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

Description

Komatsu PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Hydraulic Excavator Shop Manual UEN02223-03 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Hydraulic Excavator Shop Manual UEN02223-03 – PDF DOWNLOAD

Language : English
Pages : 1054
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Hydraulic Excavator Shop Manual UEN02223-03 – 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
Centre 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 289
Sensor 317
KOMTRAX terminal system . 320
10 Structure, function and maintenance standard . 323
Auto Grease system 323
Outline of Auto Grease System . 324
20 Standard value table . 339
Standard service value table 339
Standard value table for engine related parts . 340
Standard value table for chassis related parts 341
30 Testing and adjusting 351
Testing and adjusting, part 1 . 351
Tools for testing, adjusting and troubleshooting 353
Measuring engine speed 357
Measuring air boost pressure 358
Measuring exhaust temperature . 359
Measuring exhaust gas color . 360
Adjusting valve clearance . 361
Measuring compression pressure 363
Measuring blow-by pressure 365
Measuring engine oil pressure . 366
Handling fuel system parts 367
Releasing residual pressure from fuel system 367
Measuring fuel pressure . 368
Handling during cylinder cut-out operation 369
Handling during no injection cranking operation . 369
Measuring fuel return rate and leakage 370
Bleeding air from fuel circuit 373
Checking fuel circuit for leakage . 374
Checking and adjusting fan belt and alternator belt . 375
Checking and adjusting air conditioner compressor belt tension 376
Measuring swing circle bearing clearance 377
Checking and adjusting track shoe tension . 378
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits 379
Measuring control circuit basic pressure 383
Checking and adjusting pump PC control circuit oil pressure . 384
Checking and adjusting pump LS control circuit oil pressure . 387
Measuring solenoid valve output pressure 392
Measuring PPC valve output pressure . 395
Adjusting play of work equipment and swing PPC valves . 396
Inspecting locations of hydraulic drift of work equipment . 397
Releasing residual pressure from hydraulic circuit 399
Measuring oil leakage amount 400
Bleeding air from various parts . 403
30 Testing and adjusting 407
Testing and adjusting, Part 2 . 407
Special functions of machine monitor 408
30 Testing and adjusting 465
Testing and adjusting, Part 3 . 465
Handling voltage circuit of engine controller . 466
Preparation work for troubleshooting of electrical system . 467
Procedure for testing diodes 472
Pm Clinic service . 473
Undercarriage troubleshooting report 479
40 Troubleshooting 481
Failure code table and fuse locations . 481
Failure codes table . 482
Fuse locations 485
40 Troubleshooting 489
General information on troubleshooting 489
Points to remember when troubleshooting . 490
Sequence of events in troubleshooting . 491
Checks before troubleshooting . 492
Classification and troubleshooting steps 493
Information in troubleshooting table 494
Wiring table for connector pin numbers 499
T-adapter box and T-adapter table . 531
40 Troubleshooting 537
Troubleshooting by failure code (Display of code), Part 1 . 537
Failure code [A000N1] Eng. Hi Out of Std 539
Failure code [AA10NX] Air cleaner Clogging 540
Failure code [AB00KE] Charge Voltage Low 542
Failure code [B@BAZG] Eng Oil Press. Low 544
Failure code [B@BAZK] Eng Oil Level Low . 546
Failure code [B@BCNS] Eng. Water Overheat . 548
Failure code [B@BCZK] Eng Water Level Low . 550
Failure code [B@HANS] Hydr Oil Overheat . 552
Failure code [CA111] EMC Critical Internal Failure 553
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 553
Failure code [CA122] Chg Air Press Sensor High Error 554
Failure code [CA123] Chg Air Press Sensor Low Error . 556
Failure code [CA131] Throttle Sensor High Error . 558
Failure code [CA132] Throttle Sensor Low Error 560
Failure code [CA135] Eng Oil Press Sensor High Error 562
Failure code [CA141] Eng Oil Press Sensor Low Error . 564
Failure code [CA144] Coolant Temp Sens High Error . 566
Failure code [CA145] Coolant Temp Sens Low Error 568
Failure code [CA153] Chg Air Temp Sensor High Error . 570
Failure code [CA154] Chg Air Temp Sensor Low Error 572
