KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00039-03) – PDF DOWNLOAD

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KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00039-03)

KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00039-03) – PDF DOWNLOAD:

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KOMATSU GALEO PC400,400LC-7 PC450,450LC-7 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL (TEN00039-03)

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 (TEN00039-03)

COVER.................................................................................................................................................................................  1
FOREWORD..............................................................................................................................................................................  3
	FOREWORD..........................................................................................................................................................................  4
	SAFETY INFORMATION................................................................................................................................................................  7
	INTRODUCTION......................................................................................................................................................................  9
		DIRECTIONS OF MACHINE.........................................................................................................................................................  9
		BREAKING-IN THE NEW MACHINE...................................................................................................................................................  9
	PRODUCT INFORMATION............................................................................................................................................................... 10
		PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE.................................................................................................................. 10
		ENGINE SERIAL NUMBER PLATE AND ITS LOCATION................................................................................................................................... 10
		SERVICE METER LOCATION........................................................................................................................................................ 11
		YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR................................................................................................................................... 11
CONTENTS.............................................................................................................................................................................. 12
SAFETY................................................................................................................................................................................ 17
	SAFETY INFORMATION................................................................................................................................................................ 18
	SAFETY LABELS..................................................................................................................................................................... 20
		LOCATION OF SAFETY LABELS..................................................................................................................................................... 20
		SAFETY LABELS................................................................................................................................................................. 21
	SAFETY INFORMATION................................................................................................................................................................ 26
		SAFETY RULES.................................................................................................................................................................. 26
		IF PROBLEMS ARE FOUND......................................................................................................................................................... 26
		WORKING WEAR AND PERSONAL PROTECTIVE ITEMS.................................................................................................................................... 26
		FIRE EXTINGUISHER AND FIRST AID KIT........................................................................................................................................... 26
		SAFETY EQUIPMENT.............................................................................................................................................................. 26
		KEEP MACHINE CLEAN............................................................................................................................................................ 27
		KEEP OPERATOR'S COMPARTMENT CLEAN............................................................................................................................................. 27
		LEAVING OPERATOR'S SEAT WITH LOCK............................................................................................................................................. 27
		HANDRAILS AND STEPS........................................................................................................................................................... 28
		PRECAUTIONS WHEN WORKING IN HIGH PLACES....................................................................................................................................... 28
		MOUNTING AND DISMOUNTING...................................................................................................................................................... 28
		NO PERSONS ON ATTACHMENTS..................................................................................................................................................... 28
		DO NOT GET CAUGHT IN ARTICULATED PORTION...................................................................................................................................... 29
		BURN PREVENTION............................................................................................................................................................... 29
		FIRE PREVENTION AND EXPLOSION PREVENTION...................................................................................................................................... 30
		ACTION IF FIRE OCCURS......................................................................................................................................................... 31
		WINDSHIELD WASHER FLUID....................................................................................................................................................... 31
		FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION.............................................................................................................. 31
		ATTACHMENT INSTALLATION....................................................................................................................................................... 31
		ATTACHMENT COMBINATIONS....................................................................................................................................................... 31
		CAB WINDOW GLASSES............................................................................................................................................................ 31
		UNAUTHORIZED MODIFICATIONS.................................................................................................................................................... 32
		SAFETY AT JOBSITE............................................................................................................................................................. 32
		WORKING ON LOOSE GROUND....................................................................................................................................................... 32
		DISTANCE TO HIGH VOLTAGE CABLES............................................................................................................................................... 33
		ENSURE GOOD VISIBILITY........................................................................................................................................................ 33
		VENTILATION FOR ENCLOSED AREA................................................................................................................................................. 34
		SIGNALMAN'S SIGNAL AND SIGNS.................................................................................................................................................. 34
		EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................ 34
		ASBESTOS DUST HAZARD PREVENTION............................................................................................................................................... 34
	SAFETY MACHINE OPERATION.......................................................................................................................................................... 35
		STARTING ENGINE............................................................................................................................................................... 35
			CHECKS BEFORE STARTING ENGINE............................................................................................................................................. 35
			SAFETY RULES FOR STARTING ENGINE.......................................................................................................................................... 36
			STARTING ENGINE IN COLD WEATHER........................................................................................................................................... 36
		OPERATION..................................................................................................................................................................... 37
			CHECKS BEFORE OPERATION................................................................................................................................................... 37
