Komatsu Hydraulic Excavator PC450, PC450LC, PC450HD Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC450-6, PC450LC-6, PC450LC-8, PC450HD-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC450-6, PC450LC-6, PC450LC-8, PC450HD-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,943 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEBM0076012 - Hydraulic Excavator PC450LC-8 Shop Manual.pdf
UEBM000100 - Hydraulic Excavator PC450-6, PC450LC-6 Shop Manual.pdf
CEBM007602 - Hydraulic Excavator PC450LC-8, PC450HD-8 Shop Manual.pdf
CEAM021901 - Hydraulic Excavator PC450LC-8 Operation & Maintenance Manual.pdf
UEAM007200 - Hydraulic Excavator PC450-8, PC450LC-8 Operation & Maintenance Manual.pdf
MAIN SECTIONS
CEAM021901 - Hydraulic Excavator PC450LC-8 Operation & Maintenance Manual....2
COVER....2
INTRODUCTION....4
FOREWORD....5
SAFETY INFORMATION....6
INTRODUCTION....8
Directions Of Machine....8
Visibility From Operator's Seat....9
Proximity Visibility....9
12 m Circumference Visibility....10
Breaking-in The New Machine....11
Product Information....12
Product Identification Number (PIN)/machine Serial No. Plate....12
EPA Regulations, Engine Number Plate....12
Service Meter Location....13
Your Machine Serial Numbers And Distributor....13
TABLE OF CONTENTS....14
SAFETY....22
SAFETY AND WARNING DECALS....23
Location Of The Safety Decals....23
Safety Labels....24
Optional Systems Decal....30
Optional Decal Locations....33
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....34
Precautions Before Starting Operation....34
Ensuring Safe Operation....34
Understanding The Machine....34
Preparations For Safe Operation....34
Precautions Regarding Safety-related Equipment....34
Inspecting Machine....34
SAFETY INFORMATION....34
Safety Rules....34
If Problems Are Found....35
Working Wear And Personal Protective Items....35
Fire Extinguisher And First Aid Kit....35
Safety Equipment....36
Keep Machine Clean....36
Keep Operator's Compartment Clean....36
Leaving Operator's Seat With Lock....36
Handrails And Steps....37
Precautions When Working In High Places....37
Mounting And Dismounting....37
No Persons On Attachments....37
Do Not Get Caught In Articulated Portion....38
Burn Prevention....38
Protection Against Falling Or Flying Objects....38
Fire Prevention And Explosion Prevention....39
Action If Fire Occurs....40
Windshield Washer Fluid....40
Falling Objects, Flying Objects And Intruding Objects Prevention....40
Attachment Installation....41
Attachment Combinations....41
Cab Window Glasses....41
Unauthorized Modifications....41
Safety At Jobsite....41
Working On Loose Ground....42
Distance To High Voltage Cables....43
Ensure Good Visibility....43
Ventilation For Enclosed Area....44
Signalman's Signal And Signs....44
Emergency Exit From Operator's Cab....44
Asbestos Dust Hazard Prevention....44
SAFETY MACHINE OPERATION....45
Starting Engine....45
Checks Before Starting Engine....45
Safety Rules For Starting Engine....46
Starting Engine In Cold Weather....46
OPERATION....47
Checks Before Operation....47
Safety Rules For Changing Machine Directions....47
Safety Rules For Traveling....48
Traveling On Slopes....48
Operations On Slopes....49
Prohibited Operations....50
Operations On Snow....51
Parking Machine....52
TRANSPORTATION....53
Loading And Unloading....53
Shipping The Machine....53
BATTERY....54
Battery Hazard Prevention....54
Starting Engine With Booster Cables....55
TOWING....56
Safety Rules For Towing....56
LIFTING OBJECTS WITH BUCKET....56
Safety Rules For Lifting Objects....56
SAFETY MAINTENANCE INFORMATION....57
Warning Tag....57
Keep Work Place Clean And Tidy....57
Appoint Leader When Working With Others....57
Stop Engine Before Carrying Out Maintenance....58
Two Workers For Maintenance When Engine Is Running....59
Proper Tools....59
Accumulator, Gas Spring....60
Personnel....60
Attachments....60
Work Under The Machine....60
Noise....60
When Using Hammer....61
Welding Works....61
Removing Battery Terminals....61
Safety First When Using High-pressure Grease To Adjust Track Tension....61
Do Not Disassemble Recoil Springs....62
Safety Rules For High-pressure Oil....62
Precaution For High Fuel Pressure....62
Safety Handling High-pressure Hoses....63
Precaution For High Voltage....63
Waste Materials....63
Air Conditioner Maintenance....64
Compressed Air....64
Periodic Replacement Of Safety Critical Parts....64
OPERATION....66
MACHINE VIEW ILLUSTRATIONS....67
OVERALL MACHINE VIEW....67
Controls And Gauges....68
Machine Monitor....69
DETAILED CONTROLS AND GAUGES....70
Monitoring System....70
Basic Operation Of Machine Monitor....71
Emergency Monitors....76
Caution Monitors....78
Basic Check Monitors....80
Meter Display Portion....82
Gauges And Meter....86
Monitor Switches Portion....90
Maintenance Selector Switch....106
SWITCHES....138
CONTROL LEVERS AND PEDALS....143
SUN ROOF....146
WINDSHIELD....146
EMERGENCY ESCAPE HAMMER....153
DOOR LOCK....153
CAP WITH LOCK....154
DRINK BOX....156
MAGAZINE BOX....156
ASHTRAY....156
AIR CONDITIONER CONTROLS....157
Air Conditioner Control Panel....157
Method Of Operation....162
Automatic Operation....162
Stopping Automatic Operation....163
Manual Operation....163
Stopping Manual Operation....165
Operation With Cold Air To Face And Warm Air To Feet....165
Defroster Operation....167
RADIO....170
Control Panel....170
Controls Of Radio....172
AUXILIARY ELECTRIC POWER....175
24v Power Source....175
12v Power Source....175
FUSE....176
FUSIBLE LINK....177
CONTROLLER....177
TOOL BOX....178
GREASE PUMP HOLDER....178
FIRE EXTINGUISHER....178
MACHINE OPERATIONS AND CONTROLS....179
Before Starting Engine....179
Walk-around Checks....179
Checks Before Starting....181
Adjustment....187
Seat Adjustment....187
Adjusting Angle Of Rear View Camera....189
Rear View Mirrors....191
Seat Belt....194
Operations Before Starting Engine....195
Starting Engine....197
After Starting Engine....200
Breaking-in the New Machine....200
Engine Warm Up....201
Hydraulic System Warm-up....203
Operation After Completion Of Warming-up Operation....209
Stopping The Engine....211
MACHINE OPERATION....212
Preparations For Moving The Machine....212
Moving Machine Forward....213
Moving Machine Backward....214
Stopping Machine....215
Steering The Machine....216
Swinging....218
Work Equipment Controls And Operations....219
Working Mode....221
Prohibited Operations....223
General Operation Information....228
Traveling On Slopes....230
Escape From Mud....232
Recommended Applications....233
BUCKET REPLACEMENT AND INVERSION....235
Replacement....235
Inversion....237
PARKING MACHINE....239
MACHINE INSPECTION AFTER DAILY WORK....241
Locking....241
TRANSPORTATION....242
Transportation Procedure....242
Long Distance Transport Mode....243
Normal Mode Display....243
Long Distance Transport Mode Display....243
Loading And Unloading With Trailer....245
Loading....246
Securing Machine....249
Unloading....252
LIFTING MACHINE....254
TRANSPORTATION POSTURE....256
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....259
COLD WEATHER OPERATION....261
AFTER DAILY WORK COMPLETION....263
AFTER COLD WEATHER SEASON....263
LONG TERM STORAGE....264
Before Storage....264
During Storage....264
After Storage....265
Starting Machine After Long-Term Storage....265
TROUBLES AND ACTIONS....266
Running Out Of Fuel....266
Phenomena That Are Not Failures....267
Towing The Machine....268
Lightweight Towing Hole....269
Severe Job Condition....269
Discharged Battery....270
Starting Engine With Booster Cables....272
OTHER TROUBLE....274
Electrical System....274
Chassis....275
Engine....276
Electronic Control System....277
MAINTENANCE....280
MAINTENANCE INFORMATION....281
OUTLINE OF SERVICE....283
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....283
Oil....283
Fuel....284
Coolant And Water For Dilution....284
Grease....285
Carrying Out KOWA (Komatsu Oil Wear Analysis)....285
KOWA Analysis Items....285
Oil Sampling....286
Storing Oil And Fuel....286
Filters....286
Electric System Maintenance....286
WEAR PARTS....287
Wear Parts List....287
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....288
TIGHTENING TORQUE SPECIFICATIONS....291
Tightening Torque List....291
SAFETY CRITICAL PARTS....292
Safety Critical Parts List....292
MAINTENANCE SCHEDULE....293
Maintenance Schedule Chart....293
Maintenance Interval For Hydraulic Breaker....295
MAINTENANCE PROCEDURE....296
Initial 1000 Hours Maintenance (Only After The First 1000 Hours)....296
When Required....297
Check, Clean And Replace Air Cleaner Element....297
Clean Inside Of Cooling System....303
Check And Tighten Track Shoe Bolts....307
Check And Adjust Track Tension....308
Replace Bucket Teeth (Vertical Pin Type)....310
Replace Bucket Teeth (Horizontal Pin Type)....313
Replace Bucket Side Cutter, Shroud....315
Adjust Bucket Clearance....316
Check Window Washer Fluid Level, Add Fluid....317
Check And Maintenance Air Conditioner....318
Wash Washable Floor....319
Check Gas Spring....322
Bleeding Air From Hydraulic System....323
Check Before Starting....325
Every 50 Hours Maintenance....326
Lubricating....326
Every 250 Hours Maintenance....327
Lubricate Swing Circle....327
Check Oil Level In Swing Machinery Case, Add Oil....328
Check Oil Level In Final Drive Case, Add Oil....329
Check Level Of Battery Electrolyte....330
Check Fan Belt, Alternator Belt Tension, Adjust....332
Check Air Conditioner Compressor Belt Tension, Adjust....333
Every 500 Hours Maintenance....334
Lubricating....334
Replace Fuel Pre-filter Cartridge....336
Check Swing Pinion Grease Level, Add Grease....338
Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge....339
Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins And Condenser Fins....341
Clean Air Conditioner Fresh/recirc Filters....343
Replace Breather Element In Hydraulic Tank....344
Every 1000 Hours Maintenance....345
Replace Fuel Main Filter Cartridge....345
Replace Hydraulic Oil Filter Element....348
Change Oil In Swing Machinery Case....349
Check Oil Level In Damper Case, Add Oil....350
Check All Tightening Points Of Engine Exhaust Pipe Clamps....350
Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)....350
Replace Hydraulic Tank Additional Breather Element....351
Replace Corrosion Resistor Cartridge (If Equipped)....352
Every 2000 Hours Maintenance....353
Change Oil In Final Drive Case....353
Clean Hydraulic Tank Strainer....354
Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)....355
Checking Function Of Accumulator....356
Releasing Pressure In Hydraulic Circuit....358
Check Alternator....359
Check Engine Valve Clearance, Adjust....359
Check Vibration Damper....359
Every 4000 Hours Maintenance....360
Check Water Pump....360
Check Starting Motor....360
Replace Accumulator (For Control Circuit)....360
Check For Looseness Of High-pressure Piping Clamp, Hardening Of Rubber....361
Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber....361
Every 5000 Hours Maintenance....362
Change Oil In Hydraulic Tank....362
Every 8000 Hours Maintenance....364
Replace High-pressure Piping Clamp....364
Replace Fuel Spray Prevention Cap....364
SPECIFICATIONS....366
SPECIFICATIONS....367
OPTIONS, ATTACHMENTS....370
GENERAL PRECAUTIONS FOR SAFETY....371
Precautions When Selecting....371
Read The Instruction Manual Thoroughly....371
Precautions When Removing Or Installing....371
Precautions When Using....371
BUCKET WITH HOOK....372
Hook Condition....372
Prohibited Operations....372
MACHINE READY FOR ATTACHMENT....373
Locations....373
ATTACHMENT REMOVAL AND INSTALLATION....383
Attachment Removal....383
Attachment Installation....385
ATTACHMENT OPERATIONS....387
Long Term Storage....388
Specifications....388
ATTACHMENT GUIDE....389
Attachment Combinations....389
Track Shoes Selection....391
Selecting Shoes....391
RECOMMENDED ATTACHMENT OPERATIONS....392
Hydraulic Breaker....392
HANDLING MACHINES EQUIPPED WITH KOMTRAX....397
CEBM0076012 - Hydraulic Excavator PC450LC-8 Shop Manual....398
CEBM007602 - PC450LC-8 sn A10001 and up....398
CONTENTS....399
REVISED PAGES....400
SAFETY....410
Safety Notice....410
Important Safety Notice....410
General Precautions....410
Preparations For Work....410
Precautions During Work....410
GENERAL....413
HOW TO READ THE SHOP MANUAL....414
Volumes....414
Distribution And Updating....414
Filing Method....414
Revised Edition Mark....414
Revisions....414
Symbols....414
HOISTING INSTRUCTIONS....415
Hoisting....415
Wire Ropes....415
PUSH PULL COUPLER....416
Type 1....416
Disconnection....416
Connection....416
Type 2....417
Disconnection....417
Connection....417
Type 3....418
Disconnection....418
Connection....418
EXPLANATION OF MAINTENANCE STANDARD TERMS....419
STANDARD TIGHTENING TORQUE....421
Bolts And Nuts....421
Tightening Torque Of Hose Nuts....422
Tightening Torque Of Split Flange Bolts....422
Tightening Torque For Flared Nuts....422
Tightening Torques For O-ring Boss Piping Joints....423
Table Of Tightening Torques For O-ring Boss Plugs....423
Torque Table For Hoses (Taper Seal Type And Face Seal Type)....423
ELECTRIC WIRE CODE....424
Classification By Thickness....424
Classification By Color And Code....424
How To Read Electric Wire Code....425
CONVERSION TABLES....428
Method Of Using The Conversion Table....428
COATING MATERIALS....434
01 GENERAL....436
SPECIFICATION DIMENSION DRAWINGS....437
Dimensions....437
Working Ranges....438
SPECIFICATIONS....439
WEIGHT TABLE....443
FUEL, COOLANT AND LUBRICANTS....445
Lubrication Chart....447
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD....448
ENGINE AND COOLING SYSTEM....451
Engine Related Parts....451
Radiator, Oil Cooler and Aftercooler....452
POWER TRAIN....454
Power Train....454
Final Drive....455
Sprocket....457
Swing Machinery....459
Swing Circle....461
UNDERCARRIAGE AND FRAME....463
Track Frame and Recoil Spring....463
Idler....465
Carrier Roller....467
Track Roller....469
Track Shoe....471
Triple Grouser Shoe....473
HYDRAULIC SYSTEM....475
Hydraulic Piping Drawing....475
Hydraulic Tank and Filter....477
Hydraulic Pump....479
LS Valve....485
PC Valve....490
LS(PC)-EPC Valve....498
Variable Volume Valve....501
Control Valve....503
CLSS (Closed Center Load Sensing System)....515
Functions and Operation by Valve....519
Unload Valve....521
LS Bypass Valve....524
Pressure Compensation Valve....525
Pressure Compensation Valve Inner Shuttle Valve....528
Boom Regeneration Circuit....530
Arm Regeneration Circuit....532
Merge-Divider Valve....534
LS Select Valve....536
Self Pressure Reducing Valve....537
Travel Junction Valve....540
Travel PPC Shuttle Valve....542
Boom Drift Preventive Valve....544
Arm Drift Preventive Valve....547
Quick Return Valve....551
Lift Check Valve....553
Main Relief Valve....554
2-Stage Safety-Suction Valve....555
Variable Pressure Compensation Valve....557
Attachment Circuit Selector Valve....559
Holding Valve....561
Valve Control....566
PPC Valve....567
Travel PPC Valve....573
Service PPC Valve (With EPC Valve)....583
Solenoid Valve....585
PPC Accumulator....587
Return Oil Filter....588
Center Swivel Joint....589
Travel Motor....591
Brake Valve....599
Swing Motor....605
Reverse Prevention Valve....611
Hydraulic Cylinder....615
Boom Cylinder....615
Arm Cylinder....615
Bucket Cylinder....615
WORK EQUIPMENT....617
Work Equipment....617
Dimensions Of Components....619
Dimension Of Arm....619
Dimension Of Bucket....621
AIR CONDITIONER PIPING....623
ELECTRICAL SYSTEM....624
Engine Control....624
Fuel Control Dial....626
Engine Controller....627
Sensors....631
Rotation Sensor....631
Oil Pressure Switch....631
Ambient Pressure Sensor....632
Boost Pressure Sensor....632
Boost Temperature Sensor....633
Coolant Temperature Sensor....633
Hydraulic Oil Temperature Sensor....633
EGR Valve Stroke Sensor....634
Engine Oil Level Sensor....635
ELECTRONIC CONTROL SYSTEM....636
Engine And Pump Composite Control Function....639
Pump and Valve Control....645
2-Stage Relief Function....646
Power Maximizing and Machine Push-up....647
Auto-Deceleration....649
Auto-Warm-Up and Overheat Prevention....651
Swing Control....653
Travel Control....655
Attachment Flow Control and Circuit Selector....657
System Component Parts....658
PPC Oil Pressure Switch....658
Oil Pressure Sensor....659
Pump Pressure Sensor (High Pressure)....660
Pump Controller....661
MONITOR SYSTEM....664
Machine Monitor....665
Monitor Control, Display Portion....669
Monitor Items And Display....671
Switches....675
Komtrax Logic....686
Sensors....693
KOMTRAX TERMINAL SYSTEM....696
Komtrax Communication Modem - TH300....697
20 STANDARD VALUE TABLES....700
STANDARD VALUE TABLES....701
Engine Related....701
Chassis Related....702
30 TESTING AND ADJUSTING....710
SERVICE TOOLS....712
Sketches of Special Tools....717
ENGINE....718
Engine Speed....718
Air Boost Pressure....720
Exhaust Temperature....721
Exhaust Gas Color....722
Valve Clearance....724
Compression Pressure....726
Blow-By Pressure....729
Engine Oil Pressure....730
EGR Valve Drive Pressure....731
Handling Fuel System Parts....732
Releasing Residual Pressure From Fuel System....732
Fuel Pressure....733
Cylinder Cut-Out Operation....734
No Injection Cranking Operation....734
Fuel Return Rate and Leakage....735
Bleeding Air from Fuel Circuit....738
Fuel Circuit, Checking for Leakage....740
FAN BELT AND ALTERNATOR BELT TENSION....741
AIR CONDITIONER COMPRESSOR BELT TENSION....742
SWING CIRCLE BEARING CLEARANCE....743
TRACK SHOE TENSION....744
OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....745
CONTROL CIRCUIT - BASIC PRESSURE....751
PUMP PC CONTROL CIRCUIT....752
PUMP LS CONTROL CIRCUIT....756
SOLENOID VALVE - OUTPUT PRESSURE....761
PPC VALVE - OUTPUT PRESSURE....764
WORK EQUIPMENT PPC VALVE AND SWING PPC VALVE - PLAY ADJUSTMENT....766
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE....767
HYDRAULIC CIRCUIT - RELEASING REMAINING PRESSURE....769
Oil Leakage Measurement....770
BLEEDING AIR FROM VARIOUS PARTS....773
MACHINE MONITOR - SPECIAL FUNCTIONS....776
Ordinary Functions and Special Functions of Machine Monitor....778
Operator Mode (Outline)....780
Display of Komatsu Logo....781
Display of Inputting Password....781
Display of Check of Breaker Mode....782
Display of Check Before Starting....782
Display of Warning after Check Before Starting....782
Display of Ending of Maintenance Interval....783
Display of Check of Working Mode and Travel Speed....783
Display of Ordinary Screen....783
Display of End Screen....784
Selection of Auto-Deceleration....784
Selection of Working Mode....784
Selection of Travel Speed....785
Operation to stop Alarm Buzzer....785
Operation of Windshield Wiper....786
Operation of Window Washer....786
Operation of Air Conditioner/Heater....786
Operation to Display Camera Mode (If camera is installed)....787
Operation to Display Clock and Service Meter....788
Check of Maintenance Information....788
Setting and Display of User Mode....788
KOMTRAX Message....789
Display of Energy-Saving Guidance....789
Display of Caution Monitor....789
Display of Automatic Judgment of Breaker....790
Display of User Code and Failure Code....790
Function of Checking Display of LCD (Liquid Crystal Display)....792
Function of Checking Service Meter....792
Function of Changing Attachment/Maintenance Password....793
