Komatsu Pc400-5, Pc400Lc-5, Pc400-5 Mighty, Pc400Lc-5 Mighty, Pc400Hd-5 Hydraulic Excavator Operation & Maintenance Manual – PDF DOWNLOAD

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Komatsu Pc400-5, Pc400Lc-5, Pc400-5 Mighty, Pc400Lc-5 Mighty, Pc400Hd-5 Hydraulic Excavator Operation & Maintenance Manual

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Komatsu Pc400-5, Pc400Lc-5, Pc400-5 Mighty, Pc400Lc-5 Mighty, Pc400Hd-5 Hydraulic Excavator Operation & Maintenance Manual

Model Specification: KOMATSU PC400-5, PC400LC-5, PC400-5 MIGHTY, PC400LC-5 MIGHTY, PC400HD-5 HYDRAULIC EXCAVATOR
Language: English
File Format: PDF
Total Pages: 262
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES

KOMATSU PC400-5, PC400LC-5, PC400-5 MIGHTY, PC400LC-5 MIGHTY, PC400HD-5 HYDRAULIC EXCAVATOR OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Pc400-5, Pc400Lc-5, Pc400-5 Mighty, Pc400Lc-5 Mighty, Pc400Hd-5 Hydraulic Excavator Operation & Maintenance Manual

FOREWORD:

• This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
• If you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual.
• Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require.

TABLE OF CONTENTS:

Komatsu Pc400-5, Pc400Lc-5, Pc400-5 Mighty, Pc400Lc-5 Mighty, Pc400Hd-5 Hydraulic Excavator Operation & Maintenance Manual

