………………………………………………………………………………………..H- 
Piping, R.H. (/) ………………………………………………………………………………………………………………..H- 
Selector Valve ……………………………………………………………………………………………………………………H- 
Piping, R.H. (/) ………………………………………………………………………………………………………………..H- 
Return Filter ………………………………………………………………………………………………………………………H- 
Return Piping …………………………………………………………………………………………………………………….H- 
Accumulator ………………………………………………………………………………………………………………………H- 
Accumulator Mounting ………………………………………………………………………………………………………..H- 
Pilot Filter Mounting ……………………………………………………………………………………………………………H- 
Pilot Filter ………………………………………………………………………………………………………………………….H- 
Pilot Piping ………………………………………………………………………………………………………………………..H- 
Multi Control Pattern Unit (Control Pattern Change Over Valve (ISO/BACKHOE)) …………………………….(X-)
Control Pattern Change Over Valve ……………………………………………………………………………………..H- 
Piping ……………………………………………………………………………………………………………………………….H- 
Multi Control Pattern Unit (Control Pattern Change Over Valve (ISO/BACKHOE), With -additional
Actuator Piping, Accumulator) …………………………………………………………………………………………………….(X-)
Control Pattern Change Over Valve ……………………………………………………………………………………..H- 
Piping ……………………………………………………………………………………………………………………………….H- 
Travel Piping ……………………………………………………………………………………………………………………………(X-)
H- 
Swing Piping …………………………………………………………………………………………………………………………….(X-)
H- 
Fan Motor Piping ………………………………………………………………………………………………………………………(X-)
H- 
LS Piping …………………………………………………………………………………………………………………………………(X-)
H- 
LS Piping (With -additional Actuator Piping, Accumulator) ……………………………………………………………(X-)
H- 

Solenoid Valve …………………………………………………………………………………………………………………………(X-)
Inner Parts, Solenoid Valve …………………………………………………………………………………………………H- 
Accumulator ………………………………………………………………………………………………………………………H- 
Piping ……………………………………………………………………………………………………………………………….H- 
Solenoid Valve (-additional Actuator Piping, Accumulator) ……………………………………………………………(X-)
Inner Parts, Solenoid Valve …………………………………………………………………………………………………H- 
Accumulator ………………………………………………………………………………………………………………………H- 
Piping ……………………………………………………………………………………………………………………………….H- 
Pressure Switch Block ……………………………………………………………………………………………………………….(X-)
Block ………………………………………………………………………………………………………………………………..H- 
Slow Return Valve (/) ………………………………………………………………………………………………………H- 
Slow Return Valve (/) ………………………………………………………………………………………………………H- 
Valve Bracket …………………………………………………………………………………………………………………….H- 
Proportional Pressure Control (PPC) Travel Piping ……………………………………………………………………….(X-)
H- 
FRAME AND ITS RELATED PARTS
Revolving Frame (With Deck Guard) …………………………………………………………………………………………..(X-)
(/) ………………………………………………………………………………………………………………………………….J- 
(/) ………………………………………………………………………………………………………………………………….J- 
Boom Foot Pin ………………………………………………………………………………………………………………………….(X-)
J- 
OPERATOR’S COMPARTMENT AND CONTROL SYSTEM
Operator’s Seat ………………………………………………………………………………………………………………………..(X-)
(/) ………………………………………………………………………………………………………………………………….K- 
(/) ………………………………………………………………………………………………………………………………….K- 
Seat Belt ………………………………………………………………………………………………………………………………….(X-)
K- 
Floor Mat …………………………………………………………………………………………………………………………………(X-)
K- 
Floor Mat (-additional Actuator Piping, Accumulator) ……………………………………………………………………(X-)
K- 
Window Washer ……………………………………………………………………………………………………………………….(X-)
K- 
Air Conditioner Unit …………………………………………………………………………………………………………………..(X-)
Compressor ……………………………………………………………………………………………………………………….K- 
Compressor Mounting …………………………………………………………………………………………………………K- 
Receiver Tank ……………………………………………………………………………………………………………………K- 
Cooler Piping ……………………………………………………………………………………………………………………..K- 
Heater Piping Clamp …………………………………………………………………………………………………………..K- 
Cab (With Vandalism Protection) ………………………………………………………………………………………………..(X-)
Cab Body and Window ……………………………………………………………………………………………………….K- 
Front Window …………………………………………………………………………………………………………………….K- 
Front Lower Window …………………………………………………………………………………………………………..K- 
Roof Ventilator …………………………………………………………………………………………………………………..K- 
Door …………………………………………………………………………………………………………………………………K- 
Door Lock ………………………………………………………………………………………………………………………….K- 
Open Lock and Door Catch …………………………………………………………………………………………………K- 
Wiper and Room Lamp ……………………………………………………………………………………………………….K- 
Inner Parts, Rubber Antenna ……………………………………………………………………………………………….K- 
Speaker and Window Washer Hose ……………………………………………………………………………………..K- 
Roof Cover, Hanger, Drink Holder and Air Intake ……………………………………………………………………K- 
Grip ………………………………………………………………………………………………………………………………….K- 
KOMTRAX Antenna ……………………………………………………………………………………………………………K- 
KOMATSU Mark ………………………………………………………………………………………………………………..K- 
Cab In Parts, Monitor and Cover ………………………………………………………………………………………….K- 
Cab In Parts, Monitor Cover ………………………………………………………………………………………………..K- 
Cab In Parts, Washer Hose Mounting …………………………………………………………………………………..K- 

