Page 1 EEAM008402 Operation & Maintenance Manual PC450 PC450LC HYDRAULIC EXCAVATOR PC450-6K - K30001 SERIAL NUMBERS AND UP PC450LC-6K - K30001 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 near the machine for reference and periodically reviewed by all personnel who will come into contact with it.
Page 3: Foreword
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.
Page 4: Safety Information
If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact Komatsu or your Komatsu distributor.
Page 5 2. SAFETY INFORMATION 2.2. NOISE Operator ears noise value Ambient noise value (Sound pressure level) (Sound power level) 95/27/EC 95/27/EC Noise level indicated is the guaranteed value as specified in the directive 86/662/EEC as amended by 95/27/EC 2.3. VIBRATION • The weighted root mean square acceleration value to which the operator’s arms are subjected does not exceed 2.5 m/s •...
Page 6: Introduction
If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user.
Page 7: Location Of Plates, Table To Enter Serial No. And Distributor
The engine dataplate is located on the fuel pump side of the rocker housig. 4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No.: Engine serial No.: Manufactureres name: Komatsu UK Ltd Address Durham Road Birtley Chester-Le-Street County Durham DH32QX...
Page 8: Machine Serial Plate
4.4 MACHINE SERIAL PLATE. MODEL SERIAL No MANUFACTURING YEAR WEIGHT ENGINE POWER MANUFACTURER Produced by Komatsu UK Ltd. for Komatsu Ltd, Tokyo, Japan.
Page 9: Table Of Contents
5. CONTENTS Foreword ............................0-1 Safety information ..........................0-2 Introduction ............................0-4 Location of plates, table to enter serial No. and distributor ..............0-5 SAFETY General Precautions .......................... 1-2 Precautions during operation ......................1-8 7.1 Before starting engine ........................1-8 7.2 Operating machine ........................
Page 10 5. CONTENTS 12. Operation 12.1 Check before starting engine ....................2-38 12.2 Starting engine ........................2-48 12.3 Operations and checks after starting engine ................2-51 12.4 Moving machine off ......................... 2-57 12.5 Steering machine ........................2-60 12.6 Stopping machine ........................2-62 12.7 Swinging ..........................
Page 11 5. CONTENTS MAINTENANCE 17. Guides to maintenance ........................3-2 18. Outlines of service ..........................3-5 18.1 Outline of oil, fuel, coolant ......................3-5 18.2 Outline of electric system ......................3-9 18.3 Outline of hydraulic system ....................3-10 19. Wear parts list ..........................3-11 20.
Page 12 5. CONTENTS OPTIONS AND ATTACHMENTS 26 General Precautions .......................... 5-2 26.1 General precautions related to safety ..................5-2 26.2 Precautions when installing attachments ................... 5-3 27. Handling bucket with hook ......................... 5-4 27.1 Checking for damage to bucket with hook ................. 5-4 27.2 Prohibited operations .........................
Page 13: Safety
SAFETY WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equipment and attachments.
Page 14: General Precautions
WARNING: For reasons of safety, 6. GENERAL PRECAUTIONS always follow these safety precautions. SAFETY RULES • ONLY trained and authorised personnel can operate and maintain the machine. • Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
Page 15: Unauthorised Modification
UNAUTHORISED MODIFICATION • Any modification made without authorisation from Komatsu can create hazards. • Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorised modification. ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT •...
Page 16 WARNING: For reasons of safety, always follow these safety precautions. 6. GENERAL PRECAUTIONS FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARD- OUS. • Keep flames away from flammable fluids. •...
Page 17: Asbestos Dust Hazard Prevention
Asbestos dust can be HAZARDOUS to your health if it is inhaled. Your Komatsu machine and genuine Komatsu spare parts do not contain any asbestos. Use only genuine Komatsu spare parts. If spare parts containing asbestos are used, the following precautions must be observed: •...
Page 18 For details of safety guards, please contact your Komatsu distributor. Also, even for other types of work, if there is any danger of being hit by falling or flying objects or of objects entering the operator’s cab, select and install a guard that matches the working conditions.
Page 19 • Do not use attachments that are not authorised by Komatsu or your Komatsu distributor. Use of unauthor- ised attachments could create a safety problem and adversely affect the proper operation and useful life of the machine.
Page 20: Precautions During Operation
7. PRECAUTIONS DURING OPERATION 7.1 BEFORE STARTING ENGINE SAFETY AT WORKSITE • Before starting the engine, thoroughly check the area for any unu- sual conditions that could be dangerous. • Before starting the engine, examine the terrain and soil conditions of the worksite.
Page 21 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION VENTILATION FOR ENCLOSED AREAS • If it is necessary to start the engine within an enclosed area, provide adequate ventilation. Exhaust fumes from the engine can KILL. PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS •...
Page 22: Operating Machine
WARNING: For reasons of safety, always follow these safety precautions. 7. PRECAUTIONS DURING OPERATION 7.2 OPERATING MACHINE WHEN STARTING THE ENGINE • Walk around for machine again just before mounting it, to check for people and objects that might be in the way.
Page 23 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION PRECAUTIONS WHEN TRAVELLING • Fold in the work equipment as shown in the diagram below, and keep it at a height of 40-50 cm (16 to 20 in) from the ground level before starting to travel.
Page 24 WARNING: For reasons of safety, always follow these safety precautions. 7. PRECAUTIONS DURING OPERATION PROHIBITED OPERATIONS • Do not dig the work face under an overhang. This may cause the overhang to collapse and fall on top of the machine. •...
Page 25: Ensure Good Visibility
WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION DO NOT HIT WORK EQUIPMENT • When working in places where there are height limits, such as in tunnels, under bridges, under electric cables, or in garages, be extremely careful not to hit the boom or arm.
Page 26: Operations On Slopes
WARNING: For reasons of safety, always follow these safety precautions. 7. PRECAUTIONS DURING OPERATION OPERATIONS ON SLOPES INCORRECT • When working on slopes, there is danger that the machine may lose its balance and turn over when the swing or work equip- ment are operated.
Page 27: Transportation
WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.3 TRANSPORTATION LOADING AND UNLOADING • Loading and unloading the machine always involves potential hazards. EXTREME CAUTION SHOULD BE USED. When loading or unloading the machine, run the engine at low idling and travel at low speed. •...
Page 28: Battery
WARNING: For reasons of safety, always follow these safety precautions. 7. PRECAUTIONS DURING OPERATION 7.4 BATTERY BATTERY HAZARD PREVENTION • Battery electrolyte contains sulphuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. •...
Page 29: Towing
WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.5 TOWING WHEN TOWING, ATTACH WIRE TO FRAME • Injury or death could result if a disabled machine is towed incorrectly. • If you machine is towed by another machine, ALWAYS use a wire rope with a sufficient towing capacity. •...
Page 30: Bucket With Hook
WARNING: For reasons of safety, 7. PRECAUTIONS DURING OPERATION always follow these safety precautions. 7.6 BUCKET WITH HOOK 7.6.1 GENERAL PRECAUTIONS SPECIAL HOOK • When carrying out lifting work, the special lifting hook is nec- GEFAHR essary. • The following operations are prohibited. °...
Page 31 WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION OPERATION SUPERVISOR • Before performing lifting operation, designate an operation supervisor. Always execute operation according to his instructions. ° Execute operating methods and procedures under his direction. °...
Page 32: Precautions For Lifting Operation
WARNING: For reasons of safety, always follow these safety precautions. 7. PRECAUTIONS DURING OPERATION 7.6.2 PRECAUTIONS FOR LIFTING OPERATION GRADUAL LIFTING OPERATION • When carrying out lifting operations, run the engine at low idling and use the L.O. (lifting operation mode). •...
Page 33: Precautions For Maintenance
8. PRECAUTIONS FOR MAINTENANCE 8.1 BEFORE CARRYING OUT MAINTENANCE WARNING TAG • If others start the engine or operate the controls while you are performing service or lubrication, you could suffer serious injury or death. • ALWAYS attach the WARNING TAG to the control lever in the operator’s cab to alert others that you are working on the machine.
Page 34 WARNING: For reasons of safety, always follow these safety precautions. 8. PRECAUTIONS FOR OPERATION STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE • Always stop the machine on firm flat ground and stop the engine before carrying out inspection and main- tenance.
Page 35: Radiator Water Level
Failure to follow these safety precau- tions may lead to a serious accident. 8. PRECAUTIONS FOR OPERATION RADIATOR WATER LEVEL • If it is necessary to add water to the radiator, stop the engine and allow the engine and radiator to cool down before adding the water.
Page 36: During Maintenance
WARNING: For reasons of safety, always follow these safety precautions. 8. PRECAUTIONS FOR MAINTENANCE 8.2 DURING MAINTENANCE PERSONNEL • Only authorised personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and using a sledge-hammer. ATTACHMENTS •...
Page 37 WARNING: For reasons of safety, always follow these safety precautions. 8. PRECAUTIONS FOR OPERATION PRECAUTIONS WITH BATTERY • When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the battery to stop the flow of current. HANDLING HIGH-PRESSURE HOSES •...
Page 38 WARNING: For reasons of safety, 8. PRECAUTIONS FOR MAINTENANCE always follow these safety precautions. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE • Immediately after stopping operations, the engine cooling water and oil at all parts is at high temperature and under high pressure.