Service Mode....796
Monitoring....798
Abnormality Record (Mechanical Systems)....802
Abnormality Record (Electrical Systems)....803
Abnormality Record (Air-Conditioning System/Heater System)....809
Maintenance Record....810
Maintenance Mode Change....811
Phone Number Entry....814
Default (Key-On Mode)....815
Default (Unit)....816
Default (With/Without Attachment)....817
Default (Attachment/Maintenance Password)....818
Default (Camera)....819
Default (ECO Display)....820
Default (Breaker Detect)....822
Adjustment (Pump Absorption Torque (F))....823
Adjustment (Low Speed)....824
Adjustment (Attachment Flow Adjustment)....825
Determining a Defective Cylinder....826
Cylinder Cut-Out....827
No Injection....828
Fuel Consumption....830
KOMTRAX Settings (Terminal Status)....831
Long Distance Transport Mode....832
KOMTRAX Settings (GPS & Communication Status)....834
KOMTRAX Setting (Modem S/N: TH300)....835
Display of KOMTRAX Message....836
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER....837
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM....838
DIODE INSPECTION PROCEDURES....843
PM CLINIC SERVICE....844
40 TROUBLESHOOTING....854
FAILURE CODES TABLE....858
FUSE LOCATIONS....861
Connection Table of Fuse Box....861
Location of Fuse Box and Fuse Numbers....862
GENERAL INFORMATION....865
Points to Remember when Troubleshooting....865
Sequence of Events in Troubleshooting....867
Handling Electric Equipment and Hydraulic Components....868
Connectors newly used for Tier 3 Engines....876
Checks before Troubleshooting....880
Classification and Troubleshooting Steps....881
Classification of Troubleshooting....881
Information in Troubleshooting Table....883
Possible Problems and Troubleshooting No....885
Connection Table for Connector Pin Numbers....888
T-adapter Box and T-adapter Table....923
FAILURE CODE (DISPLAY OF CODE)....926
989L00 - Engine Controller Lock Caution 1....926
989M00 - Engine Controller Lock Caution 2....926
989N00 - Engine Controller Lock Caution 3....927
AA10NX - Air Cleaner Clogging....929
AB00KE - Charge Voltage Low....931
B@BAZG - Engine Oil Pressure Low....933
B@BAZK - Engine Oil Level Low....935
B@BCNS - Engine Coolant Overheat....937
B@BCZK - Engine Coolant Level Low....939
B@HANS - Hydraulic Oil Overheat....941
CA111 - EMC Critical Internal Failure....943
CA115 - Engine Ne And Bkup Speed Sensor Error....945
CA122 - Charge Air Pressure Sensor High Error....947
CA123 - Charge Air Pressure Sensor Low Error....949
CA131 - Throttle Sensor High Error....951
CA132 - Throttle Sensor Low Error....953
CA135 - Engine Oil Pressure Sensor High Error....955
CA141 - Engine Oil Pressure Sensor Low Error....957
CA144 - Coolant Temperature Sensor High Error....959
CA145 - Coolant Temperature Sensor Low Error....961
CA153 - Charge Air Temperature Sensor High Error....963
CA154 - Charge Air Temperature Sensor Low Error....965
CA187 - Sensor Power Supply 2 Volt Low Error....967
CA221 - Ambient Pressure Sensor High Error....969
CA222 - Ambient Pressure Sensor Low Error....971
CA227 - Sensor Supply 2 Volt High Error....973
CA234 - Engine Overspeed....975
CA238 - NE Speed Sensor Supply Voltage Error....976
CA263 - Fuel Temperature Sensor High Error....977
CA265 - Fuel Temperature Sensor Low Error....979
CA271 - IMV/PCV1 Short Error....980
CA272 - IMV/PCV1 Open Error....981
CA273 - PCV2 Short Error....982
CA274 - PCV2 Open Error....983
CA322 - Injector #1 Open/short Error....985
CA323 - Injector #5 Open/short Error....987
CA324 - Injector #3 Open/short Error....989
CA325 - Injector #6 Open/short Error....991
CA331 - Injector #2 Open/short Error....993
CA332 - Injector #4 Open/short Error....995
CA342 - Calibration Code Incompatibility....997
CA351 - Injectors Drive Circuit Error....999
CA352 - Sensor Supply 1 Volt Low Error....1001
CA386 - Sensor Supply 1 Volt High Error....1003
CA441 - Battery Voltage Low Error....1005
CA442 - Battery Voltage High Error....1007
CA449 - Rail Pressure Very High Error....1009
CA451 - Rail Pressure Sensor High Error....1013
CA452 - Rail Pressure Sensor Low Error....1015
CA553 - Rail Pressure High Error....1017
CA554 - Rail Pressure Sensor In Range Error....1018
CA559 - Rail Pressure Low Error....1019
CA689 - Engine Ne Speed Sensor Error....1023
CA731 - Engine Bkup Speed Sensor Phase Error....1025
CA757 - All Persistent Data Lost Error....1027
CA778 - Engine Bkup Speed Sensor Error....1029
CA1228 - EGR Valve Servo Error 1....1031
CA1625 - EGR Valve Servo Error 2....1032
CA1633 - KOMNET Datalink Timeout Error....1033
CA2185 - Throttle Sensor Supply Volt High Error....1035
CA2186 - Throttle Sensor Supply Volt Low Error....1037
CA2249 - Rail Pressure Very Low Error....1038
CA2272 - EGR Valve Lift Sensor Low Error....1041
CA2351 - EGR Valve Solenoid Operation Short Circuit....1043
CA2555 - Grid Htr Relay Volt High Error....1047
CA2556 - Grid Htr Relay Volt Low Error....1049
D110KB - Battery Relay Drive Short Circuit....1051
D19JKZ - Personal Code Relay Abnormality....1053
D862KA - GPS Antenna Discon....1055
DA22KK - Pump Solenoid Power Low Error....1057
DA25KP - 5 V Sensor Power Supply Output 1 Abnormality....1059
DA29KQ - Model Selection Abnormality....1063
DA2RMC - CAN Discon (Pump Con Detected)....1065
DAF8KB - Short circuit in camera power supply....1067
DAFGMC - GPS Module Error....1069
DAFRMC - CAN Discon (Monitor Detected)....1071
DGH2KB - Hyd Oil Sensor Short....1073
DHPAMA - F Pump Pressure Sensor Abnormality....1075
DHPBMA - R Pump Pressure Sensor Abnormality....1078
DHS3MA - Arm Curl In PPC Sensor Abnormality....1081
DHS4MA - Bucket Curl PPC Pressure Sensor Abnormality....1083
DHX1MA - Overload Sensor Abnormality (Analog)....1085
DW43KA - Travel Speed Solenoid Disconnection....1087
DW43KB - Travel Speed Solenoid Short Circuit....1089
DW45KA - Swing Brake Solenoid Disconnection....1091
DW45KB - Swing Brake Solenoid Short Circuit....1095
DW91KA - Travel Junction Solenoid Disconnection....1097
DW91KB - Travel Junction Solenoid Short Circuit....1099
DWA2KA - Attachment Sol Open Circuit....1101
DWA2KB - Attachment Sol Short Circuit....1103
DWJ0KA - Merge-divider Solenoid Disconnection....1105
DWJ0KB - Merge-divider Solenoid Short Circuit....1107
DWK0KA - 2-stage Relief Solenoid Disconnection....1109
DWK0KB - 2-stage Relief Solenoid Short Circuit....1111
DXA0KA - PC-EPC Solenoid Disconnection....1113
DXA0KB - PC-EPC Solenoid Short Circuit....1115
DXE0KA - LS-EPC Solenoid Disconnection....1117
DXE0KB - LS-EPC Solenoid Short Circuit....1119
DXE4KA - Service Current EPC Disconnection....1121
DXE4KB - Service Current EPC Short Circuit....1122
DY20KA - Wiper Working Abnormality....1123
DY20MA - Wiper Parking Abnormality....1125
DY2CKA - Washer Drive Open Circuit....1127
DY2CKB - Washer Drive Short Circuit....1129
DY2DKB - Wiper Drive (Fwd) Short Circuit....1131
DY2EKB - Wiper Drive (Rev) Short Circuit....1133
E-MODE (ELECTRICAL SYSTEM)....1135
Before Carrying Out Troubleshooting Of Electrical System....1135
Information Contained In Troubleshooting Table....1137
E-1 Engine Does Not Start....1139
E-2 Auto-decelerator Does Not Operate....1143
E-3 Automatic Warming-up System Does Not Operate....1145
E-4 Preheater Does Not Operate....1147
E-5 All Work Equipment, Swing, And Travel Mechanism Do Not Move....1149
E-6 Power Maximizing Function Does Not Operate....1151
E-7 Machine Monitor Does Not Display At All....1153
E-8 Machine Monitor Does Not Display Some Items....1155
E-9 Contents Of Display By Machine Monitor Are Different From Applicable Machine....1155
E-10 Fuel Level Monitor Was Lighted In Red While Engine Running....1156
E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally....1157
E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally....1159
E-13 Fuel Level Gauge Does Not Indicate Normally....1160
E-14 Swing Lock Monitor Does Not Indicate Normally....1161
E-15 When Monitor Switch Is Operated, Monitor Displays Nothing....1163
E-16 Windshield Wiper And Window Washer Do Not Operate....1165
E-17 Machine Push-up Function Does Not Operate Normally....1169
E-18 Monitoring Function Fails To Display Boom Raise Normally....1171
E-19 Monitoring Function Fails To Display Boom Lower Normally....1173
E-20 Monitoring Function Fails To Display Arm In Normally....1175
E-21 Monitoring Function Fails To Display Arm OUT Normally....1177
E-22 Monitoring Function Fails To Display Bucket CURL Normally....1179
E-23 Monitoring Function Fails To Display Bucket DUMP Normally....1181
E-24 Monitoring Function Fails To Display Swing Normally....1183
E-25 Monitoring Function Fails To Display Travel Normally....1185
E-26 Monitoring Function Fails To Display Travel Differential Pressure Normally....1187
E-27 Monitoring Function Fails To Display Service Normally....1189
E-28 KOMTRAX System Does Not Operate Normally....1191
E-29 Air Conditioner Does Not Operate....1193
E-30 Travel Alarm Does Not Sound Or Does Not Stop Sounding....1195
E-31 Horn Does Not Sound....1197
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)....1199
System Chart For Hydraulic And Mechanical System....1199
Information Contained In Troubleshooting Table....1201
H-1 All Work Equipment Lack Power, Or Travel And Swing Speeds Are Slow....1203
H-2 Engine Speed Sharply Drops Or Engine Stalls....1205
H-3 No Work Equipment, Swing Or Travel Move....1206
H-4 Abnormal Noise Is Heard From Around Hydraulic Pump....1206
H-5 Auto-decelerator Does Not Work....1207
H-6 Fine Control Mode Does Not Function Or Responds Slow....1207
H-7 Boom Moves Slowly Or Lacks Power....1208
H-8 Arm Moves Slowly Or Lacks Power....1209