Failure code [CA187] Sens Supply 2 Volt Low Error . 574
Failure code [CA221] Ambient Press Sens High Error 576
Failure code [CA222] Ambient Press Sens Low Error . 578
Failure code [CA227] Sens Supply 2 Volt High Error 580
Failure code [CA234] Eng Overspeed 581
Failure code [CA238] Ne Speed Sens Supply Volt Error 582
Failure code [CA263] Fuel Temp Sensor High Error 584
Failure code [CA265] Fuel Temp Sensor Low Error . 586
Failure code [CA271] IMV/PCV1 Short Error . 587
Failure code [CA272] IMV/PCV1 Open Error 588
Failure code [CA273] PCV2 Short Error . 590
Failure code [CA274] PCV2 Open Error 591
Failure code [CA322] Inj #1 Open/Short Error 592
Failure code [CA323] Inj #5 Open/Short Error 594
Failure code [CA324] Inj #3 Open/Short Error 596
Failure code [CA325] Inj #6 Open/Short Error 598
Failure code [CA331] Inj #2 Open/Short Error 600
Failure code [CA332] Inj #4 Open/Short Error 602
40 Troubleshooting 605
Troubleshooting by failure code (Display of code), Part 2 . 605
Failure code [CA342] Calibration Code Incompatibility . 607
Failure code [CA351] Injectors Drive Circuit Error 608
Failure code [CA352] Sens Supply 1 Volt Low Error . 610
Failure code [CA386] Sens Supply 1 Volt High Error 612
Failure code [CA441] Battery Voltage Low Error 614
Failure code [CA442] Battery Voltage High Error . 616
Failure code [CA449] Rail Press Very High Error . 618
Failure code [CA451] Rail Press Sensor High Error . 622
Failure code [CA452] Rail Press Sensor Low Error 624
Failure code [CA553] Rail Press High Error 626
Failure code [CA554] Rail Press Sensor In Range Error . 627
Failure code [CA559] Rail Press Low Error . 628
Failure code [CA689] Eng Ne Speed Sensor Error 630
Failure code [CA731] Eng Bkup Speed Sens Phase Error 632
Failure code [CA757] All Persistent Data Lost Error . 634
Failure code [CA778] Eng Bkup Speed Sensor Error 636
Failure code [CA1228] EGR valve servo error 1 . 638
Failure code [CA1625] EGR valve servo error 2 . 639
Failure code [CA1633] KOMNET Datalink Timeout Error . 640
Failure code [CA2185] Throt Sens Sup Volt High Error 642
Failure code [CA2186] Throt Sens Sup Volt Low Error . 643
Failure code [CA2249] Rail Press Very Low Error . 644
Failure code [CA2271] EGR valve lift sensor high error 646
Failure code [CA2272] EGR valve lift sensor low error . 648
Failure code [CA2351] EGR valve solenoid operation short circuit 650
Failure code [CA2352] EGR valve solenoid operation disconnect . 652
Failure code [CA2555] Grid Htr Relay Volt High Error 654
Failure code [CA2556] Grid Htr Relay Volt Low Error . 656
Failure code [D110KB] Battery Relay Drive S/C . 658
Failure code [DA25KP] 5V sensor power supply output 1 abnormality . 660
Failure code [DA2RMC] Pump Comm. Abnormality 664
Failure code [DA2SKQ] Model Selection Abnormality . 666
40 Troubleshooting 669
Troubleshooting by failure code (Display of code), Part 3 . 669
Failure code [DA2RMC] CAN discon (Pump con detected) 672
Failure code [DHPAMA] F Pump Press Sensor Abnormality . 674
Failure code [DHPBMA] R Pump Press Sensor Abnormality . 676
Failure code [DHS3MA] Arm Curl PPC Sen. Abnormality . 678
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 680
Failure code [DW43KA] Travel Speed Sol. Disc 682
Failure code [DW43KB] Travel Speed Sol. S/C . 684
Failure code [DW45KA] Swing Brake Sol. Disc . 686
Failure code [DW45KB] Swing Brake Sol. S/C 690
Failure code [DW91KA] Travel Junction Sol. Disc . 692
Failure code [DW91KB] Travel Junction Sol. S/C 694
Failure code [DWJ0KA] Merge-divider Sol. Disc . 696
Failure code [DWJ0KB] Merge-divider Sol. S/C 698
Failure code [DWK0KA] 2-stage Relief Sol. Disc 700
Failure code [DWK0KB] 2-stage Relief Sol. S/C . 702
Failure code [DXA0KA] PC-EPC Sol. Disc 704
Failure code [DXA0KB] PC-EPC Sol. S/C . 706
Failure code [DXE0KA] LS-EPC Sol. Disc 708
Failure code [DXE0KB] LS-EPC Sol. S/C . 710
Failure code [DXE4KA] Service Current EPC Disc 712
Failure code [DXE4KB] Service Current EPC S/C . 713
Failure code [DY20KA] Wiper Working Abnormality . 714
Failure code [DY20MA] Wiper Parking Abnormality . 716
Failure code [DY2CKB] Washer Drive Short 718
Failure code [DY2DKB] Wiper Drive (For) Short . 720
Failure code [DY2EKB] Wiper Drive (Rev) Short . 722
40 Troubleshooting 725
Troubleshooting of electrical system (E-mode) . 725
Before carrying out troubleshooting of electrical system 728
Information contained in troubleshooting table 730
