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SEBM014508 MACHINE MODEL SERIAL NUMBER PC400-6 PC400LC-6 PC450-6 PC450LC-6 32001 32001 12001 12001 and and and and up up up up • This shop manual may contain attachments and optional equipment that are not available in your area Please consult your local Komatsu distributor for those items you may require Materials and specifications are subject to change without notice • PC400, 450-6 mount the SA6D125-2 engine For details of the engine, see the 125-2 Series Engine Shop Manual © 2004 All Rights Reserved Printed in Japan 09-04(01) 00-1 (8) CONTENTS No of page 01 GENERAL 01-1 10 STRUCTURE AND FUNCTION 10-1 20 TESTING AND ADJUSTING 20-1 30 DISASSEMBLY AND ASSEMBLY 30-1 40 MAINTENANCE STANDARD 40-1 90 OTHERS 90-1 00-2 PC400, 450-6 LIST OF REVISED PAGES The affected pages are indicated by the use of the following marks It is requested that necessary actions be taken to these pages according to the table below Mark Indication Action required fi Page to be newly added Add ‡ Page to be replaced Replace Page to be deleted Discard ( ) Pages having no marks are those previously revised or made additions LIST OF REVISED PAGE Mark Page Time of revision ‡ 00- (8) 01- 00- (2) 01- (5) 10- ‡ 00- 2-1 (8) 01- (4) 10-10 ‡ 00- 2-2 (8) 01- 3-1 (5) 10-12 ‡ 00- 2-3 (8) 01- (5) ‡ 00- 2-4 (8) 01- ‡ 00- 2-5 (8) ‡ Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page 10-39 10-65 10-40 10-66 10-41 10-67 (5) 10-42 10-68 10-13 (4) 10-43 10-69 10-14 (5) 10-44 10-70 01- 10-15 (5) 10-45 10-71 00- 01- 10-16 (4) 10-46 10-72 ‡ 00- 01- 7-1 (5) 10-17 10-46-2 (5) 10-73 ‡ 00- 01- 7-2 (5) 10-18 10-46-3 (5) 10-74 ‡ 00- 01- (5) 10-19 10-48 10-75 ‡ 00- 01- 10-20 10-49 10-76 ‡ 00- 01-10 10-21 10-50 10-77 ‡ 00- 01-11 10-22 10-51 10-78 ‡ 00-10 01-11-1 (5) 10-24 10-52 10-80 ‡ 00-11 01-11-2 (5) 10-25 10-53 10-81 ‡ 00-12 01-12 (4) 10-26 10-55 10-82 ‡ 00-13 01-13 10-27 10-56 10-84 ‡ 00-14 10-28 10-57 10-85 ‡ 00-15 10-29 10-58 ‡ 00-16 10- 10-30 10-59 ‡ 00-17 10- 10-31 10-59-1 (5) 10-89 ‡ 00-18 10- 10-32 10-59-2 (5) 10-90 ‡ 00-19 10- 10-33 10-60 10-92 ‡ 00-20 10- 10-34 10-61 10-93 ‡ 00-21 10- 10-35 10-62 10-94 ‡ 00-22 10- (4) 10-36 10-63 10-96 10- 7-1 (4) 10-38 10-64 10-97 PC400, 450-6 10- (5) (4) (5) (5) Time of revision 10-86 10-88 00-2-1 (8) LIST OF REVISED PAGES Mark Page Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision 10-98 10-144 10-192 20- (5) 20-119-1 (4) 10-100 10-145 10-193 20- 9-1 (5) 20-119-2 (4) 10-101 10-146 10-194 20- 9-2 (5) 20-120 (4) 10-102 10-147 10-196 20- 9-3 (5) 20-121 (4) 10-104 10-148 10-197 20- 9-4 (5) 20-122 (1) 10-105 10-149 10-198 20- 9-5 (5) 20-123 (1) 10-106 (6) 10-151 10-199 20- 9-6 (5) 20-124 (1) 10-108 10-152 10-200 20- 9-7 (5) 20-125 (1) 10-109 10-153 10-201 20- 9-8 (5) 20-126 (1) 10-110 10-154 10-202 20-10 (1) 20-127 (1) 10-112 10-155 10-203 20-11 (1) 20-128 (4) 10-113 10-156 10-204 20-12 (6) 20-129 (1) 10-114 10-157 10-205 20-13 (6) 20-130 (1) 10-116 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20-214 (6) 10-140 10-188 20- (1) 20-117 (4) 20-215 (4) 10-141 10-189 20- (1) 20-117-1 (4) 20-216 (1) 10-142 10-190 20- (1) 20-118 (1) 20-217 (1) 10-191 20- (1) 20-119 (4) 20-218 (1) 10-143 00-2-2 (8) Time of revision (6) PC400, 450-6 LIST OF REVISED PAGES Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Time of revision Page 20-219 (1) 20-357 (1) 20-416 (1) 20-483 (6) 20-561 (1) 20-220 (1) 20-358 (6) 20-417 (1) 20-484 (6) 20-562 (1) 20-221 (1) 20-359 (6) 20-418 (1) 20-485 (6) 20-564 (1) 20-222 (1) 20-360 (1) 20-419 (1) 20-486 (6) 20-565 (1) 20-223 (1) 20-361 (1) 20-420 (1) 20-487 (6) 20-566 (1) 20-224 (1) 20-362 (6) 20-421 (1) 20-488 (1) 20-567 (1) 20-225 (1) 20-363 (6) 20-422 (1) 20-489 (6) 20-568 (1) 20-226 (1) 20-364 (6) 20-423 (1) 20-490 (6) 20-569 (1) 20-227 (1) 20-365 (6) 20-491 (6) 20-570 (1) 20-228 (1) 20-366 (6) 20-451 (6) 20-492 (6) 20-571 (1) 20-229 (6) 20-367 (6) 20-452 (1) 20-493 (6) 20-572 (1) 20-230 (6) 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(4) 