H-9 Bucket Moves Slowly Or Lacks Power....1210
H-10 Work Equipment Does Not Move In Individual Operation....1210
H-11 Work Equipment Has A Bit Too Fast Hydraulic Drift....1211
H-12 Work Equipment Has Long Time Lag....1213
H-13 Other Work Equipment Moves When Relieving Single Circuit....1213
H-14 Power Max. Switch Does Not Operate....1214
H-15 Machine Push-up Function Does Not Operate....1214
H-16 In Compound Operation Of Work Equipment, Speed Of Part Loaded More Is Low....1215
H-17 In Swing + Boom Raise Operation, Boom Moves Slowly....1215
H-18 In Swing + Travel Operation, Travel Speed Drops Sharply....1215
H-19 Machine Swerves In Travel....1216
H-20 Machine Travels Slowly....1217
H-21 Machine Cannot Be Easily Steered Or Lacks Power....1218
H-22 Travel Speed Does Not Shift, Or It Is Too Slow Or Fast....1219
H-23 Travel System Does Not Turn (On One Side Only)....1220
H-24 Machine Does Not Swing....1221
H-25 Swing Acceleration Is Poor, Or Swing Speed Is Slow....1223
H-26 Excessive Overrun When Stopping Swing....1225
H-27 There Is Big Shock When Stopping Swing....1226
H-28 Large Sound Is Made When Upper Structure Stops Swinging....1226
H-29 Swing Hydraulic Drift Is Too Big....1227
H-30 Attachment Circuit Is Not Changed....1228
H-31 Oil Flow In Attachment Circuit Cannot Be Controlled....1229
50 DISASSEMBLY AND ASSEMBLY....1230
HOW TO READ THIS MANUAL....1234
SPECIAL TOOLS LIST....1237
SKETCHES OF SPECIAL TOOLS....1241
CONNECTOR REPAIR PROCEDURES....1246
Contact Terminal Removal (HD30 Type)....1246
Striping Insulation....1247
Crimping Contact Terminal (HD30 Type)....1248
Insertion Of Contact Terminal (HD30 Type)....1249
Contact Terminal Removal (DT Type)....1250
Striping Insulation....1251
Crimping Contact Terminal (DT Type)....1252
Insertion Of Contact Terminal (DT Type)....1253
ENGINE COMPONENTS....1254
Fuel Supply Pump....1254
Removal....1254
Installation....1258
Fuel Injector....1260
Removal....1260
Installation....1264
Engine Front Seal....1268
Removal....1268
Installation....1270
Engine Rear Seal....1271
Removal....1271
Installation....1273
Cylinder Head....1276
Removal....1276
Installation....1285
Oil Pan Gasket....1289
RADIATOR....1290
Removal....1290
Installation....1291
HYDRAULIC OIL COOLER....1292
Removal....1292
Installation....1293
AFTERCOOLER....1294
Removal....1294
Installation....1295
ENGINE AND HYDRAULIC OIL PUMP....1296
Removal....1296
Installation....1305
DRIVE ASSEMBLY....1306
Removal....1306
Installation....1306
Disassembly....1307
Assembly....1312
SWING MOTOR AND SWING MACHINERY....1318
Removal....1318
Installation....1319
Disassembly....1320
Assembly....1324
SWING CIRCLE....1330
Removal....1330
Installation....1330
CARRIER ROLLER....1331
Assembly....1331
TRACK ROLLER....1333
Assembly....1333
IDLER....1334
Disassembly....1334
ASSEMBLY....1335
RECOIL SPRING....1338
Disassembly....1338
Assembly....1339
SPROCKET....1341
Removal....1341
Installation....1341
TRACK SHOE....1342
Expansion of Track Shoe....1342
Installation of Track Shoe....1343
REVOLVING FRAME....1344
Removal....1344
Installation....1345
COUNTERWEIGHT....1347
Removal....1347
Installation....1348
COUNTERWEIGHT REMOVER....1349
Removing....1350
Installing....1356
CENTER SWIVEL JOINT....1358
Removal....1358
Installation....1359
Disassembly....1360
Assembly....1361
HYDRAULIC TANK....1362
Removal....1362
Installation....1363
CONTROL VALVE....1364
Removal....1364
Installation....1367
Disassembly....1368
Assembly....1370
HYDRAULIC PUMP....1373
Removal....1373
Installation....1375
HYDRAULIC PUMP INPUT SHAFT OIL SEAL....1376
Removal....1376
Installation....1376
WORK EQUIPMENT PPC VALVE....1377
Disassembly....1377
Assembly....1377
TRAVEL PPC VALVE....1379
Disassembly....1379
Assembly....1380
HYDRAULIC CYLINDER....1382
Disassembly....1382
Assembly....1385
WORK EQUIPMENT....1388
Removal....1388
Installation....1390
CAB....1391
Removal....1391
Installation....1394
Cab Glass (Stuck Glass)....1395
Removal....1396
Installation....1397
Front Window....1406
Removal....1406
Installation....1408
Floor Frame....1414
Removal....1414
Installation....1418
ELECTRICAL SYSTEMS....1419
Air Conditioner Unit....1419
Removal....1419
Installation....1423
KOMTRAX Communication Modem....1424
Removal....1424
Installation....1424
Monitor....1425
Removal....1425
Installation....1426
Pump Controller....1427
Removal....1427
Installation....1427
Engine Controller....1430
Removal....1430
Installation....1431
60 AIR CONDITIONER....1432
STRUCTURE AND FUNCTION....1435
Air Conditioner Component....1435
Configuration and Function of Refrigerating cycle....1437
Outline of Refrigerating Cycle....1438
Air Conditioner Unit....1441
Functions of Major Components in the Air Conditioner Unit....1443
Control Plate....1445
Compressor....1448
Condenser and Receiver Drier....1449
TESTING AND ADJUSTING....1450
Caution About Refrigerant....1450
Troubleshooting Procedure....1451
Block Diagram....1452
Circuit Diagram and Arrangement of Connector Pins....1453
Detail of Air Conditioner Unit....1455
Part and Connector Locations....1457
Testing Air Leakage (Ducts)....1461
Testing with Self-diagnosis Function....1463
Testing Temperature Control....1466
Testing Vent (Mode) Changeover....1469
Testing Recirc/Fresh Changeover....1473
Testing Inner Sensor....1475
Testing Evaporator Temperature Sensor....1476
Testing Sunlight Sensor....1478
Testing (Dual) Pressure Switch for Refrigerant....1479
Testing Relays....1481
TROUBLESHOOTING....1483
Troubleshooting Chart 1....1483
Troubleshooting Chart 2....1484
Troubleshooting for Electrical System (E mode)....1487
E-1 Power Supply System (Air Conditioner does not Operate)....1488
E-2 Compressor System (Air is Not Cooled)....1492
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)....1495
E-4 Temperature Cannot be Controlled....1499
E-5 Vent (Mode) Cannot be Changed Over....1502
E-6 Recirc/Fresh Air Cannot be Changed Over....1505
Troubleshooting With Gauge Pressure....1508
Connection of Service Tool....1511
Precautions for connecting air conditioner piping....1513
Handling of Compressor Oil....1514
Control of Compressor Oil....1514
Adding of Compressor Oil....1514
Compressor Replacement....1515
Applying Compressor Oil for O-ring....1515
Desiccant Replacement Procedure....1516
90 OTHERS....1518
Hydraulic circuit diagram....1520
Electrical circuit diagram (1/5)....1521
Electrical circuit diagram (2/5)....1522
Electrical circuit diagram (3/5)....1523
Electrical circuit diagram (4/5)....1524
Electrical circuit diagram (5/5)....1525
Connector list and stereogram....1526
CEBM007602 - Hydraulic Excavator PC450LC-8, PC450HD-8 Shop Manual....1527
CEBM007602 - PC450LC-8 sn A10001 and up....1527
CONTENTS....1528
REVISED PAGES....1529
SAFETY....1539
Safety Notice....1539
Important Safety Notice....1539
General Precautions....1539
Preparations For Work....1539
Precautions During Work....1539
GENERAL....1542
HOW TO READ THE SHOP MANUAL....1543
Volumes....1543
Distribution And Updating....1543
Filing Method....1543
Revised Edition Mark....1543
Revisions....1543
Symbols....1543
HOISTING INSTRUCTIONS....1544
Hoisting....1544
Wire Ropes....1544
PUSH PULL COUPLER....1545
Type 1....1545
Disconnection....1545
Connection....1545
Type 2....1546
Disconnection....1546
Connection....1546
Type 3....1547
Disconnection....1547
Connection....1547
EXPLANATION OF MAINTENANCE STANDARD TERMS....1548
STANDARD TIGHTENING TORQUE....1550
Bolts And Nuts....1550
Tightening Torque Of Hose Nuts....1551
Tightening Torque Of Split Flange Bolts....1551
Tightening Torque For Flared Nuts....1551
Tightening Torques For O-ring Boss Piping Joints....1552
Table Of Tightening Torques For O-ring Boss Plugs....1552
Torque Table For Hoses (Taper Seal Type And Face Seal Type)....1552
ELECTRIC WIRE CODE....1553
Classification By Thickness....1553
Classification By Color And Code....1553
How To Read Electric Wire Code....1554
CONVERSION TABLES....1557
Method Of Using The Conversion Table....1557
COATING MATERIALS....1563
01 GENERAL....1565
SPECIFICATION DIMENSION DRAWINGS....1566
Dimensions....1566
Working Ranges....1567
SPECIFICATIONS....1568
WEIGHT TABLE....1572
FUEL, COOLANT AND LUBRICANTS....1574
Lubrication Chart....1576
10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD....1577
ENGINE AND COOLING SYSTEM....1580
Engine Related Parts....1580
Radiator, Oil Cooler and Aftercooler....1581
POWER TRAIN....1583
Power Train....1583
Final Drive....1584
Sprocket....1586
Swing Machinery....1588
Swing Circle....1590
UNDERCARRIAGE AND FRAME....1592
Track Frame and Recoil Spring....1592
Idler....1594
Carrier Roller....1596
Track Roller....1598
Track Shoe....1600
Triple Grouser Shoe....1602
HYDRAULIC SYSTEM....1604
Hydraulic Piping Drawing....1604
Hydraulic Tank and Filter....1606
Hydraulic Pump....1608
LS Valve....1614
PC Valve....1619
LS(PC)-EPC Valve....1627
Variable Volume Valve....1630
Control Valve....1632
CLSS (Closed Center Load Sensing System)....1644
Functions and Operation by Valve....1648
Unload Valve....1650
LS Bypass Valve....1653
Pressure Compensation Valve....1654
Pressure Compensation Valve Inner Shuttle Valve....1657
Boom Regeneration Circuit....1659
Arm Regeneration Circuit....1661
Merge-Divider Valve....1663
LS Select Valve....1665
Self Pressure Reducing Valve....1666
Travel Junction Valve....1669
Travel PPC Shuttle Valve....1671
Boom Drift Preventive Valve....1673
Arm Drift Preventive Valve....1676
Quick Return Valve....1680
Lift Check Valve....1682
Main Relief Valve....1683
2-Stage Safety-Suction Valve....1684
Variable Pressure Compensation Valve....1686
Attachment Circuit Selector Valve....1688
Holding Valve....1690