Page 39: Waste Materials
WARNING: For reasons of safety, always follow these safety precautions. 8. PRECAUTIONS FOR OPERATION WASTE MATERIALS • Never dump waste oil in a sewer system, rivers, etc. • Always put oil drained from your machine in containers. Never drain oil directly on the ground. •...
Page 40: Position For Attaching Safety Labels
Always keep these labels clean. If they are lost or damage, attach them again or replace them with a new label. There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels are available from your Komatsu distributor. POSITION FOR ATTACHING SAFETY LABELS 1-28...
Page 41 • Keep the manual in machine cab near op- erator. If this manual is lost, please contact your Komatsu distributor for a replacement. 2. 2OE-00-KI230 3. 20Y-00-K2220 Warnings when opening front window • When raising window, • Emergency exit lock it in place with lock pins on both sides.
Page 42 WARNING: For reasons of safety, always follow these safety precautions. 4. 2OE-00-K1130 6. 2OE-00-K1150 WARNING - No pas- Keeping out of moving sengers area No passengers allowed to ride on machine while To prevent SEVERE IN- it is moving JURY or DEATH do the following before moving WARNING - DANGER machine or its attach-...
Page 43 WARNING: Failure to follow these safety precautions may lead to a serious accident. 10. 2OE-00-K1190 8. 2OE-00-K1310 Warning for high temperature coolant and oil • Do open Hot water and oil cover while en- hazard gine is running. To prevent hot water and oil from spurting out: •...
Page 44 MEMO 1-32...
Page 45: Operation
OPERATION...
Page 46: General View
10. GENERAL VIEW 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, the refer to the directions shown by in the arrows in the diagram below.
Page 47: General View Of Controls And Gauges
10. GENERAL VIEW 10.2 GENERAL VIEW OF CONTROLS AND GAUGES...
Page 48: Explanation Of Components
11. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the equipment and the mean- ings of the displays.
Page 49 11. EXPLANATION OF COMPONENTS B. CAUTION ITEMS (11.1.2) CAUTION If these monitor items flash, check and repair the appropriate location as soon as possible. These are items which need to be observed while the engine is run- ning. If any abnormality occurs, items which need to be repaired as soon as possible are displayed.
Page 50: A: Basic Check Items
11. EXPLANATION OF COMPONENTS 11.1.1 A: BASIC CHECK ITEMS NOTICE Do not rely on the “BASIC CHECK ITEMS” only for the check before starting Always refer to the periodic maintenance items or 12. “OPERA- TION” to carry out the checks. RADIATOR WATER LEVEL This warns that the radiator cooling water level is too low.
Page 51: B: Caution Items
11. EXPLANATION OF COMPONENTS HYDRAULIC OIL LEVEL This warns that the hydraulic oil level is too low. If the monitor lamp flashes, check the hydraulic oil level, and add oil. 11.1.2 B: CAUTION ITEMS CAUTION If the caution monitor lamp flashes, repair the problem as soon as possible.
Page 52: C: Emergency Stop Items
LOW PPC PRESSURE This warns that pilot control pressure is low if the monitor lamp flashes. Check for leaks in pilot lines. If none are found & warning persists consult your Komatsu distribu- tor. 11.1.3 C: EMERGENCY STOP ITEMS CAUTION If any monitor lamp flashes, stop the engine or run it at low idling, and take the following action.
Page 53: D: Meter Display Portion
11. EXPLANATION OF COMPONENTS 11.1.4 D: METER DISPLAY PORTION PILOT DISPLAY When the starting switch is ON, the pilot display lights up when the display items are functioning. ENGINE PRE-HEATING MONITOR This monitor lamp indicates the pre-heating time required when start- ing the engine at an ambient temperature below 0 The monitor lamp lights when the starting switch is turned to HEAT position and flashes after about 30 seconds to show that the pre-heating...
Page 54: Fuel Gauge
11. EXPLANATION OF COMPONENTS METERS ENGINE WATER TEMPERATURE GAUGE This gauge indicates the engine cooling water temperature. If the temperature is normal during operation, the green range will light up. If the red range lights up during operation, the overheat prevention system will be actuated.
Page 55 11. EXPLANATION OF COMPONENTS Manual setting When the time is displayed, depress clock switch for 2.5 sec or more. “TIME” flashes. Pressing H switch increases hours and pressing M switch creases minutes. If switch is pressed for 2.5 seconds or more, hours or minutes increase continuously.
Page 56 11. EXPLANATION OF COMPONENTS 11.1.5 E: SWITCHES WORKING MODE SELECTOR SWITCH (Basic switch) NOTICE When the breaker is used, never select the H.O. (heavy-duty op- eration) mode. REMARK H switch is also used for setting “hours” in the clock and M switch for setting “minutes”.
Page 57: Travel Speed Switch
11. EXPLANATION OF COMPONENTS AUTO-DECELERATION SWITCH (Selection switch) This switch acts to activate the function that automatically lowers the engine speed and reduces fuel consumption when the control lever is at neutral. ON lights up: Auto-deceleration is actuated. OFF: Auto-deceleration is cancelled. Each time the switch is pressed, the auto-deceleration is actuated or cancelled.
Page 58 11. EXPLANATION OF COMPONENTS POWER MAX./SWIFT SLOW-DOWN SWITCH During operations, the digging power can be increased and the speed reduced by a one-touch operation of the knob button /single click while pushing). Power max. (power up) lights up: When the working mode is heavy-duty and general operation mode only, the power can be increased while the knob button is being pressed.
Page 59: Switches
11. EXPLANATION OF COMPONENTS 11.2 SWITCHES STARTING SWITCH This switch is used to start or stop the engine. OFF position The key can be inserted or withdrawn. Except for the cab lamp, radio (if fitted) and clock, the switches for the electric system are all turned off and the engine is stopped.
Page 60: Fuel Control Dial
Pull out the lighter and light your cigarette. Nothing may be connected to the cigarette lighter without the prior permission of an authorised Komatsu distributor. SWING LOCK SWITCH WARNING • When the machine is travelling under its own power, or when the swing is not being operated, always set the switch to the ON (ACTUATED) position.
Page 61: Lamp Switch
11. EXPLANATION OF COMPONENTS LAMP SWITCH This switch turns on the working lamps and monitor illumination. Standard work lamps Standard and additional work lamps (if fitted) ALARM BUZZER STOP SWITCH This is used to stop the alarm buzzer when it has sounded to warn of some abnormality in the EMERGENCY STOP ITEMS while the engine is running.
Page 62 11. EXPLANATION OF COMPONENTS 13. TWO STAGE PRESSURE RELIEF This switch is used to switch the safety valve set pressure at the head end of the boom cylinder to two levels. Low pressure setting: The boom thrust force is weak, so the swaying of the chassis is small during digging operations, and digging opera- tions can be carried out smoothly.
Page 63: Control Levers, Pedals
11. EXPLANATION OF COMPONENTS 11.3 CONTROL LEVERS, PEDALS SAFETY LOCK LEVER WARNING • When leaving the operator’s compartment, set the safety lock lever securely to the LOCK position. If the control levers are not locked, and they are touched by mistake, this may lead to a serious accident.
Page 64 11. EXPLANATION OF COMPONENTS This lever locks the work equipment, swing and attachment controls. This lock lever is a hydraulic lock, so even if it is in the lock position, the work equipment control lever will move, but the work equipment and swing motor will not work.
Page 65 11. EXPLANATION OF COMPONENTS LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device) WARNING If any lever is operated when in the deceleration range, the en- gine speed will suddenly increase, so be careful when operating the levers. This lever is used to operate the arm and upper structure. Arm operation Swing operation Arm OUT...
Page 66 11. EXPLANATION OF COMPONENTS ATTACHMENT CONTROL PEDAL WARNING Do not put your foot on the pedal except when operating the pedal. If resting your foot on the pedal during operation, and it is depressed by accident by accident, the attachment may move suddenly and cause serious damage or injury.
Page 67: Hydraulic Oil Flow
11. EXPLANATION OF COMPONENTS HYDRAULIC OIL FLOW When the front of the pedal is depressed, the oil flows to the left piping for the work equipment; when the rear of the pedal is depressed, the oil flows to the right piping for the work equipment. (When the breaker is installed, only the front of the pedal is used.) BREAKER, GENERAL ATTACHMENT (CRUSHER, ETC.) SELECTOR VALVE (OPTION)
Page 68: Roof Hatch
11. EXPLANATION OF COMPONENTS 11.4 ROOF HATCH When opening Lock the safety lock lever securely. Check for an ceiling window movement by pulling lock located on both sides, then push up and open the ceiling window grasping grip When closing Close the ceiling window grasping grip and lock it with lock .
Page 69: Front Window
11. EXPLANATION OF COMPONENTS 11.5 FRONT WINDOW WARNING When opening the front window, always hold grip firmly with both hands and pull up. If you use only one hand, your hand may slip and get caught. It is possible to store (pull up) the front window (top) in the roof of the operator’s compartment.
Page 70 11. EXPLANATION OF COMPONENTS From the inside of the operator’s cab, hold the bottom grip with the left hand and the top grip with the right hand, pull up the window, and push it in fully until it is locked by catch Lock with lock pins on the left and right sides.
