Complete service repair manual for Komatsu 450FXL Crawler Feller Bunchers/Harvesters, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu 450FXL Crawler Feller Bunchers/Harvesters workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM023102 – Komatsu 450FXL Crawler Feller Bunchers_Harvesters Shop Manual (SN 450FXL-1 A10001 & up – Engine QSC 8.3).pdf
PRODUCT DETAILS:
Total Pages: 410 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
01 GENERAL . . . . 01-1
30 TESTING AND ADJUSTING . . . . 30-1
40 TROUBLESHOOTING . . . . 40-1
50 DISASSEMBLY AND ASSEMBLY. . . . 50-1
60 AIR CONDITIONER . . . . 60-1
90 DIAGRAMS AND SCHEMATICS. . . . 90-1
CEBM023102 450FXL-1….1
CONTENTS….7
00 – FOREWORD….8
Safety Notice….8
Important Safety Notice….8
General Precautions….8
Preparations For Work….8
Precautions During Work….8
GENERAL….11
HOW TO READ THE SHOP MANUAL….12
Volumes….12
Distribution And Updating….12
Filing Method….12
Revised Edition Mark….12
Revisions….12
Symbols….12
HOISTING INSTRUCTIONS….13
Hoisting….13
Wire Ropes….13
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS….14
Points To Remember When Handling Electric Equipment….14
Points To Remember When Handling Hydraulic Equipment….20
PUSH PULL COUPLER….22
Type 1….22
Disconnection….22
Connection….22
Type 2….23
Disconnection….23
Connection….23
Type 3….24
Disconnection….24
Connection….24
EXPLANATION OF MAINTENANCE STANDARD TERMS….25
STANDARD TIGHTENING TORQUE….27
Bolts And Nuts….27
GENERAL INSTRUCTIONS….28
Introduction….28
Cleaning….28
Replacement….28
Hoses and Tubes….28
Inspection….28
Installation….28
Hydraulic Pumps….29
Replacement….29
Pressure Testing….29
Leveling Cylinders and Debris Deflector Skirting….29
Hydraulic Fitting Torque Values….31
JIC 37 Flare Torque Values….31
37 Flare, Tube To Fitting Assembly….32
SAE Straight Thread O-Ring Fitting (Adjustable) To Port Assembly….33
Seal-Lok Straight and Adjustable Fitting (Steel)….34
Flare and Flareless Port Ends….34
SAE Straight Thread O-Ring Fitting (Non-Adjustable)….35
Fitting To Port Assembly….35
Port Assembly For SAE Straight Thread Plugs….36
4-Bolt Split Flange Assembly, Fitting To Port SAE….37
Code 61 (3000 psi) and Code 62 (6000 psi)….37
Pipe Thread Port Assembly, Fitting To Port….38
Standard Bolt Torque Chart (Inches)….39
CONVERSION TABLES….40
Method Of Using The Conversion Table….40
COATING MATERIALS….46
01 – GENERAL….49
SPECIFICATIONS….51
Dimensions….51
BOOM AND ARM SWEEP DIAGRAMS….52
SPECIFICATIONS….56
Engine….57
Fuel Quality Requirements….58
Engine Oil Performance Information….58
Hydraulic and Engine Oil Selection, Lubricating Oils, and Grease….59
New Engine “Break-in” Oils….59
Coolant Quality Requirements….59
Coolant and Water for Dilution….59
Hydraulic Oil Information….60
Hydraulic Oil Type….60
Hydraulic Oil Viscosity….60
Hydraulic Oil Viscosity Selection….61
ISO Code Rating….61
General Hydraulic Oil Specification….62
Minimum Technical Hydraulic Oil Requirements….62
Track Final Drive Oil Information….62
Hydraulic System….63
General:….63
Pump Drive:….63
Implement Pump:….63
Track Drive Pump (2):….63
Track Drive Charge Pump:….63
Return Oil Filtration:….63
Hydraulic Tank:….63
Implement Control Valve:….63
Typical Hydraulic Valve Set-up….64
VOAC K220 Valve, Typical….65
VOAC L90LS Valve, Typical….67
Lubricant and Fill Capacities….69
30 – TESTING AND ADJUSTING….71
30 TESTING AND ADJUSTING….71
FIRE SUPPRESSION SYSTEM (OPTIONAL)….73
Ansul™ Fire Suppression Controls (Optional)….73
Ansul Fire Suppression Daily Inspections….73
Ansul Fire Suppression Monthly Inspections….74
Maintenance….74
HYDRAULIC PRESSURE SETTINGS….75
Hydraulic Pressure Gauges….75
Implement Pump Pressure Settings….75