COVER..........................................................................................................  1
1. FOREWORD....................................................................................................  3
2. SAFETY INFORMATION..........................................................................................  4
3. INTRODUCTION................................................................................................  5
	3.1 INTENDED USE...........................................................................................  5
	3.2 FEATURES...............................................................................................  5
	3.3 BREAKING IN THE MACHINE................................................................................  5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...............................................  6
	4.1 MACHINE SERIAL NO. PLATE POSITION......................................................................  6
	4.2 ENGINE SERIAL NO. PLATE POSITION.......................................................................  6
	4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR..............................................................  6
5. CONTENTS....................................................................................................  7
SAFETY......................................................................................................... 13
	6. GENERAL PRECAUTIONS..................................................................................... 14
	7. PRECAUTIONS DURING  OPERATION .......................................................................... 20
		7.1 BEFORE STARTING ENGINE ............................................................................ 20
		7.2 OPERATING MACHINE ................................................................................. 22
		7.3 TRANSPORTATION .................................................................................... 27
		7.4 BATTERY ........................................................................................... 28
		7.5 TOWING............................................................................................. 29
		7.6 BUCKET WITH HOOK................................................................................... 30
			7.6.1 GENERAL PRECAUTIONS.......................................................................... 30
			7.6.2 PRECAUTIONS FOR LIFTING OPERATION ........................................................... 32
	8. PRECAUTIONS FOR MAINTENANCE ............................................................................ 33
		8.1 BEFORE CARRYING OUT MAINTENANCE ................................................................... 33
		8.2 DURING MAINTENANCE ................................................................................ 36
	9. POSITION FOR ATTACHING SAFETY LABELS ................................................................... 40
OPERATION...................................................................................................... 45
	10. GENERAL VIEW .......................................................................................... 46
		10.1 GENERAL VIEW OF MACHINE .......................................................................... 46
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES .............................................................. 47
	11. EXPLANATION OF COMPONENTS ............................................................................. 48
		11.1 MACHINE MONITOR .................................................................................. 48
		11.2 METER ............................................................................................ 58
		11.3 SWITCHES ......................................................................................... 59
		11.4 CONTROL LEVERS, PEDALS ........................................................................... 62
		11.5 OPERATOR’S SEAT .................................................................................. 65
		11.6 DUST INDICATOR ................................................................................... 65
		11.7 CEILING WINDOW ................................................................................... 66
		11.8 FRONT WINDOW ..................................................................................... 67
		11.9 DOOR LOCK ........................................................................................ 69
		11.10 CAP, COVER WITH LOCK ............................................................................ 70
			11.10.1 METHOD OF OPENING AND CLOSING CAP  WITH LOCK (For the fuel tank filler port) .............. 70
			11.10.2 METHOD OF OPENING AND CLOSING  HYDRAULIC TANK FILLER CAP  open ............................ 70
		11.11 RADIO............................................................................................ 71
			11.11.1 EXPLANATION OF COMPONENTS.................................................................. 71
			11.11.2 HOW TO SET STATION SELECTOR BUTTONS ....................................................... 72
			11.11.3 PRECAUTIONS WHEN USING RADIO .............................................................. 72
			11.11.4 TROUBLESHOOTING GUIDE ..................................................................... 72
		11.12 FUSE ............................................................................................ 73
		11.13 MONITOR PANEL ................................................................................... 73
		11.14 FUSIBLE LINK .................................................................................... 74
		11.15 CONTROLLERS ..................................................................................... 74
		11.16 HANDLING ACCUMULATOR ............................................................................ 77
			11.16.1 METHOD OF RELEASING PRESSURE IN  CONTROL CIRCUIT ON MACHINE  EQUIPPED WITH ACCUMULATOR .... 78
	12. OPERATION ............................................................................................. 79
		12.1 CHECK BEFORE STARTING ENGINE ..................................................................... 79
			12.1.1 WALK-AROUND CHECK........................................................................... 79
			12.1.2 CHECK BEFORE STARTING ...................................................................... 81
			12.1.3 ADJUSTMENT BEFORE OPERATION ................................................................ 85
			12.1.4 OPERATIONS AND CHECKS BEFORE STARTING  ENGINE .............................................. 86
		12.2 STARTING ENGINE .................................................................................. 88
			12.2.1 NORMAL STARTING ............................................................................ 88
