Komatsu GALEO PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Excavator Shop Manual PDF

Description

Komatsu GALEO PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Hydraulic Excavator Shop Manual UEN02223 – PDF DOWNLOAD

FILE DETAILS:

Komatsu GALEO PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Hydraulic Excavator Shop Manual UEN02223 – PDF DOWNLOAD

Language : English
Pages : 1016
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu GALEO PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Hydraulic Excavator Shop Manual UEN02223 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC450-8             K50001and up
  PC450LC-8         K50001and up
  PC450LCD-8      K50001and up
  PC450LCHD-8   K50001and up

00 Index and foreword . 3
Index . 3
Composition of shop manual 4
Table of contents . 6
00 Index and foreword . 15
Foreword and general information 15
Safety notice . 16
How to read the shop manual . 21
Explanation of terms for maintenance standard . 23
Handling electric equipment and hydraulic component . 25
How to read electric wire code 37
Precautions when carrying out operation . 40
Method of disassembling and connecting push-pull type coupler . 43
Standard tightening torque table 46
Conversion table 50
01 Specification 57
Specification and technical data 57
Specification dimension drawings 58
Specifications 60
Weight table 62
Table of fuel, coolant and lubricants . 64
10 Structure, function and maintenance standard . 67
Engine and cooling system . 67
Engine related parts 68
Radiator, oil cooler and aftercooler 69
10 Structure, function and maintenance standard . 71
Power train . 71
Power train . 72
Final drive . 74
Sprocket 76
Swing machinery . 78
Swing circle 80
10 Structure, function and maintenance standard . 83
Undercarriage and frame . 83
Track frame and recoil spring . 84
Idler . 86
Carrier roller 88
Track roller 89
Track shoe 90
10 Structure, function and maintenance standard . 95
Hydraulic system, Part 1 95
Hydraulic equipment layout drawing 96
Hydraulic tank and filter . 98
Hydraulic pump 100
10 Structure, function and maintenance standard . 125
Hydraulic system, Part 2 125
Control valve . 126
CLSS 138
Functions and operation by valve 142
Merge-divider valve . 157
Attachment circuit selector valve . 182
Holding valve . 184
10 Structure, function and maintenance standard . 191
Hydraulic system, Part 3 191
Valve control . 192
PPC valve . 194
Solenoid valve 210
PPC accumulator . 212
Return oil filter . 213
Center swivel joint . 214
Travel motor 215
Swing motor . 227
Hydraulic cylinder 236
10 Structure, function and maintenance standard . 239
Work equipment 239
Work equipment 240
Dimensions of components 242
10 Structure, function and maintenance standard . 247
Cab and its attachments . 247
Air conditioner piping 248
10 Structure, function and maintenance standard . 251
Electrical system . 251
Engine control 252
Electronic control system . 263
Monitor system 288
Sensor 315
KOMTRAX terminal system . 318
20 Standard value table . 321
Standard service value table 321
Standard value table for engine related parts . 322
Standard value table for chassis related parts 323
30 Testing and adjusting 333
Testing and adjusting, part 1 . 333
Tools for testing, adjusting and troubleshooting 335
Measuring engine speed 339
Measuring air boost pressure 340
Measuring exhaust temperature . 341
Measuring exhaust gas color . 342
Adjusting valve clearance . 343
Measuring compression pressure 345
Measuring blow-by pressure 347
Measuring engine oil pressure . 348
Handling fuel system parts 349
Releasing residual pressure from fuel system 349
Measuring fuel pressure . 350
Handling during cylinder cut-out operation 351
Handling during no injection cranking operation . 351
Measuring fuel return rate and leakage 352
Bleeding air from fuel circuit 355
Checking fuel circuit for leakage . 356