			SAFETY RULES FOR CHANGING MACHINE DIRECTIONS.............................................................................................................................. 37
			SAFETY RULES FOR TRAVELING................................................................................................................................................ 38
			TRAVELING ON SLOPES....................................................................................................................................................... 38
			OPERATIONS ON SLOPES...................................................................................................................................................... 39
			PROHIBITED OPERATIONS..................................................................................................................................................... 39
			OPERATIONS ON SNOW........................................................................................................................................................ 41
			PARKING MACHINE........................................................................................................................................................... 42
		TRANSPORTATION................................................................................................................................................................ 43
			LOADING AND UNLOADING..................................................................................................................................................... 43
			SHIPPING THE MACHINE...................................................................................................................................................... 43
		BATTERY....................................................................................................................................................................... 44
			BATTERY HAZARD PREVENTION................................................................................................................................................. 44
			STARTING ENGINE WITH BOOSTER CABLES....................................................................................................................................... 45
		TOWING........................................................................................................................................................................ 46
			SAFETY RULES FOR TOWING................................................................................................................................................... 46
		LIFTING OBJECTS WITH BUCKET................................................................................................................................................... 47
			SAFETY RULES FOR LIFTING OBJECTS.......................................................................................................................................... 47
	SAFETY MAINTENANCE INFORMATION.................................................................................................................................................... 48
		WARNING TAG................................................................................................................................................................... 48
		KEEP WORK PLACE CLEAN AND TIDY................................................................................................................................................ 48
		APPOINT LEADER WHEN WORKING WITH OTHERS....................................................................................................................................... 48
		STOP ENGINE BEFORE CARRYING OUT MAINTENANCE................................................................................................................................... 49
		TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING............................................................................................................................ 50
		PROPER TOOLS.................................................................................................................................................................. 50
		ACCUMULATOR, GAS SPRING....................................................................................................................................................... 51
		PERSONNEL..................................................................................................................................................................... 51
		ATTACHMENTS................................................................................................................................................................... 51
		WORK UNDER THE MACHINE........................................................................................................................................................ 51
		NOISE......................................................................................................................................................................... 51
		WHEN USING HAMMER............................................................................................................................................................. 52
		WELDING WORKS................................................................................................................................................................. 52
		REMOVING BATTERY TERMINALS.................................................................................................................................................... 52
		SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.......................................................................................................... 52
		DO NOT DISASSEMBLE RECOIL SPRINGS............................................................................................................................................. 52
		SAFETY RULES FOR HIGH-PRESSURE OIL............................................................................................................................................ 53
		SAFETY HANDLING HIGH-PRESSURE HOSES........................................................................................................................................... 53
		WASTE MATERIALS............................................................................................................................................................... 53
		AIR CONDITIONER MAINTENANCE................................................................................................................................................... 53
		COMPRESSED AIR................................................................................................................................................................ 54
		PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................................................................................................. 54
OPERATION............................................................................................................................................................................. 55
	MACHINE VIEW ILLUSTRATIONS........................................................................................................................................................ 56
		OVERALL MACHINE VIEW.......................................................................................................................................................... 56
		CONTROLS AND GAUGES........................................................................................................................................................... 57
	DETAILED CONTROLS AND GAUGES...................................................................................................................................................... 58
		MONITORING SYSTEM............................................................................................................................................................. 58
		SWITCHES...................................................................................................................................................................... 71
		CONTROL LEVERS AND PEDALS..................................................................................................................................................... 76
		SUN ROOF...................................................................................................................................................................... 79
		WINDSHIELD.................................................................................................................................................................... 79
		EMERGENCY EXIT FROM OPERATOR'S CAB............................................................................................................................................ 84
		DOOR LOCK..................................................................................................................................................................... 84
		CAP WITH LOCK................................................................................................................................................................. 85
		HOT AND COOL BOX.............................................................................................................................................................. 86
		MAGAZINE BOX.................................................................................................................................................................. 87
		ASHTRAY....................................................................................................................................................................... 87
		AIR CONDITIONER CONTROLS...................................................................................................................................................... 88
		RADIO.........................................................................................................................................................................102
		AUXILIARY ELECTRIC POWER......................................................................................................................................................107
		FUSE..........................................................................................................................................................................108
