KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00038-03) – PDF DOWNLOAD

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KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00038-03)

KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00038-03) – PDF DOWNLOAD:

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KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00038-03)

This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions 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. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.

TABLE OF CONTENTS:

KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00038-03)

COVER....................................................................................................................................................................................  1
FOREWORD.................................................................................................................................................................................  2
	FOREWORD.............................................................................................................................................................................  3
	SAFETY INFORMATION...................................................................................................................................................................  6
	INTRODUCTION.........................................................................................................................................................................  8
		DIRECTIONS OF MACHINE............................................................................................................................................................  8
		BREAKING-IN THE NEW MACHINE......................................................................................................................................................  8
	PRODUCT INFORMATION..................................................................................................................................................................  9
		PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.....................................................................................................................  9
		ENGINE SERIAL NUMBER PLATE AND ITS LOCATION......................................................................................................................................  9
		SERVICE METER LOCATION........................................................................................................................................................... 10
		YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...................................................................................................................................... 10
CONTENTS................................................................................................................................................................................. 11
SAFETY................................................................................................................................................................................... 15
	SAFETY INFORMATION................................................................................................................................................................... 16
	SAFETY LABELS........................................................................................................................................................................ 18
		LOCATION OF SAFETY LABELS........................................................................................................................................................ 18
		SAFETY LABELS.................................................................................................................................................................... 19
	SAFETY INFORMATION................................................................................................................................................................... 24
		SAFETY RULES..................................................................................................................................................................... 24
		IF PROBLEMS ARE FOUND............................................................................................................................................................ 24
		WORKING WEAR AND PERSONAL PROTECTIVE ITEMS....................................................................................................................................... 24
		FIRE EXTINGUISHER AND FIRST AID KIT.............................................................................................................................................. 24
		SAFETY EQUIPMENT................................................................................................................................................................. 24
		KEEP MACHINE CLEAN............................................................................................................................................................... 25
		KEEP OPERATOR'S COMPARTMENT CLEAN................................................................................................................................................ 25
		LEAVING OPERATOR'S SEAT WITH LOCK................................................................................................................................................ 25
		HANDRAILS AND STEPS.............................................................................................................................................................. 26
		PRECAUTIONS WHEN WORKING IN HIGH PLACES.......................................................................................................................................... 26
		MOUNTING AND DISMOUNTING......................................................................................................................................................... 26
		NO PERSONS ON ATTACHMENTS........................................................................................................................................................ 26
		DO NOT GET CAUGHT IN ARTICULATED PORTION......................................................................................................................................... 27
		BURN PREVENTION.................................................................................................................................................................. 27
		FIRE PREVENTION AND EXPLOSION PREVENTION......................................................................................................................................... 28
		ACTION IF FIRE OCCURS............................................................................................................................................................ 29
		WINDSHIELD WASHER FLUID.......................................................................................................................................................... 29
		FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION................................................................................................................. 29
		ATTACHMENT INSTALLATION.......................................................................................................................................................... 29
		ATTACHMENT COMBINATIONS.......................................................................................................................................................... 29
		CAB WINDOW GLASSES............................................................................................................................................................... 29
		UNAUTHORIZED MODIFICATIONS....................................................................................................................................................... 30
		SAFETY AT JOBSITE................................................................................................................................................................ 30
		WORKING ON LOOSE GROUND.......................................................................................................................................................... 30
		DISTANCE TO HIGH VOLTAGE CABLES.................................................................................................................................................. 31
		ENSURE GOOD VISIBILITY........................................................................................................................................................... 31
		VENTILATION FOR ENCLOSED AREA.................................................................................................................................................... 32
		SIGNALMAN'S SIGNAL AND SIGNS..................................................................................................................................................... 32
		EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................... 32
		ASBESTOS DUST HAZARD PREVENTION.................................................................................................................................................. 32
	SAFETY MACHINE OPERATION............................................................................................................................................................. 33
		STARTING ENGINE.................................................................................................................................................................. 33
			CHECKS BEFORE STARTING ENGINE................................................................................................................................................ 33
			SAFETY RULES FOR STARTING ENGINE............................................................................................................................................. 34
			STARTING ENGINE IN COLD WEATHER.............................................................................................................................................. 34