Checking and adjusting fan belt and alternator belt . 357
Checking and adjusting air conditioner compressor belt tension 358
Measuring swing circle bearing clearance 359
Checking and adjusting track shoe tension . 360
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits 361
Measuring control circuit basic pressure 365
Checking and adjusting pump PC control circuit oil pressure . 366
Checking and adjusting pump LS control circuit oil pressure . 369
Measuring solenoid valve output pressure 374
Measuring PPC valve output pressure . 377
Adjusting play of work equipment and swing PPC valves . 378
Inspecting locations of hydraulic drift of work equipment . 379
Releasing residual pressure from hydraulic circuit 381
Measuring oil leakage amount 382
Bleeding air from various parts . 385
30 Testing and adjusting 389
Testing and adjusting, Part 2 . 389
Special functions of machine monitor 390
30 Testing and adjusting 447
Testing and adjusting, Part 3 . 447
Handling voltage circuit of engine controller . 448
Preparation work for troubleshooting of electrical system . 449
Procedure for testing diodes 454
Pm Clinic service . 455
Undercarriage troubleshooting report 461
40 Troubleshooting 463
Failure code table and fuse locations . 463
Failure codes table . 464
Fuse locations 467
40 Troubleshooting 471
General information on troubleshooting 471
Points to remember when troubleshooting . 472
Sequence of events in troubleshooting . 473
Checks before troubleshooting . 474
Classification and troubleshooting steps 475
Information in troubleshooting table 476
Wiring table for connector pin numbers 481
T-adapter box and T-adapter table . 514
40 Troubleshooting 519
Troubleshooting by failure code (Display of code), Part 1 . 519
Failure code [A000N1] Eng. Hi Out of Std 521
Failure code [AA10NX] Air cleaner Clogging 522
Failure code [AB00KE] Charge Voltage Low 524
Failure code [B@BAZG] Eng Oil Press. Low 526
Failure code [B@BAZK] Eng Oil Level Low . 528
Failure code [B@BCNS] Eng. Water Overheat . 530
Failure code [B@BCZK] Eng Water Level Low . 532
Failure code [B@HANS] Hydr Oil Overheat . 534
Failure code [CA111] EMC Critical Internal Failure 535
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 535
Failure code [CA122] Chg Air Press Sensor High Error 536
Failure code [CA123] Chg Air Press Sensor Low Error . 538
Failure code [CA131] Throttle Sensor High Error . 540
Failure code [CA132] Throttle Sensor Low Error 542
Failure code [CA135] Eng Oil Press Sensor High Error 544
Failure code [CA141] Eng Oil Press Sensor Low Error . 546
Failure code [CA144] Coolant Temp Sens High Error . 548
Failure code [CA145] Coolant Temp Sens Low Error 550
Failure code [CA153] Chg Air Temp Sensor High Error . 552
Failure code [CA154] Chg Air Temp Sensor Low Error 554
Failure code [CA187] Sens Supply 2 Volt Low Error . 556
Failure code [CA221] Ambient Press Sens High Error 558
Failure code [CA222] Ambient Press Sens Low Error . 560
Failure code [CA227] Sens Supply 2 Volt High Error 562
Failure code [CA234] Eng Overspeed 563
Failure code [CA238] Ne Speed Sens Supply Volt Error 564
Failure code [CA263] Fuel Temp Sensor High Error 566
Failure code [CA265] Fuel Temp Sensor Low Error . 568
Failure code [CA271] IMV/PCV1 Short Error . 569
Failure code [CA272] IMV/PCV1 Open Error 570
Failure code [CA273] PCV2 Short Error . 572
Failure code [CA274] PCV2 Open Error 573
Failure code [CA322] Inj #1 Open/Short Error 574
Failure code [CA323] Inj #5 Open/Short Error 576
Failure code [CA324] Inj #3 Open/Short Error 578
Failure code [CA325] Inj #6 Open/Short Error 580
Failure code [CA331] Inj #2 Open/Short Error 582
Failure code [CA332] Inj #4 Open/Short Error 584
40 Troubleshooting 587
Troubleshooting by failure code (Display of code), Part 2 . 587
Failure code [CA342] Calibration Code Incompatibility . 589
Failure code [CA351] Injectors Drive Circuit Error 590