30-21 (2) 30-59 (2) 30-73 (4) 30-94-19 (3) 20-641 (4) 30-22 (2) 30-59-1 (3) 30-74 (4) 30-94-20 (3) 20-641-1 (4) 30-23 (2) 30-59-2 (3) 30-75 (2) 30-94-21 (3) 20-642 (4) 30-24 (2) 30-59-3 (3) 30-76 (2) 30-95 (2) 20-643 (4) 30-25 (2) 30-59-4 (3) 30-77 (2) 30-96 (2) 20-644 (4) 30-26 (2) 30-59-5 (3) 30-78 (2) 30-97 (2) 20-645 (4) 30-27 (2) 30-59-6 (3) 30-79 (4) 30-98 (2) 20-646 (4) 30-28 (2) 30-59-7 (3) 30-80 (4) 30-99 (2) 30-29 (2) 30-59-8 (3) 30-81 (2) 30-100 (2) 30-30 (2) 30-59-9 (3) 30-82 (2) 30-101 (2) 30- (6) 30-31 (2) 30-59-10 (3) 30-83 (2) 30-102 (2) 30- (3) 30-32 (2) 30-59-11 (3) 30-84 (2) 30-103 (2) 30- (2) 30-33 (2) 30-59-12 (3) 30-85 (2) 30-104 (2) 30- (2) 30-34 (2) 30-59-13 (3) 30-86 (2) 30-105 (2) 30- (2) 30-35 (2) 30-59-14 (3) 30-87 (2) 30-106 (2) 30- (2) 30-36 (2) 30-59-15 (3) 30-88 (2) 30-107 (2) 00-2-4 (8) Time of revision PC400, 450-6 LIST OF REVISED PAGES Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision Mark Page Time of revision 30-108 (2) 30-148 (2) 40-23 90-15 (5) 30-109 (2) 30-149 (2) 40-24 90-17 (5) 30-110 (2) 30-150 (2) 40-25 90-19 (5) 30-111 (2) 30-151 (2) 40-26 90-21 (5) 30-112 (2) 30-152 (2) 40-27 30-113 (2) 30-153 (2) 40-28 30-114 (2) 30-154 (2) 40-29 30-115 (2) 30-155 (2) 40-30 30-116 (2) 30-156 (2) 40-31 30-117 (4) 30-157 (2) 40-32 30-118 (2) 30-158 (2) 40-33 30-119 (4) 30-159 (2) 40-34 30-120 (2) 30-160 (2) 40-35 30-121 (2) 30-161 (2) 40-36 30-122 (2) 30-162 (2) 40-37 30-123 (2) 30-163 (2) 40-38 (4) 30-124 (2) 30-164 (2) 40-40 (4) 30-125 (2) 40-40-1 (4) 30-126 (2) 30-127 (2) 30-128 (2) 40- 40-43 30-129 (2) 40- 40-43-1 (5) 30-130 (2) 40- 40-44 (5) 30-131 (2) 40- (4) 40-45 30-132 (2) 40- (4) 40-45-1 (5) 30-133 (2) 40- 40-45-2 (5) 30-134 (2) 30-135 (2) fi 40- 9-1 (8) 40-47 30-136 (2) fi 40- 9-2 (8) 40-48 30-137 (2) 40-10 30-138 (2) 40-12 30-139 (2) 40-13 30-140 (2) 40-14 90- 30-141 (2) 40-15 90- 30-142 (2) 40-16 90- 3-2 30-143 (2) 40-17 90- 30-144 (2) 40-18 90- 30-145 (2) 40-19 90- 30-146 (2) 40-20 90-11 (4) 30-147 (2) 40-22 90-13 (4) PC400, 450-6 Mark Page Time of revision 40-41 ‡ 40- (8) 40-42 (5) 40-46 40- 40-49 (5) (5) 00-2-5 (8) SAFETY SAFETY NOTICE SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose To prevent injury to workers, the symbol k is used to mark safety precautions in this manual The cautions accompanying these symbols should always be followed carefully If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous Read the Operation and Maintenance Manual carefully BEFORE operating the machine Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine When carrying out any operation, always wear safety shoes and helmet Do not wear loose work clothes, or clothes with buttons missing • • Always wear safety glasses when hitting parts with a hammer Always wear safety glasses when grinding parts with a grinder, etc If welding repairs are needed, always have a trained, experienced welder carry out the work When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work When carrying out any operation with two or more workers, always agree on the operating procedure before starting Always inform your fellow workers before starting any step of the operation Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment Keep all tools in good condition and learn the correct way to use them Decide a place in the repair workshop to keep tools and removed parts Always keep the tools and parts in their correct places Always keep the work area clean and make sure that there is no dirt or oil on the floor Smoke only in the areas provided for smoking Never smoke while working PREPARATIONS FOR WORK Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving Before starting work, lower blade, ripper, bucket or any other work equipment to the ground If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling In addition, be sure to lock all the control levers and hang warning signs on them When disassembling or assembling, support the machine with blocks, jacks or stands before starting work 10.Remove