Komatsu PC450-8, PC450LC-8 Service Manual
UEAM007200
Operation &
Maintenance Manual
PC450
PC450LC
HYDRAULIC EXCAVATOR
SERIAL NUMBER
PC450-8 - K50001
PC450LC-8 - K50001
PC450LCD-8 - K50001
PC450LCHD-8 - K50001
-8
-8
and up
and up
and up
and up
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personel who
will come into contact with the machine.
FOREWORD
11
FOREWORD FOREWORD
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most acciden ts
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machi nes. Accidents can be prevented by knowing beforehand conditio ns that may cause a haz ard when performing op eration
and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe
the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manu al carefully so that they shou ld be understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that
all personnel involved in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediat ely contact Komatsu or your Komatsu distributor
to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together
with the machine.
In this manual, measurements are expressed in internationa l standard units (SI). For the reference purpose, weight units used in the p ast are also displayed in ( ).
Storage loca tion for the Operation and Maintenance Manual:
magazine box on the left side of the operator's seat.
1-2
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION 1
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
DANGER
WARNING
CAUTION
Example of safety message using signal word
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury . This word is used also to alert against unsafe practices that may cause
property damage.
WARNING
When standing up from the operator's seat, always place the lock lever in the LOCK position.
If you accidentally touch the control levers when they are n ot locked, this may ca use a serious inju ry or
death.
Other signal words
In addition to the above, the following signal words are used to indicate precaution s that shou ld be followed to protect the machine or to give information that is useful to know.
NOTICE
REMARKS
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
1-3
SAFETY INFORMATION FOREWORD
q Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety pr ocedur es.
Example of safety label using words
Part No
Safety labels using pictogram
Safety pictograms use a picture to expre ss a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or
maintenance worker understand the level and type of hazardous condition at all times.
Safety pictograms show the type of hazardous condition at the
top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazardous condition is displayed inside a triangle and the method
of avoiding the hazardous condition is shown inside a circle.
Part No
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintena nce.
Therefore, the safety messages in this manual and on the machine may not include all po ssible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. 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 of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 J (1))
1-4
FOREWORD SAFETY INFORMATION
Noise emission levels 1
Two labels ind icating the machine noise level a re affixed on the
machine.
q Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
q Sound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
107
1-5
SAFETY INFORMATION FOREWORD
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the operator’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is less than or equal to 0.5 m/s².
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
Operating condition:
Excavating (Digging-loading-rotating-unloading-rotating)
Guide to Reduce Vibration Levels on Machine 1
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
q Tension of crawler (for crawler machines)
q Brake and steering systems
q Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
q Remove any large rocks or obstacles
q Fill any ditches and holes
q Site manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
q Adjust the seat and suspension for the weight and size of the operator
q Wear seat belt
q Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, and move the attachment levers and pedals slowly so that the machine moves
smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
q When pushing with bucket or blade, avoid sudden loading; load gradually
q Drive around obstacles and rough terrain conditions
q Slow down when it is necessary to go over rough terrain
q Make the curve radius of traveling path as large as possible
q Travel at low speed when traveling around sharp curves
1-6
FOREWORD SAFETY INFORMATION
7. Minimize vibrations for long work cycle or long distance traveling
q Reduce speed to prevent bounce
q Transport machines long distances between work sites
8. The following guidelines can be effective to minimize risks of low back pain
q Operate the machine only when you are in good he alt h.
q Provide breaks to reduce long periods of sitting in the same posture
q Do not jump down from the cab or machine
q Do not repeatedly handle and lift loads
1-7
INTRODUCTION FOREWORD
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
q Digging work
q Leveling work
q Ditching work
q Loading work
q Demolition work
See the section “RECOMMENDED APPLICATIONS (3-162)“ for further details.
DIRECTIONS OF MACHINE 1
(A) Front (E) Operator's seat
(B) Rear (F) Sprocket
(C) Left
(D) Right
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
1-8
FOREWORD INTRODUCTION
VISIBILITY FROM OPERATOR'S SEAT 1
The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
PROXIMITY VISIBILITY 1
The visibility of this machine in the area 1 m from the outside surface of the machine at a height of 1.5 m is shown
in the diagram below. The hatched area (A) shows the area where the view is blocked by part of the machine when
mirrors or other aids to visibility are installed as standard. Please be fully aware that there are places that cannot
be seen when operating the machine.
12M CIRCUMFERENCE VISIBILITY 1
The visibility at a radius of 12 m from the machine is as shown in the diagram below. The hatched areas (B) show
the areas where the view is blocked when mirrors or other aids to visibility are installed as standard. Please be
fully aware that there are places that cannot be seen when operating the machine.
1-9
INTRODUCTION FOREWORD
BREAKING-IN THE NEW MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. However, ope rating the machine under full load before bre aking the machine in can adverse ly affect the perf ormance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
q Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
q Idle the engine for 5 minutes after starting it up.
q Avoid operation with heavy loads or at high speeds.
q Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.