Failure code [CA352] Sens Supply 1 Volt Low Error . 592
Failure code [CA386] Sens Supply 1 Volt High Error 594
Failure code [CA441] Battery Voltage Low Error 596
Failure code [CA442] Battery Voltage High Error . 598
Failure code [CA449] Rail Press Very High Error . 600
Failure code [CA451] Rail Press Sensor High Error . 604
Failure code [CA452] Rail Press Sensor Low Error 606
Failure code [CA553] Rail Press High Error 608
Failure code [CA554] Rail Press Sensor In Range Error . 609
Failure code [CA559] Rail Press Low Error . 610
Failure code [CA689] Eng Ne Speed Sensor Error 612
Failure code [CA731] Eng Bkup Speed Sens Phase Error 614
Failure code [CA757] All Persistent Data Lost Error . 616
Failure code [CA778] Eng Bkup Speed Sensor Error 618
Failure code [CA1228] EGR valve servo error 1 . 620
Failure code [CA1625] EGR valve servo error 2 . 621
Failure code [CA1633] KOMNET Datalink Timeout Error . 622
Failure code [CA2185] Throt Sens Sup Volt High Error 624
Failure code [CA2186] Throt Sens Sup Volt Low Error . 625
Failure code [CA2249] Rail Press Very Low Error . 626
Failure code [CA2271] EGR valve lift sensor high error 628
Failure code [CA2272] EGR valve lift sensor low error . 630
Failure code [CA2351] EGR valve solenoid operation short circuit 632
Failure code [CA2352] EGR valve solenoid operation disconnect . 634
Failure code [CA2555] Grid Htr Relay Volt High Error 636
Failure code [CA2556] Grid Htr Relay Volt Low Error . 638
Failure code [D110KB] Battery Relay Drive S/C . 640
Failure code [DA25KP] 5V sensor power supply output 1 abnormality . 642
Failure code [DA2RMC] Pump Comm. Abnormality 646
Failure code [DA2SKQ] Model Selection Abnormality . 648
40 Troubleshooting 651
Troubleshooting by failure code (Display of code), Part 3 . 651
Failure code [DA2RMC] CAN discon (Pump con detected) 654
Failure code [DHPAMA] F Pump Press Sensor Abnormality . 656
Failure code [DHPBMA] R Pump Press Sensor Abnormality . 658
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality . 660
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 662
Failure code [DW43KA] Travel Speed Sol. Disc 664
Failure code [DW43KB] Travel Speed Sol. S/C . 666
Failure code [DW45KA] Swing Brake Sol. Disc . 668
Failure code [DW45KB] Swing Brake Sol. S/C 672
Failure code [DW91KA] Travel Junction Sol. Disc . 674
Failure code [DW91KB] Travel Junction Sol. S/C 676
Failure code [DWJ0KA] Merge-divider Sol. Disc . 678
Failure code [DWJ0KB] Merge-divider Sol. S/C 680
Failure code [DWK0KA] 2-stage Relief Sol. Disc 682
Failure code [DWK0KB] 2-stage Relief Sol. S/C . 684
Failure code [DXA0KA] PC-EPC Sol. Disc 686
Failure code [DXA0KB] PC-EPC Sol. S/C . 688
Failure code [DXE0KA] LS-EPC Sol. Disc 690
Failure code [DXE0KB] LS-EPC Sol. S/C . 692
Failure code [DXE4KA] Service Current EPC Disc 694
Failure code [DXE4KB] Service Current EPC S/C . 695
Failure code [DY20KA] Wiper Working Abnormality . 696
Failure code [DY20MA] Wiper Parking Abnormality . 698
Failure code [DY2CKB] Washer Drive Short 700
Failure code [DY2DKB] Wiper Drive (For) Short . 702
Failure code [DY2EKB] Wiper Drive (Rev) Short . 704
40 Troubleshooting 707
Troubleshooting of electrical system (E-mode) . 707
Before carrying out troubleshooting of electrical system 710
Information contained in troubleshooting table 712
E-1 Engine does not start . 713
E-2 Auto-decelerator does not operate . 716
E-3 Automatic warming-up system does not operate 718
E-4 Preheater does not operate 720
E-5 All work equipment, swing, and travel mechanism do not move . 722
E-6 Power maximizing function does not operate 724
E-7 Machine monitor does not display at all . 726
E-8 Machine monitor does not display some items . 728
E-9 Contents of display by machine monitor are different from applicable machine 728
E-10 Fuel level monitor was lighted in red while engine running . 729
E-11 Engine coolant temperature gauge does not indicate normally 730