Page 71: Door Lock
11. EXPLANATION OF COMPONENTS Lock securely with lock pins at the left and right sides Removing front window (bottom) Ensure lower wiper (if fitted) is in correct park position. With the front window open, remove lock pins , and the bottom part of the front window can be removed.
Page 72: Cap, Cover With Lock
11. EXPLANATION OF COMPONENTS 11.7 CAP, COVER WITH LOCK The fuel filler, operator’s cab, engine hood, battery box cover, right side door and left side door of the machine body are fitted with locks. Use the starting switch key to lock or unlock these places. 11.7.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port) To open the cap...
Page 73: Luggage Tray
11. EXPLANATION OF COMPONENTS 11.8 LUGGAGE TRAY This tray is located to the rear of the operator’s seat. Always keep the operation & maintenance manual in this box for easy reading access. 11.9 ASHTRAY This is on the side of the operator’s seat. Always make sure that you extinguish the cigarette before closing the lid.
Page 74: Air Conditioner
11. EXPLANATION OF COMPONENTS Temperature control slider This adjust out air temperature To increase temperature of outlet air: move slides to left (red) To decrease temperature of outlet air: move slides to right (blue) Air flow selector switch This switch adjust air flow in three steps Defroster selector lever This lever is used to remove condensation or ice on the front window.
Page 75 11. EXPLANATION OF COMPONENTS Outlet air distribution Outlet air can be distributed through various vents in the operators cab. Sending air to lower area of Sending air to upper area Purpose operator’s seat of operator’s seat. Lever position Air outlets Inlet air control slider Changes between internal air recirculation &...
Page 76: Precaution When Using Air Conditioner
11. EXPLANATION OF COMPONENTS Defroster selector lever This lever is used to remove condensation on the front window during winter or rainy season. Selector lever forward: defrost Selector lever backwards: warms operator’s feet Defroster is available when air outlet slider is in the position shown by decal: Defroster Feet...
Page 77: Cab Radio (Option)
11. EXPLANATION OF COMPONENTS 11.12 CAB RADIO (OPTION) Refer to the separate operation manual for radio cassette. Note Ensure radio is switched off when leaving the machine for long periods to prevent draining of battery charge. Antenna If the reception is weak or generates noise, extend the antenna. If the reception is to strong, adjust the sensitivity by retracting the antenna.
Page 78: Fuse
11. EXPLANATION OF COMPONENTS 11.13 FUSE NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse.
Page 79: Fusible Link
Never splash or spill water, mud or drink over the controllers as this may cause a fault. • If a fault occurs in the controller, do not attempt repair, but con- sult your Komatsu distributor. 11.16 TOOL BOX This is used for keeping the tools. 11.17 REFUELLING PUMP (Option) WARNING •...
Page 80: Handling The Accumulator
When disposing of the accumulator, it is necessary to release the gas from the accumulator, so please contact your Komatsu distributor. This machine is equipped with the accumulator in the control circuit. The accumulator is a device to store the pressure in the control circuit, and when it is installed, the control circuit can be operated for a short time even after the engine is stopped.
Page 81: Method For Releasing Pressure In Control Circuit Of Machines Equipped With Accumulator
11. EXPLANATION OF COMPONENTS 11.18.1 METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR Lower the work equipment to the ground. Close any attachment such as the crusher attachment jaws, etc. Stop the engine. Move the safety lock lever completely in the FREE position. Move the work equipment control lever and attachment control pedal full to the back and forth, right and left so as to release the pressure in the control circuit.
Page 82: Operation
Check carefully, and if any abnormality is found, always repair it or contact your Komatsu distributor. Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leakage of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Page 83 Check bucket with hook for damage Check the hook, catcher and hook foot for damage. If damage is found, contact your Komatsu distributor for repair. 2-39...
Page 84: Check Before Starting
12. OPERATION 12.1.2 CHECK BEFORE STARTING Always carry out the items in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. When checking the coolant, always check the radiator reserve tank when the engine is cold.
Page 85 12. OPERATION If the oil is above the H mark, drain the excess engine oil from drain valve , and check the oil level again. If the oil level is correct, tighten the oil filler cap securely and close the engine hood. REMARK When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking.
Page 86: Check Oil Level In Hydraulic Tank, Add Oil
12. OPERATION CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING • When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap. • If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from the drain plug If the work equipment is not in the condition shown in the diagram on...
Page 87 Check the following points carefully. • Battery • Starting motor • Alternator Please contact your Komatsu distributor for investigation and correction of the cause. CHECK FOR WATER IN FUEL FILTERS, DRAIN WATER The fuel filters are fitted on the engine With the engine off open the engine cover and locate the water drain at the bottom of the fuel filters.
Page 88: Adjustment Before Operation Operator's Seat
12. OPERATION 12.1.3 ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT (A) Fore-and-aft adjustment of seat Pull lever up. After the seat is set to the desired position, release the lever. Adjustable distance: 160 mm (B) Adjustment of reclining seat Pull lever up. After the seat back is set to the optimum position for easy operation, release the lever.
Page 89 12. OPERATION (D) Armrest height adjustment Armrest can be raised and lowered by loosening the bolts in the rear of the armrest columns, adjusting the height and retightening the bolts (E) Fore-and-aft adjustment of whole seat After lever is pulled up and the seat is set to the desired position, release the lever.
Page 90: Operations And Checks Before Starting Engine
• Air cleaner clogging monitor • Swing lock monitor If the monitors or gauges do not light up or the buzzer does not sound, there is probably a broken bulb or disconnection in the monitor wiring, so contact your Komatsu distributor for repairs. 2-46...
Page 91 • Fuel gauge (2) Press lamp switch to turn on the head lamps. If the lamp switch do not light up, there is probably a broken bulb or disconnection in the wiring, so contact your Komatsu distributor for repairs. 2-47...
Page 92: Starting Engine
12. OPERATION 12.2 STARTING ENGINE 12.2.1 NORMAL STARTING WARNING Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 93: Starting In Cold Weather
12. OPERATION 12.2.2 STARTING IN COLD WEATHER WARNING • Check that there are no persons or obstacles in the surround- ing area, then sound the horn and start the engine. • Never use starting aid fluids as they may cause explosions. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds.
Page 94 12. OPERATION When preheating monitor flashes, turn the key in starting switch to the START position to start the engine. Ambient temperature Preheating time Above 0 C to -10 20 seconds C to -20 30 seconds When the engine starts, release the key in starting switch The key will return automatically to the ON position.
Page 95: Operations And Checks After Starting Engine
12. OPERATION 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE WARNING • Emergency stop If there has been any abnormal actuation or trouble, turn the starting switch key to the OFF position. • If the work equipment is operated without warming the ma- chine up sufficiently, the response of the work equipment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always...
Page 96 12. OPERATION Set the safety lock lever to the FREE position, and raise the bucket from the ground. FREE Operate bucket control lever and arm control lever slowly to move the bucket cylinder and arm cylinder to the end of the stroke. Carry out bucket and arm operation for 5 minutes at full stroke, alter- nating between bucket operation and arm operation at 30 second intervals.
Page 97: In Cold Areas (Automatic Warming-Up Operation)
12. OPERATION Press working mode switch on the monitor panel until the lamp of the mode to be used lights up. 12.3.2 IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION) When starting the engine in cold areas, carry out the automatic warming-up operation after starting the engine. When the engine is started, if the engine water temperature is low (below 30 C (86...
Page 98 12. OPERATION Press working mode switch on the monitor panel until H.O (heavy duty operation) mode lamp lights up. Turn fuel control dial to the mid-range speed position. Set safety lock lever to the FREE position and raise the bucket from the ground.
Page 99 12. OPERATION Turn fuel control dial to the full speed (MAX) position and carry out the operation is Step 6 for 3 -5 minutes. Repeat the following operation 3 - 5 times and operate slowly. • Boom operation RAISE LOWER •...
Page 100 12. OPERATION NOTICE Cancelling automatic warming-up operation If it becomes necessary in an emergency to lower the engine speed to low idling, cancel the automatic warming-up operation as follows. Turn fuel control dial to the full speed (MAX) position and hold it for 3 seconds.
Page 101: Moving Machine Off
12. OPERATION 12.4 MOVING MACHINE OFF 12.4.1 MOVING MACHINE FORWARD WARNING • Before operating the travel levers, check the direction of the track frame. If the sprocket is at front, the operation of the track levers is reversed. • When moving off, check that the area around the machine is safe, and sound the horn before moving.
Page 102: Moving Machine Backward
12. OPERATION Operate right and left travel levers or right and left travel pedals as follows. • When the sprocket is at the rear of the machine. Push levers forward slowly or depress the front part of pedals slowly to move the machine off. •...
Page 103 12. OPERATION Turn fuel control dial towards the full speed (MAX) position to in- crease the engine speed. Set safety lock lever in the FREE position, fold the work equip- ment, and raise it 40 - 50 cm (16 to 20 in) from the ground. Operate right and left travel levers or right and left travel pedals as follows.