		OPERATION........................................................................................................................................................................ 35
			CHECKS BEFORE OPERATION...................................................................................................................................................... 35
			SAFETY RULES FOR CHANGING MACHINE DIRECTIONS................................................................................................................................. 35
			SAFETY RULES FOR TRAVELING................................................................................................................................................... 36
			TRAVELING ON SLOPES.......................................................................................................................................................... 36
			OPERATIONS ON SLOPES......................................................................................................................................................... 37
			PROHIBITED OPERATIONS........................................................................................................................................................ 37
			OPERATIONS ON SNOW........................................................................................................................................................... 39
			PARKING MACHINE.............................................................................................................................................................. 40
		TRANSPORTATION................................................................................................................................................................... 41
			LOADING AND UNLOADING........................................................................................................................................................ 41
			SHIPPING THE MACHINE......................................................................................................................................................... 41
		BATTERY.......................................................................................................................................................................... 42
			BATTERY HAZARD PREVENTION.................................................................................................................................................... 42
			STARTING ENGINE WITH BOOSTER CABLES.......................................................................................................................................... 43
		TOWING........................................................................................................................................................................... 44
			SAFETY RULES FOR TOWING...................................................................................................................................................... 44
		LIFTING OBJECTS WITH BUCKET...................................................................................................................................................... 45
			SAFETY RULES FOR LIFTING OBJECTS............................................................................................................................................. 45
	SAFETY MAINTENANCE INFORMATION....................................................................................................................................................... 46
		WARNING TAG...................................................................................................................................................................... 46
		KEEP WORK PLACE CLEAN AND TIDY................................................................................................................................................... 46
		APPOINT LEADER WHEN WORKING WITH OTHERS.......................................................................................................................................... 46
		STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...................................................................................................................................... 47
		TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................................................................................................... 48
		PROPER TOOLS..................................................................................................................................................................... 48
		ACCUMULATOR, GAS SPRING.......................................................................................................................................................... 49
		PERSONNEL........................................................................................................................................................................ 49
		ATTACHMENTS...................................................................................................................................................................... 49
		WORK UNDER THE MACHINE........................................................................................................................................................... 49
		NOISE............................................................................................................................................................................ 49
		WHEN USING HAMMER................................................................................................................................................................ 50
		WELDING WORKS.................................................................................................................................................................... 50
		REMOVING BATTERY TERMINALS....................................................................................................................................................... 50
		SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION............................................................................................................. 50
		DO NOT DISASSEMBLE RECOIL SPRINGS................................................................................................................................................ 50
		SAFETY RULES FOR HIGH-PRESSURE OIL............................................................................................................................................... 51
		SAFETY HANDLING HIGH-PRESSURE HOSES.............................................................................................................................................. 51
		WASTE MATERIALS.................................................................................................................................................................. 51
		AIR CONDITIONER MAINTENANCE...................................................................................................................................................... 51
		COMPRESSED AIR................................................................................................................................................................... 52
		PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.................................................................................................................................... 52
OPERATION................................................................................................................................................................................ 53
	MACHINE VIEW ILLUSTRATIONS........................................................................................................................................................... 54
		OVERALL MACHINE VIEW............................................................................................................................................................. 54
		CONTROLS AND GAUGES.............................................................................................................................................................. 55
	DETAILED CONTROLS AND GAUGES......................................................................................................................................................... 57
		MONITORING SYSTEM................................................................................................................................................................ 57
		SWITCHES......................................................................................................................................................................... 82
		CONTROL LEVERS AND PEDALS........................................................................................................................................................ 87
		SUN ROOF......................................................................................................................................................................... 90
		WINDSHIELD....................................................................................................................................................................... 90
		EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................... 95
		DOOR LOCK........................................................................................................................................................................ 95
		CAP WITH LOCK.................................................................................................................................................................... 96
		HOT AND COOL BOX................................................................................................................................................................. 97
		MAGAZINE BOX..................................................................................................................................................................... 98
		ASHTRAY.......................................................................................................................................................................... 98