			12.2.2 STARTING IN COLD WEATHER ................................................................... 89
			12.2.3 SPECIAL STARTING ........................................................................... 90
		12.3 OPERATIONS AND CHECKS AFTER  STARTING ENGINE ..................................................... 91
			12.3.1 WHEN NORMAL................................................................................. 91
			12.3.2 IN COLD AREAS  (AUTOMATIC WARMING-UP OPERATION) ............................................ 93
		12.4 MOVING MACHINE OFF ............................................................................... 97
			12.4.1 MOVING MACHINE FORWARD ..................................................................... 97
			12.4.2MOVING MACHINE BACKWARD ..................................................................... 98
		12.5 STEERING MACHINE .................................................................................100
			12.5.1 STEERING (CHANGING DIRECTION) ..............................................................100
		12.6 STOPPING MACHINE .................................................................................102
		12.7 SWINGING..........................................................................................103
		12.8 OPERATION OF WORK EQUIPMENT ......................................................................104
		12.9 METHOD OF USING MODE SELECTOR  SWITCHES ..........................................................105
		12.10 PROHIBITIONS FOR OPERATION ......................................................................107
		12.11 PRECAUTIONS FOR OPERATION .......................................................................109
		12.12 PRECAUTIONS WHEN TRAVELING UP OR  DOWN HILLS ....................................................110
		12.13 HOW TO ESCAPE FROM MUD ..........................................................................112
			12.13.1 WHEN ONE SIDE IS STUCK.....................................................................112
			12.13.2 WHEN BOTH SIDES ARE STUCK .................................................................112
		12.14 WORK POSSIBLE USING HYDRAULIC  EXCAVATOR ........................................................113
			12.14.1 BACKHOE WORK ..............................................................................113
			12.14.2 SHOVEL WORK ...............................................................................113
			12.14.3 DITCHING WORK .............................................................................113
			12.14.4 LOADING WORK ..............................................................................113
		12.15 REPLACEMENT AND INVERSION  OF BUCKET ............................................................114
			12.15.1 REPLACEMENT................................................................................114
			12.15.2 INVERSION .................................................................................115
		12.16 PARKING MACHINE .................................................................................116
		12.17 CHECK AFTER FINISHING WORK  , ...................................................................117
		12.18 STOPPING ENGINE .................................................................................118
		12.19 CHECK AFTER STOPPING ENGINE .....................................................................119
		12.20 LOCKING .........................................................................................119
	13. TRANSPORTATION ........................................................................................120
		13.1 LOADING, UNLOADING WORK ..........................................................................120
		13.2 PRECAUTIONS FOR LOADING ..........................................................................122
		13.3 PRECAUTIONS FOR TRANSPORTATION ...................................................................122
		13.4 METHOD OF LIFTING CHASSIS  (machines equipped with lifting hook) .................................123
		13.5 DIVING THE MACHINE ...............................................................................124
		13.6 PROCEDURE FOR INCREASING OR  REDUCING TRACK FRAME GAUGE ..........................................128
	14. COLD WEATHER OPERATION ................................................................................130
		14.1 PRECAUTIONS FOR LOW TEMPERATURE ..................................................................130
			14.1.1 FUEL AND LUBRICANTS ........................................................................130
			14.1.2 COOLANT ....................................................................................130
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK..............................................................132
		14.3 AFTER COLD WEATHER ...............................................................................132
	15. LONG-TERM STORAGE .....................................................................................133
		15.1 BEFORE STORAGE ...................................................................................133
		15.2 DURING STORAGE ...................................................................................134
		15.3 AFTER STORAGE ....................................................................................134
		15.4 STARTING MACHINE AFTER LONG-TERM STORAGE..........................................................134
	16. TROUBLESHOOTING .......................................................................................135
		16.1 PHENOMENA THAT ARE NOT FAILURES...................................................................135
		16.2 METHOD OF TOWING MACHINE .........................................................................135
		16.3 USING METHOD FOR LIGHT-WEIGHT  TOWING HOLE .......................................................135
		16.4 PRECAUTIONS ON PARTICULAR JOBSITES ...............................................................136
		16.5 IF BATTERY IS DISCHARGED .........................................................................136
			165.1 STARTING ENGINE WITH BOOSTER CABLE ..........................................................137
		16.6 OTHER TROUBLE  ...................................................................................140
			16.6.1 ELECTRICAL SYSTEM...........................................................................140
			16.6.2 CHASSIS.....................................................................................141
			16.6.3 ENGINE......................................................................................142
			16.6.4 ELECTRONIC CONTROL SYSTEM ..................................................................144
