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Komatsu PC450LC-6K Hydraulic Excavator Operation & Maintenance Manual 12144 and up – PDF DOWNLOAD
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Description
Komatsu PC450LC-6K Hydraulic Excavator Operation & Maintenance Manual
FILE DETAILS:
Komatsu PC450LC-6K Hydraulic Excavator Operation & Maintenance Manual
Language : English
Pages : 255
Downloadable : Yes
File Type : PDF
Size:2.32 MB
Book Code: EEAM008404
KOMATSU PC450LC-6K HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL 12144 AND UP – PDF DOWNLOAD:
DESCRIPTION:
Komatsu PC450LC-6K Hydraulic Excavator Operation & Maintenance Manual
FOREWORD:
- This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
- If you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information for your machine or for questions regarding information in this manual.
TABLE OF CONTENTS:
Komatsu PC450LC-6K Hydraulic Excavator Operation & Maintenance Manual
MAIN MENU................................................................................. 0 COVER..................................................................................... 1 1. FOREWARD............................................................................... 2 2. SAFETY INFORMATION..................................................................... 3 2.1 SAFETY MESSAGES................................................................... 3 2.2 NOISE............................................................................. 4 2.3 VIBRATION......................................................................... 4 3. INTRODUCTION........................................................................... 5 3.1 INTENDED USE...................................................................... 5 3.2 FEATURES.......................................................................... 5 3.3 BREAKING IN YOUR NEW MACHINE..................................................... 5 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.......................... 6 4.1 MACHINE SERIAL NO. PLATE POSITION................................................. 6 4.2 ENGINE SERIAL NO. PLATE POSITION.................................................. 6 4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR......................................... 6 4.4 MACHINE SERIAL PLATE.............................................................. 7 5. CONTENTS............................................................................... 8 SAFETY.................................................................................... 12 6. GENERAL PRECAUTIONS................................................................ 13 7. PRECAUTIONS DURING OPERATION....................................................... 19 7.1 BEFORE STARTING ENGINE........................................................ 19 7.2 OPERATING MACHINE............................................................. 21 7.3 LOADING AND UNLOADING......................................................... 26 7.4 BATTERY....................................................................... 27 7.5 TOWING........................................................................ 28 7.6 BUCKET WITH HOOK.............................................................. 29 7.6.1 GENERAL PRECAUTIONS..................................................... 29 7.6.2 PRECAUTIONS FOR LIFTING OPERATION....................................... 31 8. PRECAUTIONS FOR MAINTENANCE........................................................ 32 8.1 BEFORE CARRYING OUT MAINTENANCE............................................... 32 8.2 DURING MAINTENANCE............................................................ 35 9. POSITION FOR ATTACHING SAFETY LABELS............................................... 39 OPERATION................................................................................. 44 10. GENERAL VIEW...................................................................... 45 10.1 GENERAL VIEW OF MACHINE...................................................... 45 10.2 GENERAL VIEW OF CONTROLS AND GAUGES.......................................... 46 11. EXPLANATION OF COMPONENTS......................................................... 47 11.1 MACHINE MONITOR.............................................................. 47 11.2 SWITCHES..................................................................... 58 11.3 CONTROL LEVERS, PEDALS....................................................... 62 11.4 ROOF HATCH................................................................... 67 11.5 FRONT WINDOW................................................................. 68 11.6 DOOR LOCK.................................................................... 70 11.7 CAP, COVER WITH LOCK......................................................... 71 11.8 LUGGAGE TRAY................................................................. 72 11.9 ASHTRAY...................................................................... 72 11.10 AIR CONDITIONER............................................................. 73 11.11 CAB RADIO (OPTION).......................................................... 76 11.12 FUSE........................................................................ 77 11.13 FUSIBLE LINK................................................................ 78 11.14 CONTROLLERS................................................................. 78 11.15 TOOL BOX/GREASE GUN HOLDER.................................................. 78 11.16 REFUELLING PUMP (OPTION).................................................... 78 11.17 HANDLING THE ACCUMULATOR.................................................... 79 12. OPERATION......................................................................... 81 12.1 CHECK BEFORE STARTING ENGINE................................................. 81 12.2 STARTING ENGINE.............................................................. 91 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................. 