all mud and oil from the steps or other places used to get on and off the machine Always use the handrails, ladders or steps when getting on or off the machine Never jump on or off the machine If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing 00-3 SAFETY PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned Wait for the oil and water to cool before carrying out any work on the oil or water circuits 13.Before starting work, remove the leads from the battery Always remove the lead from the negative (–) terminal first 14.When raising heavy components, use a hoist or crane Check that the wire rope, chains and hooks are free from damage Always use lifting equipment which has ample capacity Install the lifting equipment at the correct places Use a hoist or crane and operate slowly to prevent the component from hitting any other part Do not work with any part still raised by the hoist or crane 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides Slowly release the pressure, then slowly loosen the bolts to remove 16.When removing components, be careful not to break or damage the wiring Damaged wiring may cause electrical fires 17.When removing piping, stop the fuel or oil from spilling out If any fuel or oil drips onto the floor, wipe it up immediately Fuel or oil on the floor can cause you to slip, or can even start fires 18.As a general rule, not use gasoline to wash parts In particular, use only the minimum of gasoline when washing electrical parts 00-4 SAFETY NOTICE 19.Be sure to assemble all parts again in their original places Replace any damaged parts with new parts • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated 20.When installing high pressure hoses, make sure that they are not twisted Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits Also, check that connecting parts are correctly installed 21.When assembling or installing parts, always use the specified tightening torques When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly 22.When aligning two holes, never insert your fingers or hand Be careful not to get your fingers caught in a hole 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements 24.Take care when removing or installing the tracks of track-type machines When removing the track, the track separates suddenly, so never let anyone stand at either end of the track FOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements Make sure you understand the contents of this manual and use it to full effect at every opportunity This shop manual mainly contains the necessary technical information for operations performed in a service workshop For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components STRUCTURE AND FUNCTION This section explains the structure and function of each component It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs Troubleshooting charts correlating "Problems" with "Causes" are also included in this section DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts The contents of this section may be described in STRUCTURE AND FUNCTION OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams In addition, this section may give the specifications of attachments and options together NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice Use the specifications given in the book with the latest date 00-5 ... 549.7 5 56. 9 564 .2 571.4 80 578 .6 585.9 593.1 60 0.3 60 7 .6 614.8 62 2.0 62 9.3 63 6.5 64 3.7 90 65 1.0 65 8.2 66 5.4 67 2.7 67 9.9 68 7.1 69 4.4 701 .6 708.8 7 16. 1 100 723.3 730.5 737.8 745.0 752.2 759.5 766 .7... 20-242 (6) 20-381 (1) 20- 466 (6) 20-509 (6) 20-585 (1) 20-243 (6) 20- 467 (6) 20-510 (6) 20-244 (6) 20-401 (1) 20- 468 (6) 20-511 (6) 20 -60 1 (1) 20-245 (6) 20-402 (1) 20- 469 (6) 20-512 (6) 20 -60 2 (1)... 497.8 512.0 5 26. 3 540.5 554.7 40 568 .9 583.2 597.4 61 1 .6 625.8 64 0.1 65 4.3 66 8.5 68 2.7 69 6.9 50 711.2 725.4 739 .6 753.8 768 .1 782.3 7 96. 5 810.7 825.0 839.2 60 853.4 867 .6 881.8 8 96. 1 910.3 924.5