1-10
FOREWORD PRODUCT INFORMATION
PRODUCT INFORMATION 1
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1
On the bottom right of the operator's cab
The design of the nameplate differs according to the territory.
EPA REGULATIONS, ENGINE NUMBER PLATE 1
On the upper side of the engine cylinder head cover.
EPA: Environmental Protection Agency, U.S.A.
1-11
PRODUCT INFORMATION FOREWORD
SERVICE METER LOCATION 1
On top of the machine monitor
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product identification number (PIN)
Manufacturers name
Address
Distributor name
Address
Service Personnel
Phone/Fax
KOMATSU UK LTD.
Durham Road
Birtley
Chester-Le Street
County Durham DH32QX
United Kingdom
1-12
FOREWORD PRODUCT INFORMATION
MACHINE SERIAL PLATE 1
MANUFACTURING YEAR
MODEL
SERIAL
WEIGHT
ENGINE POWER
PRODUCT
IDENTIFICATION
NUMBER
MANUFACTURER
MODEL
SERIAL No.
MANUFACT. YEAR
MASS
ENGINE POWER
Product Identification Number
MANUFACTURER
Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan
Komatsu UK Ltd, Birtley, Co Durham, United Kingdom
kg
kW
205-00-K1291
1-13
CONTENTS
CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................1-2
SAFETY INFORMATION...................................................................................................................................... 1-3
Noise emission levels ...................................... ... ... ... ... .... ... ... ... .... ..............................................................1-5
Vibration levels............................................................................................................................................1-6
Guide to Reduce Vibration Levels on Machine..................................................................................1-6
INTRODUCTION................................................................................................................................................... 1-8
DIRECTIONS OF MACHINE ...................................................................................................................... 1-8
VISIBILITY FROM OPERATOR'S SEAT............................... .....................................................................1-9
PROXIMITY VISIBILITY ....................................................................................................................1-9
12M CIRCUMFERENCE VISIBILITY ................................................................................................ 1-9
BREAKING-IN THE NEW MACHINE ....................................................................................................... 1-10
PRODUCT INFORMATION................................................................................................................................1-11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...................................... 1-11
EPA REGULATIONS, ENGINE NUMBER PLATE .......... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 1-11
SERVICE METER LOCATION .................................................................................................................1-12
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ................................................................... 1-12
MACHINE SERIAL PLATE ....................................................................................................................... 1-13
SAFETY
SAFETY INFORMATION...................................................................................................................................... 2-2
SAFETY LABELS.................................................................................................................................................2-4
LOCATION OF SAFETY LABELS..............................................................................................................2-4
SAFETY LABELS ........................ ... .... ... ... ... .... ...................................... .... ... ... ........................................... 2-5
SAFETY INFORMATION.................................................................................................................................... 2-13
SAFETY MACHINE OPERATION...................................................................................................................... 2-22
STARTING ENGINE.................................................................................................................................2-22
OPERATION.............................................................................................................................................2-24
TRANSPORTATION................................................................................................................................. 2-30
BATTERY ................................................................................................................................................. 2-31
TOWING ................................................................................................................................................... 2-33
LIFTING OBJECTS WITH BUCKET......................................................................................................... 2-34
SAFETY MAINTENANCE INFORMATION........................................................................................................2-35
1-14
CONTENTS
OPERATION
MACHINE VIEW ILLUSTRATIONS ..................................................................................................................... 3-2
OVERALL MACHINE VIEW........................................................................................................................ 3-2
CONTROLS AND GAUGES....................................................................................................................... 3-3
Machine Monitor ......................................................................................................................................... 3-4
DETAILED CONTROLS AND GAUGES.............................................................................................................. 3-5
MONITORING SYSTEM............................................................................................................................. 3-5
Basic Operation of Machine Monitor.................................................................................................. 3-6
Emergency Monitors........................................................................................................................ 3-11
Caution Monitors................................. ... ... ... ....................................... ... .... ... ... ... .... ... ... ... ................ 3-13
Basic Check Monitors...................................................................................................................... 3-16
Meter Display Portion ...................................................................................................................... 3-18
Monitor Switches Portion................................................................................................................. 3-25
Handling Function Switches ............................................................................................................ 3-33
Attachment 2 Setting ....................................................................................................................... 3-54
SWITCHES............................................................................................................................................... 3-69
CONTROL LEVERS AND PEDALS ......................................................................................................... 3-75
SUN ROOF............................................................................................................................................... 3-78
WINDSHIELD ........................................................................................................................................... 3-79
EMERGENCY ESCAPE HAMMER.......................................................................................................... 3-84
DOOR LOCK ............................................................................................................................................ 3-85
CAP WITH LOCK...................................................................................................................................... 3-85
DRINK BOX.............................................. ... ... ... ... .... ... ... ... ....................................... ... .... ......................... 3-87
MAGAZINE BOX....................................................................................................................................... 3-87
ASHTRAY................................................................................................................................................. 3-87
AIR CONDITIONER CONTROLS............................................................................................................. 3-88
Air Conditioner Control Panel.......................................................................................................... 3-88
Method of Operation........................................................................................................................ 3-92
Use Air Conditioner with Care ............... ... ... .... ... ... ... .... ... ... ... .... ... .......................................... ......... 3-98
Inspection and maintenance of Air Conditioner Equipped Machine................................................ 3-99
RADIO..................................................................................................................................................... 3-100
Control Panel......... ... ... ... .... ...................................... .... ... ... ... .... ... ... ... ... ........................................ 3-100
Controls of Radio........................................................................................................................... 3-102
Use Radio with Care...................................................................................................................... 3-104
Space for radio cassette................................................................................................................ 3-104
AUXILIARY ELECTRIC POWER.......................... .... ... ... ... .......................................... ........................... 3-105
24V Power Source......................................................................................................................... 3-105
12V Power Source......................................................................................................................... 3-105
FUSE ...................................................................................................................................................... 3-106
FUSIBLE LINK...... ... ....................................... ... ... .... ... ... ... ....................................... ... .... ....................... 3-107
CONTROLLER ....................................................................................................................................... 3-107
TOOL BOX.............................................................................................................................................. 3-108
GREASE PUMP HOLDER.............................................................................................................