Page 104: Steering Machine
12. OPERATION 12.5 STEERING MACHINE 12.5.1 STEERING (changing direction) WARNING Before operating the travel levels, check the position of the sprocket. If the sprocket is at the front, the operation of the travel levels is reversed. Use the travel levers to change direction. Avoid sudden changes of direction as far as possible.
Page 105 12. OPERATION When making counter-rotation turn (spin turn) When turning left using counter-rotation, pull the left travel lever back and push the right travel lever forward. REMARK When turning to the right using counter-rotation, pull the right travel lever back and push the left travel lever forward. 2-61...
Page 106: Stopping Machine
12. OPERATION 12.6 STOPPING MACHINE WARNING • Avoid stopping suddenly. Give yourself ample room when stopping. • When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert chocks underneath the wheels. As an additional safety measure, thrust the bucket into the ground.
Page 107: Swinging
12. OPERATION 12.7 SWINGING WARNING When operating the swing, check that the area around the ma- chine is safe. Before operating the swing, turn swing lock switch (CANCELLED). NOTICE Check that swing lock lamp goes out at the same time. Operate the left work equipment control lever to swing the upper structure.
Page 108: Operation Of Work Equipment
12. OPERATION 12.8 OPERATION OF WORK EQUIPMENT WARNING If any lever is operated when in the deceleration range, the en- gine speed will suddenly increase, so be careful when operat- ing the levers. The work equipment is operated by the left and right work equip- ment control levers.
Page 109: Working Mode Selection
12. OPERATION 12.9 WORKING MODE SELECTION WORKING MODE The mode selector switches can be used to switch the mode to match the conditions and purpose of work, thereby enabling efficient operation. Use the following procedures to make the most effective use of each mode.
Page 110 12. OPERATION POWER MAX./SWIFT SLOW-DOWN During operation, power up/speed down of work equipment can be performed by one-touch. Use this function effectively in combination with working mode. When starting switch is turned ON, the power up lamp turns on. When SET switch is pressed once, the speed down lamp turns on and the power up lamp goes out, and when pressed again, the oppo- site occurs.
Page 111: Prohibitions For Operation
12. OPERATION 12.10 PROHIBITIONS FOR OPERATION WARNING • If it is necessary to operate the work equipment control lever when the machine is travelling, stop the machine before oper- ating the work equipment control lever. • If the lever is moved inside the deceleration range, engine speed will suddenly rise.
Page 112 12. OPERATION Prohibited operations using dropping force of machine. Do not use the dropping force of the machine for digging. Digging rocky ground It is better to excavate hard rocky ground after breaking it up by some other means. This will not only reduce damage to the machine but make for better economy.
Page 113: Precaution For Operation
12. OPERATION 12.11 PRECAUTIONS FOR OPERATION PRECAUTIONS WHEN TRAVELLING When travelling over obstacles such as boulders or tree stumps, the machine (in particular, the undercarriage) is subjected to a large shock, so reduce the travel speed and travel over the obstacle at the center of the tracks.
Page 114: Precaution When Travelling Up Or Down Hills
12. OPERATION 12.12 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS WARNING • When travelling, raise the bucket approx. 20 - 30 cm (8 -12 in) from the ground. Do not travel downhill in reverse. • When travelling over ridges or other obstacles, keep the work equipment close to the ground and travel slowly.
Page 115 12. OPERATION Braking when travelling downhill To brake the machine during downhill runs, put the travelling and steering lever in the neutral position. This will cause the brake to be auto- matically applied. If shoes slip When travelling uphill, if the shoes slip or it is impossible to travel uphill using the force of the track only, it is possible to use pulling force of the arm to help the machine travel uphill.
Page 116: How To Escape From Mud
12. OPERATION 12.13 HOW TO ESCAPE FROM MUD Always operate carefully to avoid getting stuck in mud. If the ma- chine does get stuck in mud, use the following procedures to get the ma- chine out. • Place the two stage pressure relief switch at poistion .
Page 117: Work Possible Using Hydraulic Excavator
12. OPERATION 12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR In addition to the following, it is possible to further increase the range of applications by using various attachments. 12.14.1 BACKHOE WORK When condition of the machine is as shown in the diagram at right, each cylinders maximum pushing excavation force is obtained when the bucket cylinder and link, arm cylinder and arm are at 90 When excavating, use this angle effectively to optimise your work...
Page 118: Replacement And Inversion Of Bucket
12. OPERATION 12.15 REPLACEMENT AND INVERSION OF BUCKET WARNING • When knocking the pin in with a hammer, metal particles may fly and cause serious injury, particularly if they get into your eyes. When carrying out this operation, always wear goggles, helmet, gloves, and other protective equipment.
Page 119 12. OPERATION 12.15.2 INVERSION Place the bucket in contact with a flat surface. REMARK When removing the pins, place the bucket so that it is in light contact with the ground. If the bucket is lowered strongly to the ground, the resistance will be increased and it will be difficult to remove the pins.
Page 120: Parking The Machine
12. OPERATION 12.16 PARKING THE MACHINE WARNING • Avoid stopping suddenly. Give yourself ample room when stopping. • When stopping the machine, select flat hard ground and avoid dangerous places. If it is unavoidably necessary to park the machine on a slope, insert chocks underneath the wheels. As an additional safety measure, thrust the bucket into the ground.
Page 121: Check After Finishing Work
12. OPERATION Lower the bucket horizontally until the bottom touches the ground. Set safety lock lever in the LOCK position. FREE 12.17 CHECK AFTER FINISHING WORK Check the engine water temperature, engine oil pressure and fuel level on the monitor. 2-77...
Page 122: Stopping Engine
12. OPERATION 12.18 STOPPING ENGINE NOTICE If the engine is abruptly stopped before it has cooled down, en- gine Iife may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop Run the engine at low idling speed for about 5 minutes to allow it to gradually cool down.
Page 123: Check After Stopping Engine
12. OPERATION 12.19 CHECK AFTER STOPPING ENGINE Walk around the machine and check the work equipment, paintwork, and undercarriage, and check also for leakage of oil or water. If any abnormalities are found, repair them. Fill the fuel tank. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
Page 124: Transportation
13. TRANSPORTATION When transporting the machine, observe all related laws and regula- tions, and be careful to assure safety. 13.1 LOADING, UNLOADING WORK WARNING • Loading or unloading the machine can be a dangerous opera- tion, so be particularly careful. When loading or unloading the machine, run the engine at low idling and travel at low speed.
Page 125 13. TRANSPORTATION Set the travel speed switch to the Lo position. Turn the auto-deceleration switch OFF, and return the fuel control dial to reduce the engine speed. Turn the swing lock switch ON to apply the swing lock. Set in the direction of the ramps, lower the work equipment as far as possible without letting it hit the trailer, then travel slowly to load or unload the machine.
Page 126: Precautions For Loading
13. TRANSPORTATION 13.2 PRECAUTIONS FOR LOADING WARNING When loading the machine, park the trailer on a flat firm road- bed. Keep a fairly long distance between the road shoulder and the machine. After loading to the specified position, secure the machine as fol- lows.
Page 127: Precautions For Transportation
13. TRANSPORTATION 13.3 PRECAUTIONS FOR TRANSPORTATION WARNING • Determine the route for transporting the machine by taking into account the width, height and weight of the machine. • Always check that the door on the cab is closed and locked before transporting the machine.
Page 128: Procedure For Increasing Or Reducing Track Frame Gauge
13. TRANSPORTATION On commencement of lifting. Take up slack in the rope and check for work equipment movement, (due to possible hydraulic drift) adjust lifting hook position, if required, to maintain rope length(s) and angles as shown in the figure on the right.
Page 129: Cold Weather Operation
14. COLD WEATHER OPERATION 14.1 PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows. 14.1.1 FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see 20.
Page 130: Precautions After Completion Of Work
14. COLD WEATHER OPERATION 14.2 PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move the following morning, al- ways observe the following precautions. • Mud and water on the machine body should be completely removed. This is to prevent damage to the seal caused by mud or dirt getting inside the seal with frozen drops of water.
Page 131: Long-Term Storage
15. LONG-TERM STORAGE 15.1 BEFORE STORAGE NOTICE To protect the cylinder rod when the machine is not being used, set the work equipment in the posture shown in the diagram. (This prevents rusting of the cylinder rod) When putting the machine in storage for a long time, do as follows. •...
Page 132: During Storage
15.3 AFTER STORAGE NOTICE If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu distributor for service. Carry out the following procedure when taking the machine out of long-term storage. • Wipe off the grease from the hydraulic cylinder rods.
Page 133: Troubleshooting
16. TROUBLESHOOTING 16.1 PHENOMENA THAT ARE NOT FAILURES Note that the following phenomena are not failures: When the arm is pulled in, the speed of movement will drop momen- tarily when the arm is more or less vertical. The arm speed will drop momentarily when the bucket teeth are more or less horizontal.
Page 134: Precautions On Particular Jobsites
16. TROUBLESHOOTING 16.4 PRECAUTIONS ON PARTICULAR JOBSITES When carrying out digging operations in water, if the work equipment mounting pin goes into the water, carry out greasing every time the operation is carried out. For heavy-duty operations and deep digging, carry out greasing of the work equipment mounting pins every time before operation.
Page 135: Starting Engine With Booster Cable
16. TROUBLESHOOTING 16.5.1 STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: Precautions when connecting and disconnecting booster cable WARNING • When connecting the cables, never contact the positive = + and negative - terminals. •...