E-1 Engine does not start . 731
E-2 Auto-decelerator does not operate . 734
E-3 Automatic warming-up system does not operate 736
E-4 Preheater does not operate 738
E-5 All work equipment, swing, and travel mechanism do not move . 740
E-6 Power maximizing function does not operate 742
E-7 Machine monitor does not display at all . 744
E-8 Machine monitor does not display some items . 746
E-9 Contents of display by machine monitor are different from applicable machine 746
E-10 Fuel level monitor was lighted in red while engine running . 747
E-11 Engine coolant temperature gauge does not indicate normally 748
E-12 Hydraulic oil temperature gauge does not indicate normally . 750
E-13 Fuel level gauge does not indicate normally 751
E-14 Swing lock monitor does not indicate normally 752
E-15 When monitor switch is operated, monitor displays nothing 754
E-16 Windshield wiper and window washer do not operate 756
E-17 Machine push-up function does not operate normally . 760
E-18 Monitoring function fails to display “boom raise” normally . 762
E-19 Monitoring function fails to display “boom lower” normally . 764
E-20 Monitoring function fails to display “arm IN” normally . 766
E-21 Monitoring function fails to display “arm OUT” normally 768
E-22 Monitoring function fails to display “bucket CURL” normally 770
E-23 Monitoring function fails to display “bucket DUMP” normally 772
E-24 Monitoring function fails to display “swing” normally 774
E-25 Monitoring function fails to display “travel” normally . 776
E-26 Monitoring function fails to display “travel differential pressure” normally . 778
E-27 Monitoring function fails to display “service” normally 780
E-28 KOMTRAX system does not operate normally . 782
E-29 Air conditioner does not operate . 784
E-30 Travel alarm does not sound or does not stop sounding 786
E-31 Horn does not sound 788
40 Troubleshooting 791
Troubleshooting of hydraulic and mechanical system (H-mode) . 791
System chart for hydraulic and mechanical system 794
Information contained in troubleshooting table 796
H-1 All work equipment lack power, or travel and swing speeds are slow 798
H-2 Engine speed sharply drops or engine stalls . 800
H-3 No work equipment, swing or travel move . 801
H-4 Abnormal noise is heard from around hydraulic pump 801
H-5 Auto-decelerator does not work 802
H-6 Fine control mode does not function or responds slow 802
H-7 Boom moves slowly or lacks power 803
H-8 Arm moves slowly or lacks power . 804
H-9 Bucket moves slowly or lacks power 805
H-10 Work equipment does not move in its single operation . 805
H-11 Work equipment has a bit too fast hydraulic drift 806
H-12 Work equipment has big time lag 808
H-13 Other work equipment moves when relieving single circuit . 808
H-14 Power max. switch does not operate . 808
H-15 Machine push-up function does not operate 809
H-16 In compound operation of work equipment, speed of part loaded more is low 810
H-17 When machine swings and raises boom simultaneously, boom rising speed is low . 810
H-18 When machine swings and travels simultaneously, travel speed lowers largely 810
H-19 Machine deviates during travel . 811
H-20 Travel speed is low 812
H-21 Machine is not steered well or steering power is low . 813
H-22 Travel speed does not change or travel speed is low or high 814
H-23 Travel system does not move (only one side) 815
H-24 Upper structure does not swing . 816
H-25 Swing acceleration or swing speed is low . 818
H-26 Upper structure overruns remarkably when it stops swinging . 820
H-27 Large shock is made when upper structure stops swinging 821
H-28 Large sound is made when upper structure stops swinging 821
H-29 Hydraulic drift of swing is large 822
H-30 Attachment circuit is not changed 823
H-31 Oil flow in attachment circuit cannot be controlled 823
40 Troubleshooting 825
Troubleshooting of engine (S-mode) 825
Method of using troubleshooting chart . 827
S-1 Starting performance is poor 830
S-2 Engine does not start . 832
S-3 Engine does not pick up smoothly 836
S-4 Engine stops during operations 837
S-5 Engine does not rotate smoothly . 838
S-6 Engine lacks output (or lacks power) 839
S-7 Exhaust smoke is black (incomplete combustion) 840
S-8 Oil consumption is excessive (or exhaust smoke is blue) . 841
S-9 Oil becomes contaminated quickly 842
S-10 Fuel consumption is excessive 843
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 844