FIRE EXTINGUISHER............................................................................................................................ 3-108
REFUELLING PUMP.............................................................................................................................. 3-109
ACCUMULATOR.................................................................................................................................... 3-110
......... 3-108
1-15
CONTENTS
Releasing Hydraulic Pressure With Accumulator .......................................................................... 3-110
MACHINE OPERATIONS AND CONTROLS................................................................................................... 3-111
BEFORE STARTING ENGINE ........... ... ....................................... ... ... ... .... ... ... ... ... .... .............................3-111
Walk-around Checks ..................................................................................................................... 3-111
Checks Before Starting..................................................................................................................3-112
Adjustment..................................................................................................................................... 3-119
Seat Belt .......................... ... ... .... ...................................... .... ... ... ... .... ............................................. 3-125
Operations Before Starting Engine...................................................... ... ... ... .... ... ... ... .... ... ... ... ... ....3-126
STARTING ENGINE............................................................................................................................... 3-128
AFTER STARTING ENGINE ................. .......................................... ... .......................................... .......... 3-131
Engine Warm Up .......................................... ... ... .... ... ... ... .... ... ... ....................................... ............. 3-131
Hydraulic Equipment Warm Up .....................................................................................................3-133
Operation After Completion Of Warm-Up Operation ..................................................................... 3-139
STOPPING THE ENGINE ........................ ... .... ...................................... .... ... ... ... ... .................................3-141
MACHINE OPERATION ......................................................................................................................... 3-142
Preparations for Moving the Machine............................................................................................3-142
Moving Machine Forward .............................................................................................................. 3-143
Moving Machine Backward............................................................................................................3-144
Stopping Machine..........................................................................................................................3-145
STEERING THE MACHINE....................................................................................................................3-146
Steering .........................................................................................................................................3-146
SWINGING ............................................................................................................................................. 3-148
WORK EQUIPMENT CONTROLS AND OPERATIONS ........................................................................3-149
WORKING MODE...................................................................................................................................3-151
PROHIBITED OPERATIONS .................................................................................................................3-153
GENERAL OPERATION INFORMATION ..............................................................................................3-157
TRAVELING ON SLOPES...................................................................................................................... 3-159
ESCAPE FROM MUD............................................................................................................................. 3-161
Track on One Side Stuck...............................................................................................................3-161
Tracks on Both Sides Stuck........................................................................................................... 3-161
RECOMMENDED APPLICATIONS........................................................................................................3-162
Backhoe Work ...............................................................................................................................3-162
Shovel Work ..................................................................................................................................3-162
Ditching Work ......................................... ... ... ... ... .... ...................................... .... ... ... ... .... ................3-162
Loading Work................................................ ... ... .... ... ... ... ....................................... ... .... ................3-163
BUCKET REPLACEMENT AND INVERSION........................................................................................3-164
Replacement.................................................................................................................................. 3-164
Inversion ........................................................................................................................................ 3-165
PARKING MACHINE ......... ....................................... ... .... ... ....................................... ... ... ... ....................3-166
MACHINE INSPECTION AFTER DAILY WORK....................................................................................3-168
LOCKING................................................................................................................................................3-168
TRANSPORTATION...............................................................................................................................