		AIR CONDITIONER CONTROLS......................................................................................................................................................... 99
		RADIO............................................................................................................................................................................113
		AUXILIARY ELECTRIC POWER.........................................................................................................................................................118
		FUSE.............................................................................................................................................................................119
		FUSIBLE LINK.....................................................................................................................................................................120
		CONTROLLER.......................................................................................................................................................................120
		TOOL BOX.........................................................................................................................................................................121
		GREASE GUN HOLDER................................................................................................................................................................121
		ACCUMULATOR......................................................................................................................................................................122
	MACHINE OPERATIONS AND CONTROLS......................................................................................................................................................123
		BEFORE STARTING ENGINE...........................................................................................................................................................123
		STARTING ENGINE..................................................................................................................................................................138
		AFTER STARTING ENGINE............................................................................................................................................................142
		STOPPING THE ENGINE..............................................................................................................................................................151
		MACHINE OPERATION................................................................................................................................................................152
		STEERING THE MACHINE.............................................................................................................................................................156
		SWINGING.........................................................................................................................................................................158
		WORK EQUIPMENT CONTROLS AND OPERATIONS...........................................................................................................................................159
		WORKING MODE.....................................................................................................................................................................161
		PROHIBITED OPERATIONS............................................................................................................................................................162
		GENERAL OPERATION INFORMATION....................................................................................................................................................164
		TRAVELING ON SLOPES..............................................................................................................................................................166
		ESCAPE FROM MUD..................................................................................................................................................................168
		RECOMMENDED APPLICATIONS.........................................................................................................................................................169
		BUCKET REPLACEMENT AND INVERSION.................................................................................................................................................171
		PARKING MACHINE..................................................................................................................................................................174
		CHECK AFTER SHUT OFF ENGINE......................................................................................................................................................175
		MACHINE INSPECTION AFTER DAILY WORK..............................................................................................................................................175
		LOCKING..........................................................................................................................................................................176
	TRANSPORTATION.......................................................................................................................................................................177
		PRECAUTIONS FOR TRANSPORTATION...................................................................................................................................................177
		LOADING AND UNLOADING WITH TRAILER...............................................................................................................................................178
		LIFTING MACHINE..................................................................................................................................................................186
		TRANSPORTATION POSTURE...........................................................................................................................................................188
	COLD WEATHER OPERATION...............................................................................................................................................................191
		COLD WEATHER OPERATION INFORMATION...............................................................................................................................................191
		AFTER DAILY WORK COMPLETION......................................................................................................................................................194
		AFTER COLD WEATHER SEASON........................................................................................................................................................194
	LONG TERM STORAGE....................................................................................................................................................................195
		BEFORE STORAGE...................................................................................................................................................................195
		DURING STORAGE...................................................................................................................................................................195
		AFTER STORAGE....................................................................................................................................................................195
		STARTING MACHINE AFTER LONG-TERM STORAGE.........................................................................................................................................196
	TROUBLES AND ACTIONS.................................................................................................................................................................197
		RUNNING OUT OF FUEL..............................................................................................................................................................197
		PHENOMENA THAT ARE NOT FAILURES..................................................................................................................................................198
		TOWING THE MACHINE...............................................................................................................................................................199
		LIGHTWEIGHT TOWING HOLE..........................................................................................................................................................200
		SEVERE JOB CONDITION.............................................................................................................................................................200
		DISCHARGED BATTERY...............................................................................................................................................................201
		OTHER TROUBLE....................................................................................................................................................................205
MAINTENANCE..............................................................................................................................................................................211
	MAINTENANCE INFORMATION..............................................................................................................................................................212
	OUTLINE OF SERVICE...................................................................................................................................................................214
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...........................................................................................................................214
		ELECTRIC SYSTEM MAINTENANCE......................................................................................................................................................217
	WEAR PARTS...........................................................................................................................................................................218