Page 136 16. TROUBLESHOOTING Connecting the booster cables Keep the starting switch at the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. Make sure that the starting switches of the normal machine and problem machine are both at the OFF position.
Page 137 16. TROUBLESHOOTING Disconnecting the booster cables After the engine has started, disconnect the booster cables in the reverse of the order in which they were connected. Remove one clip of booster cable from the engine block of the problem machine. Remove the other clip of booster cable from the negative - terminal of the normal machine.
Page 138: Other Trouble
OTHER TROUBLE 16.6.1 ELECTRICAL SYSTEM • ( ): Always contact your Komatsu distributor when dealing with these items. • In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy •...
Page 139 16. TROUBLESHOOTING 16.6.2 CHASSIS • ( ): Always contact your Komatsu distributor when dealing with these items. • In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy Speed of travel, swing, boom, arm, •...
Page 140 16. TROUBLESHOOTING 16.6.3 ENGINE • ( ): Always contact your Komatsu distributor when dealing with these items. • In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for repairs. Problem Main causes Remedy •...
Page 141 16. TROUBLESHOOTING ENGINE (cont’d( (16.6.3) Problem Main causes Remedy • Too much oil in oil pan • Add oil to specified level Exhaust gas is white or blue “CHECK BEFORE STARTING” • Change to specified fuel • Improper fuel • Clogged air cleaner element •...
Page 142: Electronic Control System
If applying the swing brake, manu- ally operate the swing brake using the swing lock switch. In this case, immediately have the swing brake system inspected by your Komatsu distributor. (*) Governor system error Governor will not execute the control function.
Page 143: Maintenance
MAINTENANCE WARNING Before carrying out maintenance, always attach the warning tag to the control lever in the operator’s cab .
Page 144: Guides To Maintenance
Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosity’s specified for ambient tem- perature. Always use clean washer fluid: Use automobile window washer fluid and be careful not to let any dirt get into it.
Page 145 17. GUIDES TO MAINTENANCE Warning tag: Attach the warning tag to the starting switch or other appropriate control lever to avoid someone who is not aware of the circumstances from starting the engine. Obey precautions: During the operation, always obey the precautions on the safety label attached to the machine. Welding instructions: •...
Page 146 17. GUIDES TO MAINTENANCE Pre-and post-work checks: Before starting work in mud, rain, snow or at seashore, check plugs and valves for tightness. Wash the machine immediately after the work to protect components from rusting. Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they are submerged in water.
Page 147: Outlines Of Service
When changing the oil, always replace the related filters at the same time. • We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.
Page 148 When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual. • Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system.
Page 149: Storing Oil And Fuel
• When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found, please contact your Komatsu distributor. • Do not open packs of spare filters until just before they are to be used.
Page 150: Key To Lubrication Points
18. OUTLINES OF SERVICE KEY TO LUBRICATION POINTS Engine oil Check level refer to 24.2.2 Change oil refer to 24.5.10 Hydraulic oil Check level refer to 24.2.4 Change oil refer to 24.8.2 Boom cylinder foot pin Grease refer to 24.3.1 Boom foot pin Grease refer to 24.3.1...
Page 151: Outline Of Electric System
• Since the controller for the control system may cause malfunction due to external wave interference, before installing a radio receiver and a walkie-talkie or citizen band, consult your Komatsu distributor. • When working on the seashore, carefully clean the electric system to prevent corrosion.
Page 152: Outline Of Hydraulic System
18. OUTLINES OF SERVICE 18.3 OUTLINE OF HYDRAULIC SYSTEM • During operation and immediately after operation is ended, the temperature of the hydraulic system still remains high. In addition, high hydraulic pressure is applied to the system. Take care when inspecting and maintaining the hydraulic system.
Page 153: Wear Parts List
Wear parts such as filter elements are to be replaced at the time of periodic maintenance. The wear parts should be changed correctly in order to use the machine economically. For part change, use Komatsu genuine parts. When ordering parts, please check the part number in the parts book.
Page 154: Use Fuel, Coolant And Lubricants According To Ambient Temperature
SAE 15W-40 ASTM D975 No.2 605 l Fuel tank Diesel fuel All lubrication fittings Grease No. 2 Multi-Purpose lithium grease with 3% molybdenum disulfide Cooling system Coolant 42.3 l See Spectrum XXX, Komatsu Genuine Lubricants ASTM D975 No. 1 3-12...
Page 155 20. USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE REMARK • We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. • Only use high quality oils wich meet internationally recognised specifications.
Page 156 MEMO 3-14...
Page 157 MEMO 3-15...
Page 158: Standard Tightening Torques For Bolts And Nuts
07951-31400 Grease cartridge 07950-90403 (Lithium base grease, 400 g) Hammer 09039-00150 Pinch bar 09055-10390 Gauge 09054-0009 Hexagon wrench Applicable width across flats 8mm 09007-00836 If any of the above tools are broken, please order them from your Komatsu distributor. 3-16...
Page 159: Torque List
The tightening torque is determined by the width across the flats <b> of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.
Page 160: Periodic Replacement Of Safety Critical Parts
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the hoses. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Komatsu distributor to replace the safety critical parts. 3-18...
Page 161 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS SAFETY CRITICAL PARTS Safety critical parts for periodic replacement Q’ty Replacement interval Every 2 years or Fuel hose (fuel tank - engine) 4000 hours, which ever comes sooner Return fuel hose (engine - fuel tank) Every 2 years or Front pump hoses (line filter - control valve) 4000 hours.
Page 162: Maintenance Schedule Chart
23. MAINTENANCE SCHEDULE CHART 23.1 MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE 3-23 SERVICE PROCEDURE WHEN REQUIRED Check, clean and replace air cleaner element 3-24 Clean inside of cooling system 3-26 Check and tighten track shoe bolts 3-32 Check and adjust track tension 3-33 Check electrical intake air heater 3-35...
Page 163 23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE Lubricating • Boom foot pin (2 points) 3-51 • Boom cylinder rod pin (2 points) 3-51 • Arm cylinder foot pin (1 point) 3-51 • Boom-arm coupling pin (1 point) 3-51 • Arm cylinder rod end (1 point) 3-51 •...
Page 164: Service Item
23. MAINTENANCE SCHEDULE CHART SERVICE ITEM PAGE EVERY 1000 HOURS SERVICE Change oil in swing machinery case 3-65 Check oil level in damper case, add oil 3-66 Check and adjust valve and injector clearance (1 1000 hour only) 3-67 EVERY 2000 HOURS SERVICE Change oil level in final drive case, add oil 3-73 Change oil in hydraulic tank, clean strainer...
Page 165: Service Procedure
24. SERVICE PROCEDURE 3-23...
Page 166: When Required
24. SERVICE PROCEDURE 24.1 WHEN REQUIRED 24.1.1 CHECK, CLEAN AND REPLACE THE AIR CLEANER ELEMENT WARNING • Never clean or replace the air cleaner element with the engine running. • When using pressured air to clean the element, wear safety glasses or goggles to protect the eyes. Checking If air cleaner clogging monitor flashes, clean the air cleaner element.
Page 167 24. SERVICE PROCEDURE If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning, replace the element. NOTICE Do not use an element whose folds or gasket or seal are damaged.
Page 168: Clean Inside Of Cooling System
24. SERVICE PROCEDURE 24.1.2 CLEAN INSIDE OF COOLING SYSTEM WARNING • Soon after the engine has been stopped, the coolant is hot and can cause personal injury. Allow the engine to cool before draining the coolant. • Since cleaning is performed while the engine is running, it is very dangerous to enter the rear side of the machine as the machine may suddenly start moving.
Page 169: Changing Coolant Filter
Antifreeze is flammable, so keep it away from any flame. • Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. • We recommend use of an antifreeze density gauge to control the mixing proportions.
Page 170: Installation
24. SERVICE PROCEDURE REMOVAL WARNING • Hot, scalding coolant can spray out if the radiator cap is removed suddenly. Relieve system pressure by slowly turning the cap to the first notch or lifting the safety lever (if equipped). Use extreme caution when adding coolant to the radiator to avoid being burned.
Page 171 24. SERVICE PROCEDURE Open the cab water heater valves, if equipped. Allow the system to completely drain into a suitable container. Do not let drain outlets plug up during draining. Close the radiator drain valve. Close the cab heater water valves, if equipped. Do not allow the cooling sytem to dry out.
Page 172: Cleaning The System
24. SERVICE PROCEDURE 24.1.6 CLEANING THE SYSTEM At 6,000 hours or after two years of service, whichever comes first, clean the cooling system as follows: Drain the system into a suitable container. Refer to “DRAINING THE SYSTEM”. Drain and clean the reserve tank. Close the radiator drain.
Page 173: Refilling An Overheated System
24. SERVICE PROCEDURE 24.1.8 REFILLING AN OVERHEATED SYSTEM Do not add coolant to the radiator of an overheated engine unless absolutely necessary. However, if necessary: Remove the radiator cap. Refer to “RADIATOR CAP” in this section. Be sure all the drains are closed. WARNING Use extreme caution when adding coolant to a hot radiator to avoid being burned.