TRANSPORTATION PROCEDURE....................................................................................................... 3-169
LOADING AND UNLOADING WITH TRAILER ...................................................................................... 3-170
Loading.......................................................................................................................................... 3-171
Securing Machine.......................................................................................................................... 3-173
1-16
..........3-169
CONTENTS
Unloading....................................................................................................................................... 3-176
LIFTING MACHINE................................................................................................................................. 3-178
TRANSPORTATION POSTURE ............................................................................................................ 3-180
PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE...................................... 3-182
COLD WEATHER OPERATION...................................................................................................................... 3-184
COLD WEATHER OPERATION INFORMATION................................................................................... 3-184
Fuel and Lubricants...................................................... .......................................... ....................... 3-184
Cooling System Coolant................................................................................................................ 3-184
Battery ........................................................................................................................................... 3-185
AFTER DAILY WORK COMPLETION.................................................................................................... 3-186
AFTER COLD WEATHER SEASON......................................................................................................3-186
LONG TERM STORAGE.................................................................................................................................. 3-187
BEFORE STORAGE............................................................................................................................... 3-187
DURING STORAGE............................................................................................................................... 3-187
AFTER STORAGE.................................................................................................................................. 3-188
STARTING MACHINE AFTER LONG-TERM STORAGE ...................................................................... 3-188
TROUBLES AND ACTIONS ............................................................................................................................ 3-189
RUNNING OUT OF FUEL .... ... .... ... ... ... ....................................... ... .... ... ... ... ... ........................................ 3-189
PHENOMENA THAT ARE NOT FAILURES........................................................................................... 3-190
TOWING THE MACHINE ....................................................................................................................... 3-190
LIGHTWEIGHT TOWING HOLE ............................................................................................................ 3-191
SEVERE JOB CONDITION.................................................................................................................... 3-191
DISCHARGED BATTERY ...................................................................................................................... 3-192
Battery Removal and Installation................................................................................................... 3-192
Battery Charges............................................................................................................................. 3-193
Starting Engine with Booster Cables............................................... ... ... .... ... ... ... .... ... ... ... ... .... ... .... 3-194
OTHER TROUBLE ................................................................................................................................. 3-196
Electrical System........................................................................................................................... 3-196
Chassis.......................................................................................................................................... 3-197
Engine............................................................................................................................................ 3-198
Electronic Control System ............................................................................................................. 3-199
Point of Contact to Telephone when Error Occurs........................................................................ 3-200
MAINTENANCE
MAINTENANCE INFORMATION......................................................................................................................... 4-2
OUTLINE OF SERVICE........................................................................................................................................ 4-4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ............................................. ... ... .. 4-4
OIL..................................................................................................................................................... 4-4
FUEL.................................................................................................................................................. 4-5
COOLANT AND WATER FOR DILUTION ........................................................................................ 4-5
GREASE............................................................................................................................................ 4-6
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) .................................................................... 4-6
STORING OIL AND FUEL................................................................................................................. 4-7
1-17
CONTENTS
FILTERS............................................................................................................................................4-7
EXPLANATION OF LUBRICATION CHART DECAL
....................................................................................................................................................................4-8
ELECTRIC SYSTEM MAINTENANCE .....................................................................................................4-10
WEAR PARTS....................................................................................................................................................4-11
WEAR PARTS LIST..................................................................................................................................4-11
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .................................................................................4-12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU
GENUINE OIL........... ... ....................................... ... ... ... .... ... ... ....................................... ... .........................4-14
TIGHTENING TORQUE SPECIFICATIONS ...................................................................................................... 4-15
TIGHTENING TORQUE LIST...................................................................................................................4-15
SAFETY CRITICAL PARTS...............................................................................................................................4-16
SAFETY CRITICAL PARTS LIST.............................................................................. ... ... ... .... ... ... ... ......... 4-16
MAINTENANCE SCHEDULE.............................................................................................................................4-17
MAINTENANCE SCHEDULE CHART......................................................................................................4-17
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER..................................................................... 4-19
MAINTENANCE PROCEDURE.......................................................................................................................... 4-20
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...............................4-20
WHEN REQUIRED................................................................................ .... ... ... ... ... .... ...............................4-21