Implement Pump Stand-By Pressure….75
Implement Pump POR (Pressure Over-Ride) Pressure….77
Auxiliary Implement Pump Pressure Settings….78
Common Pressure Port Stand-by Pressure Adjustment….78
Common Pressure Port POR (Pressure Over-Ride) Pressure Adjustment….79
Separate Pressure Port Stand-by Pressure Adjustment….80
Separate Pressure Port POR Pressure Adjustment….81
Track Drive Circuit Pressure Settings….82
Hydrostatic Charge Pressure Relief Adjustment….82
Hydrostatic Main Relief Adjustment Procedure….82
Drive Pump Null….85
CONTROL VALVE CIRCUIT PRESSURE ADJUSTMENTS….87
Differential Pressure Adjustment….87
Load Sense Max Pressure Adjustment….88
Feed Reducer Pressure Adjustments….90
Adjustment Procedure….90
Main Control Valve Port Reliefs….91
40 – TROUBLESHOOTING….93
RELAY & FUSE LOCATIONS….95
Relay Location and Identification….95
Mini Fuse Bank A Location and Identification….96
Mini Fuse Bank A Location….97
Mini Fuse Bank B Location and Identification….98
Mini Fuse Bank B Location….99
Maxi Fuse Bank C Location and Identification….100
Maxi Fuse Bank D Location and Identification….100
GENERAL INFORMATION….101
Points to Remember….101
Sequence of Events….103
Handling Electric Equipment and Hydraulic Components….104
Connectors for Tier 3 Engines….112
Checks Before Troubleshooting….116
GENERAL HYDRAULIC PROBLEMS….117
MACHINE OVERHEAT PROBLEMS….127
IMPLEMENT FUNCTION PROBLEMS….132
TRACK DRIVE PROBLEMS….136
ENGINE PROBLEMS….146
ELECTRICAL PROBLEMS….149
AIR CONDITIONER / HEATER PROBLEMS….156
DISC SAW CIRCUIT PROBLEMS….163
50 – DISASSEMBLY AND ASSEMBLY….169
HOW TO READ THIS MANUAL….173
Removal And Installation Of Assemblies….173
Special Tools….173
Removal….173
Installation….173
Disassembly And Assembly Of Assemblies….174
Special Tools….174
Disassembly….174
Assembly….175
SPECIAL TOOLS LIST….176
CONNECTOR REPAIR PROCEDURES….177
Stripping Insulation….177
Wire Inspection….177
Contact Terminal Removal (HD30 Type)….178
Crimping Contact Terminal (HD30 Type)….179
Insertion Of Contact Terminal (HD30 Type)….180
Contact Terminal Removal (DT Type)….181
Crimping Contact Terminal (DT Type)….182
Insertion Of Contact Terminal (DT Type)….183
PRECAUTIONS DURING OPERATION….184
Precautions when Performing Removal Work….184
Precautions when Performing Installation Work….185
Precautions when Completing The Operations….186
Other Precautions….186
ARM….187
Stick ARM….187
Removal….187
Installation….188
Main Boom….190
Removal….190
Installation….191
Tool Tilt Cylinder….193
Removal….193
Installation….194
Stick Cylinder….195
Removal….195
Installation….195
Main Boom Cylinder….196
Removal….196
Installation….197
HYDRAULIC SYSTEM….199
Hydraulic Oil Tank….199
Draining….199
Removal and Disassembly….200
Cleaning….203
Assembly….204
Installation….205
Filling the Hydraulic Tank….207
Auxiliary Oil Cooler….208
Removal (Hydraulic Driven Fan)….208
Hydraulic Tank Vacuum Pump….209
Removal….209
Installation….209
Machine Start-Up After Hydraulic Component Replacement….210
Hydraulic System Start-Up for Machines Without A Vacuum Pump….210
Hydraulic System Start-Up for Machines With A Vacuum Pump….211
Rotary Manifold….212
Removal….212
Inspection….214
Installation….214
Swing Motor….216
Removal….216
Installation….217
Swing Motor Anti-Cavitation Valve….219
Removal….219
Installation….219
Swing Motor Gearbox Brake….220
Disassembly….220
Assembly….220
Swing Motor/Gearbox Assembly….221
Removal….221
Installation….221
SWING BEARING….222
Removal….222
Installation….224
Fill and Check Swing Pinion Grease Level….226
LEVELING COMPONENTS….227
Leveling Cylinder Removal….227
Leveling Cylinder Installation….228
Turntable Casting….230
Removal….230
Installation….233