94 12.4 MOVING MACHINE OFF...........................................................100 12.5 STEERING MACHINE.............................................................103 12.6 STOPPING MACHINE.............................................................105 12.7 SWINGING.....................................................................106 12.8 OPERATION OF WORK EQUIPMENT..................................................107 12.9 HANDLING ACTIVE MODE.........................................................108 12.10 WORKING MODE SELECTION......................................................109 12.11 PROHIBITIONS FOR OPERATION..................................................111 12.12 PRECAUTIONS FOR OPERATION...................................................113 12.13 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS................................114 12.14 HOW TO ESCAPE MUD...........................................................116 12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR.....................................117 12.16 REPLACEMENT AND INVERSION OF BUCKET.........................................118 12.17 PARKING THE MACHINE.........................................................120 12.18 CHECK AFTER FINISHING WORK..................................................121 12.19 STOPPING ENGINE.............................................................122 12.20 CHECK AFTER STOPPING ENGINE.................................................123 12.21 LOCKING.....................................................................123 12.22 OVERLOAD WARNING DEVICE.....................................................123 13. TRANSPORTATION....................................................................124 13.1 LOADING, UNLOADING WORK......................................................124 13.2 PRECAUTIONS FOR LOADING......................................................126 13.3 PRECAUTIONS FOR TRANSPORTATION...............................................126 13.4 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE.......................127 13.5 METHOD OF LIFTING MACHINE....................................................128 14. COLD WEATHER OPERATION............................................................129 14.1 PRECAUTIONS FOR LOW TEMPERATURE..............................................129 14.2 PRECAUTIONS AFTER COMPLETION OF WORK.........................................130 14.3 AFTER COLD WEATHER...........................................................130 15. LONG-TERM STORAGE.................................................................131 15.1 BEFORE STORAGE...............................................................131 15.2 DURING STORAGE...............................................................132 15.3 AFTER STORAGE................................................................132 15.4 STARTING MACHINE AFTER LONG-TERM STORAGE.....................................132 16. TROUBLESHOOTING...................................................................133 16.1 PHENOMENA THAT ARE NOT FAILURES..............................................133 16.2 METHOD OF TOWING MACHINE.....................................................133 16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE....................................133 16.4 PRECAUTIONS ON PARTICULAR JOBSITES...........................................134 16.5 IF BATTERY IS DISCHARGED.....................................................134 16.6 OTHER TROUBLE................................................................138 MAINTENANCE...............................................................................144 17. GUIDES TO MAINTENANCE.............................................................145 18. OUTLINES OF SERVICE...............................................................148 18.1 OUTLINE OF OIL, FUEL, COOLANT................................................148 18.2 OUTLINE OF ELECTRIC SYSTEM...................................................152 18.3 OUTLINE OF HYDRAULIC SYSTEM..................................................153 19. WEAR PARTS LIST...................................................................154 20. USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.................155 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....................................159 21.1 INTRODUCTION OF NECESSARY TOOLS..............................................159 21.2 TORQUE LIST..................................................................160 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....................................161 23. MAINTENANCE SCHEDULE CHART........................................................163 23.1 MAINTENANCE SCHEDULE CHART...................................................163 23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER.....................................165 24. SERVICE PROCEDURE.................................................................166 24.1 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)...................166 REPLACE FUEL FILTER CARTRIDGE.................................................205 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.............201 CHECK ENGINE VALVE CLEARANCE, ADJUST..........................................216 24.2 WHEN REQUIRED................................................................167 24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................167 24.2.2 CLEAN INSIDE OF COOLING SYSTEM.........................................169 24.2.3 CHECKING COOLANT LEVEL.................................................173 24.2.4 CLEANING THE SYSTEM....................................................174 24.2.5 FILLING THE SYSTEM.....................................................174 24.2.6 REFILLING AN OVERHEATED SYSTEM.........................................175 24.2.8 CLEANING THE RADIATOR PRE-SCREEN.......................................175 24.2.9 REMOVAL/INSTALLATION OF THERMOSTAT ASSEMBLY............................176 24.2.10 CHECK AND TIGHTEN TRACK SHOE BOLTS....................................177 24.2.11 CHECK AND ADJUST TRACK TENSION........................................178 24.2.12 CHECK ELECTRICAL INTAKE AIR HEATER....................................180 24.2.13 CHECK ALTERNATOR......................................................180 24.2.14 CHECK STARTER MOTOR...................................................180 24.2.15 REPLACE BUCKET SIDE CUTTERS...........................................181 24.2.16 REPLACE BUCKET TEETH..................................................181 24.2.17 INSTALLATION OF BUCKET TEETH (ESCO VERTALOK TYPE).....................182 24.2.18 REMOVAL OF BUCKET TEETH (ESCO VERTALOK TYPE)..........................184 24.2.19 ADJUST BUCKET CLEARANCE...............................................186 24.2.20 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID............................187 24.2.21 CHECK, MAINTAIN AIR CONDITIONER.......................................188 24.2.22 CLEAN INLINE FILTER...................................................189 24.3 CHECK BEFORE STARTING........................................................190 24.3.1 CHECK COOLANT LEVEL, ADD COOLANT.......................................190 24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.............................190 24.3.3 CHECK FUEL LEVEL, ADD FUEL.............................................191 24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.............................192 24.3.5 CHECK AIR CLEANER FOR CLOGGING.........................................192 24.3.6 CHECK ELECTRIC WIRINGS.................................................193 24.3.7 CHECK FUNCTION OF HORN.................................................193 24.3.8 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER...........193 24.4 EVERY 50 HOURS SERVICE.......................................................194 24.4.1 LUBRICATING............................................................194 1. BOOM CYLINDER FOOT PIN (2 POINTS)......................................195 