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT......................................................... 4-21
CLEAN INSIDE OF COOLING SYSTEM ........................................................................................ 4-27
CHECK AND TIGHTEN TRACK SHOE BOLTS..............................................................................4-30
CHECK AND ADJUST TRACK TENSION....................................................................................... 4-31
REPLACE BUCKET TEETH (VERTICAL PIN TYPE) ..................................................................... 4-33
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................................4-36
REPLACE BUCKET SIDE CUTTER, SHROUD........ ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 4-38
ADJUST BUCKET CLEARANCE ........... ... ... ... ... .... ... ... ... .......................................... .... ... ... ... ... ......4-39
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................4-40
CHECK AND MAINTENANCE AIR CONDITIONER ....................................................................... 4-41
WASH WASHABLE FLOOR .. .... ...................................... .... ... ... ... .... ... ... ... ... ................................... 4-42
BLEEDING AIR FROM HYDRAULIC SYSTEM...............................................................................4-45
CHECK BEFORE STARTING ......................................................................... ......................................... 4-47
EVERY 50 HOURS MAINTENANCE........................................................................................................4-48
LUBRICATING.................................................................................................................................4-48
EVERY 250 HOURS MAINTENANCE...................................................................................................... 4-49
LUBRICATE SWING CIRCLE ...... ....................................... ... ... ... .... ... ... ....................................... .. 4-49
CHECK LEVEL OF BATTERY ELECTROLYTE ............................................................................. 4-50
CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST..................................................... 4-52
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST..................................... 4-53
EVERY 500 HOURS MAINTENANCE...................................................................................................... 4-54
LUBRICATING.................................................................................................................................4-54
REPLACE FUEL PRE-FILTER CARTRIDGE..................................................................................4-55
CHECK SWING PINION GREASE LEVEL, ADD GREASE............................................................4-58
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....................4-59
1-18
CONTENTS
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND
CONDENSER FINS......................................................................................................................... 4-61
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS................................................................ 4-62
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK ............................................ ....... ... ... ... 4-64
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...................................................... 4-65
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL .................................................................. 4-66
EVERY 1000 HOURS MAINTENANCE....................................................................................................4-67
REPLACE FUEL MAIN FILTER CARTRIDGE ................................................................................ 4-67
REPLACE HYDRAULIC OIL FILTER ELEMENT............................................................................ 4-70
CHANGE OIL IN SWING MACHINERY CASE ............................................................................... 4-71
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL......................................................................... 4-72
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS ............................... 4-72
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT .......................................... 4-73
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker) .................... 4-73
REPLACE CORROSION RESISTOR CARTRIDGE ....................................................................... 4-74
EVERY 2000 HOURS MAINTENANCE....................................................................................................4-75
CHANGE OIL IN FINAL DRIVE CASE............................................................................................ 4-75
CLEAN HYDRAULIC TANK STRAINER ......................................................................................... 4-76
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL
CIRCUIT)......................................................................................................................................... 4-76
CHECK ALTERNATOR................................................................ ... ... ... .... ... ... ... .... ... ... ................... 4-79
CHECK ENGINE VALVE CLEARANCE, ADJUST.......................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... 4-79
CHECK VIBRATION DAMPER ................................................. ... ... ... .......................................... ... 4-79
EVERY 4000 HOURS MAINTENANCE....................................................................................................4-80
CHECK WATER PUMP................................... ... ... ... .... .......................................... ... ...................... 4-80
CHECK STARTING MOTOR........................................................... .......................................... ... ... 4-80
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT).............................................................. 4-80
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER4-81
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.............. 4-81
EVERY 5000 HOURS MAINTENANCE....................................................................................................4-82
CHANGE OIL IN HYDRAULIC TANK.............................................................................................. 4-82
EVERY 8000 HOURS MAINTENANCE....................................................................................................4-84
REPLACE HIGH-PRESSURE PIPING CLAMP .............................................................................. 4-84
REPLACE FUEL SPRAY PREVENTION CAP................................................................................ 4-84
SPECIFICATIONS
SPECIFICATIONS................................................................................................................................................ 5-2
ATTACHMENTS ANDD OPTIONS
GENERAL PRECAUTIONS FOR SAFETY.......................................................................................................... 6-2
PRECAUTIONS WHEN SELECTING....................... ... ... .......................................... ... .... ... ... ... .................. 6-2
READ THE INSTRUCTION MANUAL THOROUGHLY.............................................................................. 6-2
PRECAUTIONS WHEN REMOVING OR INSTALLING............................................................................. 6-2
PRECAUTIONS WHEN USING................... ... ... ... .... ... ... ... .... ... ... ... .......................................... .................. 6-3
1-19
CONTENTS
HYDRAULIC QUICK COUPLER PIPING.............................................................................................................6-4
LOCATIONS...................................................................................................................................... 6-4
OPERATION......................................................................................................................................6-5
BUCKET WITH HOOK ......................................................................................................................................... 6-7
HOOK CONDITION .................................................................................................................................... 6-7
PROHIBITED OPERATIONS .....................................................................................................................6-7
MACHINE READY FOR ATTACHMENT ............................................................................................................. 6-8
LOCATIONS ............................................................................................................................................... 6-8