MAINTENANCE....................................................................................................145
	17. GUIDES TO MAINTENANCE .................................................................................146
	18. OUTLINES OF SERVICE ...................................................................................149
		18.1 OUTLINE OF OIL, FUEL, COOLANT ....................................................................149
			18.1.1 OIL.........................................................................................149
			18.1.2 FUEL .......................................................................................150
			18.1.3 COOLANT ....................................................................................150
			18.1.4 GREASE .....................................................................................151
			18.1.5 STORING OIL AND FUEL .......................................................................151
			18.1.6 FILTERS ....................................................................................151
		18.2 OUTLINE OF ELECTRIC SYSTEM .......................................................................152
		18.3 OUTLINE OF HYDRAULIC SYSTEM ......................................................................153
		18.4 PRECAUTIONS WHEN DISASSEMBLING MACHINE............................................................154
		18.5 BLEEDING AIR FROM CIRCUIT ........................................................................155
	19. WEAR PARTS LIST .......................................................................................157
	20.USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING  TO  AMBIENT  TEMPERATURE ................................159
	21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.........................................................163
		21.1 INTRODUCTION OF NECESSARY TOOLS ..................................................................163
		21.2 TORQUE LIST ......................................................................................164
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .........................................................165
	23. MAINTENANCE SCHEDULE CHART ............................................................................167
		23.1 MAINTENANCE SCHEDULE CHART .......................................................................167
		23.2 MAINTENANCE INTERVAL WHEN USING  HYDRAULIC BREAKER ...............................................169
	24. SERVICE PROCEDURE .....................................................................................170
		24.1 INITIAL 250 HOURS SERVICE ........................................................................170
		24.2 WHEN REQUIRED ....................................................................................171
			24.2.1 CHECK, CLEAN AND REPLACE AIR  CLEANER ELEMENT ..............................................171
			24.2.2 CLEAN INSIDE OF COOLING SYSTEM .............................................................173
			24.2.3 CHECK AND TIGHTEN TRACK SHOE BOLTS .........................................................177
			24.2.4 CHECK AND ADJUST TRACK TENSION..............................................................178
			24.2.5 CHECK ELECTRICAL INTAKE AIR HEATER .........................................................180
			24.2.6 REPLACE BUCKET TEETH (VERTICAL PIN TYPE) ...................................................181
			24.2.7 REPLACE BUCKET TEETH  (HORIZONTAL PIN TYPE) ................................................184
			24.2.8 ADJUST BUCKET CLEARANCE ....................................................................185
			24.2.9 CLEAN LINE FILTER...........................................................................186
			24.2.10 DRAIN WATER FROM WATER SEPARATOR ..........................................................186
		24.3 CHECK BEFORE STARTING ............................................................................187
			24.3.1 CHECK COOLANT LEVEL, ADD WATER .............................................................187
			24.3.2 CHECK OIL LEVEL IN ENGINE  OIL PAN, ADD OIL ................................................187
			24.3.3 CHECK FUEL LEVEL, ADD FUEL .................................................................188
			24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL .................................................189
			24.3.5 CHECK DUST INDICATOR .......................................................................190
			24.3.6 CHECK ELECTRIC WIRINGS .....................................................................190
			24.3.7 LUBRICATE CLAMSHELL BUCKET (12 POINTS) .....................................................191
			24.3.8 CHECK FOR WATER AND SEDIMENT IN WATER  SEPARATOR, DRAIN WATER ..............................191
		24.4 EVERY 100 HOURS SERVICE ..........................................................................192
			24.4.1 LUBRICATING  1. ............................................................................192
			24.4.2 CHECK OIL LEVEL IN SWING MACHINERY CASE,  ADD OIL ..........................................194
			24.4.3 DRAIN WATER AND SEDIMENT FROM FUEL  TANK ...................................................194
		24.5 EVERY 250 HOURS SERVICE ..........................................................................195
			24.5.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD  OIL ..............................................195
			24.5.2 CHECK LEVEL OF BAlTERY ELECTROLYTE .........................................................196
			24.5.3 CHANGE OIL IN ENGINE OIL PAN, REPLACE  ENGINE OIL FILTER CARTRIDGE .........................197
			24.5.4 REPLACE HYDRAULIC FILTER ELEMENT ...........................................................198
			24.5.5 LUBRICATE SWING CIRCLE (3 POINTS) ..........................................................199
			24.5.6 CHECK FAN BELT TENSION, ADJUST .............................................................200
			24.5.7 DRAIN WATER AND SEDIMENT FROM FUEL  FILTER CARTRIDGE .......................................201
			24.5.8 REPLACE HYDRAULIC TANK BREATHER ELEMENT ....................................................201
		24.6 EVERY 500 HOURS SERVICE ..........................................................................202
			24.6.1 REPLACE FUEL FILTER CARTRIDGE ..............................................................202
			24.6.2 CHECK SWING PINION GREASE LEVEL, ADD  GREASE ...............................................204
			24.6.3 CLEAN AND INSPECT RADIATOR FINS, OIL  COOLER FINS ..........................................205
		24.7 EVERY 1000 HOURS SERVICE .........................................................................206
			24.7.1 CHANGE OIL IN SWING MACHINERY CASE .........................................................206