Page 174: Check And Tighten Track Shoe Bolts
24. SERVICE PROCEDURE 24.1.11 THERMOSTATS REMOVAL Drain the cooling system. Refer to “DRAINING THE SYSTEM” in this section. Remove the radiator hose from the termostat housing and remove the four mounting capscrews. Remove the thermostat and o-rings and clean all gasket material from either mating surfaces.
Page 175: Check And Adjust Track Tension
24. SERVICE PROCEDURE 24.1.14 CHECK AND ADJUST TRACK TENSION WARNING Carry out this operation with two workers. The operator must move the machine in accordance with the signals from the other worker. The track tension is checked with the chassis raised, so it extremely dangerous if the machine is lowered by mistake during the inspection.
Page 176 Continue to pump in grease until S becomes 0 mm. If the tension is still loose, the pin and bushing are excessively worn. so they must be either turned or replaced. Please contact your Komatsu distributor When loosening tension. WARNING It is extremely dangerous to release the grease by any method except the procedure given below.
Page 177: Check Electrical Intake Air Heater
24. SERVICE PROCEDURE 24.1.15 CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. 24.1.16 CHECK ALTERNATOR...
Page 178: Replace Bucket Side Cutters
24. SERVICE PROCEDURE 24.1.18 REPLACE BUCKET SIDE CUTTERS WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and apply the locks securely to the levers.
Page 179 24. SERVICE PROCEDURE 24.1.20 INSTALLATION OF BUCKET TEETH (ESCO VERTALOK ® TYPE) WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable condition, then stop the engine and apply the safety lock lever securely.
Page 180 24. SERVICE PROCEDURE Clean the adapter nose to make sure the point will fully seat. Check the plug for torn, cracked or seperated rubber when reusing NOSE CROSS SECTION any plug. CHECK PLUG NOTICE Plugs for Hot Slag points are not encased in rubber. MAXIMUM Replace the plug if damage is discovered.
Page 181 24. SERVICE PROCEDURE 24.1.21 REMOVAL OF BUCKET TEETH ® (ESCO VERTALOK TYPE) Replace the point before the adapter starts to wear. WARNING It is dangerous if the work equipment moves by mistake when the teeth are being replaced. Set the work equipment in a stable conditions, then stop the engine and apply the safety lock lever securely.
Page 182 24. SERVICE PROCEDURE ® The Helilok point (A) twists onto the adapter (B) and is secured by the plug (C), which is inserted into the side of the adapter, and the pin (D) which is driven in from the top. The recommended tools for installation and removal are a Removal Tool (E) and a 1 to 2 kg (2 to 4 lb.) hammer (F).
Page 183: Adjust Bucket Clearance
24. SERVICE PROCEDURE 24.1.22 ADJUST BUCKET CLEARANCE WARNING It is dangerous if the work equipment moves by mistake when the clearance is being adjusted. Set the work equipment in a stable condition, then stop the engine and lock the lever securely. WARNING •...
Page 184: Check Window Washer Fluid Level, Add Fluid
24. SERVICE PROCEDURE 24.1.23 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If air is ejected with the window washer fluid, check the fluid level in window washer tank . If showing under the level, fill with automobile window washer fluid. When adding fluid, be careful not to let dirt or dust get in.
Page 185 24. SERVICE PROCEDURE 24.1.24 CHECK AND ADJUST AIR CONDITIONER CHECK LEVEL OF REFRIGERANT (GAS) WARNING If the liquid get into your eyes or on your hands, it may cause loss of sight or frostbite, so never loosen any part of the refrigerant circuit.
Page 186: Replace Additional Breaker Filter Element
24. SERVICE PROCEDURE 24.1.25 REPLACE ADDITIONAL BREAKER FILTER ELEMENT WARNING Immediately after operating the engine, all parts still retain high temperature. never replace the filter in such condition, replace it only after each part has been sufficiently cooled. • Prepare a container for draining off oil. Place the container under the filter element.
Page 187: Check Before Starting
24. SERVICE PROCEDURE 24.2 CHECK BEFORE STARTING 24.2.1 CHECK COOLANT LEVEL, ADD COOLANT WARNING Do not open the radiator cap unless necessary. When check- ing the coolant, always check the radiator reserve tank when the engine is cold. Open the rear door on the left side of the machine and check that the coolant level is between the FULL and LOW marks on radiator re- serve tank (shown in the diagram on the right).
Page 188: Check Fuel Level, Add Fuel
24. SERVICE PROCEDURE If the oil is above the H mark, drain the excess engine oil using drain valve in the bottom of oil pan, and check the oil level again. If the oil level is correct, tighten the oil filler cap securely and close the engine hood.
Page 189 24. SERVICE PROCEDURE 24.2.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING • When removing the oil filler cap, oil may spurt out, so turn the cap slowly to release the internal pressure before removing the cap. • If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from drain plug If the work equipment is not in the condition shown in the diagram on...
Page 190: Check Air Cleaner For Clogging
Check also for loose terminals and tighten any loose parts. Check the following points carefully. • Battery • Starting motor • Alternator Please contact your Komatsu distributor for investigation and correction of the cause. 3-48...
Page 191: Every 50 Hours Service
24. SERVICE PROCEDURE 24.3 EVERY 50 HOURS SERVICE 24.3.1 LUBRICATING NOTICE For the first 100 hours on new machines where the parts are setting in, carry out greasing every 10 hours. Set the work equipment in the greasing posture below, then lower the work equipment to the ground and stop the engine.
Page 192: Boom Foot Pin (2 Points)
24. SERVICE PROCEDURE Boom cylinder foot pin (2 points) Boom foot pin (2 points) Arm -Link coupling pin (1 point) Arm-Bucket coupling pin (1 point) Link coupling pin (2 points) Bucket cylinder rod end (1 point) Bucket-Link coupling pin (1 point) 3-50...
Page 193: Every 100 Hours Service
24. SERVICE PROCEDURE 24.4 EVERY 100 HOURS SERVICE 24.4.1 LUBRICATING Set the work equipment in the greasing posture below, then lower the work equipment to the ground and stop the engine. Using a grease pump, pump in grease through the grease fittings shown by arrows.
Page 194: Check Oil Level In Swing Machinery Case, Add Oil
24. SERVICE PROCEDURE 24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carry- ing out this check. Remove dipstick and wipe the oil from the dipstick with a cloth.
Page 195: Drain Water And Sediment From Fuel Tank
24. SERVICE PROCEDURE If the oil does not reach the L mark on dipstick , add engine oil through dipstick insertion hole When refilling, remove bleeding plug For details of the oil to use, see 20. “USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
Page 196: Every 250 Hours Service
24. SERVICE PROCEDURE 24.5 EVERY 250 HOURS SERVICE 24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD WARNING • The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation.
Page 197: Check Level Of Battery Electrolyte
24. SERVICE PROCEDURE 24.5.2 CHECK LEVEL OF BATTERY ELECTROLYTE WARNING • To avoid gas explosions, do not bring fire or sparks near the battery. • Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a doctor.
Page 198: Replace Hydraulic Filter Element
24. SERVICE PROCEDURE 24.5.3 REPLACE HYDRAULIC FILTER ELEMENT WARNING When removing the oil filler cap, turn it slowly to release the internal pressure before removing it. Remove the cover over the hydraulic tank. Remove the cap from oil filler , and release the internal pressure. Loosen 4 bolts, then remove cover When doing this, the cover may fly out under the force of spring , so...
Page 199: Lubricate Swing Circle (3 Points)
24. SERVICE PROCEDURE Screw in the oil filler cap and install the cover. 10. To bleed the air, start the engine according to 12.2 “STARTING ENGINE” and run the engine at low idling for 10 minutes. 11. Stop the engine. REMARK Operate the machine after halting for more than 5 minutes to elimi- nate bubbles in the oil inside the tank.
Page 200: Belts, General
24. SERVICE PROCEDURE 24.5.5 BELTS, GENERAL WARNING Before working on the engine or electrical system, disonnect the negative (ground) battery cable. Tag the cable and controls too warn against starting. Replace badly worn, greasy or severely cracked belts immediately. These conditions prevent proper belt function.
Page 201: Check Alternator And Water Pump Belt Tension, Adjust Checking Tension
24. SERVICE PROCEDURE FAN DRIVE BELT - REMOVE Loosen the idler pulley shaft locknut. Turn the adjusting screw counterclockwise to release tension, and remove the belt. 24.5.7 CHECK ALTERNATOR AND WATER PUMP BELT TENSION, ADJUST CHECKING TENSION Use belt tension gauge to measure the belt tension. Loosen the adjusting screw locknut Loosen the adjusting link capscrew .
Page 202: Check Air Conditioner Compressor Belt Tension, Adjust
24. SERVICE PROCEDURE 24.5.8 CHECK AND ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT Testing The belt should deflect 14-16 mm (0.55-0.63in) when pressed with a finger force of approx. 6 kg (13 lb) at a point midway between the crank- shaft pulley and the compressor pulley.
Page 203: Change Oil In Engine Oil Pan, Replace Engine Oil Filter Cartridge
After draining the oil, raise the lever to close the valve. Check the drained oil, and if there are excessive metal particles or foreign material, please contact your Komatsu distributor. Close drain valve Open the engine hood. Using the filter wrench from the upper side of the engine, turn filter cartridge counterclockwise to remove it.