2. BOOM FOOT PIN (2 POINTS)...............................................195 3. ARM LINK COUPLING PIN (1 POINT)........................................195 4. ARM BUCKET COUPLING PIN (1 POINT)......................................195 5. LINK COUPLING PIN (2 POINTS)...........................................195 6. BUCKET CYLINDER ROD END (1 POINT)......................................195 7. BUCKET LINK COUPLING PIN (1 POINT).....................................195 24.5 EVERY 100 HOURS SERVICE......................................................196 24.5.1 LUBRICATING............................................................196 1. BOOM CYLINDER FOOT PIN (2 POINTS)......................................196 2. BOOM CYLINDER ROD PIN (2 POINTS).......................................196 3. ARM CYLINDER FOOT PIN (1 POINT)........................................196 4. BOOM ARM COUPLING PIN (1 POINT)........................................196 5. ARM CYLINDER ROD END (1 POINT).........................................196 6. BUCKET CYLINDER FOOT PIN (1 POINT).....................................196 24.5.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.......................197 24.5.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK................................198 24.6 EVERY 250 HOURS SERVICE......................................................199 24.6.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................199 24.6.2 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................200 24.6.3 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......201 24.6.4 LUBRICATE SWING CIRCLE (2 POINTS)......................................202 24.6.5 CHECK FAN BELT TENSION, ADJUST.........................................203 24.6.6 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...............204 24.7 EVERY 500 HOURS SERVICE......................................................205 24.7.1 REPLACE FUEL FILTER CARTRIDGE..........................................205 24.7.2 CHECK SWING PINION GREASE LEVEL, ADD GREASE............................206 24.7.3 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS....207 24.7.4 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER......................208 24.7.5 REPLACE HYDRAULIC TANK BREATHER ELEMENT................................209 24.7.6 REPLACE HYDRAULIC FILTER ELEMENT.......................................210 24.8 EVERY 1000 HOURS SERVICE.....................................................211 24.8.1 CHANGE OIL IN SWING MACHINERY CASE.....................................211 24.8.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL................................212 24.8.3 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.............................212 24.8.4 CHECK PLAY OF TURBOCHARGER ROTOR.......................................212 24.8.5 REPLACE CORROSION RESISTOR CARTRIDGE...................................213 24.9 EVERY 2000 HOURS SERVICE.....................................................214 24.9.1 CHANGE OIL IN FINAL DRIVE CASE.........................................214 24.9.2 CLEAN HYDRAULIC TANK STRAINER..........................................215 24.9.3 CLEAN ENGINE BREATHER..................................................216 24.9.4 CLEAN, CHECK TURBOCHARGER..............................................216 24.9.5 CHECK ALTERNATOR, STARTING MOTOR.......................................216 24.9.6 CHECK ENGINE VALVE CLEARANCE, ADJUST...................................216 24.9.7 CHECK VIBRATION DAMPER.................................................216 24.10 EVERY 4000 HOURS SERVICE....................................................217 24.10.1 CHECK WATER PUMP......................................................217 24.10.2 CHANGE ANTI FREEZE....................................................217 24.11 EVERY 5000 HOURS SERVICE....................................................218 24.11.1 CHANGE OIL IN HYDRAULIC TANK..........................................218 SPECIFICATIONS............................................................................222 25.1 MACHINE SPECIFICATIONS...........................................................223 25.2 EXPLANATION OF LIFTING CAPACITY CHART............................................226 OPTIONS, ATTACHMENTS......................................................................228 26. GENERAL PRECAUTIONS...............................................................229 26.1 PRECAUTIONS RELATED TO SAFETY................................................229 26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS......................................230 27. HANDLING BUCKET WITH HOOK.........................................................231 27.1 CHECKING FOR DAMAGE TO BUCKET................................................231 27.2 PROHIBITED OPERATIONS........................................................231 27.3 PRECAUTIONS DURING OPERATIONS................................................231 28. MACHINES READY FOR ATTACHMENTS....................................................232 28.1 EXPLANATION OF COMPONENTS....................................................232 28.2 HYDRAULIC CIRCUIT............................................................234 28.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE....................................236 28.4 OPERATION....................................................................238 28.5 LONG TERM STORAGE............................................................239 28.6 SPECIFICATIONS...............................................................239 29. INTRODUCTION OF ATTACHMENTS.......................................................240 29.1 SPECIFICATION, USE...........................................................240 29.2 ATTACHMENT INSTALLATION COMBINATION TABLE....................................241 29.3 SELECTION OF TRACK SHOES.....................................................242 29.4 SELECTION OF BUCKET TEETH....................................................243 29.5 HANDLING TRAPEZOIDAL BUCKET..................................................244 29.6 HANDLING THE CLAMSHELL BUCKET................................................245 30. EXTENDING MACHINE SERVICE LIFE....................................................246 30.1 HYDRAULIC BREAKER............................................................246 30.2 POWER RIPPER.................................................................249 30.3 FORK GRAB....................................................................250 30.4 GRAPPLE BUCKET...............................................................251 30.5 SCRAP GRAPPLE................................................................252 30.6 CRUSHER & SMASHER............................................................253 30.7 HYDRAULIC PILE DRIVER........................................................254 30.8 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE..................................255
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