			24.7.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL ....................................................207
			24.7.3 CHECK ALL TIGHTENING PARTS OF  TURBOCHARGER ................................................207
			24.7.4 CHECK PLAY OF TURBOCHARGER ROTOR ...........................................................207
			24.7.5 REPLACE CORROSION RESISTOR CARTRIDGE .......................................................208
		24.8 EVERY 2000 HOURS SERVICE .........................................................................209
			24.8.1 CHANGE OIL IN FINAL DRIVE CASE .............................................................209
			24.8.2 CHANGE OIL IN HYDRAULIC TANK, CLEAN  STRAINER ..............................................210
			24.8.3 CLEAN ENGINE BREATHER ......................................................................212
			24.8.4 CLEAN, CHECK TURBOCHARGER ..................................................................213
			24.8.5 CHECK ALTERNATOR, STARTING MOTOR ...........................................................213
			24.8.6 CHECK ENGINE VALVE CLEARANCE, ADJUST .......................................................213
			24.8.7 CHECK VIBRATION DAMPER .....................................................................213
		24.9 EVERY 4000 HOURS SERVICE .........................................................................214
			24.9.1 CHECK WATER PUMP ...........................................................................214
SPECIFICATIONS.................................................................................................215
	25. SPECIFICATIONS ........................................................................................216
OPTIONS, ATTACHMENTS...........................................................................................221
	26. GENERAL PRECAUTIONS ...................................................................................222
		26.1 PRECAUTIONS RELATED TO SAFETY ....................................................................222
		26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS ..........................................................223
	27. HANDLING BUCKET WITH HOOK .............................................................................224
		27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK...........................................................224
		27.2 PROHIBITED OPERATIONS ............................................................................224
		27.3 PRECAUTIONS DURING OPERATIONS ....................................................................224
	28. USING SEAT BELT .......................................................................................225
		28.1 SEAT BELT ........................................................................................225
			28.1.1 FASTEN THE BELT AND REMOVE IT ..............................................................225
			28.1.2 ADJUST THE BELT LENGTH .....................................................................226
	29. HANDLING CAR COOLER ...................................................................................227
		29.1 CONTROL PANEL ....................................................................................227
		29.2 CHECKING AND MAINTAINING  CAR COOLER .............................................................227
	30. HANDLING AIR CONDITIONER ..............................................................................228
		30.1 CONTROL PANEL ....................................................................................228
		30.2 OPERATION ........................................................................................229
		30.3 INSPECTION AND MAINTENANCE .......................................................................230
	31. OPERATION OF ATTACHMENTS ..............................................................................232
	32. INTRODUCTION OF ATTACHMENTS ...........................................................................234
		32.1 SPECIFICATION, USE ...............................................................................234
		32.2 ATTACHMENT INSTALLATION COMBINATION TABLE ........................................................235
		32.3 SELECTION OF TRACK SHOES (EXCEPT PC400,400LC-5 MIGHTY)............................................236
		32.4 SELECTION OF BUCKET TEETH ........................................................................237
		32.5 HANDLING CLAMSHELL BUCKET ........................................................................238
	33. EXTENDING MACHINE SERVICE LIFE ........................................................................239
		33.1 HYDRAULIC BREAKER ................................................................................239
		33.2 POWER RIPPER .....................................................................................242
		33.3 FORK GRAB ........................................................................................243
		33.4 GRAPPLE BUCKET ...................................................................................244
		33.5 SCRAP GRAPPLE ....................................................................................245
		33.6 CRUSHER AND CUTTER ...............................................................................246
		33.7 HYDRAULIC PILE DRIVER ............................................................................247
		33.8 HYDRAULIC EXCAVATOR WITH MULTI-  PURPOSE CRANE ...................................................248
LOADING SHOVEL.................................................................................................249
	34. GENERAL LOCATIONS .....................................................................................250
	35. INSTRUMENTS AND CONTROLS ..............................................................................251
		35.1 SWITCHES .........................................................................................251
		35.2 CONTROL LEVERS, PEDALS ...........................................................................253
	36. PRECAUTIONS FOR MACHINE OPERATION .....................................................................255
		36.1 PRECAUTIONS DURING OPERATION .....................................................................255
	37. MAINTENANCE ...........................................................................................258
		37.1 EVERY 10 HOURS SERVICE ...........................................................................258
	38. TRANSPORTATION ........................................................................................259
	39. SPECIFICATIONS ........................................................................................260

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