Page 204: Replace Corrosion Resistor Car- Tridge
After replacing the filter cartidge, add engine oil through oil filter F until the oil level is between the H and L marks on dipstick G. For details of the oil to use, see ”20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
Page 205: Every 500 Hours Service
Check if the grease is milky white. If it is milky white, it is necessary to change the grease. Please contact your Komatsu distributor. The total amount of grease is 33 l (29.7 kg) (8.7 US gal, 7.3 UK gal [65.5 lb]).
Page 206: Replace Hydraulic Tank Breather Element
24. SERVICE PROCEDURE 24.6.2 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR- CONDITIONER) WARNING If compressed air, steam, or water hit your body directly, there is danger of injury. Always wear protective glasses, mask, and safety shoes.
Page 207: Every 1000 Hours Service
24. SERVICE PROCEDURE 24.7 EVERY 1000 HOURS SERVICE Maintenance for every 50, 100, 250 and 500 hours should be carried out at the same time. 24.7.1 CHANGE OIL IN SWING MACHINERY CASE WARNING The oil is at high temperature immediately after the machine has been operated.
Page 208: Check Oil Level In Damper Case, Add Oil
24. SERVICE PROCEDURE 24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before carry- ing out maintenance. NOTICE Park the machine on flat ground and stop the engine. After waiting for more than 30 minutes after stopping the engine, check the oil level.
Page 209 24. SERVICE PROCEDURE 24.7.3 CHECK & ADJUST INJECTOR AND VALVE CLEARANCE All valve and injector adjustment must be made when the engine is cold, any stabilized coolant temperature at 60°C [140°F] or below. Remove the air piping from the intake maniflold. Remove the hose from the crankcase breather.
Page 210 24. SERVICE PROCEDURE The valves and injectors on the same cylinders are not adjusted at the same index mark on the accessory drive pulley on STC engines One pair of valves and one injector are adjusted at each pulley index mark before rotating the accessory drive to the next index mark.
Page 211 24. SERVICE PROCEDURE Place the STC tappet adjusting tool, Part No.3823348, on the upper surface of the STC injector top-cap. Rotate the tool around the tappet until the tool’s locating pin is inserted into one of the four holes in the top of the tappet.
Page 212 24. SERVICE PROCEDURE Valve Adjustment Select a feeler gauge for the correct valve lash specification Valve Lash Specification Intake 0.36 0.014 Exhaust 0.69 0.027 Insert the feeler gauge between the top ot the crosshead and the rocker lever pad. Two different methodes for establishing valve lash clearance are de- scribed below.
Page 213 24. SERVICE PROCEDURE After adjusting the injector and valves on the appropriate cylinder, rotate the accessory drive pulley and align the next valve set mark with the pointer on the gear cover. Adjust the appropriate injector and valves following the injector and valve adjustment sequence chart.
Page 214 24. SERVICE PROCEDURE Inspect the cover for cracks or damge and replace if necessary. 10. If the gasket was not damged, it can be used again. If the gasket was damged, it must be discarded and a new one used. Install the gasket on the cover.
Page 215: Every 2000 Hours Service
24. SERVICE PROCEDURE 24.8 EVERY 2000 HOURS SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours should be carried out at the same time. 24.8.1 CHANGE OIL IN FINAL DRIVE CASE WARNING • The oil is at high temperature immediately after the machine has been operated.
Page 216 24. SERVICE PROCEDURE 24.8.2 CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER WARNING The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before chang- ing the oil. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it carefully.
Page 217 24. SERVICE PROCEDURE Loosen 4 bolts, then remove cover When doing this, the cover may fly out under the force of spring so push the cover down when removing the bolts. Pull up the top of rod , and remove spring and strainer Remove the dirt stuck to strainer , then wash it in clean diesel oil or...
Page 218 24. SERVICE PROCEDURE Air bleeding procedure Follow steps 1 to 7 to bleed the air. Bleeding air from pump Loosen air bleeder plug , and check that oil oozes out from the air bleed plug. If oil does not ooze out from the plug, remove the drain hose from the pump case, and add oil through drain port to fill the pump case with hydraulic oil.
Page 219 24. SERVICE PROCEDURE Bleeding air from swing motor Run the engine at low idling, loosen air bleeding plug , and check that oil oozes out from air bleeding plug NOTICE When doing this, do not operate the swing. If oil does not ooze out, stop the engine, remove air bleeding plug , fill the motor case with hydraulic oil.
Page 220 24. SERVICE PROCEDURE Bleeding air from attachment (if installed). For machines equipped with attachments such as the breaker, actuate the attachment pedal about 10 times to bleed the air completely from the attachment circuit while running the engine at low idling. NOTE If the attachment bleeding procedure is specified by the manufacturer, bleed the attachment according to such...
Page 221: Check Alternator, Starting Motor
24.8.3 CHECK ALTERNATOR, STARTING MOTOR The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
Page 222: Every 4000 Hours
Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours should be carried out at the same time. 24.9.1 CHECK PLAY TO TURBOCHARGER ROTOR Ask Komatsu distributor to check the play ot the turbocharger rotor. 24.9.2 CHANGE ANTRIFREEZE Follow the procedure of 24.2.2 “CLEAN INSIDE OF COOLING SYS- TEM”...
Page 223 24. SERVICE PROCEDURE 24.10 EVERY 6000 HOURS SERVICE Maintenance for every 50, 100, 250, 500, 1000 and 2000 hours should be carried out at the same time. 24.10.1 Injector Remove Every 6,000 hours, clean and rebuild or replace the injectors. To clean and calibrate the injectors, remove them from the engine.
Page 224 24. SERVICE PROCEDURE Install Install three new 0-rings over the injector into the retaining grooves. Do not twist the 0-rings. Lubricate the 0-rings with clean 15W-40 oil just before installation. Check the bores in the cylinder head for burrs or sharp edges which can damage the 0-rings.
Page 225 24. SERVICE PROCEDURE Install the injector hold down and capscrew. Torque Value: 75 N•m [55 ft-lb] Install the crossheads on the valves. Rotate the rocker levers down and install the push rods and push tubes. NOTE: It is necessary to bar the engine over and install the push rods and push tubes as camshaft position allows.
Page 226 24. SERVICE PROCEDURE Inspect the rocker lever cover gasket for cuts or damage. If necessary, install a new gasket. Install the rocker lever cover. Install the 16 isolators and capscrews. Tighten the capscrews in the sequence shown. Torque Value: 15 N•m [130 in-lb] 24.10.2 Fuel Pump Remove...
Page 227 24. SERVICE PROCEDURE Remove the two fuel pump support bracket to cylinder block bracket mounting capscrews. Remove the four fuel pump mounting capscrews and the fuel pump. Remove the drive coupling. Clean the gasket surfaces of the pump support and the air compressor. Inspect the mounting surfaces for damage.
Page 228 24. SERVICE PROCEDURE Install the two fuel pump support bracket capscrews to the cylinder block bracket. Tighten the four fuel pump mounting capscrews. Torque Value: 47 N•m [35 ft-lb] Tighten the two support bracket to cylinder block capscrews. Torque Value: 47 N•m [35 ft-lb] Install the AFC air tube and fuel tubing: •...
Page 229: Specifications
SPECIFICATIONS...
Page 230 25. SPECIFICATIONS PC450-6K PC450LC-6K PC450-6K PC450LC-6K WEIGHT • Operating weight (without operator) 42.980 kg 44.120 kg. PERFORMANCE • Bucket capacity (standard bucket) SAE/CECE 1.8 m (2.08 cu.yd)/ 1.6m • Width of opening (Standard bucket) 1424 mm (56.1 in) (With side cutter) 1574 mm (62.0 in)
Page 231 25. SPECIFICATIONS PC450, PC450LC-6k [ ]: Values are for PC450LC-6k. • : Values are for trackframe in transport position.
Page 232 25. SPECIFICATIONS PC450-6k, PC450LC-6k The mark indicates the dimensions for shovel operation. Never allow other person than the operator to enter the swing range (Max. swing range, Max. digging radius).
Page 233: Explanation Of Lifting Capacity Chart
25. SPECIFICATIONS 25.2 EXPLANATION OF LIFTING CAPACITY CHART PC450-6k LEGEND : Reach from swing centre : Bucket hook height Lifting capacity (rating overfront) Lifting capacity (rating overside) LEGEND Position of lifting point Arm length: Boom length Nom 34.8 MPa 7060 Max 35.8 MPa...
Page 234 25. SPECIFICATIONS PC450LC-6k LEGEND : Reach from swing centre : Bucket hook height Lifting capacity (rating overfront) Lifting capacity (rating overside) Nom 34.8 MPa 7060 Max 35.8 MPa LEGEND Position of lifting point Arm length: Boom length Hydraulic pressure: Nom 34.8 MPa WORKING Max.
Page 235: Options And Attachments
OPTIONS, ATTACHMENTS...
Page 236: General Precautions
26. GENERAL PRECAUTIONS 26.1 PRECAUTIONS RELATED TO SAFETY If attachments or options other than those authorised by Komatsu are installed, this will not only affect the life of the machine, but will also cause problems with safety. When installing attachments not listed in this Operation and Maintenance Manual, please contact your Komatsu distributor first.