Intermediate Leveler….236
Removal….236
Installation….238
Auxiliary Pump….241
45 cc Auxiliary Pump Removal….241
45 cc Auxiliary Pump Installation….242
71 cc Auxiliary Pump Removal….243
71 cc Auxiliary Pump Installation….244
Implement Pump….246
Removal….246
Installation….248
Auxiliary Oil Cooler Fan Pump….251
Removal….251
Installation….252
Charge Pump….254
Removal….254
Charge Pump Installation….255
Right Side Drive Pump….256
Removal….256
Installation….258
Left Side Drive Pump….262
Removal….262
Installation….264
FINAL DRIVE ASSEMBLY….268
Removal….268
Disassembly….270
Disassembly of Number 1 Carrier….276
Assembly of Number 1 Carrier….276
Disassembly of Number 2 Carrier….276
Assembly of Number 2 Carrier….277
Assembly….277
Installation….287
MAIN CONTROL VALVE….289
Removal….289
Installation….290
FILL PUMP….292
Removal….292
Installation….292
CHARGE MANIFOLD HEATER….293
Removal….293
Installation….294
CHARGE FILTER MANIFOLD….296
Removal….296
Installation….297
PILOT PRESSURE MANIFOLD….298
Removal and Installation….298
RETURN OIL MANIFOLD (LOGIC BLOCK)….299
SAW STOP VALVE….300
Removal and Installation….300
ENGINE FLEXPLATE….301
Remove Hydraulic Pumps….301
Separate Pump Drive From Engine….301
Flexplate Removal….303
Flexplate Installation….303
Pump Drive Installation….304
Install Hydraulic Pumps….305
ENGINE….306
Removal….306
Installation Preparation….319
Installation….326
TRACK SYSTEM….339
Track Tension….339
Checking Track Tension….339
Increasing Track Tension….339
Decreasing Track Tension….339
Track Shoe Removal and Installation….340
Track Removal and Installation….340
Idler Wheel, Recoil Spring and Track Adjuster Assembly….345
Idler Wheel and Recoil Spring Removal….345
Idler Wheel and Recoil Spring Installation….346
Idler Wheel….346
Disassembly….346
Assembly….347
Recoil Spring….350
Disassembly….350
Assembly….351
Track Roller….352
Removal….352
Disassembly….353
Assembly….354
Installation….356
Final Drive Sprocket….357
Removal….357
Installation….357
Track Slider….358
Removal….358
Installation….358
Upper Track Roller….359
Removal….359
Installation….359
Track Frame….359
Removal….359
Installation….360
CAB….362
Removal….362
Installation….368
60 – AIR CONDITIONER….373
AIR CONDITIONER/HEATER….373
CHARGING AIR CONDITIONING SYSTEM….373
Technician Training and Certification….373
Air Conditioner/Heater Access….374
90 – DIAGRAMS AND SCHEMATICS….375
TRACK DRIVE CIRCUIT: 83381 REV. A….377
COMBINATION BAR SAW AND DISC SAW: 83382-B….378
DISC SAW: 83383-B….379
DUAL FLOW PROCESSOR #2: 83385-B….380
COMBINED FLOW PROCESSOR #3: 83386-B….381
COMBINED FLOW PROCESSOR #4: 83387-B….382
INTERMITTENT DISC SAW: 83388-B….383
BAR SAW: 83389-B….384
DUAL FLOW PROCESSOR #5: 85801-A….385
ELECTRICAL MAXI HEAD COMPUTER: 00860148; 1/2….386
ELECTRICAL MAXI HEAD COMPUTER: 00860148; 2/2….387
ELECTRICAL: 00860154 ; 1/2….388
ELECTRICAL: 00860154; 2/2….389
HYDRAULIC: 00860150….390
IQAN 1/6….391
IQAN 2/6….392
IQAN 3/6….393
IQAN 4/6….394
IQAN 5/6….395
IQAN 6/6….396
1/18 MAIN ELECTRICAL CTR, FUSE LEGEND: 28606-E 1/2….397
1/18 MAIN ELECTRICAL CTR, FUSE LEGEND: 28606-E 2/2….398
1/18 DASH PANEL: 28411-A….399
5/18 UPPER CAB HARNESS: 28413-A….400
6/18 RADIO ADAPTER: 28414-B….401
7/18 REAR UPPER LIGHT HARNESS: 28415-A….402
8/18 LOWER CAB SUB HARNESS (SHIFT COIL) : 28416-A….403
11/18 LOWER CAB HARNESS: 28417-A….404
12/18 FOPS LIGHT HARNESS: 28418-A….405
15/18 ENGINE HARNESS: 28703-B….406
16/18 VISOR LIGHT HARNESS: 28422-B….407
18/18 MAXI INTERFACE HARNESS: 83093-A….408
VAC/VENT SUB HARNESS: 27309….409
ROLLY II INSTALLATION KIT, FUSE RELAY: 28701 REV A….410
CUMMINS QSC ENGINE SCHEMATIC: 83093-A….411
Komatsu 450FXL Crawler Feller Bunchers/Harvesters Repair Service Manual