		FUSIBLE LINK..................................................................................................................................................................109
		CONTROLLER....................................................................................................................................................................109
		TOOL BOX......................................................................................................................................................................110
		GREASE GUN HOLDER.............................................................................................................................................................110
		ACCUMULATOR...................................................................................................................................................................111
	MACHINE OPERATIONS AND CONTROLS...................................................................................................................................................112
		BEFORE STARTING ENGINE........................................................................................................................................................112
		STARTING ENGINE...............................................................................................................................................................126
		AFTER STARTING ENGINE.........................................................................................................................................................130
		STOPPING THE ENGINE...........................................................................................................................................................137
		MACHINE OPERATION.............................................................................................................................................................138
		STEERING THE MACHINE..........................................................................................................................................................142
		SWINGING......................................................................................................................................................................144
		WORK EQUIPMENT CONTROLS AND OPERATIONS........................................................................................................................................145
		WORKING MODE..................................................................................................................................................................147
		PROHIBITED OPERATIONS.........................................................................................................................................................148
		GENERAL OPERATION INFORMATION.................................................................................................................................................150
		TRAVELING ON SLOPES...........................................................................................................................................................152
		ESCAPE FROM MUD...............................................................................................................................................................154
		RECOMMENDED APPLICATIONS......................................................................................................................................................155
		BUCKET REPLACEMENT AND INVERSION..............................................................................................................................................157
		PARKING MACHINE...............................................................................................................................................................160
		CHECK AFTER SHUT OFF ENGINE...................................................................................................................................................161
		MACHINE INSPECTION AFTER DAILY WORK...........................................................................................................................................161
		LOCKING.......................................................................................................................................................................162
	TRANSPORTATION....................................................................................................................................................................163
		PRECAUTIONS FOR TRANSPORTATION................................................................................................................................................163
		LOADING AND UNLOADING WITH TRAILER............................................................................................................................................164
		LIFTING MACHINE...............................................................................................................................................................172
		PRECAUTIONS WHEN LOADING......................................................................................................................................................174
		TRANSPORTATION POSTURE........................................................................................................................................................175
	COLD WEATHER OPERATION............................................................................................................................................................178
		COLD WEATHER OPERATION INFORMATION............................................................................................................................................178
		AFTER DAILY WORK COMPLETION...................................................................................................................................................180
		AFTER COLD WEATHER SEASON.....................................................................................................................................................180
	LONG TERM STORAGE.................................................................................................................................................................181
		BEFORE STORAGE................................................................................................................................................................181
		DURING STORAGE................................................................................................................................................................181
		AFTER STORAGE.................................................................................................................................................................181
		STARTING MACHINE AFTER LONG-TERM STORAGE......................................................................................................................................182
	TROUBLES AND ACTIONS..............................................................................................................................................................183
		RUNNING OUT OF FUEL...........................................................................................................................................................183
		PHENOMENA THAT ARE NOT FAILURES...............................................................................................................................................184
		TOWING THE MACHINE............................................................................................................................................................185
		LIGHTWEIGHT TOWING HOLE.......................................................................................................................................................186
		SEVERE JOB CONDITION..........................................................................................................................................................186
		DISCHARGED BATTERY............................................................................................................................................................187
		OTHER TROUBLE.................................................................................................................................................................191
MAINTENANCE...........................................................................................................................................................................197
	MAINTENANCE INFORMATION...........................................................................................................................................................198
	OUTLINE OF SERVICE................................................................................................................................................................200
		HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC........................................................................................................................200
		ELECTRIC SYSTEM MAINTENANCE...................................................................................................................................................203
	WEAR PARTS........................................................................................................................................................................204
		WEAR PARTS LIST...............................................................................................................................................................204
	LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS.......................................................................................................................................205
	TIGHTENING TORQUE SPECIFICATIONS..................................................................................................................................................209
		TIGHTENING TORQUE LIST........................................................................................................................................................209