Valve Control....1695
PPC Valve....1696
Travel PPC Valve....1702
Service PPC Valve (With EPC Valve)....1712
Solenoid Valve....1714
PPC Accumulator....1716
Return Oil Filter....1717
Center Swivel Joint....1718
Travel Motor....1720
Brake Valve....1728
Swing Motor....1734
Reverse Prevention Valve....1740
Hydraulic Cylinder....1744
Boom Cylinder....1744
Arm Cylinder....1744
Bucket Cylinder....1744
WORK EQUIPMENT....1746
Work Equipment....1746
Dimensions Of Components....1748
Dimension Of Arm....1748
Dimension Of Bucket....1750
AIR CONDITIONER PIPING....1752
ELECTRICAL SYSTEM....1753
Engine Control....1753
Fuel Control Dial....1755
Engine Controller....1756
Sensors....1760
Rotation Sensor....1760
Oil Pressure Switch....1760
Ambient Pressure Sensor....1761
Boost Pressure Sensor....1761
Boost Temperature Sensor....1762
Coolant Temperature Sensor....1762
Hydraulic Oil Temperature Sensor....1762
EGR Valve Stroke Sensor....1763
Engine Oil Level Sensor....1764
ELECTRONIC CONTROL SYSTEM....1765
Engine And Pump Composite Control Function....1768
Pump and Valve Control....1774
2-Stage Relief Function....1775
Power Maximizing and Machine Push-up....1776
Auto-Deceleration....1778
Auto-Warm-Up and Overheat Prevention....1780
Swing Control....1782
Travel Control....1784
Attachment Flow Control and Circuit Selector....1786
System Component Parts....1787
PPC Oil Pressure Switch....1787
Oil Pressure Sensor....1788
Pump Pressure Sensor (High Pressure)....1789
Pump Controller....1790
MONITOR SYSTEM....1793
Machine Monitor....1794
Monitor Control, Display Portion....1798
Monitor Items And Display....1800
Switches....1804
Komtrax Logic....1815
Sensors....1822
KOMTRAX TERMINAL SYSTEM....1825
Komtrax Communication Modem - TH300....1826
20 STANDARD VALUE TABLES....1829
STANDARD VALUE TABLES....1830
Engine Related....1830
Chassis Related....1831
30 TESTING AND ADJUSTING....1839
SERVICE TOOLS....1841
Sketches of Special Tools....1846
ENGINE....1847
Engine Speed....1847
Air Boost Pressure....1849
Exhaust Temperature....1850
Exhaust Gas Color....1851
Valve Clearance....1853
Compression Pressure....1855
Blow-By Pressure....1858
Engine Oil Pressure....1859
EGR Valve Drive Pressure....1860
Handling Fuel System Parts....1861
Releasing Residual Pressure From Fuel System....1861
Fuel Pressure....1862
Cylinder Cut-Out Operation....1863
No Injection Cranking Operation....1863
Fuel Return Rate and Leakage....1864
Bleeding Air from Fuel Circuit....1867
Fuel Circuit, Checking for Leakage....1869
FAN BELT AND ALTERNATOR BELT TENSION....1870
AIR CONDITIONER COMPRESSOR BELT TENSION....1871
SWING CIRCLE BEARING CLEARANCE....1872
TRACK SHOE TENSION....1873
OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....1874
CONTROL CIRCUIT - BASIC PRESSURE....1880
PUMP PC CONTROL CIRCUIT....1881
PUMP LS CONTROL CIRCUIT....1885
SOLENOID VALVE - OUTPUT PRESSURE....1890
PPC VALVE - OUTPUT PRESSURE....1893
WORK EQUIPMENT PPC VALVE AND SWING PPC VALVE - PLAY ADJUSTMENT....1895
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE....1896
HYDRAULIC CIRCUIT - RELEASING REMAINING PRESSURE....1898
Oil Leakage Measurement....1899
BLEEDING AIR FROM VARIOUS PARTS....1902
MACHINE MONITOR - SPECIAL FUNCTIONS....1905
Ordinary Functions and Special Functions of Machine Monitor....1907
Operator Mode (Outline)....1909
Display of Komatsu Logo....1910
Display of Inputting Password....1910
Display of Check of Breaker Mode....1911
Display of Check Before Starting....1911
Display of Warning after Check Before Starting....1911
Display of Ending of Maintenance Interval....1912
Display of Check of Working Mode and Travel Speed....1912
Display of Ordinary Screen....1912
Display of End Screen....1913
Selection of Auto-Deceleration....1913
Selection of Working Mode....1913
Selection of Travel Speed....1914
Operation to stop Alarm Buzzer....1914
Operation of Windshield Wiper....1915
Operation of Window Washer....1915
Operation of Air Conditioner/Heater....1915
Operation to Display Camera Mode (If camera is installed)....1916
Operation to Display Clock and Service Meter....1917
Check of Maintenance Information....1917
Setting and Display of User Mode....1917
KOMTRAX Message....1918
Display of Energy-Saving Guidance....1918
Display of Caution Monitor....1918
Display of Automatic Judgment of Breaker....1919
Display of User Code and Failure Code....1919
Function of Checking Display of LCD (Liquid Crystal Display)....1921
Function of Checking Service Meter....1921
Function of Changing Attachment/Maintenance Password....1922
Service Mode....1925
Monitoring....1927
Abnormality Record (Mechanical Systems)....1931
Abnormality Record (Electrical Systems)....1932
Abnormality Record (Air-Conditioning System/Heater System)....1938
Maintenance Record....1939
Maintenance Mode Change....1940
Phone Number Entry....1943
Default (Key-On Mode)....1944
Default (Unit)....1945
Default (With/Without Attachment)....1946
Default (Attachment/Maintenance Password)....1947
Default (Camera)....1948
Default (ECO Display)....1949
Default (Breaker Detect)....1951
Adjustment (Pump Absorption Torque (F))....1952
Adjustment (Low Speed)....1953
Adjustment (Attachment Flow Adjustment)....1954
Determining a Defective Cylinder....1955
Cylinder Cut-Out....1956
No Injection....1957
Fuel Consumption....1959
KOMTRAX Settings (Terminal Status)....1960
Long Distance Transport Mode....1961
KOMTRAX Settings (GPS & Communication Status)....1963
KOMTRAX Setting (Modem S/N: TH300)....1964
Display of KOMTRAX Message....1965
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER....1966
PREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM....1967
DIODE INSPECTION PROCEDURES....1972
PM CLINIC SERVICE....1973
40 TROUBLESHOOTING....1983
FAILURE CODES TABLE....1987
FUSE LOCATIONS....1990
Connection Table of Fuse Box....1990
Location of Fuse Box and Fuse Numbers....1991
GENERAL INFORMATION....1994
Points to Remember when Troubleshooting....1994
Sequence of Events in Troubleshooting....1996
Handling Electric Equipment and Hydraulic Components....1997
Connectors newly used for Tier 3 Engines....2005
Checks before Troubleshooting....2009
Classification and Troubleshooting Steps....2010
Classification of Troubleshooting....2010
Information in Troubleshooting Table....2012
Possible Problems and Troubleshooting No....2014
Connection Table for Connector Pin Numbers....2017
T-adapter Box and T-adapter Table....2052
FAILURE CODE (DISPLAY OF CODE)....2055
989L00 - Engine Controller Lock Caution 1....2055
989M00 - Engine Controller Lock Caution 2....2055
989N00 - Engine Controller Lock Caution 3....2056
AA10NX - Air Cleaner Clogging....2058
AB00KE - Charge Voltage Low....2060
B@BAZG - Engine Oil Pressure Low....2062
B@BAZK - Engine Oil Level Low....2064
B@BCNS - Engine Coolant Overheat....2066
B@BCZK - Engine Coolant Level Low....2068
B@HANS - Hydraulic Oil Overheat....2070
CA111 - EMC Critical Internal Failure....2072
CA115 - Engine Ne And Bkup Speed Sensor Error....2074
CA122 - Charge Air Pressure Sensor High Error....2076
CA123 - Charge Air Pressure Sensor Low Error....2078
CA131 - Throttle Sensor High Error....2080
CA132 - Throttle Sensor Low Error....2082
CA135 - Engine Oil Pressure Sensor High Error....2084
CA141 - Engine Oil Pressure Sensor Low Error....2086
CA144 - Coolant Temperature Sensor High Error....2088
CA145 - Coolant Temperature Sensor Low Error....2090
CA153 - Charge Air Temperature Sensor High Error....2092
CA154 - Charge Air Temperature Sensor Low Error....2094
CA187 - Sensor Power Supply 2 Volt Low Error....2096
CA221 - Ambient Pressure Sensor High Error....2098
CA222 - Ambient Pressure Sensor Low Error....2100
CA227 - Sensor Supply 2 Volt High Error....2102
CA234 - Engine Overspeed....2104
CA238 - NE Speed Sensor Supply Voltage Error....2105
CA263 - Fuel Temperature Sensor High Error....2106
CA265 - Fuel Temperature Sensor Low Error....2108
CA271 - IMV/PCV1 Short Error....2109
CA272 - IMV/PCV1 Open Error....2110
CA273 - PCV2 Short Error....2111
CA274 - PCV2 Open Error....2112
CA322 - Injector #1 Open/short Error....2114
CA323 - Injector #5 Open/short Error....2116
CA324 - Injector #3 Open/short Error....2118
CA325 - Injector #6 Open/short Error....2120
CA331 - Injector #2 Open/short Error....2122
CA332 - Injector #4 Open/short Error....2124
CA342 - Calibration Code Incompatibility....2126
CA351 - Injectors Drive Circuit Error....2128
CA352 - Sensor Supply 1 Volt Low Error....2130
CA386 - Sensor Supply 1 Volt High Error....2132
CA441 - Battery Voltage Low Error....2134
CA442 - Battery Voltage High Error....2136
CA449 - Rail Pressure Very High Error....2138
CA451 - Rail Pressure Sensor High Error....2142
CA452 - Rail Pressure Sensor Low Error....2144
CA553 - Rail Pressure High Error....2146
CA554 - Rail Pressure Sensor In Range Error....2147
CA559 - Rail Pressure Low Error....2148
CA689 - Engine Ne Speed Sensor Error....2152
CA731 - Engine Bkup Speed Sensor Phase Error....2154
CA757 - All Persistent Data Lost Error....2156
CA778 - Engine Bkup Speed Sensor Error....2158
CA1228 - EGR Valve Servo Error 1....2160
CA1625 - EGR Valve Servo Error 2....2161
CA1633 - KOMNET Datalink Timeout Error....2162
CA2185 - Throttle Sensor Supply Volt High Error....2164
CA2186 - Throttle Sensor Supply Volt Low Error....2166
CA2249 - Rail Pressure Very Low Error....2167
CA2272 - EGR Valve Lift Sensor Low Error....2170
CA2351 - EGR Valve Solenoid Operation Short Circuit....2172
CA2555 - Grid Htr Relay Volt High Error....2176
CA2556 - Grid Htr Relay Volt Low Error....2178
D110KB - Battery Relay Drive Short Circuit....2180
D19JKZ - Personal Code Relay Abnormality....2182