		WEAR PARTS LIST..................................................................................................................................................................218
	LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS..........................................................................................................................................219
	TIGHTENING TORQUE SPECIFICATIONS.....................................................................................................................................................223
		TIGHTENING TORQUE LIST...........................................................................................................................................................223
	SAFETY CRITICAL PARTS................................................................................................................................................................224
		SAFETY CRITICAL PARTS LIST.......................................................................................................................................................224
	MAINTENANCE SCHEDULE.................................................................................................................................................................225
		MAINTENANCE SCHEDULE CHART.......................................................................................................................................................225
		MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER.......................................................................................................................................227
	MAINTENANCE PROCEDURE................................................................................................................................................................228
		INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...................................................................................................................228
		INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS).................................................................................................................228
		WHEN REQUIRED....................................................................................................................................................................229
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.................................................................................................................................229
			CLEAN INSIDE OF COOLING SYSTEM...............................................................................................................................................234
			CHECK AND TIGHTEN TRACK SHOE BOLTS...........................................................................................................................................236
			CHECK AND ADJUST TRACK TENSION...............................................................................................................................................237
			CHECK ELECTRICAL INTAKE AIR HEATER...........................................................................................................................................238
			REPLACE BUCKET TEETH (VERTICAL PIN TYPE).....................................................................................................................................239
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...................................................................................................................................242
			REPLACE BUCKET SIDE CUTTER, SHROUD...........................................................................................................................................243
			ADJUST BUCKET CLEARANCE......................................................................................................................................................244
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...................................................................................................................................245
			CHECK AND MAINTENANCE AIR CONDITIONER........................................................................................................................................246
			WASH WASHABLE FLOOR..........................................................................................................................................................247
			BLEEDING AIR FROM HYDRAULIC SYSTEM...........................................................................................................................................250
			METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT..................................................................................................................252
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)..........................................................................................................253
		CHECK BEFORE STARTING............................................................................................................................................................254
		EVERY 50 HOURS MAINTENANCE.......................................................................................................................................................255
			LUBRICATING..................................................................................................................................................................255
		EVERY 250 HOURS MAINTENANCE......................................................................................................................................................256
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.............................................................................................................................256
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.................................................................................................................................257
			CHECK LEVEL OF BATTERY ELECTROLYTE...........................................................................................................................................258
			LUBRICATE SWING CIRCLE (2 POINTS)............................................................................................................................................261
			CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST..............................................................................................................................261
			CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST........................................................................................................................262
		EVERY 500 HOURS MAINTENANCE......................................................................................................................................................263
			LUBRICATING..................................................................................................................................................................263
			REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CARTRIDGE)...................................................................................265
			CHECK, WASH FUEL STRAINER....................................................................................................................................................267
			CHECK SWING PINION GREASE LEVEL, ADD GREASE..................................................................................................................................268
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE............................................................................................................269
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, FUEL COOLER 
FINS, AND AIR CONDITIONER CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)....271
			CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...................................................................................................................................272
			REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...................................................................................................................................273
			REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WITH MACHINES).........................................................................................................274
		EVERY 1000 HOURS MAINTENANCE.....................................................................................................................................................276
			REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITH ADDITIONAL FUEL FILTER CARTRIDGE)......................................................................................276
			REPLACE HYDRAULIC OIL FILTER ELEMENT.........................................................................................................................................278
			CHANGE OIL IN SWING MACHINERY CASE...........................................................................................................................................279
			CHECK OIL LEVEL IN DAMPER CASE, ADD OIL......................................................................................................................................280
			CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...................................................................................................................................280
			CHECK PLAY TURBOCHARGER ROTOR................................................................................................................................................280
			REPLACE CORROSION RESISTOR CARTRIDGE.........................................................................................................................................281
			REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT...........................................................................................................................282