	SAFETY CRITICAL PARTS.............................................................................................................................................................210
		SAFETY CRITICAL PARTS LIST....................................................................................................................................................210
	MAINTENANCE SCHEDULE..............................................................................................................................................................211
		MAINTENANCE SCHEDULE CHART....................................................................................................................................................211
		MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER....................................................................................................................................213
	MAINTENANCE PROCEDURE.............................................................................................................................................................214
		INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)................................................................................................................214
		INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)..............................................................................................................214
		WHEN REQUIRED.................................................................................................................................................................215
			CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..............................................................................................................................215
			CLEAN INSIDE OF COOLING SYSTEM............................................................................................................................................220
			CHECK AND TIGHTEN TRACK SHOE BOLTS........................................................................................................................................222
			CHECK AND ADJUST TRACK TENSION............................................................................................................................................223
			CHECK ELECTRICAL INTAKE AIR HEATER........................................................................................................................................224
			REPLACE BUCKET TEETH (VERTICAL PIN TYPE)..................................................................................................................................225
			REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)................................................................................................................................228
			REPLACE BUCKET SIDE CUTTER, SHROUD........................................................................................................................................229
			ADJUST BUCKET CLEARANCE...................................................................................................................................................230
			CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID................................................................................................................................231
			CHECK AND MAINTENANCE AIR CONDITIONER.....................................................................................................................................232
			WASH WASHABLE FLOOR.......................................................................................................................................................233
			BLEEDING AIR FROM HYDRAULIC SYSTEM........................................................................................................................................236
			METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................238
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT).......................................................................................................239
		CHECK BEFORE STARTING.........................................................................................................................................................240
		EVERY 50 HOURS MAINTENANCE....................................................................................................................................................241
			LUBRICATING...............................................................................................................................................................241
		EVERY 100 HOURS MAINTENANCE...................................................................................................................................................242
			LUBRICATING...............................................................................................................................................................242
		EVERY 250 HOURS MAINTENANCE...................................................................................................................................................244
			CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL..........................................................................................................................244
			CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..............................................................................................................................245
			CHECK LEVEL OF BATTERY ELECTROLYTE........................................................................................................................................246
			LUBRICATE SWING CIRCLE....................................................................................................................................................249
			CHECK FAN BELT, ALTERNATOR BELT TENSION, ADJUST...........................................................................................................................249
			CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.....................................................................................................................250
		EVERY 500 HOURS MAINTENANCE...................................................................................................................................................251
			REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITHOUT ADDITIONAL FUEL FILTER CARTRIDGE)................................................................................251
			CHECK, WASH FUEL STRAINER.................................................................................................................................................253
			CHECK SWING PINION GREASE LEVEL, ADD GREASE...............................................................................................................................254
			CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.........................................................................................................255
			CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND AIR CONDITIONER CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)....257
			CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS................................................................................................................................258
			REPLACE BREATHER ELEMENT IN HYDRAULIC TANK................................................................................................................................259
			REPLACE ADDITIONAL FUEL FILTER CARTRIDGE (IF EQUIPPED WITH MACHINES)......................................................................................................260
		EVERY 1000 HOURS MAINTENANCE..................................................................................................................................................262
			REPLACE FUEL FILTER CARTRIDGE (MACHINES EQUIPPED WITH ADDITIONAL FUEL FILTER CARTRIDGE)...................................................................................262
			REPLACE HYDRAULIC OIL FILTER ELEMENT......................................................................................................................................264
			CHANGE OIL IN SWING MACHINERY CASE........................................................................................................................................265
			CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...................................................................................................................................266
			CHECK ALL TIGHTENING PARTS OF TURBOCHARGER................................................................................................................................266
			CHECK PLAY TURBOCHARGER ROTOR.............................................................................................................................................266
			REPLACE CORROSION RESISTOR CARTRIDGE......................................................................................................................................267
			REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT........................................................................................................................268
			CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)...........................................................................................................268
		EVERY 2000 HOURS MAINTENANCE..................................................................................................................................................269
			CHANGE OIL IN FINAL DRIVE CASE............................................................................................................................................269
			CHECK INJECTOR............................................................................................................................................................269
			CLEAN HYDRAULIC TANK STRAINER.............................................................................................................................................270
			CLEAN ENGINE BREATHER.....................................................................................................................................................270