Cab In Parts, Luggage Plate and Cigarette Lighter …………………………………………………………………K- 
Cab In Parts, Air Duct …………………………………………………………………………………………………………K- 
Cab In Parts, Air Duct and Fresh Air Filter ……………………………………………………………………………..K- 
Cab In Parts, Partition and Recirculation Air Filter …………………………………………………………………..K- 
Cab In Parts, Pump Controller and Relay ………………………………………………………………………………K- 
Cab In Parts, Air Conditioner Controller …………………………………………………………………………………K- 
Cab In Parts, Main Wiring Harness Clamp …………………………………………………………………………….K- 
Cab In Parts, Rear Cover (/) …………………………………………………………………………………………….K- 
Cab In Parts, Rear Cover (/) …………………………………………………………………………………………….K- 
Controller and Monitor ………………………………………………………………………………………………………..K- 
Floor, Frame ………………………………………………………………………………………………………………………K- 
PPC Valve for Travel …………………………………………………………………………………………………………..K- 
Floor, Travel Control Lever ………………………………………………………………………………………………….K- 
Floor, Footrest, L.H. ……………………………………………………………………………………………………………K- 
Floor, Footrest, R.H. ……………………………………………………………………………………………………………K- 
Floor, Base ………………………………………………………………………………………………………………………..K- 
Wiring Harness …………………………………………………………………………………………………………………..K- 
Battery Cable …………………………………………………………………………………………………………………….K- 
Floor, Wiring Harness Clamp and Ground ……………………………………………………………………………..K- 
Floor, Window Washer Hose ……………………………………………………………………………………………….K- 
Floor, Work Equipment Control Lever, L.H. ……………………………………………………………………………K- 
PPC Valve for Work Equipment, L.H. ……………………………………………………………………………………K- 
Floor, PPC Valve Mounting for Work Equipment, L.H. …………………………………………………………….K- 
Floor, Console, L.H. ……………………………………………………………………………………………………………K- 
Floor, Radio and Work Equipment Lock Lever ……………………………………………………………………….K- 
Floor, Armrest, L.H. …………………………………………………………………………………………………………….K- 
Floor, Work Equipment Control Lever, R.H. …………………………………………………………………………..K- 
PPC Valve for Work Equipment, R.H. ……………………………………………………………………………………K- 
Floor, PPC Valve Mounting for Work Equipment, R.H. …………………………………………………………….K- 
Floor, Console, R.H. ……………………………………………………………………………………………………………K- 
Floor, Armrest, R.H. ……………………………………………………………………………………………………………K- 
Inner Parts, Air Conditioner Unit (/) ……………………………………………………………………………………K- 
Inner Parts, Air Conditioner Motor ………………………………………………………………………………………..K- 
Inner Parts, Air Conditioner Unit (/) ……………………………………………………………………………………K- 
Floor, Air Conditioner Mounting and Secondary Engine Stop Switch …………………………………………K- 
Floor, Air Conditioner Piping ………………………………………………………………………………………………..K- 
Floor, PPC Valve Piping for Travel ……………………………………………………………………………………….K- 
Floor, PPC Valve Piping for Work Equipment …………………………………………………………………………K- 
Floor, Piping Mounting ………………………………………………………………………………………………………..K- 
Floor, P, T Block …………………………………………………………………………………………………………………K- 
Floor, Seal …………………………………………………………………………………………………………………………K- 
Cab (With Vandalism Protection, -additional Actuator Piping, Accumulator) ……………………………………(X-)
Cab Body and Window ……………………………………………………………………………………………………….K- 
Front Window …………………………………………………………………………………………………………………….K- 
Front Lower Window …………………………………………………………………………………………………………..K- 
Roof Ventilator …………………………………………………………………………………………………………………..K- 
Door …………………………………………………………………………………………………………………………………K- 
Door Lock ………………………………………………………………………………………………………………………….K- 
Open Lock and Door Catch …………………………………………………………………………………………………K- 
Wiper and Room Lamp ……………………………………………………………………………………………………….K- 
Inner Parts, Rubber Antenna ……………………………………………………………………………………………….K- 
Speaker and Window Washer Hose ……………………………………………………………………………………..K- 
Roof Cover, Hanger, Drink Holder and Air Intake ……………………………………………………………………K- 
Grip ………………………………………………………………………………………………………………………………….K- 
KOMTRAX Antenna ……………………………………………………………………………………………………………K- 
KOMATSU Mark ………………………………………………………………………………………………………………..K- 
Cab In Parts, Monitor and Cover ………………………………………………………………………………………….K- and more

Pages: 546
Language: English
Format: PDF

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