E-12 Hydraulic oil temperature gauge does not indicate normally . 732
E-13 Fuel level gauge does not indicate normally 733
E-14 Swing lock monitor does not indicate normally 734
E-15 When monitor switch is operated, monitor displays nothing 736
E-16 Windshield wiper and window washer do not operate 738
E-17 Machine push-up function does not operate normally . 742
E-18 Monitoring function fails to display “boom raise” normally . 744
E-19 Monitoring function fails to display “boom lower” normally . 746
E-20 Monitoring function fails to display “arm IN” normally . 748
E-21 Monitoring function fails to display “arm OUT” normally 750
E-22 Monitoring function fails to display “bucket CURL” normally 752
E-23 Monitoring function fails to display “bucket DUMP” normally 754
E-24 Monitoring function fails to display “swing” normally 756
E-25 Monitoring function fails to display “travel” normally . 758
E-26 Monitoring function fails to display “travel differential pressure” normally . 760
E-27 Monitoring function fails to display “service” normally 762
E-28 KOMTRAX system does not operate normally . 764
E-29 Air conditioner does not operate . 766
E-30 Travel alarm does not sound or does not stop sounding 768
E-31 Horn does not sound 770
40 Troubleshooting 773
Troubleshooting of hydraulic and mechanical system (H-mode) . 773
System chart for hydraulic and mechanical system 776
Information contained in troubleshooting table 778
H-1 All work equipment lack power, or travel and swing speeds are slow 780
H-2 Engine speed sharply drops or engine stalls . 782
H-3 No work equipment, swing or travel move . 783
H-4 Abnormal noise is heard from around hydraulic pump 783
H-5 Auto-decelerator does not work 784
H-6 Fine control mode does not function or responds slow 784
H-7 Boom moves slowly or lacks power 785
H-8 Arm moves slowly or lacks power . 786
H-9 Bucket moves slowly or lacks power 787
H-10 Work equipment does not move in its single operation . 787
H-11 Work equipment has a bit too fast hydraulic drift 788
H-12 Work equipment has big time lag 790
H-13 Other work equipment moves when relieving single circuit . 790
H-14 Power max. switch does not operate . 790
H-15 Machine push-up function does not operate 791
H-16 In compound operation of work equipment, speed of part loaded more is low 792
H-17 When machine swings and raises boom simultaneously, boom rising speed is low . 792
H-18 When machine swings and travels simultaneously, travel speed lowers largely 792
H-19 Machine deviates during travel . 793
H-20 Travel speed is low 794
H-21 Machine is not steered well or steering power is low . 795
H-22 Travel speed does not change or travel speed is low or high 796
H-23 Travel system does not move (only one side) 797
H-24 Upper structure does not swing . 798
H-25 Swing acceleration or swing speed is low . 800
H-26 Upper structure overruns remarkably when it stops swinging . 802
H-27 Large shock is made when upper structure stops swinging 803
H-28 Large sound is made when upper structure stops swinging 803
H-29 Hydraulic drift of swing is large 804
H-30 Attachment circuit is not changed 805
H-31 Oil flow in attachment circuit cannot be controlled 805
40 Troubleshooting 807
Troubleshooting of engine (S-mode) 807
Method of using troubleshooting chart . 809
S-1 Starting performance is poor 812
S-2 Engine does not start . 814
S-3 Engine does not pick up smoothly 818
S-4 Engine stops during operations 819
S-5 Engine does not rotate smoothly . 820
S-6 Engine lacks output (or lacks power) 821
S-7 Exhaust smoke is black (incomplete combustion) 822
S-8 Oil consumption is excessive (or exhaust smoke is blue) . 823
S-9 Oil becomes contaminated quickly 824
S-10 Fuel consumption is excessive 825
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 826
S-12 Oil pressure drops . 827
S-13 Oil level rises (Entry of coolant or fuel) . 828