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)..............................................................................................................282
		EVERY 2000 HOURS MAINTENANCE.....................................................................................................................................................283
			CHANGE OIL IN FINAL DRIVE CASE...............................................................................................................................................283
			CHECK INJECTOR...............................................................................................................................................................283
			CLEAN HYDRAULIC TANK STRAINER................................................................................................................................................284
			CLEAN ENGINE BREATHER........................................................................................................................................................284
			CLEAN, CHECK TURBOCHARGER....................................................................................................................................................285
			CHECK ALTERNATOR, STARTING MOTOR.............................................................................................................................................285
			CHECK ENGINE VALVE CLEARANCE, ADJUST.........................................................................................................................................285
			CHECK VIBRATION DAMPER.......................................................................................................................................................285
		EVERY 4000 HOURS MAINTENANCE.....................................................................................................................................................286
			CHECK WATER PUMP.............................................................................................................................................................286
			CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER.......................................................................................................286
			CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.............................................................................................................287
			REPLACE INJECTOR NOZZLE ASSEMBLY.............................................................................................................................................287
		EVERY 5000 HOURS MAINTENANCE.....................................................................................................................................................288
			CHANGE OIL IN HYDRAULIC TANK.................................................................................................................................................288
		EVERY 8000 HOURS MAINTENANCE.....................................................................................................................................................290
			REPLACE HIGH-PRESSURE PIPING CLAMP...........................................................................................................................................290
			REPLACE FUEL SPRAY PREVENTION CAP............................................................................................................................................290
SPECIFICATIONS...........................................................................................................................................................................291
	SPECIFICATIONS.......................................................................................................................................................................292
ATTACHMENTS, OPTIONS.....................................................................................................................................................................295
	GENERAL PRECAUTIONS FOR SAFETY.......................................................................................................................................................296
		PRECAUTIONS WHEN SELECTING.......................................................................................................................................................296
		READ THE INSTRUCTION MANUAL THOROUGHLY...........................................................................................................................................296
		PRECAUTIONS WHEN REMOVING OR INSTALLING..........................................................................................................................................296
		PRECAUTIONS WHEN USING...........................................................................................................................................................296
	MACHINE READY FOR ATTACHMENT.........................................................................................................................................................297
		LOCATIONS........................................................................................................................................................................297
		HYDRAULIC CIRCUIT................................................................................................................................................................301
		ATTACHMENT REMOVAL AND INSTALLATION..............................................................................................................................................305
		ATTACHMENT OPERATIONS............................................................................................................................................................307
		LONG TERM STORAGE................................................................................................................................................................309
		SPECIFICATIONS...................................................................................................................................................................309
	ATTACHMENT GUIDE.....................................................................................................................................................................310
		ATTACHMENT COMBINATIONS..........................................................................................................................................................310
	RECOMMENDED ATTACHMENT OPERATIONS....................................................................................................................................................312
		HYDRAULIC BREAKER................................................................................................................................................................312
LOADING SHOVEL...........................................................................................................................................................................316
	EXPLANATION OF COMPONENTS............................................................................................................................................................317
		SWITCHES.........................................................................................................................................................................317
	OPERATIONS...........................................................................................................................................................................320
		OPERATION OF WORK EQUIPMENT......................................................................................................................................................320
		PRECAUTIONS DURING OPERATION.....................................................................................................................................................322
		EXCAVATOR WORK...................................................................................................................................................................326
	PRECAUTIONS WHEN DISASSEMBLING MACHINE...............................................................................................................................................327
		RELEASING PRESSURE...............................................................................................................................................................327
	TRANSPORTATION.......................................................................................................................................................................328
		MACHINE CONFIGURATION FOR TRANSPORT..............................................................................................................................................328
	MAINTENANCE..........................................................................................................................................................................332
		CHECK BEFORE STARTING............................................................................................................................................................332
		EVERY 10 HOURS MAINTENANCE.......................................................................................................................................................333
	SPECIFICATION........................................................................................................................................................................334
	COMBINATION OF WORK EQUIPMENT........................................................................................................................................................336
		COMBINATION OF WORK EQUIPMENT....................................................................................................................................................336
INDEX....................................................................................................................................................................................338

PLEASE NOTE:

⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]