HYDRAULIC CIRCUIT..............................................................................................................................6-12
Switching Hydraulic Circuit ........................... ................................................................................... 6-12
Adjusting Oil Flow............................................................................................................................ 6-12
Switching Between Breaker and General Attachment...................... ... ... ... ... .... ... ... ... .... ... ...............6-12
Hydraulic Circuit Connection ........................................................................................................... 6-13
Oil Flow Path ...................................................................................................................................6-14
Replace Additional Breaker Filter Element......................................................................................6-15
ATTACHMENT REMOVAL AND INSTALLATION.................................................................................... 6-17
Attachment Removal ....................................................................................................................... 6-17
Attachment Installation ................................. ... ... .... ... ... ... ....................................... ... .... ... ...............6-19
ATTACHMENT OPERATIONS................................................................................................................. 6-21
Operation When Using Breaker.......................................................................................................6-21
Operation When Using General Attachment 1 (e.g. Crusher). ........................................................6-23
Working Mode Selection.................................................. .... ... ... ... .... ... ... ... ... ................................... 6-24
Operation When Using Attachment 2 (e.g clamshell rotation, crusher rotation)..............................6-25
LONG TERM STORAGE.......................................................................................................................... 6-25
SPECIFICATIONS....................................................................................................................................6-25
ATTACHMENT GUIDE.......................................................................................................................................6-26
ATTACHMENT COMBINATIONS............................................................................................................. 6-26
SELECTION OF TRACK SHOES.............................................................................................................6-28
METHOD OF SELECTING SHOES ................................................................................................6-28
RECOMMENDED ATTACHMENT OPERATIONS............................................................................................. 6-29
HYDRAULIC BREAKER...........................................................................................................................6-29
HANDLING MACHINES EQUIPPED WITH KOMTRAX....................................................................................6-33
BASIC PRECAUTIONS ............ ... ... .... ... ... ... .... ... ... ....................................... ... ... ... .... ... ... ... .... ... ...............6-33
SUPER LONG FRONT BOOM AND ARM.........................................................................................................6-34
OPERATION INSTRUCTION ................................................................................................................... 6-34
WORKING MODES .................................................................................................................................. 6-35
CHECKS BEFORE STARTING....................................................................................................... 6-36
USING SUPER LONG FRONT .......................................................................................................6-36
METHOD OF WORK................................................. ... ... ....................................... ... .... ... ... ... ......... 6-38
WHEN TRAVELLING ...................................................................................................................... 6-38
CONTROL LEVERS, PEDALS........................................................................................................6
-39
TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE ........................................................6-42
INSTALLATION OF SUPPORTING LINK ....................................................................................... 6-42
1-20
CONTENTS
TRANSPORTATION OF SUPER LONG FRONT MACHINE.......................................................... 6-43
WORKING RANGE OF SUPER LONG FRONT....................................................................................... 6-44
LIFTING CAPACITY PC450 LC 20m SUPER LONG FRONT ........................................................ 6-45
MAINTENANCE........................................................................................................................................ 6-46
SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT.......... 6-46
EVERY 50 HOURS SERVICE......................................................................................................... 6-47
EVERY 100 HOURS SERVICE...................................................................................................... 6-48
HIGH REACH DEMOLITION EQUIPMENT 27M
GENERAL VIEW OF MACHINE........................................................................................................................... 7-2
CAUTION ITEMS............................................................................................................................... 7-3
POSITION FOR ATTACHING SAFETY LABELS................................................................................................ 7-4
POSITION FOR ATTACHING SAFETY LABELS....................................................................................... 7-4
SAFETY LABELS ....................................................................................................................................... 7-5
CONTROL LEVERS AND SWITCHES ................................................................................................................ 7-6
SAFETY LOCK LEVER .............................................................................................................................. 7-6
TRAVEL LEVERS....................................................................................................................................... 7-7
WORK EQUIPMENT CONTROL LEVERS................................................................................................. 7-8
ATTACHMENT ROTATION (with auto-deceleration)................................................................................. 7-9
INTERMEDIATE LINK CONTROL PEDAL (with auto-deceleration) ........................................................ 7-10
CRUSHER CONTROL FOR OPENING AND CLOSING.......................................................................... 7-11
TILTING CAB MECHANISM OPERATION............................................................................................... 7-12
BOOM ANGLE ALARM BUZZER CANCEL SWITCH.................................... .... ... ... ... .... ... ... ... ... .... ... ... ... 7-13
CEILING WINDOW WIPER SWITCH....................................................................................................... 7-14
MACHINE OPERATIONS AND CONTROLS..................................................................................................... 7-15
BEFORE STARTING ENGINE ................................................................................................................. 7-15
FUNCTION CHECK.................................................................................................................................. 7-16
PRECAUTIONS WHEN OPERATING......................... ... .......................................... ... .............................7-16
PROHIBITON OF WORK OUTSIDE SPECIFIED WORKING RANGE.................................................... 7-17
PROHIBITION OF WORK AT THE STROKE END OF A CYLINDER...................................................... 7-20
PROHIBITION OF WORK WITH HYDRAULIC BREAKER ...................................................................... 7-21
WHEN WORKING IN MEDIUM REACH CONFIGURATION ................................................................... 7-21
OPERATION....................................................................................................................................................... 7-22