Page 237: Precautions When Installing Attachments
• Always follow the correct procedure when installing the boom and arm. If the correct procedure is not followed, this may lead to serious damage or injury, so please consult your Komatsu distributor before carrying out installation.
Page 238: Handling Bucket With Hook
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK Check that there is no damage to the hook, stopper, or hook mount. If any abnormality is found, please contact your Komatsu distributor. INCORRECT 27.2 PROHIBITED OPERATIONS The standard work equipment must not be used for lifting loads. If this machine is to be used for lifting loads, it is necessary to install the special bucket with hook.
Page 239: Machines Ready For Attachments
28. MACHINES READY FOR ATTACHMENTS 28.1 EXPLANATION OF COMPONENTS STOP VALVE This valve stops the flow of the hydraulic oil. FREE : Hydraulic oil flows. LOCK : Hydraulic oil stops. Set this valve to the LOCK position when removing or installing at- tachments.
Page 240 28. MACHINES READY FOR ATTACHMENTS ATTACHMENT CONTROL PANEL This is used to operate the attachment. When the operator depresses the pedal at the front, neutral or rear portions, the attachment moves as follows. Hydraulic crusher Hydraulic breaker Pedal front : actuated Pedal front : actuated Pedal neutral...
Page 241: Hydraulic Circuit
• The set pressure of the relief valve is set to 20600 kPa (210 kg/ , 2980 psi) as standard when delivered from the factory. If a breaker by another manufacturer is installed, adjustment is required. Consult your Komatsu distributor.
Page 242 28. MACHINES READY FOR ATTACHMENTS 28.2.1 CONNECTING HYDRAULIC CIRCUIT When connecting the attachment, connect the circuit as follows. Remove blind plugs located on the end of the stop valve piping (2 places, left and right). Take care not to lose or damage the removed parts. Connect attachment tubes supplied by the attachment manufac- turer to the end from which the plug was removed in step 1.
Page 243: Attachment Mounting/Dismounting Procedure
28. MACHINES READY FOR ATTACHMENTS 28.3. ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE DISMOUNTING PROCEDURE Place the attachment on the ground and stop the engine. Free After stopping the engine, operate each work equipment control Lock lever and the attachment control pedal back and forth, left and right at full stroke 2 to 3 times to eliminate the internal pressure in the hydraulic circuit.
Page 244: Mounting Procedure
28. MACHINES READY FOR ATTACHMENTS MOUNTING PROCEDURE Remove the bucket. For bucket dismounting procedure, see 12.15 “REPLACEMENT AND INVERSION OF BUCKET’’. Place the attachment on a flat place, install pins to the arm in that order. After mounting the attachment, stop the engine. Operate each work equipment control lever and the attachment control pedal to full stroke back and forth, right and left to eliminate the internal pressure in the hydraulic circuit.
Page 245: Operation
28. MACHINES READY FOR ATTACHMENTS 28.4 OPERATION WARNING • If the pedal is operated inside the deceleration range, the engine speed will rise suddenly. Be careful. • If the operator rests his foot on the attachment pedal while operating the machine, if he carelessly depresses the pedal, the attachment may move suddenly and result in serious trouble.
Page 246: Long-Term Storage
In addition, valves with a safety valve relief set pressure of 24500 kPa (250 kg/cm , 3560 psi) and safety valve crackingpressure of 20.000 kPa (205 kg/cm , 2920 psi) are also available, so please contact your Komatsu distributor. 5-12...
Page 247: Introduction Of Attachments
29. INTRODUCTION OF ATTACHMENTS 29.1 SPECIFICATION, USE • PC450, 450 LC Name Specifications, use Name Specifications, use Narrow bucket Capacity 1.2 m Track shoes Triple grouser shoe width 700 mm Outside width 1,120 mm (PC450) Triple grouser shoe width 800 mm Narrow bucket Capacity 1.4 m...
Page 248 29. INTRODUCTIONS OF ATTACHMENTS 29.2 ATTACHMENT INSTALLATION COMBINATION TABLE PC450-6K, PC450LC-6K This table lists the combination of attachments which can be installed to the different arms. Can be used. Can be used only for light duty work Cannot be used.
Page 249: Selection Of Track Shoes
(swampy ground) • Travel at Hi speed only on flat ground, and if it is impossible to avoid going over obstacles, shift down and travel at half speed in Lo. Table 2 PC450-6K PC450LC-6K Specifications Categroy Specifications Category...
Page 250: Selection Of Bucket Teeth
29. INTRODUCTIONS OF ATTACHMENTS 29.4 SELECTION OF BUCKET TEETH Select suitable bucket teeth to match the operating conditions. METHOD OF SELECTING TEETH The standard teeth can be used over a wide range, but according to the operating conditions, we recommend the following teeth.
Page 251: Handling Trapezoidal Bucket
29. INTRODUCTIONS OF ATTACHMENTS 29.5 HANDLING TRAPEZOIDAL BUCKET This bucket is used to dig trapezoidal ditches on paddy fields, farmland ect. and can dig 3 types of ditch gradients ( 45 , 40 and 38 when a movable plate is attached. •...
Page 252: Handling The Clamshell Bucket
29. INTRODUCTIONS OF ATTACHMENTS 29.6 HANDLING THE CLAMSHELL BUCKET This bucket is used for digging and loading in side-ditches or the confined spaces. How to perform excavation This clamshell digs by pushing the boom against the ground. However, when perform bucket operation, perform digging while gradually raising the boom.
Page 253: Extending Machine Service Life
NOTICE Select the attachment most suited to the machine body. • The machine models to which attachments can be mounted vary. For selection of attachment and machine model, consult your Komatsu distributor. 30.1 HYDRAULIC BREAKER MAIN FIELDS OF APPLICATION °...
Page 254 30. EXTENDING MACHINE SERVICE LIFE When applying continuous impact to the same impact surface, if the chisel does not penetrate or break the surface within 1 minute, change the point of impact and carry out breaking operations closer to the edge. The direction of penetration of the chisel and the direction of the breaker body will gradually move out of line with each other, so always adjust the bucket cylinder to keep them aligned.
Page 255 30. EXTENDING MACHINE SERVICE LIFE Moving the chisel while carrying out impacting operations Holding the chisel horizontal or pointed up when carrying out impacting operations Twisting the chisel when it has penetrated the rock Pecking operations Extending the bucket cylinder fully and thrusting to raise the machine off the ground 5-21...
Page 256: Power Ripper
30. EXTENDING MACHINE SERVICE LIFE 30.2 POWER RIPPER MAIN FIELDS OF APPLICATIONS • Road repair work • Demolition work This attachment can be used for a wide range of work including peeling off and crushing pavement roads, demolishing wooden houses and buildings, and crushing foundation and roadbeds.
Page 257: Fork Grab
30. EXTENDING MACHINE SERVICE LIFE 30.3 FORK GRAB MAIN FIELDS OF APPLICATION ° Disposing of industrial waste ° Disposing of demolition waste This can be used for a wide range of work including collecting or loading demolition waste materials and debris, timber, grass. MISTAKEN METHODS OF USE To ensure that the machine has a long life, and to ensure that operations are carried out in safety, do not operate the machine in ‘...
Page 258: Grapple Bucket
30. EXTENDING MACHINE SERVICE LIFE 30.4 GRAPPLE BUCKET MAIN FIELDS OF APPLICATION ° Demolition ° Disposing of industrial waste ° Forestry This bucket is widely used for demolition including breaking-up work, grading and digging, clean-up work after natural disasters, dumping industrial waste, and forestry work, etc.
Page 259: Scrap Grapple
30. EXTENDING MACHINE SERVICE LIFE 30.5 SCRAP GRAPPLE MAIN FIELDS OF APPLICATION ° Disposal of rock or debris This attachment is mounted to the arm end and used to grasp rock, debris etc. by opening and closing the claws (3 to 5) corresponding to the extension and retraction of the hydraulic cylinder.
Page 260: Crusher & Smasher
30. EXTENDING MACHINE SERVICE LIFE 30.6 CRUSHER & SMASHER MAIN FIELDS OF APPLICATION ° Demolition ° Road repair work This is the optimum attachment for demolition of steel frame reinforced structures, and for crushing of concrete blocks and rock, etc. The unique blade shape provides heavy crushing power.
Page 261: Hydraulic Pile Driver
30. EXTENDING MACHINE SERVICE LIFE 30.7 HYDRAULIC PILE DRIVER MAIN FIELDS OF APPLICATION ° Foundation work ° River work ° Water supply and sewerage This is a piling machine employing the hydraulic power source of the excavator. The machine features a long arm and a chuck unit. This facilitates operations such as driving and removing long piles, driving in piles at corners, etc.
Page 262: Hydraulic Excavator With Multipurpose Crane
30. EXTENDING MACHINE SERVICE LIFE 30.8 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE MAIN FIELDS OF APPLICATION ° Site preparation ° Water supply and sewerage ° River work ° Agricultural, civil engineering work Crane operation can be carried out without removing the bucket. This machine is used for laying U section gutters and pipes for water supply and sewerage as well as river and canal work, agricultural, civil engineering work and site preparation.

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