S-12 Oil pressure drops . 845
S-13 Oil level rises (Entry of coolant or fuel) . 846
S-14 Coolant temperature becomes too high (overheating) . 848
S-15 Abnormal noise is made . 849
S-16 Vibration is excessive . 850
40 Troubleshooting 853
Troubleshooting of Auto Grease system . 853
50 Disassembly and assembly . 861
General information on disassembly and assembly . 861
How to read this manual . 862
Coating materials list 864
Special tools list 867
Sketches of special tools . 871
50 Disassembly and assembly . 875
Engine and cooling system . 875
Removal and installation of fuel supply pump assembly . 876
Removal and installation of fuel injector assembly 880
Removal and installation of engine front seal . 886
Removal and installation of engine rear seal 887
Removal and installation of cylinder head assembly 890
Removal and installation of radiator assembly . 899
Removal and installation of hydraulic oil cooler assembly . 901
Removal and installation of aftercooler assembly 903
Removal and installation of engine and hydraulic oil pump assembly 904
50 Disassembly and assembly . 913
Power train . 913
Removal and installation of final drive assembly 914
Disassembly and assembly of final drive assembly 915
Removal and installation of swing motor and swing machinery assembly 923
Disassembly and assembly of swing motor and swing machinery assembly 924
Removal and installation of swing circle assembly . 931
50 Disassembly and assembly . 933
Undercarriage and frame . 933
Disassembly and assembly of carrier roller assembly . 934
Disassembly and assembly of track roller assembly . 936
Disassembly and assembly of idler assembly 937
Disassembly and assembly of recoil spring assembly 940
Removal and installation of sprocket 942
Expansion and installation of track shoe assembly . 943
Removal and installation of revolving frame assembly 945
Removal and installation of counterweight assembly 948
50 Disassembly and assembly . 951
Hydraulic system 951
Removal and installation of centre swivel joint assembly 952
Disassembly and assembly of centre swivel joint assembly 954
Removal and installation of hydraulic tank assembly . 955
Removal and installation of control valve assembly 957
Disassembly and assembly of control valve assembly 960
Removal and installation of hydraulic pump assembly . 964
Removal and installation of oil seal in hydraulic pump input shaft 967
Disassembly and assembly of work equipment PPC valve assembly . 968
Disassembly and assembly of travel PPC valve assembly . 969
Disassembly and assembly of hydraulic cylinder assembly . 970
50 Disassembly and assembly . 977
Work equipment 977
Removal and installation of work equipment assembly . 978
50 Disassembly and assembly . 983
Cab and its attachments . 983
Removal and installation of operator cab assembly . 984
Removal and installation of operator cab glass (stuck glass) 987
Removal and installation of front window assembly . 997
Removal and installation of floor frame assembly 1004
50 Disassembly and assembly .1009
Electrical system .1009
Removal and installation of air conditioner unit assembly .1010
Removal and installation of KOMTRAX communication modem assembly 1013
Removal and installation of monitor assembly 1014
Removal and installation of pump controller assembly 1016
Removal and installation of engine controller .1018
90 Diagrams and drawings 1021
Hydraulic diagrams and drawings .1021
Hydraulic circuit diagram . 0
Hydraulic circuit diagram . 0
90 Diagrams and drawings 1029
Electrical diagrams and drawings 1029
Connector arrangement diagram 1 . 0
PC450, PC450LC, PC450LCD, PC450LCHD-8 . 0
Electrical circuit diagram K50001 – K50349 (1/5) 0
Electrical circuit diagram K50001 – K50349 (2/5) 0
Electrical circuit diagram K50001 – K50349 (3/5) 0
Electrical circuit diagram K50001 – K50349 (4/5) 0
Electrical circuit diagram K50001 – K50349 (5/5) 0
Electrical circuit diagram K50350 – Up (1/5) 0
Electrical circuit diagram K50350 – Up (2/5) 0
Electrical circuit diagram K50350 – Up (3/5) 0
Electrical circuit diagram K50350 – Up (4/5) 0
Electrical circuit diagram K50350 – Up (5/5) 0

DESCRIPTION:

Komatsu PC450-8,PC450LC-8,PC450LCD-8,PC450LCHD-8 Hydraulic Excavator Shop Manual UEN02223-03 – PDF DOWNLOAD

SERIAL NUMBERS

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

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

G.B 29/12/24