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