ADJUSTMENT OF HYDRAULIC VARIABLE GAUGE UNDERCARRIAGE, (Where Fitted).................... 7-22
OPERATING WORK EQUIPMENT .......................... ... ... ... .... ... ... ... .... ...................................... ... .... ... ...... 7-23
ATTACHMENT CONTROL................................ ... .......................................... .......................................... 7-24
RAISING WORK EQUIPMENT................................................................................................................. 7-25
WORKING RANGE AND USING RANGE OF BOOM.............................................................................. 7-27
POSTURE WHEN LEAVING MACHINE .................................................................................................. 7-30
DEMOLITION DIGGING BOOM INSTALLATION AND REMOVAL.................................................................. 7-31
PROCEDURE FOR INSTALLATION AND REMOVAL OF DEMOLITION DIGGING EQUIPMENT........ 7-31
REMOVAL OF HIGH REACH WORK EQUIPMENT....................................................................... 7-31
1-21
CONTENTS
FITTING DEMOLITION DIGGING EQUIPMENT.......... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .. 7-35
REMOVAL OF DEMOLITION DIGGING EQUIPMENT...................................................................7-39
CONNECTING DIGGING ARM TO DEMOLITION DIGGING BOOM............................................. 7-39
MEDIUM REACH.............................................................................................................................7-40
PURGING AIR PROCEDURES.......................................................................................................................... 7-41
PURGING PROCEDURE TO REMOVE AIR FROM HYDRAULIC CYLINDER LINES............................ 7-41
PROCEDURE FOR PURGING AIR FROM BOOM LOCK VALVE PPC CIRCUIT................................... 7-41
PURGING AIR FROM HYDRAULIC DRIFT PREVENTATIVE VALVE PPC CIRCUITS OF MID LINK AND
ARM CYLINDER....................................................................................................................................... 7-43
TRANSPORTATION
(high reach demolition equipment fitted) .......................................................................................................7-45
PROCEDURE FOR LOADING ON TO TRAILER..................................................................................... 7-45
TRANSPORTATION (demolition digging equipment fitted)......................................................................7-46
PROCEDURE FOR LOADING ON TO TRAILER............................................................................ 7-46
TRANSPORTATION (high reach demolition equipment alone)................................................................ 7-46
PROCEDURE FOR LOADING ON TO TRAILER............................................................................ 7-46
SPECIFICATIONS.............................................................................................................................................. 7-51
WORKING RANGE (PC450LCD HIGH REACH) .....................................................................................7-51
WORKING RANGE (PC450LCD MEDIUM REACH)................................................................................ 7-52
WORKING RANGE (PC450LCD LOW REACH) ......................................................................................7-53
WORKING RANGE (PC450LCD DIGGING) ............................................................................................7-54
WEIGHTS AND DIMENSIONS.................................................................................................................7-55
TRANSPORTATION (High and Medium Reach work equipment) - PC450LCD ......................................7-56
TRANSPORTATION (Digging equipment) - PC450LCD.......................................................................... 7-57
EXPLANATION OF LIFTING CAPACITY CHART....................................................................................7-58
INDEX
COLOPHON
1-22
SAFETY
12
WARNING
Please read and make sure that you fully understand the
precautions described in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precautions strictly.
SAFETY INFORMATION SAFETY
SAFETY INFORMATION 2
SAFETY LABELS................................................................................................................................................ 2-42
LOCATION OF SAFETY LABELS............................ ... ... .... ... ... ... .... ... ... ... ....................................... ............ 2-42
SAFETY LABELS.........................................................................................................................................2-52
SAFETY INFORMATION
Safety rules................................................................................................................................................ 2-132
If problems are found.................................................................................................................................2-132
Working wear and personal protective items.............................................................................................2-132
Fire extinguisher and first aid kit ................................................................................................................ 2-132
Safety equipment.......................................................................................................................................2-142
Keep machine clean...................................................................................................................................2-142
Keep operator's compartment clean ..........................................................................................................2-142
Leaving operator's seat with lock............................................................................................................... 2-142
Handrails and steps .................. ... ... ... .... ... .......................................... .......................................................2-152
Precautions when working in high place.................................................................................................... 2-152
Mounting and dismounting.........................................................................................................................2-152
No persons on attachments.......................................................................................................................2-152
Do not get caught in articulated portion ........................................................................ ... ... ... ....................2-152
Burn prevention..........................................................................................................................................2-162
Fire prevention and explosion prevention..................................................................................................2-162
Action if fire occurs.....................................................................................................................................2-172
Windshield washer fluid ............... ... ... .... ... ... ... .... ... ... ... ... .... ... .......................................... ..........................2-172
Falling objects, flying objects and intruding objects prevention ................................................................. 2-182
Attachment installation.... ... .......................................... .......................................... .................................... 2-182
Attachment combinations.................................... ... ... ... ... .......................................... ................................. 2-182
Cab window glasses .................... ... ... .... ... ... ... .......................................... .................................................2-182
Unauthorized modifications ........................................................................................................................ 2-192
Safety at jobsite.......................................................................................................................................... 2-192
Working on loose ground........................................................................................................................... 2-19
Distance to high voltage cables .................................................................................................................2-202
Ensure good visibility .................................................................................................................................2-202
Ventilation for enclosed area......................................................................................................................2-212