D862KA - GPS Antenna Discon....2184
DA22KK - Pump Solenoid Power Low Error....2186
DA25KP - 5 V Sensor Power Supply Output 1 Abnormality....2188
DA29KQ - Model Selection Abnormality....2192
DA2RMC - CAN Discon (Pump Con Detected)....2194
DAF8KB - Short circuit in camera power supply....2196
DAFGMC - GPS Module Error....2198
DAFRMC - CAN Discon (Monitor Detected)....2200
DGH2KB - Hyd Oil Sensor Short....2202
DHPAMA - F Pump Pressure Sensor Abnormality....2204
DHPBMA - R Pump Pressure Sensor Abnormality....2207
DHS3MA - Arm Curl In PPC Sensor Abnormality....2210
DHS4MA - Bucket Curl PPC Pressure Sensor Abnormality....2212
DHX1MA - Overload Sensor Abnormality (Analog)....2214
DW43KA - Travel Speed Solenoid Disconnection....2216
DW43KB - Travel Speed Solenoid Short Circuit....2218
DW45KA - Swing Brake Solenoid Disconnection....2220
DW45KB - Swing Brake Solenoid Short Circuit....2224
DW91KA - Travel Junction Solenoid Disconnection....2226
DW91KB - Travel Junction Solenoid Short Circuit....2228
DWA2KA - Attachment Sol Open Circuit....2230
DWA2KB - Attachment Sol Short Circuit....2232
DWJ0KA - Merge-divider Solenoid Disconnection....2234
DWJ0KB - Merge-divider Solenoid Short Circuit....2236
DWK0KA - 2-stage Relief Solenoid Disconnection....2238
DWK0KB - 2-stage Relief Solenoid Short Circuit....2240
DXA0KA - PC-EPC Solenoid Disconnection....2242
DXA0KB - PC-EPC Solenoid Short Circuit....2244
DXE0KA - LS-EPC Solenoid Disconnection....2246
DXE0KB - LS-EPC Solenoid Short Circuit....2248
DXE4KA - Service Current EPC Disconnection....2250
DXE4KB - Service Current EPC Short Circuit....2251
DY20KA - Wiper Working Abnormality....2252
DY20MA - Wiper Parking Abnormality....2254
DY2CKA - Washer Drive Open Circuit....2256
DY2CKB - Washer Drive Short Circuit....2258
DY2DKB - Wiper Drive (Fwd) Short Circuit....2260
DY2EKB - Wiper Drive (Rev) Short Circuit....2262
E-MODE (ELECTRICAL SYSTEM)....2264
Before Carrying Out Troubleshooting Of Electrical System....2264
Information Contained In Troubleshooting Table....2266
E-1 Engine Does Not Start....2268
E-2 Auto-decelerator Does Not Operate....2272
E-3 Automatic Warming-up System Does Not Operate....2274
E-4 Preheater Does Not Operate....2276
E-5 All Work Equipment, Swing, And Travel Mechanism Do Not Move....2278
E-6 Power Maximizing Function Does Not Operate....2280
E-7 Machine Monitor Does Not Display At All....2282
E-8 Machine Monitor Does Not Display Some Items....2284
E-9 Contents Of Display By Machine Monitor Are Different From Applicable Machine....2284
E-10 Fuel Level Monitor Was Lighted In Red While Engine Running....2285
E-11 Engine Coolant Temperature Gauge Does Not Indicate Normally....2286
E-12 Hydraulic Oil Temperature Gauge Does Not Indicate Normally....2288
E-13 Fuel Level Gauge Does Not Indicate Normally....2289
E-14 Swing Lock Monitor Does Not Indicate Normally....2290
E-15 When Monitor Switch Is Operated, Monitor Displays Nothing....2292
E-16 Windshield Wiper And Window Washer Do Not Operate....2294
E-17 Machine Push-up Function Does Not Operate Normally....2298
E-18 Monitoring Function Fails To Display Boom Raise Normally....2300
E-19 Monitoring Function Fails To Display Boom Lower Normally....2302
E-20 Monitoring Function Fails To Display Arm In Normally....2304
E-21 Monitoring Function Fails To Display Arm OUT Normally....2306
E-22 Monitoring Function Fails To Display Bucket CURL Normally....2308
E-23 Monitoring Function Fails To Display Bucket DUMP Normally....2310
E-24 Monitoring Function Fails To Display Swing Normally....2312
E-25 Monitoring Function Fails To Display Travel Normally....2314
E-26 Monitoring Function Fails To Display Travel Differential Pressure Normally....2316
E-27 Monitoring Function Fails To Display Service Normally....2318
E-28 KOMTRAX System Does Not Operate Normally....2320
E-29 Air Conditioner Does Not Operate....2322
E-30 Travel Alarm Does Not Sound Or Does Not Stop Sounding....2324
E-31 Horn Does Not Sound....2326
H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)....2328
System Chart For Hydraulic And Mechanical System....2328
Information Contained In Troubleshooting Table....2330
H-1 All Work Equipment Lack Power, Or Travel And Swing Speeds Are Slow....2332
H-2 Engine Speed Sharply Drops Or Engine Stalls....2334
H-3 No Work Equipment, Swing Or Travel Move....2335
H-4 Abnormal Noise Is Heard From Around Hydraulic Pump....2335
H-5 Auto-decelerator Does Not Work....2336
H-6 Fine Control Mode Does Not Function Or Responds Slow....2336
H-7 Boom Moves Slowly Or Lacks Power....2337
H-8 Arm Moves Slowly Or Lacks Power....2338
H-9 Bucket Moves Slowly Or Lacks Power....2339
H-10 Work Equipment Does Not Move In Individual Operation....2339
H-11 Work Equipment Has A Bit Too Fast Hydraulic Drift....2340
H-12 Work Equipment Has Long Time Lag....2342
H-13 Other Work Equipment Moves When Relieving Single Circuit....2342
H-14 Power Max. Switch Does Not Operate....2343
H-15 Machine Push-up Function Does Not Operate....2343
H-16 In Compound Operation Of Work Equipment, Speed Of Part Loaded More Is Low....2344
H-17 In Swing + Boom Raise Operation, Boom Moves Slowly....2344
H-18 In Swing + Travel Operation, Travel Speed Drops Sharply....2344
H-19 Machine Swerves In Travel....2345
H-20 Machine Travels Slowly....2346
H-21 Machine Cannot Be Easily Steered Or Lacks Power....2347
H-22 Travel Speed Does Not Shift, Or It Is Too Slow Or Fast....2348
H-23 Travel System Does Not Turn (On One Side Only)....2349
H-24 Machine Does Not Swing....2350
H-25 Swing Acceleration Is Poor, Or Swing Speed Is Slow....2352
H-26 Excessive Overrun When Stopping Swing....2354
H-27 There Is Big Shock When Stopping Swing....2355
H-28 Large Sound Is Made When Upper Structure Stops Swinging....2355
H-29 Swing Hydraulic Drift Is Too Big....2356
H-30 Attachment Circuit Is Not Changed....2357
H-31 Oil Flow In Attachment Circuit Cannot Be Controlled....2358
50 DISASSEMBLY AND ASSEMBLY....2359
HOW TO READ THIS MANUAL....2363
SPECIAL TOOLS LIST....2366
SKETCHES OF SPECIAL TOOLS....2370
CONNECTOR REPAIR PROCEDURES....2375
Contact Terminal Removal (HD30 Type)....2375
Striping Insulation....2376
Crimping Contact Terminal (HD30 Type)....2377
Insertion Of Contact Terminal (HD30 Type)....2378
Contact Terminal Removal (DT Type)....2379
Striping Insulation....2380
Crimping Contact Terminal (DT Type)....2381
Insertion Of Contact Terminal (DT Type)....2382
ENGINE COMPONENTS....2383
Fuel Supply Pump....2383
Removal....2383
Installation....2387
Fuel Injector....2389
Removal....2389
Installation....2393
Engine Front Seal....2397
Removal....2397
Installation....2399
Engine Rear Seal....2400
Removal....2400
Installation....2402
Cylinder Head....2405
Removal....2405
Installation....2414
Oil Pan Gasket....2418
RADIATOR....2419
Removal....2419
Installation....2420
HYDRAULIC OIL COOLER....2421
Removal....2421
Installation....2422
AFTERCOOLER....2423
Removal....2423
Installation....2424
ENGINE AND HYDRAULIC OIL PUMP....2425
Removal....2425
Installation....2434
DRIVE ASSEMBLY....2435
Removal....2435
Installation....2435
Disassembly....2436
Assembly....2441
SWING MOTOR AND SWING MACHINERY....2447
Removal....2447
Installation....2448
Disassembly....2449
Assembly....2453
SWING CIRCLE....2459
Removal....2459
Installation....2459
CARRIER ROLLER....2460
Assembly....2460
TRACK ROLLER....2462
Assembly....2462
IDLER....2463
Disassembly....2463
ASSEMBLY....2464
RECOIL SPRING....2467
Disassembly....2467
Assembly....2468
SPROCKET....2470
Removal....2470
Installation....2470
TRACK SHOE....2471
Expansion of Track Shoe....2471
Installation of Track Shoe....2472
REVOLVING FRAME....2473
Removal....2473
Installation....2474
COUNTERWEIGHT....2476
Removal....2476
Installation....2477
COUNTERWEIGHT REMOVER....2478
Removing....2479
Installing....2485
CENTER SWIVEL JOINT....2487
Removal....2487
Installation....2488
Disassembly....2489
Assembly....2490
HYDRAULIC TANK....2491
Removal....2491
Installation....2492
CONTROL VALVE....2493
Removal....2493
Installation....2496
Disassembly....2497
Assembly....2499
HYDRAULIC PUMP....2502
Removal....2502
Installation....2504
HYDRAULIC PUMP INPUT SHAFT OIL SEAL....2505
Removal....2505
Installation....2505
WORK EQUIPMENT PPC VALVE....2506
Disassembly....2506
Assembly....2506
TRAVEL PPC VALVE....2508
Disassembly....2508
Assembly....2509
HYDRAULIC CYLINDER....2511
Disassembly....2511
Assembly....2514
WORK EQUIPMENT....2517
Removal....2517
Installation....2519
CAB....2520
Removal....2520
Installation....2523
Cab Glass (Stuck Glass)....2524
Removal....2525
Installation....2526
Front Window....2535
Removal....2535
Installation....2537
Floor Frame....2543
Removal....2543
Installation....2547
ELECTRICAL SYSTEMS....2548
Air Conditioner Unit....2548
Removal....2548
Installation....2552
KOMTRAX Communication Modem....2553
Removal....2553
Installation....2553
Monitor....2554
Removal....2554
Installation....2555
Pump Controller....2556
Removal....2556
Installation....2556
Engine Controller....2559
Removal....2559
Installation....2560
60 AIR CONDITIONER....2561
STRUCTURE AND FUNCTION....2564
Air Conditioner Component....2564
Configuration and Function of Refrigerating cycle....2566
Outline of Refrigerating Cycle....2567
Air Conditioner Unit....2570
Functions of Major Components in the Air Conditioner Unit....2572
Control Plate....2574
Compressor....2577
Condenser and Receiver Drier....2578
TESTING AND ADJUSTING....2579
Caution About Refrigerant....2579
Troubleshooting Procedure....2580
Block Diagram....2581
Circuit Diagram and Arrangement of Connector Pins....2582
Detail of Air Conditioner Unit....2584
