Komatsu PC450-8 Manual

PC450 -8
PC450LC -8
SERIAL NUMBER
PC450-8 - K50001 and up
PC450LC-8 - K50001 and up
PC450LCD-8 - K50001 and up
PC450LCHD-8 - K50001 and up
HYDRAULIC EXCAVATOR
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.
Operation &
Maintenance Manual
UEAM007200
WARNING

FOREWORD
11

FOREWORD FOREWORD
1-2
FOREWORD 1
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions in this manual must be followed at all times when performing operation and maintenance. Most accidents
are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
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 manual carefully so that they should be under-
stood 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, immediately 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 international standard units (SI). For the reference pur-
pose, weight units used in the past are also displayed in ( ).
Storage location for the Operation and Maintenance Manual:
magazine box on the left side of the operator's seat.

FOREWORD SAFETY INFORMATION
1-3
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 situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Example of safety message using signal word
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 not locked, this may cause a serious injury or
death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.
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.
NOTICE This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
REMARKS This word is used for information that is useful to know.
DANGER
WARNING
CAUTION

SAFETY INFORMATION FOREWORD
1-4
qSafety 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 procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety pic-
tograms use pictures in order to let the operator or
maintenance worker understand the level and type of hazard-
ous 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 con-
dition at the bottom or right side. In addition, the type of haz-
ardous condition is displayed inside a triangle and the method
of avoiding the hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility 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: 1J(1))
Part No
Part No

FOREWORD SAFETY INFORMATION
1-5
Noise emission levels 1
Two labels indicating the machine noise level are affixed on the
machine.
qSound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
qSound 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

SAFETY INFORMATION FOREWORD
1-6
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera-
tor’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
qTension of crawler (for crawler machines)
qBrake and steering systems
qControls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
qRemove any large rocks or obstacles
qFill any ditches and holes
qSite 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
qAdjust the seat and suspension for the weight and size of the operator
qWear seat belt
qInspect 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
qWhen pushing with bucket or blade, avoid sudden loading; load gradually
qDrive around obstacles and rough terrain conditions
qSlow down when it is necessary to go over rough terrain
qMake the curve radius of traveling path as large as possible
qTravel at low speed when traveling around sharp curves

FOREWORD SAFETY INFORMATION
1-7
7. Minimize vibrations for long work cycle or long distance traveling
qReduce speed to prevent bounce
qTransport machines long distances between work sites
8. The following guidelines can be effective to minimize risks of low back pain
qOperate the machine only when you are in good health.
qProvide breaks to reduce long periods of sitting in the same posture
qDo not jump down from the cab or machine
qDo not repeatedly handle and lift loads

INTRODUCTION FOREWORD
1-8
INTRODUCTION 1
This Komatsu machine is designed to be used mainly for the following work:
qDigging work
qLeveling work
qDitching work
qLoading work
qDemolition work
See the section “RECOMMENDED APPLICATIONS (3-162)“ for further details.
DIRECTIONS OF MACHINE 1
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.
(A) Front (E) Operator's seat
(B) Rear (F) Sprocket
(C) Left
(D) Right

FOREWORD INTRODUCTION
1-9
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.

INTRODUCTION FOREWORD
1-10
BREAKING-IN THE NEW MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How-
ever, operating the machine under full load before breaking the machine in can adversely affect the perfor-
mance 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.
qRun the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
qIdle the engine for 5 minutes after starting it up.
qAvoid operation with heavy loads or at high speeds.
qImmediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.

FOREWORD PRODUCT INFORMATION
1-11
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.

PRODUCT INFORMATION FOREWORD
1-12
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 KOMATSU UK LTD.
Address Durham Road
Birtley
Chester-Le Street
County Durham DH32QX
United Kingdom
Distributor name
Address
Service Personnel
Phone/Fax

FOREWORD PRODUCT INFORMATION
1-13
MACHINE SERIAL PLATE 1
205-00-K1291
MODEL
SERIAL No.
MANUFACT. YEAR
MASS
ENGINE POWER
Product Identification Number
kg
kW
MANUFACTURER Manufactured by Komatsu UK Ltd.
for Komatsu Ltd.,Tokyo,Japan
MODEL
SERIAL
MANUFACTURING YEAR
WEIGHT
ENGINE POWER
MANUFACTURER
Komatsu UK Ltd, Birtley, Co Durham, United Kingdom
PRODUCT
IDENTIFICATION
NUMBER

CONTENTS
1-14
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

CONTENTS
1-15
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...................................................................................................................... 3-108
FIRE EXTINGUISHER............................................................................................................................ 3-108
REFUELLING PUMP.............................................................................................................................. 3-109
ACCUMULATOR.................................................................................................................................... 3-110

CONTENTS
1-16
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.........................................................................................................................................3-169
TRANSPORTATION PROCEDURE.......................................................................................................3-169
LOADING AND UNLOADING WITH TRAILER ......................................................................................3-170
Loading..........................................................................................................................................3-171
Securing Machine..........................................................................................................................3-173

CONTENTS
1-17
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

CONTENTS
1-18
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