Signalman's signal and signs.............................. .......................................... ... ... ... ... ................................. 2-212
Emergency exit from operator's cab .......................................................................................................... 2-212
Asbestos dust hazard prevention............................................................................................................... 2-212
2
SAFETY MACHINE OPERATION .................................................................................................................... 2-222
STARTING ENGINE..................................................................................................................................2-222
Checks before starting engine ............................................................................................................2-222
Safety rules for starting engine ...........................................................................................................2-232
Starting engine in cold weather...........................................................................................................2-232
OPERATION.............................................................................................................................................. 2-242
Checks before operation.....................................................................................................................2-242
Safety rules for changing machine directions ..................................................................................... 2-242
Safety rules for traveling .....................................................................................................................2-252
Traveling on slopes............................................................................................................................. 2-252
Operations on slopes................................................................ ... ... ... .... ... .......................................... 2-262
Prohibited operations.......................................................................................................................... 2-272
Operations on snow..................................................................... ... ... .... ... .......................................... 2-282
Parking machine................................... ... .... ... ... ... ... .... ... ... ....................................... ... .......................2-292
TRANSPORTATION..................................................................................................................................2-302
Loading and unloading........................................................................................................................2-302
Shipping the machine .........................................................................................................................2-302
BATTERY................................................................................................................................................... 2-312
2-2
SAFETY SAFETY INFORMATION
Battery hazard prevention................................................................................................................... 2-312
Starting engine with booster cables.................................................................................................... 2-322
TOWING ....................................................................................................................................................2-332
Safety rules for towing ........................................................................................................................ 2-332
LIFTING OBJECTS WITH BUCKET.......................................................................................................... 2-342
Safety rules for lifting objects..............................................................................................................2-342
SAFETY MAINTENANCE INFORMATION....................................................................................................... 2-352
Warning Tag .............................................................................................................................................. 2-352
Keep Work Place Clean and Tidy... ... ... ... .... ... ... ... .......................................... ... .... ... ... ... ........................... 2-352
Appoint Leader when Working with Others.................. ... ... ... .... ... ... ... .... ... ................................................. 2-352
Stop Engine Before Carrying Out Maintenance.........................................................................................2-362
Two Workers for Maintenance when Engine is Running ........................................................................... 2-36 2
Proper Tools ......... ....................................... ... ... ... ... .... ... ....................................... ... ... .............................. 2-372
Accumulator, Gas spring............................................................................................................................ 2-372
Personnel...................................................................................................................................................2-372
Attachments............................................................................................................................................... 2-382
Work Under the Machine ........................................................................................................................... 2-382
Noise.......................................................................................................................................................... 2-382
When Using Hammer................................................................................................................................. 2-382
Welding Works............................ .... ... ... ... .... ...................................... .... ... ... ... ... ........................................ 2-382
Removing Battery Terminals................. ... .... ... ... ... .......................................... ........................................... 2-392
Safety First when Using High-pressure Grease to Adjust Track Tension.................................................. 2-392
Do Not Disassemble Recoil Springs.......................................................................................................... 2-392
Safety Rules for High-pressure Oil ............................................................................................................ 2-392
Precaution for High Fuel Pressure............................... ... ... ... .... ... ... ... .... ... ... ..............................................2-402
Safety Handling High-pressure Hoses....................................................................................................... 2-402
Precaution for High Voltage................................................................... .................................................... 2-402
Waste Materials ......................................................................................................................................... 2-412
Air Conditioner Maintenance...................................................................................................................... 2-412
Compressed Air......................................................................................................................................... 2-412
Periodic Replacement of Safety Critical Parts ................................................................................
........... 2-412
2-3
SAFETY LABELS SAFETY
SAFETY LABELS 2
The following warning signs and safety labels are used on this machine.
q Be sure that you fully understand the correct position and content of labels.
q To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
q There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
q If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
LOCATION OF SAFETY LABELS 2
a: if equipped
2-4
SAFETY SAFETY LABELS
SAFETY LABELS
1. (20Y-00-K2020)
q Warnings for operation , inspection and maintenance
q Improper operation and maintenance can cause serious
injury or death.
q Read the manual and labels before operation and mainte-
nance.
Follow instructions and warnings in manual and in labels on
machine.
q Warning!
q a. Read the manual before operating, maintenance, disas-
sembly, assembly and transportation.
2-5
SAFETY LABELS SAFETY
q b. Always apply lock when leaving operator’s seat.
q c. WARNING - No passengers
No passengers allowed to ride on machine while it is moving
q d. WARNING - DANGER OF FALLING OBJECTS
Do not operate where a danger of falling objects exists.
Consult your dealer for fitting of FOPS protection
.
2-6
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