Part and Connector Locations....2586
Testing Air Leakage (Ducts)....2590
Testing with Self-diagnosis Function....2592
Testing Temperature Control....2595
Testing Vent (Mode) Changeover....2598
Testing Recirc/Fresh Changeover....2602
Testing Inner Sensor....2604
Testing Evaporator Temperature Sensor....2605
Testing Sunlight Sensor....2607
Testing (Dual) Pressure Switch for Refrigerant....2608
Testing Relays....2610
TROUBLESHOOTING....2612
Troubleshooting Chart 1....2612
Troubleshooting Chart 2....2613
Troubleshooting for Electrical System (E mode)....2616
E-1 Power Supply System (Air Conditioner does not Operate)....2617
E-2 Compressor System (Air is Not Cooled)....2621
E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)....2624
E-4 Temperature Cannot be Controlled....2628
E-5 Vent (Mode) Cannot be Changed Over....2631
E-6 Recirc/Fresh Air Cannot be Changed Over....2634
Troubleshooting With Gauge Pressure....2637
Connection of Service Tool....2640
Precautions for connecting air conditioner piping....2642
Handling of Compressor Oil....2643
Control of Compressor Oil....2643
Adding of Compressor Oil....2643
Compressor Replacement....2644
Applying Compressor Oil for O-ring....2644
Desiccant Replacement Procedure....2645
90 OTHERS....2647
Hydraulic circuit diagram....2649
Electrical circuit diagram (1/5)....2650
Electrical circuit diagram (2/5)....2651
Electrical circuit diagram (3/5)....2652
Electrical circuit diagram (4/5)....2653
Electrical circuit diagram (5/5)....2654
Connector list and stereogram....2655
UEAM007200 - Hydraulic Excavator PC450-8, PC450LC-8 Operation & Maintenance Manual....2656
FOREWORD....2658
FOREWORD....2659
SAFETY INFORMATION....2660
Noise emission levels....2662
Vibration levels....2663
Guide to Reduce Vibration Levels on Machine....2663
INTRODUCTION....2665
DIRECTIONS OF MACHINE....2665
VISIBILITY FROM OPERATOR'S SEAT....2666
PROXIMITY VISIBILITY....2666
12M CIRCUMFERENCE VISIBILITY....2666
BREAKING-IN THE NEW MACHINE....2667
PRODUCT INFORMATION....2668
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....2668
EPA REGULATIONS, ENGINE NUMBER PLATE....2668
SERVICE METER LOCATION....2669
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR....2669
MACHINE SERIAL PLATE....2670
FOREWORD....2671
SAFETY....2671
OPERATION....2672
MAINTENANCE....2674
SPECIFICATIONS....2676
ATTACHMENTS ANDD OPTIONS....2676
HIGH REACH DEMOLITION EQUIPMENT 27M....2678
INDEX....2679
COLOPHON....2679
SAFETY....2680
SAFETY INFORMATION....2681
SAFETY LABELS....2683
LOCATION OF SAFETY LABELS....2683
SAFETY LABELS....2684
SAFETY INFORMATION....2692
SAFETY MACHINE OPERATION....2701
STARTING ENGINE....2701
OPERATION....2703
TRANSPORTATION....2709
BATTERY....2710
TOWING....2712
LIFTING OBJECTS WITH BUCKET....2713
SAFETY MAINTENANCE INFORMATION....2714
OPERATION....2722
MACHINE VIEW ILLUSTRATIONS....2723
OVERALL MACHINE VIEW....2723
CONTROLS AND GAUGES....2724
Machine Monitor....2725
DETAILED CONTROLS AND GAUGES....2726
MONITORING SYSTEM....2726
Basic Operation of Machine Monitor....2727
Emergency Monitors....2732
Caution Monitors....2734
Basic Check Monitors....2737
Meter Display Portion....2739
Monitor Switches Portion....2746
Handling Function Switches....2754
Attachment 2 Setting....2775
SWITCHES....2790
CONTROL LEVERS AND PEDALS....2796
SUN ROOF....2799
WINDSHIELD....2800
EMERGENCY ESCAPE HAMMER....2805
DOOR LOCK....2806
CAP WITH LOCK....2806
DRINK BOX....2808
MAGAZINE BOX....2808
ASHTRAY....2808
AIR CONDITIONER CONTROLS....2809
Air Conditioner Control Panel....2809
Method of Operation....2813
Use Air Conditioner with Care....2819
Inspection and maintenance of Air Conditioner Equipped Machine....2820
RADIO....2821
Control Panel....2821
Controls of Radio....2823
Use Radio with Care....2825
Space for radio cassette....2825
AUXILIARY ELECTRIC POWER....2826
24V Power Source....2826
12V Power Source....2826
FUSE....2827
FUSIBLE LINK....2828
CONTROLLER....2828
TOOL BOX....2829
GREASE PUMP HOLDER....2829
FIRE EXTINGUISHER....2829
REFUELLING PUMP....2830
ACCUMULATOR....2831
Releasing Hydraulic Pressure With Accumulator....2831
MACHINE OPERATIONS AND CONTROLS....2832
BEFORE STARTING ENGINE....2832
Walk-around Checks....2832
Checks Before Starting....2833
Adjustment....2840
Seat Belt....2846
Operations Before Starting Engine....2847
STARTING ENGINE....2849
AFTER STARTING ENGINE....2852
Engine Warm Up....2852
Hydraulic Equipment Warm Up....2854
Operation After Completion Of Warm-Up Operation....2860
STOPPING THE ENGINE....2862
MACHINE OPERATION....2863
Preparations for Moving the Machine....2863
Moving Machine Forward....2864
Moving Machine Backward....2865
Stopping Machine....2866
STEERING THE MACHINE....2867
Steering....2867
SWINGING....2869
WORK EQUIPMENT CONTROLS AND OPERATIONS....2870
WORKING MODE....2872
PROHIBITED OPERATIONS....2874
GENERAL OPERATION INFORMATION....2878
TRAVELING ON SLOPES....2880
ESCAPE FROM MUD....2882
Track on One Side Stuck....2882
Tracks on Both Sides Stuck....2882
RECOMMENDED APPLICATIONS....2883
Backhoe Work....2883
Shovel Work....2883
Ditching Work....2883
Loading Work....2884
BUCKET REPLACEMENT AND INVERSION....2885
Replacement....2885
Inversion....2886
PARKING MACHINE....2887
MACHINE INSPECTION AFTER DAILY WORK....2889
LOCKING....2889
TRANSPORTATION....2890
TRANSPORTATION PROCEDURE....2890
LOADING AND UNLOADING WITH TRAILER....2891
Loading....2892
Securing Machine....2894
Unloading....2897
LIFTING MACHINE....2899
TRANSPORTATION POSTURE....2901
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....2903
COLD WEATHER OPERATION....2905
COLD WEATHER OPERATION INFORMATION....2905
Fuel and Lubricants....2905
Cooling System Coolant....2905
Battery....2906
AFTER DAILY WORK COMPLETION....2907
AFTER COLD WEATHER SEASON....2907
LONG TERM STORAGE....2908
BEFORE STORAGE....2908
DURING STORAGE....2908
AFTER STORAGE....2909
STARTING MACHINE AFTER LONG-TERM STORAGE....2909
TROUBLES AND ACTIONS....2910
RUNNING OUT OF FUEL....2910
PHENOMENA THAT ARE NOT FAILURES....2911
TOWING THE MACHINE....2911
LIGHTWEIGHT TOWING HOLE....2912
SEVERE JOB CONDITION....2912
DISCHARGED BATTERY....2913
Battery Removal and Installation....2913
Battery Charges....2914
Starting Engine with Booster Cables....2915
OTHER TROUBLE....2917
Electrical System....2917
Chassis....2918
Engine....2919
Electronic Control System....2920
Point of Contact to Telephone when Error Occurs....2921
MAINTENANCE....2922
MAINTENANCE INFORMATION....2923
OUTLINE OF SERVICE....2925
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....2925
OIL....2925
FUEL....2926
COOLANT AND WATER FOR DILUTION....2926
GREASE....2927
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)....2927
STORING OIL AND FUEL....2928
FILTERS....2928
EXPLANATION OF LUBRICATION CHART DECAL....2929
ELECTRIC SYSTEM MAINTENANCE....2931
WEAR PARTS....2932
WEAR PARTS LIST....2932
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....2933
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....2935
TIGHTENING TORQUE SPECIFICATIONS....2936
TIGHTENING TORQUE LIST....2936
SAFETY CRITICAL PARTS....2937
SAFETY CRITICAL PARTS LIST....2937
MAINTENANCE SCHEDULE....2938
MAINTENANCE SCHEDULE CHART....2938
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....2940
MAINTENANCE PROCEDURE....2941
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)....2941
WHEN REQUIRED....2942
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....2942
CLEAN INSIDE OF COOLING SYSTEM....2948
CHECK AND TIGHTEN TRACK SHOE BOLTS....2951
CHECK AND ADJUST TRACK TENSION....2952
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....2954
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....2957
REPLACE BUCKET SIDE CUTTER, SHROUD....2959
ADJUST BUCKET CLEARANCE....2960
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....2961
CHECK AND MAINTENANCE AIR CONDITIONER....2962
WASH WASHABLE FLOOR....2963
BLEEDING AIR FROM HYDRAULIC SYSTEM....2966
CHECK BEFORE STARTING....2968
EVERY 50 HOURS MAINTENANCE....2969
LUBRICATING....2969
EVERY 250 HOURS MAINTENANCE....2970
LUBRICATE SWING CIRCLE....2970
CHECK LEVEL OF BATTERY ELECTROLYTE....2971
CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST....2973
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....2974
EVERY 500 HOURS MAINTENANCE....2975
LUBRICATING....2975
REPLACE FUEL PRE-FILTER CARTRIDGE....2976
CHECK SWING PINION GREASE LEVEL, ADD GREASE....2979
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....2980
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND CONDENSER FINS....2982
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS....2983
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK....2985
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL....2986
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....2987
EVERY 1000 HOURS MAINTENANCE....2988
REPLACE FUEL MAIN FILTER CARTRIDGE....2988
REPLACE HYDRAULIC OIL FILTER ELEMENT....2991
CHANGE OIL IN SWING MACHINERY CASE....2992
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL....2993
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS....2993
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT....2994
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)....2994
REPLACE CORROSION RESISTOR CARTRIDGE....2995
EVERY 2000 HOURS MAINTENANCE....2996
CHANGE OIL IN FINAL DRIVE CASE....2996
CLEAN HYDRAULIC TANK STRAINER....2997
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)....2997
CHECK ALTERNATOR....3000
CHECK ENGINE VALVE CLEARANCE, ADJUST....3000
CHECK VIBRATION DAMPER....3000
EVERY 4000 HOURS MAINTENANCE....3001
CHECK WATER PUMP....3001
CHECK STARTING MOTOR....3001