S-14 Coolant temperature becomes too high (overheating) . 830
S-15 Abnormal noise is made . 831
S-16 Vibration is excessive . 832
50 Disassembly and assembly . 835
General information on disassembly and assembly . 835
How to read this manual . 836
Coating materials list 838
Special tools list 841
Sketches of special tools . 845
50 Disassembly and assembly . 849
Engine and cooling system . 849
Removal and installation of fuel supply pump assembly . 850
Removal and installation of fuel injector assembly 854
Removal and installation of engine front seal . 860
Removal and installation of engine rear seal 861
Removal and installation of cylinder head assembly 864
Removal and installation of radiator assembly . 873
Removal and installation of hydraulic oil cooler assembly . 875
Removal and installation of aftercooler assembly 877
Removal and installation of engine and hydraulic oil pump assembly 878
50 Disassembly and assembly . 887
Power train . 887
Removal and installation of final drive assembly 888
Disassembly and assembly of final drive assembly 889
Removal and installation of swing motor and swing machinery assembly 897
Disassembly and assembly of swing motor and swing machinery assembly 898
Removal and installation of swing circle assembly . 905
50 Disassembly and assembly . 907
Undercarriage and frame . 907
Disassembly and assembly of carrier roller assembly . 908
Disassembly and assembly of track roller assembly . 910
Disassembly and assembly of idler assembly 911
Disassembly and assembly of recoil spring assembly 914
Removal and installation of sprocket 916
Expansion and installation of track shoe assembly . 917
Removal and installation of revolving frame assembly 919
Removal and installation of counterweight assembly 922
50 Disassembly and assembly . 925
Hydraulic system 925
Removal and installation of centre swivel joint assembly 926
Disassembly and assembly of centre swivel joint assembly 928
Removal and installation of hydraulic tank assembly . 929
Removal and installation of control valve assembly 931
Disassembly and assembly of control valve assembly 934
Removal and installation of hydraulic pump assembly . 938
Removal and installation of oil seal in hydraulic pump input shaft 941
Disassembly and assembly of work equipment PPC valve assembly . 942
Disassembly and assembly of travel PPC valve assembly . 943
Disassembly and assembly of hydraulic cylinder assembly . 944
50 Disassembly and assembly . 951
Work equipment 951
Removal and installation of work equipment assembly . 952
50 Disassembly and assembly . 957
Cab and its attachments . 957
Removal and installation of operator cab assembly . 958
Removal and installation of operator cab glass (stuck glass) 961
Removal and installation of front window assembly . 971
Removal and installation of floor frame assembly 978
50 Disassembly and assembly . 983
Electrical system . 983
Removal and installation of air conditioner unit assembly . 984
Removal and installation of KOMTRAX communication modem assembly 987
Removal and installation of monitor assembly 988
Removal and installation of pump controller assembly 990
Removal and installation of engine controller . 992
90 Diagrams and drawings 995
Hydraulic diagrams and drawings . 995
Hydraulic circuit diagram . 997
Hydraulic circuit diagram . 999
90 Diagrams and drawings 1003
Electrical diagrams and drawings 1003
Electrical circuit diagram (1/5) 1005
Electrical circuit diagram (2/5) 1007
Electrical circuit diagram (3/5) 1009
Electrical circuit diagram (4/5) 1011
Electrical circuit diagram (5/5) 1013

DESCRIPTION:

Komatsu GALEO PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Hydraulic Excavator Shop Manual UEN02223 – PDF DOWNLOAD

• SERIAL NUMBERS
  PC450-8             K50001and up
  PC450LC-8         K50001and up
  PC450LCD-8      K50001and up
  PC450LCHD-8   K50001and up

G.B 26/12/24