			CLEAN, CHECK TURBOCHARGER.................................................................................................................................................271
			CHECK ALTERNATOR, STARTING MOTOR..........................................................................................................................................271
			CHECK ENGINE VALVE CLEARANCE, ADJUST......................................................................................................................................271
			CHECK VIBRATION DAMPER....................................................................................................................................................271
		EVERY 4000 HOURS MAINTENANCE..................................................................................................................................................272
			CHECK WATER PUMP..........................................................................................................................................................272
			CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER....................................................................................................272
			CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER..........................................................................................................273
			REPLACE INJECTOR NOZZLE ASSEMBLY..........................................................................................................................................273
		EVERY 5000 HOURS MAINTENANCE..................................................................................................................................................274
			CHANGE OIL IN HYDRAULIC TANK..............................................................................................................................................274
		EVERY 8000 HOURS MAINTENANCE..................................................................................................................................................276
			REPLACE HIGH-PRESSURE PIPING CLAMP........................................................................................................................................276
			REPLACE FUEL SPRAY PREVENTION CAP.........................................................................................................................................276
SPECIFICATIONS........................................................................................................................................................................277
	SPECIFICATIONS....................................................................................................................................................................278
ATTACHMENTS, OPTIONS..................................................................................................................................................................281
	GENERAL PRECAUTIONS FOR SAFETY....................................................................................................................................................282
		PRECAUTIONS WHEN SELECTING....................................................................................................................................................282
		READ THE INSTRUCTION MANUAL THOROUGHLY........................................................................................................................................282
		PRECAUTIONS WHEN REMOVING OR INSTALLING.......................................................................................................................................282
		PRECAUTIONS WHEN USING........................................................................................................................................................282
	MACHINE READY FOR ATTACHMENT......................................................................................................................................................283
		LOCATIONS.....................................................................................................................................................................283
		HYDRAULIC CIRCUIT.............................................................................................................................................................287
		ATTACHMENT REMOVAL AND INSTALLATION...........................................................................................................................................291
		ATTACHMENT OPERATIONS.........................................................................................................................................................293
		LONG TERM STORAGE.............................................................................................................................................................294
		SPECIFICATIONS................................................................................................................................................................294
	ATTACHMENT GUIDE..................................................................................................................................................................295
		ATTACHMENT COMBINATIONS.......................................................................................................................................................295
	RECOMMENDED ATTACHMENT OPERATIONS.................................................................................................................................................297
		HYDRAULIC BREAKER.............................................................................................................................................................297
MULTI-MONITOR SPECIFICATION...........................................................................................................................................................301
	CONTENTS..........................................................................................................................................................................302
	OPERATION.........................................................................................................................................................................  0
		MACHINE VIEW ILLUSTRATIONS....................................................................................................................................................303
			CONTROLS AND GAUGES.......................................................................................................................................................303
		DETAILED CONTROLS AND GAUGES..................................................................................................................................................305
			MONITORING SYSTEM.........................................................................................................................................................305
		MACHINE OPERATIONS AND CONTROLS...............................................................................................................................................330
			BEFORE STARTING ENGINE....................................................................................................................................................330
			STARTING ENGINE...........................................................................................................................................................333
			AFTER STARTING ENGINE.....................................................................................................................................................337
			MACHINE OPERATION.........................................................................................................................................................346
			SWINGING..................................................................................................................................................................349
			WORKING MODE..............................................................................................................................................................350
			GENERAL OPERATION INFORMATION.............................................................................................................................................351
			CHECK AFTER SHUT OFF ENGINE...............................................................................................................................................352
			MACHINE INSPECTION AFTER DAILY WORK.......................................................................................................................................352
		COLD WEATHER OPERATION........................................................................................................................................................353
			MONITOR...................................................................................................................................................................353
	MAINTENANCE.......................................................................................................................................................................  0
		MAINTENANCE PROCEDURE.........................................................................................................................................................354
			WHEN REQUIRED.............................................................................................................................................................354
	ATTACHMENTS AND OPTIONS...........................................................................................................................................................  0
		MACHINE READY FOR ATTACHMENT..................................................................................................................................................359
			ATTACHMENT OPERATIONS.....................................................................................................................................................359
INDEX.................................................................................................................................................................................361

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]