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)....3001
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER....3002
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....3002
EVERY 5000 HOURS MAINTENANCE....3003
CHANGE OIL IN HYDRAULIC TANK....3003
EVERY 8000 HOURS MAINTENANCE....3005
REPLACE HIGH-PRESSURE PIPING CLAMP....3005
REPLACE FUEL SPRAY PREVENTION CAP....3005
SPECIFICATIONS....3006
SPECIFICATIONS....3007
ATTACHMENTS ANDD OPTIONS....3016
GENERAL PRECAUTIONS FOR SAFETY....3017
PRECAUTIONS WHEN SELECTING....3017
READ THE INSTRUCTION MANUAL THOROUGHLY....3017
PRECAUTIONS WHEN REMOVING OR INSTALLING....3017
PRECAUTIONS WHEN USING....3018
HYDRAULIC QUICK COUPLER PIPING....3019
LOCATIONS....3019
OPERATION....3020
BUCKET WITH HOOK....3022
HOOK CONDITION....3022
PROHIBITED OPERATIONS....3022
MACHINE READY FOR ATTACHMENT....3023
LOCATIONS....3023
HYDRAULIC CIRCUIT....3027
Switching Hydraulic Circuit....3027
Adjusting Oil Flow....3027
Switching Between Breaker and General Attachment....3027
Hydraulic Circuit Connection....3028
Oil Flow Path....3029
Replace Additional Breaker Filter Element....3030
ATTACHMENT REMOVAL AND INSTALLATION....3032
Attachment Removal....3032
Attachment Installation....3034
ATTACHMENT OPERATIONS....3036
Operation When Using Breaker....3036
Operation When Using General Attachment 1 (e.g. Crusher)....3038
Working Mode Selection 6....3039
Operation When Using Attachment 2 (e.g clamshell rotation, crusher rotation)....3040
LONG TERM STORAGE....3040
SPECIFICATIONS....3040
ATTACHMENT GUIDE....3041
ATTACHMENT COMBINATIONS....3041
SELECTION OF TRACK SHOES....3043
METHOD OF SELECTING SHOES....3043
RECOMMENDED ATTACHMENT OPERATIONS....3044
HYDRAULIC BREAKER....3044
HANDLING MACHINES EQUIPPED WITH KOMTRAX....3048
BASIC PRECAUTIONS....3048
SUPER LONG FRONT BOOM AND ARM....3049
OPERATION INSTRUCTION....3049
WORKING MODES....3050
CHECKS BEFORE STARTING....3051
USING SUPER LONG FRONT....3051
METHOD OF WORK....3053
WHEN TRAVELLING....3053
CONTROL LEVERS, PEDALS....3054
TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE....3057
INSTALLATION OF SUPPORTING LINK....3057
TRANSPORTATION OF SUPER LONG FRONT MACHINE....3058
WORKING RANGE OF SUPER LONG FRONT....3059
LIFTING CAPACITY PC450 LC 20m SUPER LONG FRONT....3060
MAINTENANCE....3061
SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT....3061
EVERY 50 HOURS SERVICE....3062
EVERY 100 HOURS SERVICE....3063
HIGH REACH DEMOLITION EQUIPMENT 27M....3066
GENERAL VIEW OF MACHINE....3067
CAUTION ITEMS....3068
POSITION FOR ATTACHING SAFETY LABELS....3069
POSITION FOR ATTACHING SAFETY LABELS....3069
SAFETY LABELS....3070
CONTROL LEVERS AND SWITCHES....3071
SAFETY LOCK LEVER....3071
TRAVEL LEVERS....3072
WORK EQUIPMENT CONTROL LEVERS....3073
ATTACHMENT ROTATION (with auto-deceleration)....3074
INTERMEDIATE LINK CONTROL PEDAL (with auto-deceleration)....3075
CRUSHER CONTROL FOR OPENING AND CLOSING....3076
TILTING CAB MECHANISM OPERATION....3077
BOOM ANGLE ALARM BUZZER CANCEL SWITCH....3078
CEILING WINDOW WIPER SWITCH....3079
MACHINE OPERATIONS AND CONTROLS....3080
BEFORE STARTING ENGINE....3080
FUNCTION CHECK....3081
PRECAUTIONS WHEN OPERATING....3081
PROHIBITON OF WORK OUTSIDE SPECIFIED WORKING RANGE....3082
PROHIBITION OF WORK AT THE STROKE END OF A CYLINDER....3085
PROHIBITION OF WORK WITH HYDRAULIC BREAKER....3086
WHEN WORKING IN MEDIUM REACH CONFIGURATION....3086
OPERATION....3087
ADJUSTMENT OF HYDRAULIC VARIABLE GAUGE UNDERCARRIAGE, (Where Fitted)....3087
OPERATING WORK EQUIPMENT....3088
ATTACHMENT CONTROL....3089
RAISING WORK EQUIPMENT....3090
WORKING RANGE AND USING RANGE OF BOOM....3092
POSTURE WHEN LEAVING MACHINE....3095
DEMOLITION DIGGING BOOM INSTALLATION AND REMOVAL....3096
PROCEDURE FOR INSTALLATION AND REMOVAL OF DEMOLITION DIGGING EQUIPMENT....3096
REMOVAL OF HIGH REACH WORK EQUIPMENT....3096
FITTING DEMOLITION DIGGING EQUIPMENT....3100
REMOVAL OF DEMOLITION DIGGING EQUIPMENT....3104
CONNECTING DIGGING ARM TO DEMOLITION DIGGING BOOM....3104
MEDIUM REACH....3105
PURGING AIR PROCEDURES....3106
PURGING PROCEDURE TO REMOVE AIR FROM HYDRAULIC CYLINDER LINES....3106
PROCEDURE FOR PURGING AIR FROM BOOM LOCK VALVE PPC CIRCUIT....3106
PURGING AIR FROM HYDRAULIC DRIFT PREVENTATIVE VALVE PPC CIRCUITS OF MID LINK AND ARM CYLINDER....3108
TRANSPORTATION (high reach demolition equipment fitted)....3110
PROCEDURE FOR LOADING ON TO TRAILER....3110
TRANSPORTATION (demolition digging equipment fitted)....3111
PROCEDURE FOR LOADING ON TO TRAILER....3111
TRANSPORTATION (high reach demolition equipment alone)....3111
PROCEDURE FOR LOADING ON TO TRAILER....3111
SPECIFICATIONS....3116
WORKING RANGE (PC450LCD HIGH REACH)....3116
WORKING RANGE (PC450LCD MEDIUM REACH)....3117
WORKING RANGE (PC450LCD LOW REACH)....3118
WORKING RANGE (PC450LCD DIGGING)....3119
WEIGHTS AND DIMENSIONS....3120
TRANSPORTATION (High and Medium Reach work equipment) - PC450LCD....3121
TRANSPORTATION (Digging equipment) - PC450LCD....3122
EXPLANATION OF LIFTING CAPACITY CHART....3123
INDEX....3124
<A>....3126
<B>....3126
<C>....3126
<D>....3126
<E>....3126
<F>....3126
<G>....3126
<H>....3126
<I>....3126
<L>....3126
<M>....3126
<O>....3126
<P>....3127
<R>....3127
<S>....3127
<T>....3127
<V>....3127
<W>....3127
<Y>....3127
COLOPHON....3128
UEBM000100 - Hydraulic Excavator PC450-6, PC450LC-6 Shop Manual....3130
01 General....3150
Specification drawings....3151
Specifications....3152
Weight table....3154
Fuel, coolant and lubricants....3156
10 Structure and Function....3158
Parts related to engine....3159
Radiator, oil cooler....3161
Power train....3162
Final drive....3163
Swing circle....3164
Swing machinery....3165
Track frame, recoil spring....3166
Track shoe....3167
Hydraulic piping drawing....3169
Hydraulic circuit diagram....3171
Hydraulic tank, hydraulic filter....3172
Hydraulic pump....3174
Control valve....3195
Self-reducing pressure valve....3205
Suction safety valve....3210
CLSS....3212
Swing motor....3277
Center swivel joint....3283
Travel motor....3285
Valve control....3294
Work equipment * swing PPC valve....3295
Travel PPC valve....3299
Service PPC valve....3303
PPC safety lock valve....3306
PPC accumulator....3306
PPC shuttle valve, travel junction valve....3308
LS-EPC valve....3315
Solenoid valve....3319
Boom safety valve....3321
Overload warning device....3324
Work equipment....3326
Air conditioner....3327
Actual electric wiring diagram....3328
Electric circuit diagram....3332
Engine control....3335
Electronic control system....3342
Machine monitor system....3369
Breaker mode hydraulic performance....3380
20 Testing and Adjusting....3382
Standard value table....3383
Standard value table for engine related parts....3383
Standard value table for chassis related parts....3384
Standard value table for electrical parts....3392
Testing and adjusting....3400
Tools for testing, adjusting, and troubleshooting....3401
Measuring engine speed....3402
Measuring exhaust color....3403
Adjusting valve clearance....3404
Measuring compression pressure....3405
Measuring blow-by pressure....3405
Testing and adjusting fuel injection timing....3406
Measuring engine oil pressure....3408
Testing and adjusting fan belt tension....3409
Testing and adjusting belt tension for air conditioner compressor....3409
Adjusting engine speed sensor....3410
Measuring air supply pressure (boost pressure)....3411
Testing and adjusting governor motor lever stroke....3412
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit....3413
Testing and adjusting TVC valve output pressure (servo piston input pressure)....3416
Testing and adjusting LS valve output pressure (servo piston input pressure) and LS differential pressure....3418
Testing control circuit oil pressure (oil pressure when self-pressure is reduced)....3421
Testing solenoid valve output pressure....3422
Measuring PPC valve output pressure and testing PPC shuttle valve....3425
Adjusting work equipment, swing PPC valve....3427
Testing travel deviation....3428
Testing locations causing hydraulic drift of work equipment....3429
Measuring oil leakage....3431
Releasing remaining pressure in hydraulic circuit....3433
Testing clearance of swing circle bearing....3434
Testing wear of sprocket....3435
Testing and adjusting track shoe tension....3436
Bleeding air....3437
Troubleshooting....3440
Points to remember when troubleshooting....3441
Sequence of events in troubleshooting....3442
Points to remember when carrying out maintenance....3443
Checks before troubleshooting....3451
Connector types and mounting locations....3453
Connector arrangement diagram....3455
Connection table for connector pin numbers....3458
Explanation of control mechanism of electrical system....3468
Display method of special functions of monitor panel....3469
Method of using judgement table....3478
Method of using troubleshooting charts....3480
Details of troubleshooting and troubleshooting procedure....3482
Service code table....3487
Troubleshooting of communication abnormality system (N mode)....3488
Troubleshooting of governor, pump controller (governor control system) (E mode)....3492
Troubleshooting of engine system (S mode)....3524
Troubleshooting of governor, pump controller (pump control system) (C mode)....3548
Troubleshooting of governor, pump controller (input signal system) (F mode)....3596
Troubleshooting of hydraulic, mechanical system (H mode)....3610
Troubleshooting of machine monitor system (M mode)....3646
30 Disassembly and Assembly....3692
Method of using manual....3694
Precautions when carrying out operation....3696
Special tool list....3698
40 Maintenance Standard....3898
90 Others....3946
